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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of The Invention
This invention relates generally to downhole tools for use in well bores and methods of drilling such apparatus out of well bores, and more particularly, to such tools having drillable components made at least partially of non-metallic materials, such as engineering grade plastics, composites, and resins. This invention relates particularly to improvements in retaining packer elements commonly used in downhole drillable packer and bridge plug tools.
2. Description of The Prior Art
In the drilling or reworking of oil wells, a great variety of downhole tools are used. For example, but not by way of limitation, it is often desirable to seal tubing or other pipe in the casing of the well, such as when it is desired to pump cement or other slurry down the tubing and force the slurry out into a formation. It then becomes necessary to seal the tubing with respect to the well casing and to prevent the fluid pressure of the slurry from lifting the tubing out of the well. Downhole tools referred to as packers and bridge plugs are designed for these general purposes and are well known in the art of producing oil and gas.
When it is desired to remove many of these downhole tools from a well bore, it is frequently simpler and less expensive to mill or drill them out rather than to implement a complex retrieving operation. In milling, a milling cutter is used to grind the packer or plug, for example, or at least the outer components thereof, out of the well bore. Milling is a relatively slow process, but when milling with conventional tubular strings, it can be used on packers or bridge plugs having relatively hard components such as erosion-resistant hard steel. One such packer is disclosed in U.S. Pat. No. 4,151,875 to Sullaway, assigned to the assignee of the present invention and sold under the trademark EZ Disposal packer.
In drilling, a drill bit is used to cut and grind up the components of the downhole tool to remove it from the well bore. This is a much faster operation than milling, but requires the tool to be made out of materials which can be accommodated by the drill bit. Typically, soft and medium hardness cast iron are used on the pressure bearing components, along with some brass and aluminum items. Packers of this type include the Halliburton EZ Drill® and EZ Drill SV® squeeze packers.
The EZ Drill SV® squeeze packer, for example, includes a lock ring housing, upper slip wedge, lower slip wedge, and lower slip support made of soft cast iron. These components are mounted on a mandrel made of medium hardness cast iron. The EZ Drill® squeeze packer is similarly constructed. The Halliburton EZ Drill® bridge plug is also similar, except that it does not provide for fluid flow therethrough.
All of the above-mentioned packers are disclosed in Halliburton Services--Sales and Service Catalog No. 43, pages 2561-2562, and the bridge plug is disclosed in the same catalog on pages 2556-2557.
The EZ Drill® packer and bridge plug and the EZ Drill SV® packer are designed for fast removal from the well bore by either rotary or cable tool drilling methods. Many of the components in these drillable packing devices are locked together to prevent their spinning while being drilled, and the harder slips are grooved so that they will be broken up in small pieces. Typically, standard "tri-cone" rotary drill bits are used which are rotated at speeds of about 75 to about 120 rpm. A load of about 5,000 to about 7,000 pounds of weight is applied to the bit for initial drilling and increased as necessary to drill out the remainder of the packer or bridge plug, depending upon its size. Drill collars may be used as required for weight and bit stabilization.
Such drillable devices have worked well and provide improved operating performance at relatively high temperatures and pressures. The packers and bridge plugs mentioned above are designed to withstand pressures of about 10,000 psi (700 Kg/cm 2 ) and temperatures of about 425° F. (220° C.) after being set in the well bore. Such pressures and temperatures require using the cast iron components previously discussed.
However, drilling out iron components requires certain techniques. Ideally, the operator employs variations in rotary speed and bit weight to help break up the metal parts and reestablish bit penetration should bit penetration cease while drilling. A phenomenon known as "bit tracking" can occur, wherein the drill bit stays on one path and no longer cuts into the downhole tool. When this happens, it is necessary to pick up the bit above the drilling surface and rapidly recontact the bit with the packer or plug and apply weight while continuing rotation. This aids in breaking up the established bit pattern and helps to reestablish bit penetration. If this procedure is used, there are rarely problems. However, operators may not apply these techniques or even recognize when bit tracking has occurred. The result is that drilling times are greatly increased because the bit merely wears against the surface of the downhole tool rather than cutting into it to break it up.
In order to overcome the above long standing problems, the assignee of the present invention introduced to the industry a line of drillable packers and bridge plugs currently marketed by the assignee under the trademark FAS DRILL. The FAS DRILL line of tools consist of a majority of the components being made of non-metallic engineering grade plastics to greatly improve the drillability of such downhole tools. The FAS DRILL line of tools have been very successful and a number of U.S. patents have been issued to the assignee of the present invention, including U.S. Pat. No. 5,271,468 to Streich et al., U.S. Pat. No. 5,224,540 to Streich et al., and U.S. Pat. No. 5,390,737 to Jacobi et al. The preceding patents are specifically incorporated herein.
Notwithstanding the success of the FAS-DRILL line of drillable downhole packers and bridge plugs, the assignee of the present invention has discovered that certain metallic components still used within the FAS-DRILL line of packers and bridge plugs at the time of issuance of the above patents were preventing even quicker drill out times under certain conditions or when using certain equipment. Exemplary situations include milling with conventional jointed tubulars and in conditions in which normal bit weight or bit speed could not be obtained. Other exemplary situations include drilling or milling with non-conventional drilling techniques such as milling or drilling with relatively flexible coiled tubing.
When milling or drilling with coiled tubing, which does not provide a significant amount of weight on the tool being used, even components made of relatively soft steel, or other metals considered to be low strength, create problems and increase the amount of time required to mill out or drill out a down hole tool, including such tools as the assignee's FAS DRILL line of drillable non-metallic downhole tools.
Furthermore, packer shoes and optional back up rings made of a metallic material are employed not so much as a first choice but due to the metallic shoes and back up rings being able to withstand the temperatures and pressures typically encountered by a downhole tool deployed in a borehole.
Another shortcoming with using metallic packer shoes and optional backup rings is that upon deployment of the tool, the typically brass packer shoe may not flare outwardly as the packer portion is being compressed and therefore not expand outwardly as desired. If the brass shoe does not properly flare, it can lead to unwanted severe distortion of the shoes and subsequent cutting of the packer element which reduces its ability to hold to its rated differential pressure or lead to a complete failure of the tool.
These and other shortcomings are reduced, if not eliminated, by the present invention.
SUMMARY OF THE INVENTION
The improved downhole tool apparatus of the present invention preferably utilizes essentially all non-metallic materials, such as engineering grade plastics, resins, or composites, to reduce weight which facilitates and reduces shipping expenses, to reduce manufacturing time and labor, to improve performance through reducing frictional forces of sliding surfaces, to reduce costs and to improve drillability of the apparatus when drilling is required to remove the apparatus from the well bore. Primarily, in this disclosure, the downhole tool is characterized by a well bore packing apparatus, but it is not intended that the invention be limited to specific embodiments of such packing devices. The use of essentially only non-metallic components in the downhole tool apparatus allows for and increases the efficiency of alternative drilling and milling techniques in addition to conventional drilling and milling techniques.
In packing apparatus embodiments of the present invention, the apparatus may utilize the same general geometric configuration of previously known drillable non-metallic packers and bridge plugs such as those disclosed in U.S. Pat. No. 5,271,468 to Streich et al., U.S. Pat. No. 5,224,540 to Streich et al., and U.S. Pat. No. 5,390,737 to Jacobi et al. while replacing essentially all of the few remaining metal components of the tools disclosed in the preceding patents with non-metallic materials which can still withstand the pressures and temperatures found in many well bore applications. In other embodiments of the present invention, the apparatus may comprise specific design changes to accommodate the advantages of using essentially only plastic and composite materials and to allow for the reduced strengths thereof compared to metal components.
In a preferred embodiment of the downhole tool, the invention comprises a center mandrel and slip means disposed on the mandrel for grippingly engaging the well bore when in a set position. The apparatus further comprises a packing means disposed on the mandrel for sealingly engaging the well bore when in a set position.
The slip means comprises a slip wedge positioned around the center mandrel, a plurality of slip segments disposed in an initial position around the mandrel and adjacent to the slip wedge, retaining means for holding the slip segments in an initial position. In the preferred embodiment, the slip means utilizes separate slip segments. The retaining means is characterized by at least one retaining band extending at least partially around the slips. In another embodiment, the retaining means is characterized by a ring portion integrally formed with the slips. This ring portion is fracturable during a setting operation, whereby the slips are separated so that they can be moved into gripping engagement with the well bore. Hardened inserts may be molded into the slips. The inserts may be metallic, such as hardened steel, or non-metallic, such as a ceramic material.
In the preferred embodiment, the slip means includes a slip wedge installed on the mandrel and the slip segments, whether retained by a retaining band or whether retained by an integral ring portion, have coacting planar, or flat portions, which provide a superior sliding bearing surface especially when the slip means are made of a non-metallic material such as engineering grade plastics, resins, phenolics, or composites.
Also in the preferred embodiment of applicant's present invention, prior art packer element shoes and back up ring, such as those referred to as elements 37 and 38, 44 and 45, in the assignee's U.S. Pat. No. 5,271,468, are replaced by a non-metallic packer shoe having a multitude of co-acting segments and at least one retaining band, and preferably two non-metallic bands, for holding the shoe segments in place after initial assembly and during the running of the tool into the wellbore and prior to the setting of the associated packer element within the well bore. The preferred packer shoe assembly of the downhole tool disclosed herein further consists of packer shoe segments preferably being made of a phenolic or a composite material to withstand the stresses induced by relatively high differential pressures and high temperatures found within wellbore environments.
Additional objects and advantages of the invention will become apparent as the following detailed description of the preferred embodiments is read in conjunction with the drawings which illustrate the preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a prior art downhole packer apparatus depicting prior art packer shoe assemblies having the preferred slips and slip assemblies that can be used in connection with the present invention.
FIG. 2A is a front view of the preferred slip shown in FIG. 1 that can be used with the present invention.
FIG. 2B is a cross-sectional side view of the preferred slip segments shown in FIG. 2A.
FIG. 2C is a top view of the preferred slip segments shown in FIGS. 2A and 2B.
FIG. 3A is top view of the preferred slip wedge shown in FIG. 1 and can be used with the present invention.
FIE. 3B is a cross-sectional side view of the preferred slip wedge shown in FIG. 3A.
FIG. 3C is an isolated sectional view of one of the multiple planar surfaces of the slip wedge taken along line 3C as shown in FIG. 3A.
FIG. 4 is a cross-sectional side view of an alternative prior art packer element retainer shoe.
FIG. 5 is a cross-sectional side view of the preferred packer element retainer shoe of the present invention.
FIG. 6A is a top view of the preferred packer shoe and retaining band of the present invention. The retaining band is shown in an exageratedly expanded for clarity.
FIG. 6B is a cross-sectional side view of the packer element shoe shown in FIG. 6A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings. FIGS. 1-4 are all of prior art and have been provided for background and to show the preferred embodiment of a tool in which the present invention is particularly suitable for, but not limited to.
FIG. 1 is a prior art representation of a downhole tool 2 having a mandrel 4. The particular tool of FIG. 1 is referred to as a bridge plug due to the tool having a plug 6 being pinned within mandrel 4 by radially oriented pins 8. Plug 6 has a seal means 10 located between plug 6 and the internal diameter of mandrel 4 to prevent fluid flow therebetween. The overall tool structure, however, is quite adaptable to tools referred to as packers, which typically have at least one means for allowing fluid communication through the tool. Packers may therefore allow for the controlling of fluid passage through the tool by way of a one or more valve mechanisms which may be integral to the packer body or which may be externally attached to the packer body. Such valve mechanisms are not shown in the drawings of the present document. The representative tool may be deployed in wellbores having casings or other such annular structure or geometery in which the tool may be set.
Tool 2 includes the usage of a spacer ring 12 which is preferably secured to mandrel 4 by pins 14. Spacer ring 12 provides an abutment which serves to axially retain slip segments 18 which are positioned circumferentially about mandrel 4. Slip retaining bands 16 serve to radially retain slips 18 in an initial circumferential position about mandrel 4 as well as slip wedge 20. Bands 16 are made of a steel wire, a plastic material, or a composite material having the requisite characteristics of having sufficient strength to hold the slips in place prior to actually setting the tool and to be easily drillable when the tool is to be removed from the wellbore. Preferably bands 16 are inexpensive and easily installed about slip segments 18. Slip wedge 20 is initially positioned in a slidable relationship to, and partially underneath slip segments 18 as shown in FIG. 1. Slip wedge 20 is shown pinned into place by pins 22. The preferred designs of slip segments 18 and co-acting slip wedges 20 will be described in more detail herein.
Located below slip wedge 20 is at least one packer element, and as shown in FIG. 1, a packer element assembly 28 consisting of three expandable elements positioned about mandrel 4. At both ends of packer element assembly 28 are packer shoes 26 which provide axial support to respective ends of packer element assembly 28. Backup rings 24 which reside against respective upper and lower slip wedges 20 provide structural support to packer shoes 26 when the tool is set within a wellbore. The particular packer element arrangement show in FIG. 1 is merely representative as there are several packer element arrangements known and used within the art.
Located below lower slip wedge 20 are a plurality of multiple slip segments 18 having at least one retaining band 16 secured thereabout as described earlier.
At the lowermost terminating portion of tool 2 referenced as numeral 30 is an angled portion referred to as a mule-shoe which is secured to mandrel 4 by radially oriented pins 32. However lowermost portion 30 need not be a mule shoe but could be any type of section which serves to terminate the structure of the tool or serves to be a connector for connecting the tool with other tools, a valve, or tubing etc. It should be appreciated by those in the art, that pins 8, 14, 16, 22, and 32, if used at all, are preselected to have shear strengths that allow for the tool be set and to be deployed and to withstand the forces expected to be encountered in a wellbore during the operation of the tool.
As described in the patents referenced herein, the majority of the components in tool 2 of FIG. 1, with the exception of packer shoes 26 and back up rings 24, are made of a non-metallic material. Prior to the present invention, the use of metallic packer shoes and back up rings were required to be used in the Assignee's line of FAS DRILL downhole tool line because of the lack of a suitable non-metallic material being known or available that could withstand the pressures and temperatures typically encountered in a well-bore in which the tool was to be deployed. Additionally, a downhole tool having a packer element assembly 29 positioned about a mandrel 49 as shown in the broken away cross-sectional view of FIG. 4, it is known within the art that a metallic packer element back up shoe 27 not having a back up ring to provide additional support to the shoe can be used in certain circumstances. However, a single metallic shoe, such as shoe 27 of prior art FIG. 4, can nonetheless cause problems upon milling or drilling out the tool due to the drill and mill resistant nature of the metallic material of a prior art single shoe, especially when non-conventional milling or drilling techniques are being used.
Referring now to FIG. 5 of the drawings. A broken away cross-sectional view of a tool having a mandrel 49 which has a packer element assembly 29 positioned thereabout, shows a packer shoe 50 embodying the present invention. Improved packer shoe 50 is preferably made of a phenolic material available from General Plastics, 5727 Ledbetter, Houston, Tex., 77087-4095. Other suitable materials include a direction-specific laminate material referred to as GP3581 also available from General Plastics and structural phenolics available from commercial suppliers such as Fiberite, 501 West 3rd Street, Winona, Minn. 55987. Particularly well suited phenolic materials available from Fiberite include, but are not limited to, material designated as FM 4056J and FM 4005.
As can be seen in FIG. 5, each end most section of packer element 29 resides directly against shoe 50, which in the preferred embodiment does not employ a backup ring. Each shoe 50 preferably has circumferential grooves 54 about the external periphery of shoes 50 for accommodating retaining band 52. Retaining band 52 serves to secure shoes 50 adjacent each respective end of packer element 29 after the shoes have been initially installed, during transit, and during the running in of the tool into a well bore prior to deploying the tool.
Referring to FIG. 6A which is a view of the preferred non-metallic packer shoe 50 depicted in FIG. 5. FIG. 6B is a cross-sectional view of shoe 50. Packer shoe 50 preferably has a plurality of individual shoe segments 51 to form a shoe that encircles a mandrel or center section of a downhole tool having a packer element. Shoe segments 51 preferably include an internal surface 56 which is shaped to accommodate the endmost portion of a packer element thereagainst. Surface 56 is therefore preferably sloped as well as arcuate to provide generally a truncated conical surface which transitions from having a greater radius proximate to external surface 64 to a smaller radius at internal diameter 58. The ends of shoe segment 50 are defined by surfaces 61 and 62 which are flat and convergent with respect to a center reference point CL which, if the shoe segments were installed about a mandrel, would correspond to the axial centerline of that mandrel as depicted in FIGS. 4 and 5. End surfaces 61 and 62 need not be flat and could be of other topology.
FIG. 6A illustrates shoe 50 being made of a total of 8 shoe segments to provide a 360° annulus, or encircling, structure to provide the maximum amount of end support for a packer element that is to be retained in an axial direction. A lesser amount, or greater amount of shoes segments can be used depending on the nominal diameters of the mandrel, the packer elements, and the wellbore or casing in which the tool is to be deployed.
Shoe retaining band 52, which is shown as being exageratedly expanded and distant from outer external surfaces 64 of shoe 50. Shoe retaining band 52 is preferably made of a non-metallic material such as composite materials available from General Plastics, 5727 Ledbetter, Houston, Tex., 77087-4095. However, shoe retaining bands 52 may alternatively be of a metallic material such as ANSI 1018 steel or any other material having sufficient strength to support and retain the shoes in position prior to actually setting a tool employing such bands. Furthermore, retaining bands 50 may have either elastic or non-elastic qualities depending on how much radial, and to some extent axial, movement of the shoe segments can be tolerated prior to and during the deployment of the associated tool into a wellbore.
Shoe 50 as shown in FIG. 6B has two retaining bands 52 and respective band accommodating grooves 54. Grooves 54 are each located proximate to face 60 and proximate to upper most region where outer external surface 64 and arcuate surface 56 intersect, or the distance between the two is at minimum. As discussed earlier, a single band 52, appropriately sized and made of a preselected material, can be used. Alternatively, a multitude of bands appropriately sized and made of suitable material can be used in lieu of the preferred pair of retaining bands 52.
Tests have been performed using a downhole packer tool, similar to the representative bridge plug tool shown in FIG. 1, having the preferred packer shoe 50 wherein the shoe segments 51 were constructed in accordance with the above description and FIGS. 5-6 of the drawings. The test segments were made of a phenolic material obtained from General Plastics as referenced herein.
The test tool was installed in a test chamber and the tool was set and the tool and associated packer elements were then subjected to a maximum differential pressure of 8000 psi (562 Kg/cm 2 ) and a maximum temperature of 250° F. (120° C.). Upon inspection of the subject shoe segments after the test, the segments had flared outwardly to and were ultimately restrained by the well bore. The subject shoe segments successfully retained and supported the respective ends of the associated packer elements. Thus it is fully expected that pressures reaching 10,000 psi (700 Kg/cm 2 ) and temperatures reaching 400° (205° C.) are obtainable using shoes embodying the present invention. The subject test shoes were initially retained by a pair of retaining bands as described herein and made of a composite material obtained from General Plastics as referenced herein. The associated packer element ends were inspected after the test was performed and found to be in a satisfactory condition with only expected non-catastrophic deformation of the packer element assembly present.
Returning now to FIGS. 2-4 of the drawings. Although, it is admitted that slip segments 18 and slip wedges 20 are prior art, it is preferred that the subject slip segments and slip wedges be constructed as discussed below in order to take full advantage of features and benefits of downhole tools constructed essentially of only non-metallic components as discussed herein.
However, it is not necessary to have the particular slip segment and slip wedge construction shown in FIGS. 2-4 in order to practice the present invention, as the disclosed packer element shoes can be used in connection with any type of downhole tool employing at least one packer element whether or not the tool is made essentially of only non-metallic components or a combination of metallic and non-metallic components.
Preferably, slip segment 18 as shown in a front view of the slip segment, denoted as FIG. 2A, has an outer external face 19 in which at least one and preferably a plurality of inserts 34 have been molded into, or otherwise secured into, face 19. Inserts 34 made of zirconia ceramic have been found to be particularly suitable for a wide variety of applications. Slip segment 18 is preferably made of a composite material obtained from General Plastics as referenced herein in addition to the materials set forth in the present Assignee's patents referenced herein.
FIG. 2B is a cross-sectional view taken along line 2B of slip segment of 18 FIG. 2A. Slip segment 18 has two opposing end sections 21 and 23 and has an arcuate inner mandrel surface 40 having topology which is complementary to the outer most surface of mandrel 4. Preferably end section surface 23 is angled approximately 5°, shown in FIG. 2B as angle θ, to facilitate outward movement of the slip when setting the tool. Slip segment bearing surface 38 is flat, or planar, and is specifically designed to have topology matching a complementary surface on slip wedge 20. Such matching complementary bearing surface on slip wedge 20 is designated as numeral 42 and can be viewed in FIG. 3A of the drawings. A top view of slip segment 18, having a flat, but preferably angled, top surface 23 is shown in FIG. 2C. Location and the radial positioning of sides 25 define an angle α which is preselected to achieve an optimal number of segments for a mandrel having an outside diameter of a given size and for the casing or well bore diameter in which the tool is to be set. Angle α is preferably approximately equal to 60°. However, an angle of α ranging from 45° to 60° can be used.
Returning to FIG. 2B, the sides of slip segments 18 are designated by numeral 25. It is preferred that six to eight segments encircle mandrel 4 and be retained in place prior to setting of the tool by at least one, and preferably two slip retaining bands 16 that are accommodated by circumferential grooves 36. Slip retaining bands 16 are made of composite material obtained from General Plastics as referenced herein or other suitable materials such as ANSI 1018 steel wire available from a wide variety of commercial sources.
Referring to FIG. 3A, a top view is provided of preferred slip wedge 20 having flat, or planar, surfaces 42 which form an opposing sliding bearing surface to flat bearing surface 38 of respectively positioned slip segments 18. The relationship of such surfaces 38 and 42 as installed initially are best seen in FIG. 2B, FIG. 3C, and FIG. 1. As can be seen in FIG. 3C, which is a broken away sectional view taken along line 3C shown in FIG. 3A. It is preferred that slip wedge bearing surface 42 be defined by guides or barriers 44 to provide a circumferential restraint to slip segments 18 as the segments travel axially along slip wedge 20 and thus radially outwardly toward the casing or well bore during the actual setting of the packer tool. Preferably angle β, as shown in FIG. 3B is approximately 18°. However, other angles ranging from 15° to 20° can be used depending on the frictional resistance between the coacting surfaces 42 and 38 and the forces to be encountered by the slip and slip wedge when set in a well bore. Internal bore 46 is sized and configured to allow positioning and movement along the outer surface of mandrel 4.
It has been found that material such as the composites available from General Plastics are particularly suitable for making a slip wedge 20 from in order to achieve the desired results of providing an easily drillable slip assembly while being able to withstand temperatures and pressures reaching 10,000 psi (700 Kg/cm 2 ) and 425° F. (220° C.). Additionally, suitable material includes the materials set forth herein and in the present Assignee's patents referenced herein.
A significant advantage of using such co-acting flat or planar bearing surfaces in slip segments 18 and slip wedges 20 is that as the slips and wedges slide against each other, the area of contact is maximized, or optimized, as the slip segments axially traverse the slip wedge thereby minimizing the amount of load induced stresses being experienced in the contact area of the slip/slip wedge interface. That is as the slip axially travels along the slip wedge, there is more and more contact surface area available in which to absorb the transmitted loads. This feature reduces or eliminates the possibility of the slips and wedges binding with each other before the slips have ultimately seated against the casing or wellbore. This arrangement is quite different from slips and slip cones using conical surfaces because when using conical bearing surfaces, the contact area is maximized only at one particular slip to slip-cone position.
The practical operation of downhole tools embodying the present invention, including the representative tool depicted and described herein, is conventional and thus known in the art as evidenced by prior documents.
Furthermore, although the disclosed invention has been shown and described in detail with respect to the preferred embodiment, it will be understood by those skilled in the art that various changes in the form and detail thereof may be made without departing from the spirit and scope of this invention as claimed.
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An improved downhole tool apparatus including, but not limited to, packers and bridge plugs which more fully utilize highly stressed non-metallic components, including slips, slip wedges, and packer element retaining shoes than prior tools. The non-metallic packer element retaining shoes of the present invention are preferably made of separate shoe segments initially held in place by at least one retaining band. Such non-metallic packer element shoes do away with troublesome prior art metallic shoes and backups which tended to spin upon each other or about the mandrel while milling or drilling the tool out of a wellbore. Therefore, the subject invention increases the ability to drill or mill downhole tools out of a well bore in less time than it would take with using conventional or non-conventional drilling or milling techniques or equipment.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] The present invention relates to a bracket to hold a boarding stairs to a boat. The invention provides a quick release mechanism for both the stairs and the bracket itself.
BACKGROUND OF THE INVENTION
[0002] Boats often provide removable stairs to ease boarding. The stairs are designed to be removed when the boat leaves dock and is underway. Many boarding stairs are mounted to the boat by a bracket. These brackets stick out from the boat and it is desirable to remove the protruding bracket to avoid damaging the bracket and the area of the boat where the bracket is mounted during docking or when coming alongside another boat.
[0003] Existing boarding stairs brackets do not provide an easy means to release the stairs. Most conventional boarding stairs have a half-inch steel bar horizontally across the top of the stairs. The bar must be inserted through the stairs and through holes in the mounting bracket, then secured with cotter pins or nuts to keep the bar from sliding out. However, aligning the bar with the holes in the stairs and the bracket, while a boat is rocking in the water by a dock, is a difficult and frustrating endeavor. Moreover, the cotter pins or nuts that secure the bar can be very easily dropped and lost in the harbor water. In addition, many brackets are held to the boat by a mounting plate, allowing removal of the bracket. When the bracket is removed, the mounting plate does not protrude substantially from the boat, thereby avoiding potential damage to the boat when it comes along side a dock or another boat. The mounting plate screws to the side of the boat and is substantially flush. A vertical slot in the mounting plate accepts the bracket and a pin is inserted through a slot in the mounting plate and a hole in the bracket to hold the bracket in place. As with the boarding stairs mounting bar, the pins securing the bracket to the mounting plate are very easily dropped and lost during the removal process. Additionally, the mounting plate's vertical slot for the bracket requires several inches of free space above the mounting plate so the bracket can be dropped in. The bracket must be mounted high on the side of the boat, close to the level of the deck, so that the top stair will not require too great a last step for boarding. However, many boats have lips, rub rails, and other features that extend beyond the side of the boat, making it difficult to locate the mounting plate close to the level of the deck but also provide enough free space above the mounting plate for the bracket to be dropped in. For this reason, boats with such features cannot use releaseable boarding stairs brackets, but must rely on permanently fixed brackets. As noted above, this is undersirable, because the bracket protrudes beyond the side of the boat; the protruding bracket can be torn away during docking or coming alongside another boat, thereby damaging the hull, or it can damage other boats.
SUMMARY OF THE INVENTION
[0004] It is one object of the present invention to provide a boarding stairs bracket that provides an easy and quick release mechanism for removal of the stairs. It is another object of the present invention to provide a boarding stairs bracket with an integral latch that does not rely on extra parts, such as pins or nuts, to secure the stairs to the bracket. It is another object of the present invention to provide a boarding stairs bracket that is itself easily and quickly released from the boat. It is another object of the present invention to provide a boarding stairs bracket with an integral latch that does not rely on extra parts, such as pins, to secure the bracket to the boat. It is another object of the present invention to provide a boarding stairs bracket that allows removal of the bracket from the mounting plate without requiring much, if any, free space above the mounting plate.
[0005] In accordance with these objectives, the present invention provides a quick release mechanism for both the stairs and the bracket itself. A mounting plate is substantially flush with the side of the boat. The bracket slides down into the mounting plate and latches into place. The bracket accepts the upper bar of a boarding stairs in a slot, and a latch closes over the bar, holding the stairs in place. To remove the stairs, the latch at the top of the bracket is pivoted and the stairs can be easily and quickly lifted free. With the latch pivoted to the open position and the stairs removed, the bracket can be easily and quickly lifted from the mounting plate. The mounting plate has openings and the bracket has corresponding tabs so that the bracket can be inserted horizontally into the mounting plate then dropped and latched into place. This design s effectively eliminates the need for free space above the mounting plate for insertion of the bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a perspective view of the bracket and an exploded view of the mounting plate.
[0007] [0007]FIG. 2 is an exploded view of the bracket.
[0008] [0008]FIG. 3 a is a front view of the front plate of the mounting plate. FIG. 3 b is a top view of the front plate of the mounting plate. FIG. 3 c is a front view of the back plate of the mounting plate. FIG. 3 d is a top view of the back plate of the mounting plate. FIG. 3 e is a front view of the mounting plate assembly. FIG. 3 f is a top view of the mounting plate assembly.
[0009] [0009]FIG. 4 a is a top view of the bracket and mounting plate assembly. FIG. 4 b is a front view of the bracket and mounting plate assembly. FIG. 4 c is a side view of the bracket and mounting plate assembly, showing the latches in the locked position. FIG. 4 d is a side view of the bracket and mounting plate assembly mounted to a boat just below a rub rail, showing the latches in the open position, and showing the bracket separated from the mounting plate.
[0010] [0010]FIGS. 5 a, b and c show the steps of dropping the boarding stairs into the bracket.
[0011] [0011]FIGS. 6 a, b and c show the steps of pulling the boarding stairs up and out of the bracket.
DESCRIPTION
[0012] [0012]FIG. 1 shows the bracket assembly 10 and an exploded view of the mounting plate 27 . The bracket 10 has tabs 14 on its back surface. A cross slot 52 in the opening 24 forms a chamber 23 between the front 21 and rear 22 plates of the mounting plate assembly 27 . Holes 26 in the mounting plate 27 accept screws 25 to fasten the mounting plate 27 to a boat (not shown). As indicated by arrow 28 , the tabs 14 on the back of the bracket 10 allow the bracket 10 to be inserted horizontally into the chamber 23 of the mounting plate 27 , then the bracket 10 drops into place. As more fully described below, a top latch 11 can be pivoted, dropping a finger 15 , allowing a bottom latch 12 to pivot, thereby permitting the bracket 10 to be inserted or removed from the mounting plate 27 .
[0013] [0013]FIG. 2 shows an exploded view of the parts of the bracket 10 . Sides 31 and 32 have tabs 14 that align with corresponding tabs 37 on a back plate 36 . The sides 31 and 32 are joined to the back plate 36 by any conventional means, such as welding or securing the parts with fasteners, such as screws. Alternatively, the sides 31 and 32 and he back plate 36 can be manufactured as a single piece by a molding or machining process. The sides 31 and 32 sandwich latches 11 and 12 . Top latch 11 pivots on a screw 44 . The screw 44 extends through a hole 43 in side plate 31 , through a pivot hole 46 in latch 11 , and is received by threaded hole 45 in side plate 32 . Bottom latch 12 pivots on a screw 38 . The screw 38 extends through a hole 40 in side plate 31 , through the pivot hole 41 in latch 12 , and is received by threaded hole 39 in side plate 32 . Screws 44 and 38 may be permanently secured in side plate 32 by welding or riveting. Those skilled in the art will appreciate that screws 44 and 38 may be substituted by any appropriate axle, such as rivets or pins or the like, for the top 11 and bottom 12 latches. Top latch 11 has a finger 15 . Bottom latch 12 has a step 35 , a top finger 34 , and a bottom finger 33 . As seen in FIG. 4 c, a slot 42 in the bracket 10 can receive a boarding stairs bar ( 62 , as seen in FIGS. 5 and 6). FIG. 4 c shows the top 11 and bottom 12 latches in the closed position, with top latch finger 15 across the top of the slot 42 , barring beveled opening 47 of the slot 42 , and bottom latch finger 33 extending horizontally across and out from the bottom of the bracket, locking the bracket 10 at the bottom of the mounting plate 27 . FIG. 4 d shows the top 11 and bottom 12 latches in the position allowing the bracket 10 to be inserted into or freed from the mounting plate 27 . FIG. 4 d shows that the bracket can be releaseably mounted to the boat immediately below a rub rail 18 . The mounting plate 27 is shown screwed to a boat's hull 17 , almost immediately below a rub rail 18 , which is adjacent the deck 19 . Arrow 16 shows that the bracket 10 may be inserted into the mounting plate 27 horizontally. The lower tab 14 fits into the cross opening 52 of the mounting plate opening, and the bracket 10 can then drop into the chamber 23 and rest on the seat ( 53 , as seen in FIG. 3 a ). With this arrangement, it is possible to mount the bracket almost immediately the rub rail 18 , which allows the boarding stairs to be mounted high enough so that the top stair is an easy step to the deck 19 . To remove the bracket 10 , top latch 11 is pivoted forward and finger 15 is allowed to pivot inward. Without the stairs mounting bar ( 62 , as seen in FIGS. 5 and 6) in the slot 42 , bottom latch 12 can pivot inward, dipping step 35 to receive the finger 15 of the top latch 11 . In turn, bottom finger 33 pivots down and away, allowing the bracket 10 to be lifted and pulled out from the mounting plate 27 . In the preferred embodiment disclosed here, the top 11 and bottom 12 latches cooperate; that is, the step 35 in bottom latch 12 provides a stop for the top 11 and bottom 12 latches. However, after considering the invention disclosed here, those skilled in the art will appreciate that many other latch designs can be employed which fall within the scope of the invention. For example, top 11 and bottom 12 latches could be operated independent of each other, or a single latch could secure both the boarding stairs mounting bar ( 62 , as seen in FIGS. 5 and 6) and the bracket 10 . With respect to the latter, while such a latch design is a contemplated embodiment of the invention, the preferred embodiment shown has the advantage of preventing the bracket 10 from being inadvertently pulled out of the mounting plate 27 when the boarding stairs mounting bar ( 62 , as seen in FIGS. 5 and 6) is lifted free.
[0014] [0014]FIGS. 3 a - f show the mounting bracket. Front plate 21 has a chamber portion 29 with an opening 24 . A cross opening 52 gives the opening 24 a cross shape. The front plate 21 is mated with a back plate 22 to form the mounting plate assembly 27 . When the front plate 21 is mounted to the back plate 22 , the chamber portion 29 forms a chamber 23 . Holes 26 in the plates 21 and 22 allow the mounting plate 27 to be secured to a boat (not shown) with any suitable fasteners, such as screws ( 25 , as seen in FIG. 1). It will be appreciated that, when mounted to a boat, the back plate 22 is not needed for securing the bracket 10 in the mounting plate chamber 29 . However, the back plate 22 keeps the bracket 10 from rubbing against and damaging the boat. It will also be appreciated that the back 22 and front 21 plates forming the mounting plate assembly 27 can be manufactured as a single piece by molding or machining. Additionally, the back plate 22 of the mounting bracket 27 need not form a solid piece; it is sufficient that if a back portion is incorporated it separates the bracket 10 from the boat. A bevel 51 at the top of the opening 24 eases insertion of the bracket ( 10 , as seen in FIG. 1). As shown in FIG. 1, the tabs 14 on the back of the bracket 10 allow it to be first inserted horizontally into the cross openings 52 of the mounting plate 27 , then dropped vertically in the opening 24 where the notch ( 30 , as seen in FIG. 2) in the bracket 10 rests on the seat 53 at the bottom of the opening 24 of the mounting plate 27 . The tabs 14 and cross openings 52 make it possible to insert the bracket 10 horizontally into the mounting plate 27 , thereby substantially reducing the free space needed above the mounting plate 27 for vertical insertion. It will be appreciated by those skilled in the art that the beveled opening 51 of the mounting bracket 27 could be shaped to form a cross opening, which would allow the upper tab 14 to be inserted horizontally into the mounting plate 27 without the need for any free space above it.
[0015] [0015]FIGS. 5 a - c and 6 a - b show the boarding stairs mounting and releasing processes. The top frame of a boarding stair 61 has a bar 62 that extends out from the frame 61 . As indicated by arrow 63 in FIG. 5 a, the bar 62 is dropped into the beveled opening 47 of the bracket slot 42 . FIG. 5 b shows that the bar 62 pushes down the finger ( 15 , as seen in FIG. 5 c ), which pivots the top latch 11 . FIG. 5 c shows that the bar 62 comes to a rest at the bottom of the slot 42 , and the top latch can be pivoted back up, where finger 15 keeps the bar 62 in the bracket slot 42 , thereby securing the boarding stairs. It will be appreciated that, when the boarding stairs are in place, the bar 62 keeps the bottom latch 12 from pivoting, thereby locking the bracket 10 to the mounting plate 27 . FIGS. 6 a and b show the process of removing the boarding stairs from the bracket 10 . The top latch 11 is pivoted inward so that the finger 15 swivels down and back to clear the slot 42 . The boarding stairs 61 are lifted up and out of the slot 42 . As the bar 62 passes the top latch 11 , it pushes the latch 11 back up as it passes.
[0016] As discussed above, the mounting bracket 27 and bracket's sides, 31 and 32 , and back 36 can be manufactured by assembling them from separate parts, but those skilled in the art will appreciate that they can be molded or machined or otherwise fabricated as single pieces. It will also be appreciated that the top 11 and bottom 12 latches incorporated into the bracket 10 could be incorporated into the mounting plate 27 . Because the bracket 10 and mounting plate 27 are intended for marine use, it is preferable to construct them out of non-corrosive materials, such as aluminum, stainless steel, plastics, or other similar materials.
[0017] The drawings and description set forth here represent only some embodiments of the invention. After considering these, skilled persons will understand that there are many ways to make a boarding stairs bracket according to the principles disclosed. The inventors contemplate that the use of alternative structures, materials, or manufacturing techniques, which result in a boarding stairs bracket according to the principles disclosed, will be within the scope of the invention.
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The present invention relates to a bracket to hold a boarding ladder to a boat. The invention disclosed provides a quick release mechanism for both the ladder and the bracket itself. A mounting plate is substantially flush with the side of the boat. The bracket slides down into the mounting plate and latches into place. The bracket accepts the upper bar of a boarding ladder and closes a latch over the bar, holding the ladder in place. To remove the ladder, a latch at the top of the bracket is lifted and the ladder can be easily pulled free. To free the bracket from the mounting plate after the ladder has been removed, the latch is lifted and the bracket can be lifted out.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application having Ser. No. 60/957,113, filed on Aug. 21, 2007, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention generally relate to systems and methods for oil field cutting bioremediation. More particularly, embodiments of the present invention relate to systems and methods for bioremediation of hydrocarbon contaminated drill cuttings from oil and gas wellbores.
2. Description of the Related Art
The drilling of wells in the recovery of oil and gas typically comprises a rig drilling the well with a hollow drill string. As the well is being drilled, drilling fluids are pumped down the bore of the string. The drilling fluid passes through openings in the drill bit and returns to the surface through the annulus surrounding the string, carrying the cuttings produced by the drill bit. The drilling fluid is then recycled to remove the cuttings so that it may be used again.
Traditional methods of recycling drilling fluid include using a centrifuge to separate the liquid from the cuttings. In large drilling operations, to keep up with the volume of drilling fluid used, it is necessary to use either a very large centrifuge or to use a plurality of centrifuges. In either case, the cost of operating such a drilling fluid recycling system is substantial.
Fluid recycling system using setting tanks and centrifuges have been used. The settling tank is used as a preliminary step to settle the cuttings from the fluid. The drill cuttings often remain in suspension in the fluid and are often referred to as “solids.” Flocculating agents may be introduced into the tank to assist in the settling of the solids. The drilling fluids are pumped into the receiving end of the tank. The tank has a plurality of transverse walls or baffles that form a plurality of compartments within the tank. Each wall has an opening to permit the flow of fluid from an upstream compartment to a downstream compartment. The openings are positioned on the walls in such a manner that the fluid follows a sinuous path as it flows from the receiving end to the collecting end of the tank. As fluid flows from compartment to compartment, solids in the fluid settle to the bottom of the tank.
Once fluid reaches the collecting end of the tank, it is withdrawn from the tank to be re-used in the drilling operation. The settled or separated solids are conveyed towards the receiving end of the tank using an auger. A slurry of settled solids and fluid are withdrawn from the tank and pumped through a centrifuge. Fluid recovered from the centrifuge is re-introduced into the tank at the receiving end.
While using the combination of settling tank and centrifuge is an improvement in comparison to using a centrifuge by itself, in practice, this circuit is often unable to keep up with the throughput of drilling fluid required in drilling a well. It is often necessary to temporarily stop drilling until the settling tank and centrifuge can catch up and recover enough drilling fluid for the drilling operation.
Therefore, there is a need for a new system and method for recovering and recycling drilling fluid in sufficient quantity for typical drilling operations.
SUMMARY OF THE INVENTION
Apparatus and methods for bioremediating hydrocarbon contaminated solids. In at least one specific embodiment, the method can include introducing a slurry comprising one or more drilling fluids and one or more hydrocarbon contaminated solids to a settling system. The settling system can include one or more housings having a receiving compartment at a first end thereof and a collecting compartment at a second end thereof. A barrier can be disposed in the receiving compartment, and at least one wall can be transversely disposed in the housing between the receiving and collecting compartments. The wall can have at least one aperture formed therethrough and at least one flow-restricting baffle disposed thereon, wherein the one or more baffles can extend perpendicularly from the wall. The slurry can flow across the barrier, and the hydrocarbon contaminated solids in the slurry can be separated from the drilling fluid by causing the slurry to reverse direction and flow around the barrier. The separated hydrocarbon contaminated solids can be contacted with one or more microorganism populations disposed between the receiving compartment and the collecting department.
In at least one specific embodiment, the apparatus can include a housing having a receiving compartment at a first end thereof and a collecting compartment at a second end thereof. A substantially vertical flow-reversing barrier can be disposed in the receiving compartment. The barrier can be adapted to receive a slurry containing drilling fluid and one or more hydrocarbon contaminated solids, the barrier can be capable of causing the slurry to reverse direction and flow around the barrier and can cause at least some of the solids in the slurry to separate from the drilling fluid. At least one wall can be transversely disposed in the housing between the receiving and collecting compartments. The wall can have at least one aperture formed therethrough and at least one flow-restricting baffle disposed thereon, wherein the one or more baffles can extend perpendicularly from the wall. One or more microorganism populations can be present to selectively remove the hydrocarbons from the separated solids. A conveyor can be used for moving the separated solids from the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1A depicts a perspective view of a system for bioremediation of hydrocarbon contaminated solids from oil and gas wellbores, according to one or more embodiments.
FIG. 1B depicts a plan view of an illustrative settling system for separating solids from a used drilling fluid, according to one or more embodiments.
FIG. 2 depicts a partial cross section view of the settling system depicted in FIG. 1B .
FIG. 3 depicts a cross-sectional end view of the settling system along lines III-III shown in FIG. 2 .
FIG. 4 depicts a perspective view of the flow-reversing barrier of the settling system depicted in FIG. 1B , according to one or more embodiments.
FIG. 5 depicts a front elevation view of the flow-reversing barrier of the settling system depicted in FIG. 1B , according to one or more embodiments.
FIG. 6 depicts a top plan view of the flow-reversing barrier of the settling system depicted in FIG. 1B , according to one or more embodiments.
FIG. 7 depicts a side elevation view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
FIG. 8 depicts a perspective view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
FIG. 9 depicts a front elevation view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
FIG. 10 depicts a top plan view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
FIG. 11 depicts a side elevation view of the flow-restricting baffle of the settling system depicted in FIG. 1B , according to one or more embodiments.
DETAILED DESCRIPTION
A detailed description will now be provided. Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims. Each of the inventions will now be described in greater detail below, including specific embodiments, versions and examples, but the inventions are not limited to these embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the inventions, when the information in this patent is combined with available information and technology.
FIG. 1A depicts a plan view of an illustrative system 100 for bioremediation of hydrocarbon contaminated solids from oil and gas wellbores, according to one or more embodiments. In one or more embodiments, the system 100 can include one or more wellbores 110 , drilling fluid pumps 115 , mud tanks 120 , mixing tanks 130 , shakers 140 , centrifuges 150 , disposal bins 160 , and settling system 10 . Drilling fluid from the mud tanks 120 can be conveyed to the one or more wellbores 110 via the pump 115 . Used drilling fluids and solids, such as drill cuttings, sand, gravel, and other particulates, from the wellbore 110 can be sent to and collected in the shaker 140 via line 112 .
The shakers 140 can be any device or mechanism capable of separating liquids from solids. In one or more embodiments, the shaker 140 can have a wire cloth screen that vibrates as the drilling fluid and solids flow on top of the screen. The liquid and solids having a particle size less than the mesh openings can pass through the screen, while larger solids are retained on the screen. Those larger solids that are not allowed to pass through the mesh can eventually fall off the back of the shaker 140 into the disposal bins 160 via line 142 or simply allowed to pile behind the shaker 140 . Such disposal pile can be removed for treatment and/or disposal.
From the shakers 140 , the used drilling fluid having smaller solids contained therein is sent to the settling system 10 via line 145 . The settling system 10 can include two or more zones or compartments 11 to separate the solids from the liquids. The settling system 10 is explained in more detail below. In operation, each zone 11 provides a torturous path and pressure drop for the drilling fluid having the solids dispersed therein, allowing the solids to drop while passing along the liquid phase. The liquid phase can flow through the settling system 10 to the one or more centrifuges 150 , which can separate any fines or smaller particles that remain entrained in the drilling fluid. The drilling fluid that is free or essentially free of any solids can be returned to the mud tanks 120 via line 155 for subsequent drilling operations. The separated solids or fines from the centrifuges 150 can be directed to the one or more disposal bins 160 via line 165 , where the contents therein can be removed for treatment and/or disposal.
In one or more embodiments, any one of the one or more zones 11 can include one or more microorganism populations to selectively remove any hydrocarbons from the separated solids that collect at the bottom thereof. As mentioned above, the hydrocarbon-containing solids or hydrocarbon contaminated solids in the used drilling fluids separate and settle at the bottom of the settling system 10 while the liquid phase passes over a top portion thereof. A hydrocarbon-containing solid or hydrocarbon contaminated solid can contain as much as 99 wt % hydrocarbon. Such solids can contain of from 1 wt % to 99 wt %; or 5 wt % to 95 wt %; or 10 wt % to 90 wt %; or 15 wt % to 85 wt %; or 20 wt % to 80 wt %; or 30 wt % to 70 wt %; or 40 wt % to 60 wt %; or about 50 wt % hydrocarbon. Such solids can have a mesh size of 200 or less, such as 190 or less, 180 or less, 170 or less, 160 or less, 150 or less, 140 or less, 130 or less, 120 or less, 110 or less, 100 or less, or 50 or less.
The solids are typically slurried in the bottom of the settling system 10 with some of the drilling fluid that remains in the bottom. The microorganisms can convert the hydrocarbons on or entrained in the solids into carbon dioxide, water, and/or biomass. The resulting biomass can be disposed or further converted to useful energy. For example, the biomass can be used in conjunction with a gasification system to produce a syngas.
Suitable microorganisms have a particular appetite for hydrocarbons. As such, the microorganisms are selective toward hydrocarbons and not drilling fluids. Illustrative microorganisms include but are not limited to bacteria and fungi. Preferred microorganisms are commercially available from Rapid Energy Services.
As used herein, the term “drilling fluid” refers to any fluid that is not a hydrocarbon that is used in hydrocarbon drilling operations, including muds and other fluids that contain suspended solids, emulsified water or oil. The term “mud” as used herein refers to all types of water-base, oil-base and synthetic-base drilling fluids, including all drill-in, completion and work over fluids.
FIG. 1B depicts a plan view of an illustrative settling system 10 for separating solids from a drilling fluid, and FIG. 2 depicts a partial cross section view of the settling system 10 , according to one or more embodiments. The settling system 10 can include one or more settling tanks or housings 12 arranged in parallel or series. Each settling tank 12 can include a first end wall 8 , a second end wall 9 , side walls 13 , and a bottom 19 . The settling tank 12 can have a shape that is rectangular, square, spherical, or the like. In one or more embodiments, the settling tank 12 is rectangular having a length to width ratio of at least 5:1 (5 to 1), such as 6:1; 7:1; 8:1; 9:1; or 10:1. The height of the settling tank 12 can vary depending on the volume of drilling fluid to be processed. In one or more embodiments, the settling tank 12 has a height of about 1 foot or more, such as 3 ft, 5 ft, or 10 ft or more. In one or more embodiments, the settling tank 12 has the capacity to handle at least 10,000 gallons of fluid, such as 12,000 gallons or more, 15,000 gallons or more, or 20,000 gallons of more.
In one or more embodiments, the settling tank 12 can include two or more dividing or transverse walls 15 (three are shown) defining two or more zones therebetween. In one or more embodiments, a first transverse wall 15 can define the receiving zone 14 adjacent to the first end wall 8 ; a second transverse wall 15 can define the collecting zone 16 adjacent the second end wall 9 ; and a third transverse wall 15 can define the two intermediate zones 18 between the receiving zone 14 and the collecting zone 16 . The transverse walls 15 can define and separate the receiving zone 14 , intermediate zones 18 , and collecting zone 16 , which are within the tank 12 . Each transverse wall 15 can have an aperture or opening 23 located near or at the top thereof. In one or more embodiments, each opening 23 can be approximately 12 inches high by 18 inches wide. A flow-restricting baffle 22 can be mounted on the downstream side of each transverse wall 15 and can be aligned with the opening 23 .
In one or more embodiments, the settling system 10 can include one or more mixing zones 36 disposed or otherwise attached to the tank 12 at an end opposite the receiving zone 14 . The mixing zone 36 can contain one or more mixers 37 , as best depicted in FIG. 2 . As discussed in more detail below, the used drilling fluid having solids disposed therein can be mixed with one or more additives or agents in the mixing zone 36 to facilitate separation of the solids from the liquids. For example, the mixer 37 can be used to prepare a flocculating chemical agent that assists in settling solids from the drilling fluid. In one or more embodiments, the microorganisms can be added to the drilling fluid within the mixing zone 36 .
The used drilling fluid containing one or more solids can be collected in the holding tank 24 . The drilling fluid can be pumped or allowed to gravity flow from the holding tank 24 into the receiving zone 14 and can be directed towards the flow-reversing barrier 20 via the inlet 26 . In one or more embodiments, the used drilling fluid can be sent directly to the receiving zone 14 . Within the receiving zone 14 , the fluid flow is impeded or stopped by the flow-reversing barrier 20 and reversed around the side panels. The flow-reversing barrier 20 can be supported by a bar 40 that can run transverse across the top of the settling tank 12 . The flow-reversing panel 20 can be best understood with reference to FIGS. 4-7 . The reversal of fluid flow causes heavier solids to settle to the bottom 19 of the settling tank 12 , within the troughs 38 and 60 . As the fluid level rises in the receiving zone 14 , the fluid can overflow into the adjacent downstream intermediate zones 18 through the openings 23 in the transverse walls 15 . The fluid that flows through the openings 23 encounters the flow-restricting baffles 22 and deflects downwards to the bottom 19 of the tank 12 . The flow of the fluid through the baffle 22 causes solids in the fluid to settle to the bottom of settling tank 12 . Fluid can flow from zone to zone, by passing through successive baffles 22 in each transverse wall 15 , until the fluid reaches the collecting zone 16 . Fluid can be withdrawn from the collecting zone 16 , by the pump 34 , to be used again in the drilling operations, recycled to the holding tank 24 , and/or the receiving zone 14 .
The solids that have settled to the bottom 19 of settling tank 12 can be conveyed by the augers 30 and 31 through the troughs 38 and 60 towards the collecting zone 16 . The augers 30 and 31 can expel a slurry of solids and fluid through the outlets 32 on the end wall 9 . The augers 30 and 31 can be rotated by drive mechanism 28 . The interaction between augers 30 and 31 and the drive mechanism 28 can be best understood with reference to FIG. 3 . In one or more embodiments, the outlets 32 can be coupled to one or more pipes 33 . Each pipe 33 can be about 10 inches in diameter. The pipes 33 can extend to intersect with the plenum 56 . The plenum 56 can be made of 10 inch diameter pipe. The plenum 56 can have one or more end covers 57 . The end covers 57 can be removable to allow for cleaning-out of the plenum 56 . The plenum 56 can receive the slurry discharged from the outlets 32 and direct the slurry to the centrifuge 150 via the discharge ports 58 . The ports 58 can be about 4 inches in diameter and can be connected via tubes, pipes or hoses (not shown) to a pump (not shown) to transfer the slurry to the centrifuge 150 .
In one or more embodiments, drilling fluid can be skimmed from the collecting zone 16 and mixed with one or more chemicals, agents, and/or microorganisms in the mixer 37 . The resulting mixture can be pumped via pump 34 to the receiving zone 14 , i.e. recycled, to mix with the received drilling fluid and assist in the settling of solids contained therein. In one or more embodiments, the settling system 10 can include a walkway or grating 64 . The walkway or grating 64 can be mounted on a sidewall 13 to permit an operator to inspect the fluid as it passes through settling tank 12 . One or more sampling stations for collecting and measuring the hydrocarbon content of the slurry can be located along the sidewall 13 .
Referring to FIG. 3 , the bottom wall 19 of the settling tank 12 in combination with one or more inverted V-shaped ribs 62 can form one or more troughs (two are shown 38 , 60 ) that run lengthwise along the tank 12 from the first end wall 8 to the second end wall 9 . In troughs 38 and 60 , respectively, one or more augers (two are shown 30 , 31 ) can be used to move settled solids towards the outlets 32 located on the second end wall 9 . In at least one specific embodiment, each auger 30 and 31 can be 10 inches in diameter and have a pitch of 10 inches. The augers 30 and 31 can be operated at any speed depending on the requirements of the drilling operation. For example, the augers 30 and 31 can be designed to turn at approximately 9 revolutions per minute or more.
Each drive mechanism 28 can include an electric motor in the 2 to 3 horsepower range coupled to a gearbox (not shown). The output of the gearbox can be coupled to each auger via a belt and pulley system (not shown). To synchronize the augers 30 and 31 to turn at the same rate, each auger 30 and 31 can have a chain sprocket and can be coupled to one another via a drive chain (not shown). It should be obvious to one skilled in the art that drive mechanism 28 can also use an internal combustion engine or a hydraulic drive system as the motive power to turn the augers. It should also be obvious that the gear ratio of the gearbox and the pulley sizes are dependent on the type of motive power used in order to obtain the desired turning rate of the augers 30 and 31 .
Referring to FIGS. 4 , 5 , 6 and 7 , the flow-reversing barrier 20 can have a vertical main back panel 46 and two vertical side panels 42 perpendicular to the back panel 46 . The barrier vertical main back panel 46 and the two vertical side panels 42 can form a U-shaped structure. The flow-reversing barrier 20 can also have a bottom plate 44 disposed between the vertical side panels 42 . The bottom plate can extend from the back panel 46 and along the bottom edge of the vertical side panels 42 . The top of the flow-reversing barrier 20 can be supported by the support bar 40 . The bottom plate 44 can rest on top of the v-shaped rib 62 . One or more struts 41 can further support the flow-reversing barrier 20 . The struts 41 can extend diagonally upward from the rib 62 to the bottom edge of the back panel 46 . The top of the flow-reversing barrier 20 can be substantially flush with the top of the tank 12 .
Referring to FIGS. 8-11 , each flow-restricting baffle 22 can include a vertical back plate 52 and two vertical side walls 50 perpendicular to the vertical back plate 52 . The vertical side walls 50 are preferably arranged in a U-shape. In one or more embodiments, each vertical side wall 50 can be approximately 24 inches high by 8 inches wide. Each vertical side wall 50 of the flow-restricting baffle 22 can have two or more horizontal openings (five are shown) 54 stacked vertically on side wall 50 . In one or more embodiments, each horizontal opening can be approximately 6 inches wide by 2 inches high. When the fluid encounters the flow-restricting baffles 22 , as described above, the fluid will strike the vertical back plate 52 . Fluid can also pass through the slots 54 in the side walls 50 of the flow-restricting baffle 22 . The interaction between the fluid and vertical back plate 53 and slots 54 can increase the rate at which solids are removed from the fluid.
The settling system 10 can incorporate the use of microorganisms to help to remove hydrocarbons from the solids deposited on the bottom 19 of settling tank 12 . The microorganisms can be located within the troughs 38 and 60 at the bottom of the settling tank 12 . After a given period of time, i.e. a sufficient time for the microorganisms to convert the hydrocarbons therein to water and carbon dioxide, the augers 30 and 31 can be used to empty the tank 12 . A water flush can also be used. Afterwards, the tank 12 can be re-loaded with a fresh microorganism population and ready to process another batch of used drilling mud with cuttings.
The bioremediation of the solids in the settling tank 12 can also be continuous by employing two trains of settling tanks 10 working in parallel. One tank 12 can be off-line in clean-out mode while the other tank 12 can be in operation. This allows one tank 12 to operate at all times while the other is being flushed and/or re-loaded with the bioremediation material.
The bioremediation process can be controlled by controlling the temperature, pH, and moisture levels within settling tank 12 . In addition, the augers 30 and 31 can be useful in the bioremediation process by providing mechanical agitation to stimulate the microorganism population. The augers 30 and 31 can be co-rotating or counter-rotating depending on the amount and/or degree of agitation desired within the settling tank 12 . The moisture level can be controlled by adding or removing water to the various zones of the settling tank 12 . Other nutrients can also be added to the settling tank 12 , if needed, to accelerate or enhance the remediation process and/or to control the pH of the hydrocarbon contaminated drill cuttings.
In one or more embodiments, the microorganism population can be located in the collecting zone 16 . After the solids have had sufficient time to settle toward the bottom 19 of the tank 12 , the augers 30 and 31 can be activated to push the settled slurry to the collecting zone 16 , as described above. In the collecting zone 16 , the microorganisms can contact the solids slurry and degrade the hydrocarbon contaminated solids. In this configuration, the settling system 10 can be operated continuously with only a single tank 12 . For example, the single settling tank 12 can have zones 14 and 18 with enough capacity to handle a rate of used drilling fluid that is commensurate with the rate of remediation in the collecting zone 16 .
In one or more embodiments, the system 10 can accommodate a flow rate of drilling fluid in the range of 1 to 500 gallons per minute. It should be obvious to those skilled in the art that the size of the settling tank 12 and the volume of each zone is a function of the volume of drilling fluid to be recycled and the amount of solids that need to be removed from the drilling fluids to facilitate their reuse. The size and dimensions of the settling tank 12 can be scaled larger or smaller, accordingly, to suit the associated drilling operation. The number of transverse walls within the settling tank 12 can be varied, as necessary, to accommodate the volume of drilling fluid required for the drilling operations.
Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
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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Apparatus and methods for bioremediating hydrocarbon contaminated solids. The method can include introducing a slurry comprising one or more drilling fluids and one or more hydrocarbon contaminated solids to a settling system. The settling system can include one or more housings having a receiving compartment at a first end thereof and a collecting compartment at a second end thereof. A barrier can be disposed in the receiving compartment, and at least one wall can be disposed transversely in the housing between the receiving and collecting compartments. The wall can have at least one aperture formed therethrough and at least one flow-restricting baffle disposed thereon, wherein the one or more baffles extend perpendicularly from the wall. The separated hydrocarbon contaminated solids can be contacted with one or more microorganism populations disposed between the receiving compartment and the collecting department.
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This Application claims the benefit of U.S. Provisional Application No. 61/892,005, filed Oct. 17, 2013.
FIELD OF THE INVENTION
The present invention relates generally to locks and to other security devices that use locks and locking mechanisms. The present invention also relates to air brakes and air brake securing devices. More specifically, the present invention relates to a tamper-proof air brake securing device and assembly that is used with air brake control knobs of the type that are mounted to the dashboard of a tractor vehicle and are used to release the air brakes of the vehicle, which brakes are used to hold a parked tractor, or a parked tractor-trailer combination, against movement.
BACKGROUND OF THE INVENTION
Air brakes have long been used on heavy duty vehicles for purposes of efficiency and ease of replenishment, since air is always available. In the case of air brakes, pressurized air is used for braking and for preventing vehicles from being moved. In the case of the latter, air brakes prevent vehicle movement by locking the wheels of the vehicle. Such air brakes are set or engaged typically by pulling an air control knob of the air brake plunger outwardly from the dashboard and disengaged by pushing the knob inward or toward the dashboard. Two knobs are typically provided. One knob controls the brakes of the tractor. The other knob controls the brakes of the trailer. The function of the knobs is to control the flow of air for setting or releasing the parking brakes.
One problem with such air brake systems is that the air brake actuation knobs can be tampered with. In order to prevent this type of tampering, devices have been attempted in an effort to disable or prevent each control knob from being actuated.
SUMMARY OF THE INVENTION
What is needed is a device or assembly for securely and inexpensively locking the air brake actuation knobs to prevent the knobs from being actuated. The present invention provides such an assembly that, when used properly, helps to prevent the air brake actuation knobs from being actuated. The present invention provides for a unique locking assembly having a number of components that form such assembly. The air brake lock in accordance with the present invention is a theft-prevention device that mounts over the air brake knobs on the dash of a semi-truck cab. The air brake lock assembly of the present invention is installed between the dash and the knobs and, when locked, the assembly prevents the knobs from being pushed in. If the air brake knobs cannot be pushed back in, the air brake will remain locked and the truck and trailer will remain immobile. In one embodiment of the present invention, the assembly includes a base and an enclosure for each brake knob. An air brake lock is disposed between the knobs such that the knobs can be selectively locked and unlocked. In one embodiment, the assembly is spring-loaded. In another embodiment, the assembly is not spring-loaded. Other alternative embodiments are disclosed as well, all with the goal of creating a product that is easy to install and easy to operate. Features of one alternative embodiment may also be incorporated into another embodiment and such is not a limitation of the present invention.
The foregoing and other features of the air brake lock assembly of the present invention will be apparent from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of the first embodiment of an air brake lock assembly that is constructed in accordance with the present invention.
FIG. 2 is a perspective view of the assembly shown in FIG. 1 and illustrating a cross-sectioned view of the assembly structure.
FIG. 3 is a perspective view of the top of a portion of the assembly shown in FIG. 1 .
FIG. 4 is a perspective view of the bottom of that portion of the assembly shown in FIG. 3 .
FIG. 5 is another perspective view of the top of the assembly shown in FIG. 1 and showing one knob enclosure and spring in an exploded view.
FIGS. 6 and 7 are perspective views of the bottom of the assembly shown in FIG. 1 and showing the locking plate installed in the first embodiment of the assembly.
FIGS. 8A through 8C are perspective views showing the steps in assembly of the brake lever knobs in accordance with the present invention.
FIG. 9 is a perspective view of the second embodiment of an air brake locking assembly that is constructed in accordance with the present invention.
FIG. 10 is a perspective view of the assembly shown in FIG. 9 and illustrating a cross-sectioned view of the assembly structure.
FIG. 11 is an enlarged perspective view of a first knob enclosure constructed in accordance with the present invention.
FIG. 12 is an enlarged perspective view of a second knob enclosure constructed in accordance with the present invention.
FIG. 13 is a further enlarged and exploded perspective view of the assembly shown in FIG. 1 .
FIG. 14 is a top perspective view of a second embodiment of an air brake lock assembly that is constructed in accordance with the present invention.
FIG. 15 is an exploded perspective view of the assembly shown in FIG. 14 .
FIG. 16 is a bottom perspective view of a portion of the assembly shown in FIG. 14 .
FIG. 17 is a top perspective view of a third embodiment of an air brake lock assembly that is constructed in accordance with the present invention.
FIG. 18 is an exploded perspective view of the assembly shown in FIG. 17 .
FIG. 19 is an enlarged partial cross-sectioned view of a portion of the assembly shown in FIG. 17 .
FIG. 20 is a bottom perspective view of a portion of the assembly shown in FIG. 17 .
FIG. 21 is a top perspective view of a fourth embodiment of an air brake lock assembly that is constructed in accordance with the present invention.
FIG. 22 is an exploded perspective view of the assembly shown in FIG. 21 .
FIGS. 23A and 23B are enlarged partial cross-sectioned views of portions of the assembly shown in FIG. 21 .
FIG. 24 is another enlarged partial cross-sectioned view of a portion of the assembly shown in FIG. 21 .
FIG. 25 is a side elevational view of the assembly shown in FIG. 21 .
FIG. 26 is a top perspective view of the assembly shown in FIG. 21 and illustrating an installation shim used with the assembly.
FIG. 27 is top perspective view of a fifth embodiment of an air brake lock assembly that is constructed in accordance with the present invention.
FIG. 28 is a greatly enlarged view of one of the knob enclosures of the assembly shown in FIG. 27 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in detail, FIG. 1 is a perspective view showing a portion of a first preferred embodiment of the air brake lock assembly, generally identified 10 , that is constructed in accordance with the present invention. FIG. 13 is an exploded perspective view of the same assembly 10 . Unlike an air brake button housing of the type that is known in the art, the assembly 10 is composed of a knob enclosure 30 , 40 for each knob 130 , 140 , respectively, a lock subassembly 50 and a housing 20 that packages all of these components. Conventionally, there is provided a square knob enclosure 30 and an octagonal knob enclosure 40 , the respective knobs 130 , 140 being associated with them. The square knob 130 is used to control the brakes of the semi-truck and is yellow in color whereas the octagonal knob (or “octo knob” as may be used herein) is red and is used to control the brakes of the semi-trailer.
The air brake lock assembly 10 is operated by turning a key 51 that is inserted into a lock cylinder 52 of the lock subassembly 50 to provide “locking” and “unlocking” action to the assembly 10 . The lock cylinder 52 has a disc shaped locking plate 54 mounted to a bottom or back side 53 of the cylinder 52 . See FIGS. 2 and 6 . The locking plate 54 is bent in such a way that its cam-like outer edges 55 are inclined creating a helical profile. See also FIG. 7 . The locking plate 54 is positioned in the housing 20 so the outer edges 55 of the plate 54 rest in slots 31 , 41 that are located on the sides 32 , 42 of the knob enclosures 30 , 40 , respectively. See FIG. 11 , for example.
When the lock cylinder 52 is turned 90° back and forth, the outer inclined edges 55 of the locking plate 54 push against the knob enclosures 30 , 40 , thereby toggling the enclosures “in” and “out.” When the knob enclosures 30 , 40 are toggled out, the air brake knobs 130 , 140 are pushed “out” into the “lock” position. See FIG. 2 . When the knob enclosures 30 , 40 retract back “in,” the knobs 130 , 140 can also be pushed back into the “unlocked” position.
As illustrated in FIGS. 2 and 5 , the first embodiment of the assembly 10 is a spring loaded concept. That is, this first embodiment has springs 132 , 142 that provide additional force to push the brake knobs 130 , 140 outwardly. In this way, the load on the lock cylinder 52 is reduced, such as where a substantial amount of force is needed to move the air brake levers (not shown) outwardly. As shown, the springs 132 , 142 and knob enclosures 30 , 40 are placed into two corresponding sockets 23 , 24 of the housing 20 . See also FIG. 3 .
As shown in FIGS. 6 and 7 , the housing 20 is then flipped upside-down in order to install the locking plate 54 to the lock cylinder 52 . The locking plate 54 drops into the middle of the housing 20 and is then turned to engage the plate edges 55 with the corresponding slots 31 , 41 on the knob enclosures 30 , 40 . The locking plate 54 is then secured with a machine screw or other fastener 58 which threads into the back of the lock cylinder 52 . The installed locking plate 54 retains the knob enclosures 30 , 40 and springs 132 , 142 , respectively, in the housing 20 . It should also be noted in FIG. 7 that each of the sockets 23 , 24 includes an inwardly curved portion 25 , 26 , respectively, the curved portions 25 , 26 further comprising openings 27 , 28 . It is the openings 27 , 28 that allow a portion of the knob enclosures 30 , 40 to be exposed such that the outer edges 55 of locking plate 54 can engage them.
As illustrated in FIGS. 8A through 8C , the knobs 130 , 140 of the brake levers are unscrewed from each respective shaft 131 , 141 . With the lock assembly 10 in the unlocked position, the housing 20 slides over lever shafts 131 , 141 , and the knobs 130 , 140 are screwed back down. When the lock cylinder 52 is returned to the locked position, the knob enclosures 30 , 40 advance up and around the respective knobs 130 , 140 , preventing them from turning and becoming unscrewed.
Where the force needed to push the levers out is small enough, additional springs may not be needed to reduce the load on the lock cylinder 52 . In this case, which is a second embodiment of the assembly, generally identified 110 , the springs can simply be eliminated, which will result in the entire package being slightly more compact. See FIGS. 9 and 10 . The tooling should also be a little less complex in this second embodiment, as locating features for the springs are eliminated from other components. The remainder of the assembly procedure for the “spring-less” design is exactly the same as it is in the spring loaded concept of the first embodiment. The only difference is that the spring installation step is omitted.
Lastly, there are several options for molding the knob enclosures 30 , 40 . For example, one enclosure 140 design that is shown in FIG. 11 requires slightly more complex and expensive tooling that uses shutoffs to create the undercut slot 41 on the side 42 , but doesn't require any secondary operations. Another enclosure 44 design requires much less complex tooling without any shutoffs. This design, however, does require an additional secondary operation to cut the slot 45 in the side 47 after the part is molded.
Referring now to FIGS. 14 to 16 , a third preferred embodiment of the air brake lock assembly, generally identified 210 , that is constructed in accordance with the present invention is illustrated. Specifically referring to FIG. 16 , it will be seen that the assembly 210 comprises a “sliding lock plate” configuration. This embodiment is similar to the prior embodiments in that the assembly 210 includes a housing 220 , a square knob enclosure 230 , an octo knob enclosure 240 and a lock cylinder 250 . Referring now to FIG. 15 , it will be seen that the lock cylinder 250 includes a central portion that can be used to secure the lock cylinder 250 to the housing 220 using a lock cylinder nut 251 that is disposed to the inner side of the housing 220 . The lock cylinder 250 also comprises a bottom portion, or “tail,” 252 that is shaped to engage an aperture 262 defined within a cam plate 260 . The cam plate 260 is secured to the tail 252 of the lock cylinder 250 using a lock cylinder screw 255 and a lock washer 257 , or other suitable fastening means.
The assembly 210 further comprises a bottom plate 270 which effectively “captures” two locking plates 280 within the housing 220 . The bottom plate 270 is affixed to the housing 220 by use of fasteners, such as screws 271 . The bottom plate 270 has a central aperture 272 that is flanked to each side with opposing side apertures 274 . The side apertures 274 are profiled to match the shaft profiles of the knob enclosures 230 , 240 such that the shafts 232 , 242 of the knobs 230 , 240 can pass through them. Disposed between the bottom plate 270 and the housing 220 are the locking plates 280 , each plate 280 has somewhat of an H-shape to it and is identically configured to the other.
Referring now to FIG. 15 , it illustrates the parts whereby the locking plates 280 are captured within the housing 220 . As shown, the cam plate 260 is mounted to the tail 252 of the lock cylinder 250 . The cam plate 260 has cam-like outer edges 264 that functionally cooperate with apertures 282 disposed at a first side 284 of each locking plate 280 . Each locking plate 280 further comprises an opposing second side 286 that similarly comprises an aperture 288 defined in it. In application, the cam plate 260 slides the two locking plates 280 back and forth from an unlocked position to a locked position. With that action, the second side 286 of each locking plate 280 slides under a knob enclosure 230 , 240 to prevent the knobs (not shown) from being pushed downward.
Referring now to FIGS. 17 to 20 , a fourth preferred embodiment of the air brake lock assembly, generally 310 , that is constructed in accordance with the present invention is illustrated. The assembly 310 of the fourth preferred embodiment comprises an adjustable height arrangement. This embodiment likewise has a housing 320 , which comprises a housing subassembly 322 having an upper housing 324 and a lower housing 326 . The assembly 310 also comprises a square knob enclosure 330 , an octo knob enclosure 340 , a lock cylinder 350 and a lock cylinder insert 356 . Referring now to FIG. 18 , it will be seen that the lock cylinder 350 is inserted into the circular aperture 355 of the cylinder insert 356 , the cylinder insert 356 fitting within an aperture (not shown) of the housing 310 and extending into the housing 310 . As with the prior embodiment, the lock cylinder 350 comprises a tail 352 the end of which is engaged with a locking cam 360 . The locking cam 360 is flanked by two locking plates 380 , all of which is held in place by a spacer block 370 . Lower plates 390 are disposed below the spacer block 370 but within the lower housing 326 .
In this configuration, the housing subassembly 322 consists of the upper and lower housings 324 , 326 , respectively, which can “telescope” in and out from each other to allow for an adjustable height of the housing 320 . Set screws 321 located in each of the four corners of the housing subassembly 322 ensure that the housing height can be adjusted and remain secure in a set position. See FIG. 19 . The sliding locking plates 380 conceal the set screws 321 when the assembly 310 is in the “locked” position. This ensures the assembly 310 cannot be adjusted to a lower position such that the knobs (not shown) and the air brake security assembly 310 can be removed.
Referring now to FIG. 20 , it shows that the locking cam 360 was modified from a sheet metal plate to a cast or molded cam to provide better contact with the locking plates 380 . Functionally, the locking cam 360 and the locking plates 380 operate substantially the same as the prior assembly 210 operated, the locking cam 360 having cam-like outer edges 364 that functionally cooperate with apertures 382 disposed at a first side 384 of each locking plate 380 .
Referring now to FIGS. 21 to 26 , a fifth preferred embodiment of the air brake lock assembly, generally 410 , that is constructed in accordance with the present invention is illustrated. The assembly 410 of the fifth preferred embodiment comprises a contoured lower housing arrangement. Specifically, this embodiment also has a housing 420 , which comprises a housing subassembly 422 having an upper housing 424 and a lower housing 426 . The assembly 410 also comprises a square knob enclosure 430 , an octo knob enclosure 440 , a lock cylinder 450 and a lock cylinder insert 456 . Referring now to FIG. 22 , it will be seen that the lock cylinder 450 is inserted into the circular aperture 455 of the cylinder insert 456 , the cylinder insert 456 fitting within an aperture (not shown) of the housing 420 and extending into the housing 420 . As with the prior embodiment, the lock cylinder 450 comprises a tail 452 the end of which is engaged with a locking cam 460 . The locking cam 460 has the same two locking plates 480 to either side of it, all of which is held in place by a spacer block 470 . These plates 480 function in the same way that their previously-discussed counterparts 280 , 380 function relative to the assemblies 210 , 310 , respectively. Lower plates 490 are disposed below the spacer block 470 but within the lower housing 426 .
In this modified configuration, the housing subassembly 422 consists of the upper and lower housings 424 , 426 , respectively, and housing springs 428 to hold the lower housing 426 tightly against adjustment set screws 421 to prevent the housing 410 from vibrating and moving around. Specifically, the housing springs 428 push the upper housing 424 upwardly against the set screws 421 whereas the adjustment screws 421 push the lower housing 426 downwardly to increase the overall height of the assembly 410 . See FIGS. 23A and 23B .
Further in this embodiment, and as is shown in FIG. 24 , knob enclosure springs 432 , 442 were added in the housing subassembly 422 to ensure that the enclosures remain seated tightly against the air brake knobs 430 , 440 . That is, the knob enclosure springs 432 , 442 push the knob enclosures 430 , 440 upward against the air brake knobs (not shown). It should also be noted that the contour of the lower housing 426 was modified to fit both older and newer Freightliner® truck dashes (FREIGHTLINER is a registered mark of Daimler Trucks North America LLC). See FIG. 25 . As shown in FIG. 26 , an installation shim 400 is used to ensure that the locking plates 480 are not “pinched” to the point of binding when the housing 410 is adjusted tightly between the knobs and the dash (also not shown).
Referring lastly to FIGS. 27 and 28 , a sixth preferred embodiment of the air brake lock assembly, generally 510 , that is constructed in accordance with the present invention is illustrated. The assembly 510 of the sixth preferred embodiment comprises a modified knob enclosure arrangement. Specifically, a lip 533 , 543 was added to the outer perimeter 532 , 542 of the knob enclosures 530 , 540 , respectively, to provide more material for the operator to grip the knobs (not shown). Snap features (also not shown) were also added to secure the knobs in the knob enclosures 530 , 540 .
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details disclosed and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept.
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An air brake lock assembly helps to prevent air brake actuation knobs from being actuated. The air brake lock in accordance with the present invention is a theft-prevention device that mounts over the air brake knobs on the dash of a semi-truck cab. It is installed between the dash and the knobs and, when locked, the assembly prevents the knobs from being pushed in. If the air brake knobs cannot be pushed back in, the air brake will remain locked and the truck and trailer will remain immobile. In one embodiment of the present invention, the assembly includes a base and an enclosure for each brake knob. An air brake lock is disposed between the knobs such that the knobs can be selectively locked and unlocked. In one embodiment, the assembly is spring-loaded. In another embodiment, the assembly is not spring-loaded.
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RELATED APPLICATIONS
[0001] This application claims the Paris Convention priority of U.S. Provisional Application No. 60 / 737 , 608 entitled “Novel Enhanced Pool Drain Safety Method and Device,” filed Nov. 17, 2005, the contents of which are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] The present disclosure relates to safety devices for pools. In particular, the present disclosure relates to a pool drain safety device and related methods. Several attempts to prevent hair and clothing entanglement in drains have been attempted. These include providing drain systems with sharp edges on which the swimmer may sever tangled hair. Other attempts include grating devices that do not allow hair and clothing to enter the drain. However, such highly exclusive filtration gratings significantly restrict the flow of water into the drain or require substantial surface area, reducing the efficiency of the pool circulation system. Thus, there has been a longstanding need for a system that does not restrict the flow of water into the drain and that cuts entangled objects without requiring the swimmer's intervention. However, none of these devices address or overcome those issues ameliorated by the present invention.
[0003] The following references are relevant to attempts to address the problem: U.S. Pat. Nos. 4,868,984; 5,031,320; 6,088,842; 6,751,814; and 6,810,537, as well as published Patent Application US 2004/0093666, each of which is incorporated by reference as if fully set forth herein.
SUMMARY
[0004] The novel enhanced pool drain safety device of the present disclosure increases safety around pools and prevents unnecessary drowning. The apparatus is disposed in a pool drain system and has at least one blade connected to an axle and moved by the suction force provided by the filter system. As water moves from a pool to an intake duct via a drain, the combination of moving water and vacuum force turns blades, which cut foreign materials, such as hair, that comes through the drain grating.
[0005] The present disclosure relates to a device comprising at least one movable blade disposed in a pool drain, wherein the force of water causes the blade to move.
[0006] Similarly disclosed is a method for cutting foreign objects coming into a pool drain system comprising providing at least one moveable blade disposed in a drain system, wherein the at least one moveable blade cuts foreign objects entering the drain system.
[0007] Finally, a business method of increasing safety in water recreation environments is disclosed comprising providing at least one moveable blade disposed in a drain system, allowing the at least one moveable blade to cut at least one foreign object introduced by a human into the drain system that prevent the human from surfacing, wherein the cutting of the at least one foreign object allows the human to surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
[0009] FIG. 1 is a schematic of an embodiment of the pool drain safety device system of the present disclosure;
[0010] FIG. 2 is a perspective view of an embodiment of the pool drain safety device;
[0011] FIG. 3 is a side view of an embodiment of the pool drain safety device;
[0012] FIG. 4 is a top view of an embodiment of the pool drain safety device;
[0013] FIG. 5 is a bottom view of an embodiment of the pool drain safety device; and
[0014] FIG. 6 is a perspective view of an embodiment of the pool drain safety device of the present disclosure.
DETAILED DESCRIPTION
[0015] As used in the present disclosure, “pool” shall be understood to mean any artificial or natural body of water connected to a drain system where a swimmer's hair, clothing, or other objects that may be sucked into the drain system.
[0016] The present inventor has solved a long-standing need by providing a simple and mechanically elegant solution to the issue of pool drains becoming fouled with, for example, human hair and clothing.
[0017] The present disclosure is directed to an enhanced swimming pool drain safety method and device that satisfies these needs. The following is a summary of various aspects and advantages realizable according to various embodiments of the enhanced pool drain safety method and device according to the present disclosure. It is provided as an introduction to assist those skilled in the art to more rapidly assimilate the detailed discussion of the device that ensues and is not intended to limit the scope of the claims.
[0018] A feature of the present disclosure is to release swimmers who become entangled in pool drains by cutting the swimmer's hair, clothing, and other objects attached to a swimmer as they are sucked into the drain.
[0019] An additional object of the present disclosure is to release the entangled swimmer without requiring the swimmer to perform any act. This is accomplished by providing a cutting tool that provides the force to cut the entangled objects rather than providing a tool that requires the swimmer to provide the force.
[0020] Another object of the present disclosure is to perform the cutting without requiring a motor to operate the cutting tools. This is accomplished by driving the movement of the cutting tools by the flow of water. In an embodiment, rotating blades cut objects entering the drain. The blades may be angled such that the water flowing into the intake duct applies a force to the blades, which causes them to rotate. Alternatively, a turbine may be attached to the blades to cause them to rotate by using the flow of water over the turbine. Thus, the blades would not require a separate motor to operate.
[0021] Yet another feature of the present disclosure is to maintain flow rate efficiency of a circulation system while preventing larger objects, such as swimmer's appendages, from entering the drain. By providing a drain cover with a grating that allows only water and small objects to pass, this objective is accomplished. While pool drain covers are well known in the art, its combination with cutting tools to increase swimmer safety and improve filter efficiency comprises a novel system without compromising the function of the drain or the flow rate of the water moving through it.
[0022] The present disclosure relates to swimming pool drain safety methods and devices. According to an embodiment of the present disclosure, a pool drain safety device is disposed at the entrance of an intake duct such as a pool drain. While a pool circulation system operates, it draws water through the drain which creates a strong suction force at the entrance to the drain. A swimmer that approaches the drain too closely risks having hair or clothing sucked into the drain among other known maladies associated with pool drain suction, such as disembodiment. Hair and clothing may get tangled in the drain after being sucked into the drain, causing death by drowning or other injuries. The present devices are designed to cut hair and clothing as they come through the drain, preventing tangling or releasing the swimmer whose hair or clothing has been caught and tangled by the suction of the drain. The device also cuts other objects entering the drain into smaller pieces for more efficient filtration later in the pool circulation system. No limitations of the applicant's subject matter are intended by this illustrative example; similar devices may be applied to other intake ducts where suction force may pose a danger due to the potential for hair or clothing entanglement.
[0023] In the United States, drowning is the second leading cause of accidental death among children under 15 years of age. Every year, hundreds of children in this age group die as a result of accidental drowning and thousands more are injured. Entanglement, which occurs when a swimmer's hair or clothing is caught by an underwater drain, causes many of these deaths and injuries. At least about 41 percent of all entanglement incidents involve the victim's hair. The need to protect children from entanglement is particularly great because since 1990, 93 percent of hair entanglement deaths and injuries have been among children ages 15 and under.
[0024] Using the system disclosed herein may therefore reduce incidence of death and injury by pool drain entanglement. The safety benefits are accomplished without substantial restriction the flow rate efficiency of the circulation system by filtering objects that may otherwise tangle in the drain 12 (see for example FIG. 1 ). Further, the present disclosure does not require its own motor for operation, but rather may be driven by the flow of water. Further still, the present disclosure does not require that the entangled swimmer perform any act to operate the device.
[0025] As shown in FIG. 1 , there is shown pool drain safety device 1 of the present disclosure used in conjunction with a pool water circulation system. Artisans are well aware of a plurality of conventional makers, systems, and types of such pool water circulation systems. During operation, the water from pool 16 is drawn through drain 12 and into intake duct 13 due to suction provided by pool pump and filter system or circulation system 14 . Pool drain safety device 1 may be installed at or near drain 12 . When circulation system 14 is engaged, water passes from pool 16 to intake duct 13 . Blades 2 of pool drain safety device 1 rotate due to the flow of water against blades 2 , which act similar to a turbine. Blades 2 may also be rotated with a dedicated turbine 11 (see FIG. 6 ). As a swimmer nears drain 12 , hair or clothing that enters the drain are cut by blades 2 , preventing them from tangling in drain 12 and holding the swimmer under water. No limitations on blade shape and configuration are intended by the demonstrative embodiments shown.
[0026] Turning now to an embodiment shown in FIG. 2-5 , a pool drain safety device 1 is shown. Pool drain safety device 1 comprises a plurality of blades 2 connected to axle 4 . The blades 2 extend radially outward from the axle 4 , such that each imaginary line bisecting a blade 2 is substantially equidistant from the imaginary lines bisecting the adjacent blades 2 .
[0027] Cover 7 connects to rim 5 . Water is permitted to pass through cover 7 . A plurality of grating holes 8 prevent large objects from entering circulations system 14 . Nevertheless, smaller objects such as hair and clothing strings are often small enough to fit through grating holes 8 . As used in the present disclosure, cover 7 should have grating holes 8 large enough to allow fluid and small objects to freely travel through, but small enough to prevent entrance of a swimmer's digit or appendage. The exact specifications of cover 7 and grating holes 8 are well known in the art in many variations. The present disclosure is suited and applicable to many, if not all, of the current cover 7 variations used.
[0028] Rim 5 is provided of such shape and size that it conforms to the shape and size of drain 12 . Rim 5 connects to cover 7 . A plurality of support arms 6 extend inward from rim 5 and converge at the center of the area defined by rim 5 . Support arms provide support for axle 4 and blades 2 . One end of axle 4 connects to lower cavity 9 , which is disposed at the point of convergence of the support arms 6 . The other end of axle 4 connects to upper cavity 10 , which is disposed at the center of cover 7 . Thus, axle 4 is disposed in and spans the imaginary line between lower cavity 9 and upper cavity 10 . Each end of axle 4 connects to lower cavity 9 and upper cavity 10 such that axle 4 may rotate while rim 5 , support arms 6 , the cover 7 remain stationary relative to the movement of axle 4 .
[0029] According to embodiments, the devices of the present disclosure are adapted to commercially available covers 7 . According to these embodiments, rim 5 of pool drain safety device 1 is of such shape and size as to conform to the shapes and sizes commercially available covers 7 . Rim 5 connects to the commercially available cover 7 . According to embodiments, axle 4 connects solely to lower cavity 9 and does not require modification or adaptation of the commercially available covers 7 . Thus, according to these embodiments, no upper cavity 10 is provided. Instead, the lower cavity-axle-blade unit operates stably without substantial articulation with the commercially available cover 7 apart from the connection to rim 5 . According to similar embodiments, however, the inventors of the present disclosure expressly contemplate modification or adaptation of commercially available covers to successfully practice the teachings of the present disclosure. Moreover, the teachings of the present disclosure may be combined with preexisting anti-entanglement designed covers.
[0030] Because axle 4 may rotate rapidly, friction and excessive wear considerations must be taken into account. According to an embodiment, a pair of sealed bearings may be disposed in each of lower cavity 9 and upper cavity 10 to dissipate friction and extend the useful life of pool drain safety device 1 . It is intended that such a system would require little to no maintenance over the life of the drain component.
[0031] According to similar embodiment, axle 4 may be designed where it does not rotate with blades 2 . Rather, a blade sheath (not shown) to which blades 2 are connected, which extends a substantial length of axle 4 between lower cavity 9 and upper cavity 10 , rotates about axle 4 . Both axle 4 and axle sheath would be made of durable materials to provide a long functional life. To prevent friction between axle sheath and axle 4 , fluid, a lubricant, lubricious surface, or a sealed bearing system may be disposed between axle sheath and axle, according to embodiments. The actual implementation of such modifications and variations would be understood and known to a person of skill in the art.
[0032] According to embodiments, blades 2 are disposed radially outward from axle 4 , and one end of axle 4 is connected to upper cavity 10 of the cover 7 . Blade 2 connects to the other end of axle 7 . The entire blade-axle system requires no lower cavity 9 or support arms 6 , but functions rather at a free unit without the need of lower support.
[0033] One or more blades 2 are connected to axle 4 an axle sheath. Blades 2 rotate, when circulation system 14 is activated, with enough force to sever hair, clothing, and other small objects passing through grating holes 8 . Consequently, blades 2 must be strong enough to withstand cutting events, the chemical environment of pools, and extended service life. More particularly, blades 2 should be hard and sharp enough to cut hair, strings, and other objects. Similarly, blades 2 should be durable enough to withstand numerous cutting events over a long period of time. Cutting edges 3 therefore must remain sharp throughout this period. Naturally, blades 2 may be made from metals such as stainless steel; other strong, non-corrosive metals; plastics; or polymers. The choice of the particular blade material is understood and known to a person of ordinary skill in the art. The material used to make the blades 2 should not corrode, rust, or otherwise oxidize in fresh or salt water. Moreover, the blades 2 should not react or be affected by pool additives, such as chlorine, bromine, and other pool chemicals.
[0034] Cutting edge 3 of each blade 2 is oriented in the same direction as all other cutting edges 3 with respect to direction of rotation and cutting plane. The cutting plane is defined to be an imaginary cylinder, where the cylinder's radius is defined to be the greatest of the radii measured as the length of each blade 2 from the center point of axle 4 to the point on each blade 2 furthest from the center point of axle 4 . The height of the imaginary cylinder is measured as the cylinder height defined by the distance measured from the point of blades 2 closest to cover 7 to the point of blades 2 furthest from the cover 7 . The present disclosure contemplates at least one cutting plane. Cutting edges 3 defines the point where hair, clothing, and other objects are cut.
[0035] According to embodiments, cutting edges 8 of blades 2 are disposed to contact an inside surface of cover 7 during rotation of blades 2 about axle 4 . As the blades rotate, cutting edge 3 of blades moves along inside surface similar to the operation of an electric razor. As hair, clothing, or other foreign objects pass through grating holes 8 , they are sheared, such as by a scissoring effect, between the inner surface of cover 7 and cutting blade 3 before they are able to tangle and trap a swimmer or soon after a tangle is formed so that the swimmer may escape to the surface.
[0036] According to an embodiment, blades 2 are shaped and angled such that when water moves from pool 16 into the intake duct 13 , the force of the flow of water over the blades 2 turns them in the same way that water turns a turbine. Cutting edges 3 of blades 2 are oriented to be the leading edge with respect to the rotation.
[0037] Some pools have drains 12 with larger surface areas designed to reduce the suction force per area unit. For these types of drain systems, angling blades 2 to induce rotation may fail to provide the requisite blade velocity to enable blades 2 to sever hair, clothing, and other objects passing through grating holes 8 and into drain 12 . Consequently, turbine 11 must be introduced into the system to produce the requisite blade velocity to sever hair, clothing, and the other potential objects entering the circulation system. In these type systems, turbine 11 may be disposed in intake duct 13 pipes where the force of water aggregates to rotate blades 2 at sufficient speed to sever the hair, clothing, and other objects. Thus, it should be clear to artisans that turbine 11 and blades 2 need not be disposed in close proximity to each other.
[0038] According to an embodiment shown in FIG. 6 , turbine 11 is connected to axle 4 turns blades 2 . The flowing water turns the turbine 11 , which applies torque to axle 4 . Axle 4 then applies a torque to the blades 2 , which causes them to turn. Because blades 2 may rely on turbine 11 for the rotation, blades 2 need not act as a turbine and provide rotation for themselves. Thus, the shape and angle of blades 2 is then irrelevant, except with regard to flow rate efficiency. Indeed, in the exemplary embodiment shown in FIG. 6 , blades are thin to prevent inefficiencies in the flow of water and to reduce potential cavitation effects.
[0039] In addition to hair and clothing of trapped swimmers, the system of the present disclosure also cuts foreign objects small enough to pass through the grating holes 8 prior to entering circulation system 14 . Thus, the present disclosure also contemplates a device that reduces the size of matter passed into the pool pump and filter. Embodiments of this type have application to filters on ponds, aquariums, and other applications where human safety isn't always at issue, but where filters potentially suck in detritus and larger type materials through their intakes. Consequently, filtering efficiency improves by reducing the size of the filtered materials, which extends the life of filters and filtering materials, as well as prevent clogs of larger objects, such as algae and other organic matter, in the filter pipes.
[0040] Referring again to FIG. 1 and an embodiment of a method, pool drain safety device 1 automatically activates when circulation system 14 of pool 16 is activated. As water flows from pool 16 into intake duct 13 , it passes through drain cover 7 through grating holes 8 . The force of the water being sucked into intake duct 13 caused by the operation of the pump of circulation system 14 forces water to pass over blades 2 or turbine 11 , effective rotation of blades 2 . The rotation of blades 2 or turbine 11 causes blades 2 to rotate with sufficient speed to cut foreign objects, such as hair and clothing, that come through grating holes 8 . Consequently, hair and clothing that would otherwise potentially trap a swimmer under water, are severed before they tangle and trap the swimmer or soon thereafter.
[0041] Moreover, according to an embodiment of a business method, the system of the present disclosure may be provided in pool systems to increase the safety of recreators. As disclosed above, the system may be disposed in a pool. When a swimmer's hair or clothing becomes tangled in the drain due to suction force, the blades of the system will cut the hair or clothing, allowing the swimmer to surface, providing a safer environment in which to recreate.
[0042] While the apparatuses and methods have been described in terms of what are presently considered to be the most practical and effective embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims.
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The novel enhanced pool safety device of the present disclosure increases safety around pools and prevents unnecessary drowning. The apparatus is disposed in a pool drain system and had been at least one blade connected to an axle and moved by the suction force provided by the filter system. As water moves from a pool to an intake duct via a drain, the combination of moving water and vacuum force turns blades, which cut foreign materials, such as hair, that comes through the drain grating. The cutting of these materials prevents loss of life that may arise as humans and other objects become entangled in pool drains.
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This application claims priority of U.S. Provisional Application Ser. No. 60/670,564, filed Apr. 12, 2005, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Catch basins are surface-level inlets to sewer systems that serve to allow storm water waste to enter a sewer system. Drainage and storm water is typically collected in catch basins buried in the ground. Water from rain or snow flows into the catch basin, where it is then diverted to a sewer or drainage line.
Grates are usually present at the top surface of the catch basins to help reduce the amount of debris that enters the basin. Filters or traps are often employed to remove various pollutants and solids from the water, such as to minimize or eliminate offensive odors, prevent large solids from entering the catch basin, reduce pollutants, etc. Indeed, governmental regulations often dictate the acceptable levels of various pollutants such as sediment, hydrocarbons and debris. Filters or traps containing activated carbon are commonly used for this purpose. Often the filters are removable, so that they can be replaced once the flow of liquid through the filter becomes impeded due to the accumulation of retentate.
Installation and maintenance of conventional catch basin traps for catch basins is problematic. They must be strategically located to inhibit or prohibit floating pollutants from entering the drainage pipe, yet be easily installed and provide accessibility to the pipe for maintenance and replacement. Most conventional oil/gas traps are made of cast iron, which is very heavy and makes installation extremely difficult. Often drilling into the concrete surrounding the drainage pipe is necessary, which is time-consuming and difficult. Additional installation hardware may be necessary, and installers must often remain in the catch basin (generally an underground confined space that is 4 feet in diameter and seven feet high) for extended lengths of time to install the trap. In addition, conventional gas traps do not maintain an effective seal to prevent floating pollutants from entering the drain pipe.
It therefore would be desirable to provide a gas trap that is lightweight, easy to install, requiring minimal or no installation hardware, and provides a reliable seal once installed.
SUMMARY OF THE INVENTION
The problems of the prior art have been overcome by the present invention, which provides a method and apparatus for the treatment of waste water, particularly for the treatment and/or reduction of floating pollutants in storm water waste streams. The apparatus of the invention achieves a high containment level of floating pollutants compared to conventional oil/gas traps available for catch basin use.
In a preferred embodiment, the device of the invention is a catch basin trap that arrests the flow of pollutants, particularly floating pollutants. The trap is designed and installed in such a manner that a sealed system is created, ensuring that all fluid flow (e.g., storm water discharge) must pass through the trap and cannot bypass the trap due to unreliable trap attachment mechanisms or unsealed joints. Containment of floating pollutants is achieved.
In a second embodiment, the device of the invention also arrests the flow of oil and oil based products, most specifically in the event of a spill. Oil absorbing particulate in the trap expands, thereby blocking the passage of all waste water through the trap.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a catch basin;
FIG. 2 is a perspective view of a catch basin trap of the prior art;
FIG. 3 a is a first perspective view of the catch basin trap of the present invention;
FIG. 3 b is a second perspective view of the catch basin trap of the present invention;
FIG. 4 is a top view of the catch basin trap as used in a catch basin;
FIG. 5 is a side view of the catch basin trap of the present invention;
FIG. 6 is a top view of the catch basin trap of the present invention;
FIG. 7 is a front view of the catch basin trap of the present invention;
FIG. 8 is a front view of the removable cover of the present invention;
FIG. 9 is a perspective view of the removable canister of the present invention; and
FIG. 10 is a side view of the removable canister of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Catch basin traps are well known in the industry, and used in most catch basins to arrest the flow of pollutants into drainpipes and sewer lines. FIG. 1 illustrates a typical catch basin 10 . The basin 10 is typically constructed with concrete walls 11 and a concrete base 12 . At the top, typically a grate 20 or other entry means is located. Wastewater, as well as litter, oil, dirt and other pollutants, pass through the grate 20 and into the catch basin 10 . Optionally, additional entry means 30 are also located within the catch basin. Solid wastes 40 that are heavier than water settle at the bottom of the catch basin 10 . However, oil and other low density pollutants float on the top of the wastewater within the catch basin. To prevent these pollutants from entering outlet 50 , various techniques are used. As shown in FIG. 1 , a pipe having a bend so as to have its opening below the surface of the wastewater can be used to prevent the floating pollutants from entering outlet 50 .
Alternatively, as shown in FIG. 2 , a catch basin trap 100 (or hood) may be employed. The trap 100 is typically constructed from cast iron and is mounted to the concrete wall 11 of the basin 10 such that it covers the outlet 50 . Typically, the trap is held in position through the use of anchor screws. In the embodiment shown in FIG. 2 , the trap 100 has four mounting locations 110 , through which anchor screws are inserted and then secured to the concrete wall 11 .
The installation of the prior art trap shown in FIG. 2 is a long and tedious process, requiring the installer to remain in the catch basin for several hours while drilling holes into which the anchor screws will be mounted. Furthermore, since the trap is mounted to a curved concrete wall and held in position at only four locations, the trap 100 does not form a watertight seal with the concrete wall 11 . This allows some amount of pollutant to pass between the trap and wall and thereafter enter the drain outlet 50 , thereby defeating the purpose of the trap.
The device of the present invention overcomes these problems by providing a trap that is affixed to the catch basin with a water and oil tight seal, thereby preventing the flow of pollutants past the trap. FIGS. 3 a and 3 b illustrate perspective views of the present invention. FIGS. 4 through 7 illustrate the various views of the trap of the present invention. Unlike conventional traps, which are secured to the concrete wall of the catch basin, the present invention is inserted directly into the drain outlet. This allows the trap to be installed in less than 5 minutes. The trap 200 of the present invention is preferably constructed from high density polyethylene (HDPE) so as to be both durable and lightweight. The trap 210 has a longitudinal cylinder 210 , which is suitably sized and shaped to be effectively inserted into a standard drain outlet 50 . In the preferred embodiment, the longitudinal cylinder 210 has a length of approximately eight inches and a constant diameter along its length, although other lengths are possible and within the scope of the invention. Since most drain outlet pipes have a standard inner diameter of 12 inches, the outer diameter of the longitudinal cylinder must be smaller than this. In the preferred embodiment, the outer diameter of the longitudinal cylinder is between 11.25 and 11.75 inches.
Along the outer diameter of the longitudinal cylinder 210 are a series of preferably equally spaced ridges, or fins 220 . Each of these fins 220 preferably has a height of between roughly 0.25 and 0.50 inches and a thickness of roughly 0.5 mm. Thus, with the added height of the fin, the outer diameter of the cylinder as measured around the fin will exceed the inner diameter of the drain outlet. This combination of height and thickness also allows the fin to be pliable enough to bend to conform to the inner diameter of the drain outlet 50 . However, the fins are strong enough to provide a water tight and oil tight seal between the trap 200 and the inner diameter of the drain outlet 50 . The fins also serve to retain the trap in place in the drain outlet. While these dimensions are preferable, other combinations of thickness and height are also possible and within the scope of the invention. For example, the fins may also be tapered such that they are thicker at the base near the longitudinal cylinder and thinner at the far end. These fins are preferably molded into the longitudinal cylinder.
In the preferred embodiment, a plurality of fins 220 , most preferably between 4 and 6, is provided along the length of the longitudinal cylinder. A high number of fins increases the force required to extract the trap from the drain outlet, and improves the quality of the seal between the trap and the drain outlet. In the preferred embodiment, the fins are integral with the cylinder and therefore constructed from high density polyethylene. The materials of construction of the drain outlet can influence the extent to which the trap can be extracted. It is desirable that the force necessary to extract the trap be as high as possible, so as to reduce or eliminate trap failure and sealing issues. For example, reinforced concrete pipes have a relatively high coefficient of friction compared to HDPE pipes, so the force required to extract the trap from a reinforced concrete drain outlet is higher than that of an HDPE drain outlet. Accordingly, at least one additional fin may be desirable or necessary where the trap is to be installed in an HDPE drain pipe or the like in order to ensure a proper seal and retention of the trap therein.
The fins are spaced apart from one another so as not to touch even when inserted into the drain outlet. In the preferred embodiment, this spacing is approximately one inch, although other spacings are possible and within the scope of the invention. In the preferred embodiment, the longitudinal cylinder has a wall thickness of roughly 0.25 to 0.50 inches, most preferably 0.375 inches.
In an alternate embodiment, the longitudinal cylinder has one or more sealing means, such as gaskets or O-rings along its outer circumference. These sealing device create a water tight and oil tight seal between the longitudinal cylinder and the drain outlet.
The trap also comprises a rear wall 230 , perpendicular to the longitudinal cylinder 210 , to which the cylinder is affixed or integral. The rear wall 230 is preferably constructed from the same material as the longitudinal cylinder. Since the rear wall is in close proximity to the concrete wall of the catch basin when installed, it is preferably arcuate in shape. This arc should correspond to that of the concrete wall of the catch basin, and in the preferred embodiment, the radius of the arc is roughly 23.75 inches. The rear wall 230 is preferably 17 inches wide and 24 inches long. To insure that floating pollutants to do enter the drain outlet, the rear wall extends below the lower edge of the longitudinal cylinder 210 , preferably at least 8 inches below the lower edge of the cylinder. The rear wall 230 also extends above the upper edge of the longitudinal cylinder 210 , preferably at least 2 inches.
On either edge of the rear wall 230 are two side walls 240 which extend the entire length of the rear wall. These side walls extend perpendicularly from the rear wall. The lengthwise dimension of the rear wall and the side walls defines the area into which wastewater can flow as it enters the drain outlet. In the preferred embodiment, the wastewater enters the trap through an opening 250 that is roughly 17 inches long and 9 inches wide, and is preferably arranged so that the flow of water from the opening to the drain outlet makes a 90° turn.
In certain embodiments, the trap also may include a top wall 260 , which can extend from the upper edge of the rear wall and attaches to the upper edges of the side walls 240 . The top wall is intended to prevent wastewater from entering the drain outlet from above, thereby forcing all wastewater to enter the drain outlet through the previously described submerged opening 250 .
The trap may also have a front wall 270 that is preferably arcuate, similar to the rear wall. The front wall attaches to the top wall 260 and the two side walls 240 , leaving only an opening 250 at the bottom of the trap. The front wall 270 may include a removable cover 280 . The removable cover allows the operator or repairman to access the drain outlet directly. The removable cover 280 is preferably threaded, as is the front opening 290 into which the cover can be attached. To insure the water tightness of the connection, the cover 280 or front opening 290 may have a seal or other gasket. To ease in removal and reinsertion, the removable cover 280 preferably has a handle 281 , which can be molded into the plastic, as shown in FIG. 8 , or affixed externally. The removable cover 280 preferably has a radius at least as large as that of the longitudinal cylinder and also has its center aligned with that of the longitudinal cylinder.
In an alternative embodiment, the front opening 290 is used to insert a treatment canister 300 , as illustrated in FIG. 9 . The canister is adapted to enter the longitudinal cylinder by way of the front opening. As is the case with the removable cover 280 , the treatment canister has a handle 301 , which can be molded into the plastic or affixed externally. The treatment canister 300 can vary in length and in the preferred embodiment is dimensioned so as to extend past the distal end of the longitudinal cylinder. To insure a water tight and oil tight seal between the outer diameter of the treatment canister and the inner diameter of the longitudinal cylinder, sealing means, including but not limited to fins, gaskets, and O-rings, may be employed.
The treatment canister 300 is perforated at the end nearest the handle so as to allow the entry of wastewater into the canister. These region of the perforations can vary in length. A smaller region insures that the wastewater passes through the largest amount of treatment chemicals; while a larger region allows a greater rate of flow. The dimension of the perforated region is based on the implementation and the various criteria involved.
Within the canister are activated carbon pellets. These carbon pellets are well known in the art and have a long history of reliable use for the removal of hydrocarbons from the wastewater. In one embodiment, the entire volume of the treatment canister is filled with activated carbon pellets.
In a second embodiment, the treatment canister 300 is divided into several separate compartments. One compartment 310 , preferably the one closest to the handle 301 , contains activated carbon pellets for the removal of hydrocarbons as described above. A second compartment 320 , as shown in FIG. 10 , contains oil absorbing polymer pellets. These pellets rapidly expand as they absorb oil. Thus, in the event of an oil spill or similar accident, the polymer pellets absorb the oil as it passes through the second compartment. As the pellets absorb oil, they expand, thereby restricting the flow of wastewater through the canister. A sufficient amount of oil will cause the pellets to absorb to the point where they completely restrict the flow of wastewater through the canister. This then allows cleaning crews to respond and clean up the contaminants. Once the spill is contained and cleaned, the crew would then replace the treatment canister, thereby restoring the normal operation of the trap. In this way, wetlands and other drainage areas are not polluted by oil passing through the drain outlet before the spill is contained.
The compartments described above are preferably separated by a screen that is constructed of metal or plastic, such as HDPE. The above description details the use of one or two compartments; where the first is adapted to remove hydrocarbons and the second is adapted to remove and block the passage of oil. However, the invention is not limited to this embodiment. For example, additional or substitute compartments can be employed which remove specific contaminants from the wastewater.
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The present invention provides a method and apparatus for the treatment of waste water, particularly for the treatment and/or reduction of floating pollutants in storm water waste streams. The apparatus of the invention achieves a high containment level of floating pollutants compared to conventional oil/gas traps available for catch basin use. In a preferred embodiment, the device of the invention is a catch basin trap that arrests the flow of pollutants, particularly floating pollutants. The trap is designed and installed in such a manner that a sealed system is created, ensuring that all fluid flow (e.g., storm water discharge) must pass through the trap and cannot bypass the trap due to unreliable trap attachment mechanisms or unsealed joints. Containment of floating pollutants is achieved.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Ser. No. 11/335,591, filed Jan. 20, 2006 entitled Storm Drain Basin Gate System, now U.S. Pat. No. 7,234,894, issued Jun. 26, 2007.
BACKGROUND OF THE INVENTION
This invention relates generally to a gate system for use with a storm drain of the type typically found in the curb of a street. More particularly, this invention relates to such a system which during periods of low water flow is in a closed position to effectively prevent debris from entering into the storm drain, but which during periods of high water flow opens to allow the maximum amount of water to enter into the drain to alleviate the accumulation of water in the street and the surrounding areas.
What to do with excess runoff rain water has been an issue for urban planners and dwellers for a long time. Even in arid regions, the occasional heavy rainfall will create large volumes of run off that must be channeled effectively or flooding resulting in impassable roads at least or the loss of property and lives at worst may occur. In areas of high annual rainfall, effectively channeling that rainwater away from streets and homes is an absolute must.
For this reason, almost every city in the civilized world has an extensive underground storm drain system. And the most common inlet to the entire system is the ubiquitous curbside opening that is built into the sidewalk curb along the street. Those openings typically lead to a rather large underground chamber, often called a vault, at one end of which there is a conduit that leads to the main storm drain pipe that is usually set under the paved road adjacent the vault.
These drain systems have proven very effective in channeling runoff storm water away from the streets and populated areas, and usually into an adjacent river or into the ocean. However, another ubiquitous part of urban life—street debris and litter—also finds its way into the storm drain system. For example, some cigarette smokers seem to believe that their cigarette butts are not litter to be deposited in a trash can, but something that can be thrown on the ground wherever they happen to be when they must discard the cigarette—thrown into the gutter as they walk along the sidewalk, or thrown out of the car as they drive along. These cigarette butts, which are not environmentally friendly and do not naturally degrade easily, invariably end up in the drain system and then into the river or ocean into which it drains. Other trash, from paper cups to hamburger wrappers to envelops, all find their way into the gutters. drain systems and ultimately river and ocean. And this is just the man-made debris. Natural debris such as leaves and twigs are also commonly found in streets and gutters. and then make their way into the storm drain system when it rains, or when water from some other source makes its way into the street.
It is not just the introduction of these items into the drain system that is a problem. Most storm drain systems ultimately empty directly into a nearly body of water, often a river or the ocean. Also, the systems rarely include any type of intermediate water treatment facility, so what goes into the drain system usually ends up in river, lake or ocean, where it is unsightly and can be toxic.
Because the introduction of trash and other debris into the storm drain system is such a common occurrence, many street side drains are constructed with a sizeable open chamber into which the storm drain opening leads, with the conduit to the under-street pipe located at one end thereof. The purpose of this is to try to trap as much of the debris as possible in the vault, and only allow the water to run-off into the system. This has proven only partially effective. First, so much trash is often introduced into the vault that much of it gets into the system anyway. This is particularly true if there is an accumulation of trash in the vault when there is a heavy rainfall or other heavy flow of water into the vault. Second, this arrangement necessarily requires that the vault be periodically cleaned, and cleaning the vault cannot of course be done by the usual street sweeping equipment, but requires an entirely different piece of equipment with strong suction capability to literally vacuum the trash from the vault. Third, this arrangement is designed to allow the trash to accumulate in the vault in between cleanings, such that in a worst case scenario, the accumulated trash becomes so large that the drain becomes plugged wholly or partially, and flooding in the area occurs when it rains.
In light of these issues, various attempts have been made to prevent trash from getting into drain. For example, in some places, a sizeable plate has been securely attached over the drain opening, leaving only a little space for water to flow. This solution does prevent much of the trash from entering into the drain, but it also prevents much of the water as well, and essentially defeats the purpose of the large drain opening that was intended to prevent flooding during heavy water run off. Therefore, other attempts have been made to design a storm drain gate that would remain closed during periods of low water run off, but which would automatically open in periods of heavy water run off. One recent example is U.S. Pat. No. 6,972,088, to Yehuda, in which a Pivotal Gate For A Catch Basin Of A Storm Drain System is disclosed. That invention uses a rather complex system involving a rotatable paddle wheel and interconnected wires that interplay to open the gate when sufficient water begins to flow into the drain. While it appears workable, this system may not be desirable for widespread installation given its complexity, which translates into higher initial cost and higher cost of upkeep. It is a given in any piece of machinery that the more moving and complex the component parts, the more costly to manufacture and install, and the more costly to maintain, and more likely to malfunction. Other prior art devices suffer from one or more of these drawbacks. as the design goals of simplicity, ease of installation, durability, low maintenance, and high effectiveness are difficult to achieve.
Therefore, there exists a need in the art for such a simple, effective gate system.
SUMMARY OF THE INVENTION
The preferred embodiments of the invention herein depicted and described provides such a device wherein the gate portion of the system that prevents trash from entering into the vault or drain basin is kept in the closed position by virtue of a trip plate that is rotatably attached to the back of the gate portion. In one preferred embodiment of the invention, the trip plate is attached to the back lower portion of the gate portion, and is biased (in one preferred embodiment by a spring) to closed position that is, substantially perpendicular to and extending rearwardly from the gate portion in one preferred embodiment. The trip plate is prevented from moving backward (that is, away from the gate), which in one preferred embodiment is accomplished by two pins extending from the plate into a groove formed in each of a pair of bracket assemblies that are attached to the drain basin wall. Thus, when there is no-flow or low-flow of water through the gate portion onto or against the trip plate, the plate stays in position and in turn keeps the gate portion in a closed position, flush against the drain basin opening. When the flow of water increases to a predetermined point, however, the water weight on the trip plate increases to the point where the biasing is overcome, and the trip plate rotates into an open position. This releases the gate portion and allows it to open. When the water flow onto the trip plate stops or reduces to a sufficiently low flow, the water weight on the trip plate is no longer sufficient to overcome the biasing on the plate, and it rotates back into its closed position, which in turn causes the gate portion to rotate downward into its “closed” position against the drain basin opening. Also disclosed and claimed are improved and alternative apparatus for attaching the system to the storm drain basin, and for controlling the location of the trip plate.
The preferred embodiments of this invention will now be depicted and described. As will be apparent to those skilled in the art, however, there are many different ways of attaching the various components of this system to the basin, and to one another, and of creating the biasing of the trip plate, and there are too many different ways to do so to list and describe here. Such common variants, even if not specifically described, are nonetheless considered to be within the scope of this invention.
DESCRIPTION OF THE FIGURES
FIG. 1 is an exploded, perspective view of one embodiment of this invention.
FIG. 2 is a partial side view of the preferred embodiment of this invention, showing the interplay between the gate, the trip plate and the guide brackets.
FIG. 3 is a perspective view showing one of the preferred embodiments of the gate system in its closed position within the opening of a curb drain basin.
FIG. 4 is a perspective, exploded view, showing the component pieces of an alternative embodiment of this invention.
FIG. 5 is a perspective, exploded view, showing in isolation one side of one embodiment of the invention.
FIG. 6 is similar to FIG. 5 , expect that the component pieces are shown assembled, with the exception that the lag bolt by which this bracket piece is attached to the drain basis is shown in exploded view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking at FIG. 1 , it is seen that this preferred embodiment of the invention is for attachment to the inside of a curb-side storm drain basin 10 , adjacent to and providing a cover for the opening 12 that leads from the basin 10 to the street 14 through the curb 16 . It should be noted, however, that while the device of this invention is believed to find primary utility in this application, and is why the title of this invention includes a reference to a storm drain, the invention herein described and claimed is a gate system that is not limited to that one application. The device of this invention could be usefully applied to any situation where it is desired to screen particulate matter from a fluid flow through an aperture during no-flow and low-flow conditions, but to remove the screen from the aperture during high-flow conditions.
The overall system consists primarily of a gate assembly 18 , the biased trip plate 20 , trip plate brackets 22 , and the various means by which these components are attached to one another, and to the side of the basin 10 . All components of this system are preferably constructed of 304 stainless steel. Other materials, however, could be used so long as they exhibited the required strength and durability appropriate for the application in which the system is used.
Although FIG. 1 shows in an exploded, perspective view how all of the various components are connected, the interplay of the gate assembly 18 , the biased trip plate 20 and the trip plate bracket assemblies 22 can best be seen in FIG. 2 . The gate assembly 18 comprises in this embodiment a gate portion constructed of a pair of gate plates 24 and 26 that are held together by any conventional means, in this instance by nuts and bolts 28 . Of course, there are a myriad of other ways to attach the two gate plates together, such as welding, gluing, screws, rivets, brackets, etc. Also, the gate portion of assembly 18 does not have to be constructed of multiple plates, and could be of unitary construction, or could be of many individual plates.
In this embodiment, the gate plate assembly 18 is rotatably attached to the basin 10 by means of a hollow tube 30 that is attached to the top of the gate assembly 18 , a pair of side pins 32 that are slidably housed within either end of the tube 30 and which are biased outwardly of the tube 30 by means of a spring 34 that is also housed within the tube 30 and forces the pins 32 outwardly. The distal end of the pins 32 engage appropriately-sized holes 33 in the large side brackets 36 and 38 (seen in FIG. 1 , not shown in FIG. 2 ), which are in turn attached to the side of the basin 10 by conventional means—in this instance, by bolts 40 that are set into appropriated-sized holes 42 the side wall of the basin 10 on either side of the opening 10 . As will be appreciated, this arrangement allows for easy attachment and free rotatability of the gate assembly 18 to the large side brackets 36 and 38 , as one of the pins 32 can be placed into one of the holes 33 , and then the other pin 32 can be pushed inwardly, the tube 30 brought into alignment with the other hole 33 , and that pin 32 then allowed to extend into that hole 33 so that the entire gate assembly 18 is now firmly yet rotatably attached into position against the opening 12 . As will be apparent, the attachment inter-relationship between these components can be adjusted to ensure that the gate 18 is properly positioned flushly against the opening 12 .
To provide the desired screening function, the gate plates 24 and 26 have a number of holes 42 extending therethrough. These holes can be of any desired shape, size, configuration and distribution as desired under the circumstances. For example and not in way of limitation, commercial mesh screens could be used under the appropriate circumstances.
Referring now back to FIG. 2 , it will be seen that the trip plate 20 is rotatably attached to the lower end of the gate assembly 18 . Here, the attachment means provided are a pair of pins 44 attached to the side of the trip plate 20 and which communicate with appropriately sized holes 46 in small brackets 50 that are attached to the gate assembly 18 via the same nuts and bolts 28 that are used to attached gates plates 24 and 26 together. It will be appreciated, however, that the manner in which the trip plate 20 is attached to the gate assembly 18 is not limited to the means showed, and can be accomplished by any other conventional method and means whereby the trip plate 20 is securely but rotatably attached such that the trip plate 20 can rotate from a first or closed position to a second or open position.
Again looking at FIG. 2 , the interaction between gate assembly 18 , the trip plate 20 and the side bracket assemblies 22 can best be appreciated. At the distal end of the trip plate 20 , a pair of outwardly extending pins 52 communicate with an arcuate groove 54 formed in each of the bracket assemblies 22 . In a no-flow or low-flow situation in which no or very little water is entering into the storm drain through the gate assembly 18 , the trip plate 20 is biased upwardly so that the pins 52 are pressed against the top of the grooves 54 . In this embodiment, the biasing of the trip plate 20 upwardly is accomplished by a pair of torsion springs 56 (seen only in FIG. 1 ). One end of the torsion springs resides in hole 58 in the side bracket 50 and the other end of the torsion spring resides in the hole 60 in the trip plate 20 . Again, this is only one of many ways in which the trip plate 20 can be biased into its closed position, and this invention is not limited to the one method and means shown.
In this preferred embodiment, the side bracket assemblies 22 , the grooves 54 and the side pins 52 are all arranged such that in that position, the trip plate 20 extends in a horizontal fashion directly behind and perpendicular to the gate portion (that is, gate plates 24 and 26 ) on the gate assembly 18 . Thus, in this position, the interplay between pins 52 within the bracket grooves 54 , and the bracket assemblies 22 (which are attached to the side wall of the basin 10 ) has the effect of holding the gate plates 24 and 26 in a vertical, closed position, flushly against the opening 12 in the drain basin 10 .
In this preferred embodiment, the trip plate 20 will hold the gate portion of gate assembly 18 in that position for so long as the water flowing through the basin opening 12 and onto the trip plate 20 is sufficiently small that the weight of the water bearing down on trip plate 20 is insufficient to overcome the upward biasing on the trip plate 20 caused by the torsion springs 56 . As the flow of water increases, however, and the resultant force of the water acting on trip plate 20 increases, the upward biasing is overcome, and the trip plate 20 begins to rotate in a downward direction, shown by arrow 62 . As this occurs, the trip plate 20 moves out of its horizontal, perpendicular alignment relative to the gate portion of gate assembly 18 , which in turn allows the gate portion of gate assembly 18 to begin to rotate in an upward direction as shown by arrow 694 , effectively enlarging the open space to allow more water to flow into the basin. It will also be noted that as the trip plate 20 rotates downwardly, the side pins 52 travel downwardly within the grooves 54 . In one embodiment of this invention, the grooves 54 are provided with one or more detents 66 (only one of which is shown in FIG. 2 ) which act as intermediate stopping points during the downward movement of the trip plate 20 . In other words, as the water flow onto the trip plate 20 increases and its starts to rotate downward, it will encounter one of the detents 66 . The pins 52 are forced into the detent, and will tend to reside there until the water weight increases incrementally until the pins 52 are forced out of the detents 66 . This will allow for staged opening of the gate assembly 18 , and will also work to prevent fluttering of the gate assembly as the water flow ebbs and increases. It will be appreciated that the size and depth of the detents 66 must be controlled so as to not unduly hinder the movement of the trip plate in either the downward or upward direction.
As the water weight continues to increase, eventually the biasing and the detents are overcome, and the trip plate 20 will rotate entirely downward (as shown in shadow in FIG. 2 ). At this point, the trip plate 20 ceases to exercise any limiting function on the gate assembly 18 , which in turn is allowed to rotate entirely open. By appropriate sizing and placement of the brackets 50 , the side pins 44 and the other components, the gate assembly 18 can be allowed to rotate through a full 90 degrees such that it comes to rest against the ceiling of the drain basis, in which case the storm drain opening 12 is complete unobstructed, maximum flow of water into the basis is allowed, and even trip plate 20 is pulled up substantially away from the water flow.
In this preferred embodiment, once the water flow recedes, the biasing on the trip plate 20 will again be greater than the water force acting on the trip plate, and it will again rotate into its closed position, simultaneously forcing the gate portion of gate assembly 18 downward and into its closed position flush against the basin opening 12 .
Referring back to FIG. 1 , it will been seen that the trip plate bracket assemblies 22 are attached to the large side brackets 36 and 38 by nut and bolts 70 to provide added stability to the interplay between the trip plate pins 52 and the grooves 54 , the ends of the pins 52 can be fitted with washers 72 and screws 74 to ensure that the pins 52 remain within the grooves 54 at all times, even if the trip plate 20 happens to be subjected to an uneven, torquing force that might otherwise cause the pins to become dislodged from the grooves. Lastly, the overall system can include side plates 76 that are attached to the large side brackets 36 and 38 by conventional nut and bolts 78 and a simple flanged element 80 that is attached to the side bracket 38 by conventional nut and bolt 82 , and which acts as a “stop” to prevent the gate assembly 18 from being pulled open in the direction of the street.
Referring now to FIG. 4 , an other alternative embodiment is shown. This embodiment can be utilized in a wide variety of drain basins where the curb-side openings are of different width. In this embodiment there is a gate assembly 100 that has a gate portion 101 that comprises a frame 102 to which is attached a mesh material 104 . In this instance, the mesh material 104 is a section of metal grate commercially available that has apertures of the desired size and shape depending on the particulate matter to be kept from entering the basin when the gate portion 101 is in the closed position (as is shown in the FIGS.). The mesh material 104 is attached to the frame 102 by any conventional means, such as by welding. The upper portion of the frame 102 is attached to rod 106 . As shown here, the frame 102 is welded to circular rod 106 , but any other attachment means could be utilized so long as the attachment is secure, fixed and durable.
The rod 106 extends through a pair of appropriately sized apertures 108 and 110 , respectively, in bracket assemblies 112 and 114 . The size of apertures 108 and 110 should be only slightly larger than the diameter of rod 106 so that rod 106 can rotate, and slide side-to-side within the apertures, but is otherwise held generally in place. The overall length of rod 106 will be dictated by the overall width of the basin opening to be covered.
The bracket assemblies 112 and 114 are designed and constructed to be attached to the horizontal portion 116 of the drain basin opening 12 (compare to the brackets 36 and 38 above, which are designed to be attached to the vertical interior wall of the basin). The bracket assemblies 112 and 114 are preferably mirror images of one another, and, as best seen in FIG. 5 , (the following description also applies to each) bracket assembly 112 has a base 118 to which a flange 120 is attached, and extends perpendicularly above the base 118 . In this preferred embodiment, flange 120 has an upper tab 122 that extends perpendicularly from the flange 120 . The tab 122 has a threaded orifice 124 into which a threaded bolt 126 is screwed. Bolt 126 is used to secure the bracket within the curb opening 12 as, once the bracket assembly 112 is properly position within the curb opening 12 , bolt 126 is screwed upward against the upper surface of the curb opening 12 , thereby creating a tension fit. Flange 120 also has a pair of horizontally elongated attachment slots 128 . The other main component of bracket assembly 112 is the adjustable guide 130 . Adjustable guide 130 has a series of vertically elongated slots 132 . Guide 130 is attached to flange 120 by conventional bolts 134 , washers 136 , lock washers 138 , and nuts 140 . The combination of the dual slots 128 and the multiple slots 132 allows for a large adjustment of the guide 130 to the flange 120 . As best seen in FIG. 6 , the bracket assembly 112 is preferable secured within the curb opening 12 by means of a set bolt 142 that extends through hole 144 and engages an anchor (not shown) that has been set into the concrete of the basin opening.
As best seen in FIG. 6 , the rear (relative to the curb) portion of guide 130 is designed such that it has a rearwardly extending hook 150 . It will be noted that detent 152 of the hook 150 extends downwardly a sufficient distance so that a pin (to be described below) will reside within the hook and will restrain the pin against force asserted against it in the rearward direction. Immediately below the detent 152 , the rearward edge 154 of guide 130 slants forwardly, toward the curb.
Referring now to FIG. 4 , the purpose of the guide 130 , detent 152 and rearward edge 154 will be described. As seen in this Figure, attached to gate assembly 100 is a trip plate 160 that is attached to and extends from the rear portion of the gate portion 101 by means of hinges 162 and 164 . Hinges 162 and 164 are preferably attached to the lower corners of gate portion 101 , and can be attached by any conventional means, including welding, screws, or bolts, for example (not shown). Each of the hinges 162 and 164 have a hinge pin 166 and 168 that extend inwardly towards one another from the hinges 162 and 164 . The hinge pins 166 and 168 communicate with appropriately sized holes 170 and 172 on the side arms 174 and 176 on trip plate 160 such that when so engaged, the trip plate 160 is securely held within, but is rotatable with respect to, the hinges 162 and 164 , and hence to gate portion 101 . As will be understood by those skilled in the art, circular springs 180 and 182 fits over hinge pins 166 and 168 , and the extending spring coil legs 184 and 186 fit into properly sized holes 188 and 190 that are formed in the trip plate arm 176 and hinge 164 respectively so as to bias the trip plate 160 into an upward orientation. As will be appreciated by those skilled in the art, the biasing force can be pre-determined by selecting the size and number of coils within the springs 180 and 182 .
The remainder of this embodiment of the trip plate 160 comprises a central trough 192 that extends between the sides arms 174 and 176 . Also in this embodiment, the trip plate 160 has a pair of plates portions 194 and 196 that extend upwardly and rearwardly from the trough 192 . It will be noted that the trough 192 in this embodiment does not extend at the way to the from of the side arms 174 and 176 . Rather, there is a void area between the arms 174 / 176 , the trough 192 and the gate 101 .
The trip plate 160 also has a pair of pins 200 and 202 that extend laterally from the rear portion of the side arms 174 and 176 . In this embodiment, each of the pins 180 and 182 are of two piece construction as shown. Various different constructions are of course possible. When the gate assembly 100 is fully assembled according to the attachment dotted lines in FIG. 4 , it will be noted that when the trip plate 160 is in its closed (as shown in this embodiment, upward) position (as biased by the springs 180 and 182 , the pins 200 / 202 will be forced upwardly within the detent 152 portion of hooks 150 in the two mirror image bracket assemblies 112 / 114 . The detent portions 152 of the hooks 150 are each sized and shaped relative to the size of pins 200 / 202 such that when the pins 200 / 202 are in position within the detent 152 portion of hooks 150 , the pins 200 / 202 cannot move in a rearward direction, such movement being retrained by the detent portions 152 . As will be appreciated, this interaction between the pins 200 / 202 and detent portions 152 will hold the gate portion 101 into place in the closed position against the drain basin opening. As a low flow of water comes through the mesh material 104 of gate portion 101 , the natural tendency of moving water to adhere to an adjacent surface will cause the water entering the drain basin opening 12 mainly to flow into the void space in front of the trip plate 160 . As the water flow increases, however, some of the water will start to flow onto the trip plate 160 before cascading into the drain basis. As the water flow increases, the amount of water that is instantaneously acting against the trip plate 160 will also increase until the upward biasing force of the springs 180 / 182 is overcome. At that point, the rear portion trip plate 160 will start to move downwardly, rotating upon hinge pins 166 / 168 . Once the rear portion of trip plate 160 has moved downwardly a sufficient amount, then pins 200 / 202 are freed from hooks 150 . At that point, the pins 200 / 202 no longer act to hold the gate portion 101 in a closed position against the drain basin opening, and the pressure of water on gate portion 101 will swing it widely and immediately open. As it does, the gate portion 101 rotates on rod 106 into an open position against to top of the drain basin. Once the flow of water has receded, the gate 101 will drop back into place and the pines 200 / 202 will be brought back into position with the hooks 150 .
As will be appreciated, the size and shape of the gate portion 101 , the mesh material 104 , the trip plate 160 , the detent 150 , and the strength of the biasing springs can be varied, so long as the resultant design works to open the gate portion 101 upon the desired flow of water. As will be appreciated, as the flow of water increases, more pressure is applied to the gate portion 101 , which applies more pressure by pins 200 / 202 against the detent portions 152 , so that will have to be taken into consideration. This is easily done by those skilled in the art. A representative embodiment is shown in FIG. 4 , which is drawn generally to scale.
The final aspect of this embodiment includes side panels 206 and 208 . These side panels 206 / 208 preferably have a similar frame and mesh material construction as gate 101 , and are sized and shaped so as to fully occupy the remainder of the basin opening 12 on either side of the gate 101 (as best seen in FIG. 3 ). In this embodiment, the upper portion of the panels 206 / 208 are attached to a tubular member 210 / 212 which is sized and shaped so as to fit snugly onto rod 106 . Once in place within the complete system, it will be seen that the backside of panels 206 / 208 rest against flanges 120 and are thus held into the closed position. As will also be appreciated, where this overall system is to be installed on a number of drain basin openings of varying widths, this embodiment can be utilized with a standard gate system 100 of common size, but with the ability to easily change the size of only three components in the overall system (that being the length of rod 106 , and the width of side panels 206 / 208 ) in order to accommodate a wide variety of basin opening widths.
Lastly, in order to provide some protection to the rod 106 , an L-bar 214 can be attached to the upper portion of the basin opening 12 .
Although preferred embodiments have been shown and described, the disclosed invention and the protection afforded by this patent are not limited thereto, but are of the full scope of the following claims, and equivalents thereto.
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A gate system for an opening through which fluid flows, such as the opening to a storm drain typically found in the curb of an urban street. The system is biased to a closed condition to keep trash out of the drain during dry and low fluid flow situations, then automatically converts to an open condition during heavy fluid flow situations, and then returns to a closed condition when the heavy fluid flow condition abates. The system has a gate portion that rotates between an open position and a closed position adjacent the opening, being biased to the closed position, and a trip plate, which is also biased to a closed position. The trip plate has one or more pins that communicate with one or more grooves and/or detents in one or more adjacent bracket assemblies to hold the gate portion in the closed position until the fluid flow on or against the trip plate reaches a predetermined level such that the trip plate rotates from the closed position, releasing the gate portion and allowing the fluid flow to push the gate portion into an open position. After the fluid flow abates, both the gate portion and the trip plate rotate back to their closed positions automatically.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION:
The invention pertains to a quick latching drill pipe blowout preventer for use on a rig for a subterranean well during drilling operations.
2. DESCRIPTION OF THE PRIOR ART:
During the drilling of a subterranean well, produced hydrocarbons may start flowing through the drill pipe while a connection is being made at the well surface or during tripping, either into or out of the hole. When this occurs, the possibility of a well blowout must be prevented by closing the drill pipe string. In most instances, the fluid flowing to the top of the well through the drill string will be at a very high velocity, thus not allowing sufficient time to stab the kelly joint into the upper tool joint of the drill string to completely shut off the flow of fluid before the ejection of the fluid above the rig floor. All wells being drilled are equipped with blowout preventers to control flow of fluids coming up the drill pipe-casing annulus. However, the blowout preventers do not affect the interior of the drill pipe.
It is therefore an object of the present invention to provide a manually operable blowout preventer which may be sealingly latched onto the upper end of a drill pipe tool joint.
It is a further object of the present invention to provide a sealingly latchable drill pipe blowout preventer which is carriable by the kelly.
It is also an object of the present invention to provide a sealingly latchable blowout preventer carriable by the kelly, the outer housing of said blowout preventer being easily and quickly removable from the inner or main body thereof.
It is a further object of the present invention to provide a sealingly latchable blowout preventer carried by a kelly, the main body of said blowout preventer being separable from the outer housing thereof such that said body becomes an integral part of the tubing string for running into the well to a desired depth in order to circulate fluid to kill the well.
It is a further object of the present invention to provide a latchable blowout preventer carried by the kelly which will sealingly engage a tool joint when stabbed thereon without requiring tubular rotation for sealing engagement.
Other objects and advantages of the present invention will be apparent from a reading of the FIGS., the specification and the claims.
SUMMARY OF THE INVENTION
The present invention incorporates a drill string blowout preventer for a subterranean well, the blowout preventer depending from a kelly joint, and comprises first and second tubular housing members, one of said housing members being initially and selectively dependent from said kelly joint, the other of said housing members being engageable onto the drill string with the housing members being selectively removable from each other. The blowout preventer also has means defining a valve within one of said tubular housing members, means carried by one of said housing members for grasping said drill string, seal elements carried by said housing members for cooperation with said means defining a valve for entrainment of fluid within said blowout preventer, and means for selectively removing one of said housing members from the other of said housing members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general but complete outer view of the blowout preventer of the present invention in sealing engagement with a tool joint forming the upper end of the drill string.
FIG. 2 is a side elevational drawing depicting the various separated elements of the blowout preventer.
FIG. 3 is a longitudinal sectional drawing of the blowout preventer of the present invention sealingly stabbed over a tool joint with the valve element in closed position.
FIG. 4 is a view similar to that shown in FIG. 3 and shows the blowout preventer of the present invention in sealing engagement with a tool joint and the blowout preventer lower thread connected to the thread of the tool joint by rotation of the kelly.
FIG. 5 is a view similar to those shown in FIGS. 3 and 4 and shows the main body of the blowout preventer separated from the outer housing thereof, the valve element being in open position and a back pressure sub being engaged to the top of the blowout preventer main body.
FIG. 6 is a longitudinal diagramatic view showing the blowout preventer apparatus in relation to cooperating components of a drilling rig.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the FIGS., the apparatus A basically is comprised of an outer housing 40 which is selectively removable from an inner body 50. The outer housing 40 is composed of a split retainer ring 18 engaged within its companion grooveway 18a, the ring 18 being housed within a retainer cap member 19 connected such as by threads 11 to a central housing member 10 therebelow. Within a circumferentially extending longitudinal grooveway 23a in the central housing 10 is an elastomeric or rubber seal element 23 for sealing engagement on the exterior of a tool joint 20 (which can be a drill collar or the like) in the operation as described below.
Protruding outwardly from and forming a part of the central housing 10 is a tong ring 7 having circular sectional elements 7a and 7b which are substantially equal in circumference. The tong ring elements 7a and 7b provide grooves or holes 9a and 9b, respectively, for receipt of lock pins 9c and 9d which engage to the tong ring 7 slidable criss-crossed tong arms 5 and 6. The arms 5 and 6 are crossed within companion slide grooves 5a and 6a respectively on each side of the central housing 10, so that each tong may pivot about its respective pin 9c and 9d with respect to the other, thus permitting slight travel of the arms 5 and 6 to achieve grasping of the tool joint 20 by means of protruding grasping elements 24 interiorally formed on each of encircling tong elements 5b and 6b depending from the arms 5 and 6 of the tong ring 7. As shown in FIGS. 3 and 4, the tool joint tong arms 5 and 6 provide interiorally spaced and protruding grasping elements 24 for selective engagement upon the outer face of the tool joint 20, the outer face having an angularly protruding shoulder 20a providing resistance to upward movement of the apparatus A when the kelly joint 3 is raised or when pressure from within the drill pipe is exerted against the valve element 21.
The inner or main body 50 of the apparatus A is slidably and sealably contained within but selectively removable from the outer housing 40 and basically consists of an exterior valve control 16 for manual manipulation of a valve element 21 housed within the body 50 for control of fluid flow within a central longitudinal passage 60 which is communicable with companion passageways within the kelly joint 3 thereabove and the tool joint 20 therebelow. The body 50 also has circumferentially extending seal elements 14 housed within companion grooves 14a on the exterior of the body 50 for prevention of fluid communication between the body 50 and the outer housing 40. Thread elements 17 are provided on the uppermost portion of the body 50 for engagement with companion thread elements 34 on the kelly 3, while threads 55 are provided on the lowermost end 51 of the body 50 for engagement with companion threads 52 on the upper portion of the tool joint 20.
The valve element 21 is shown in the FIGS. as a ball type valve which may be reciprocated into the open and closed position by manipulation of the outer valve control 16, with valve port 22 providing fluid communication between the flow passage 60 and the interior of the kelly joint 3 when the valve element 21 is in open position and preventing such communication when the vlave element 21 is in closed position.
In the operation of the blowout preventer apparatus of the present invention, the apparatus A is affixed to the lower end of the kelly joint 3 (FIG. 6) which, in turn, is carried by a swivel 31 extending from a traveling block 30. A flow path within the kelly joint 3 communicates with an extending flow path provided by mud hose 2 to the mud pit (not shown), the upper end of the hose 2 being engaged within the swivel 31. The blowout preventer apparatus A is engageable on a tool joint 20 extending through the rotary table 32 on the rig floor 4 and passes through a blowout preventer stack BP therebelow.
Upon detection of a blowout, the apparatus A, with the valve element 21 reciprocated to "open" position, is lowered over the tool joint 20 by longitudinal movement of the kelly joint 3. When the tool joint tong elements 5b and 6b contact the upper end of the tool joint 20, the weight of the outer housing 40 will cause the tong arms 5 and 6 each to expand slightly outwardly to permit the tong elements 5b and 6b to pass over the top of the joint 20. During this operation, with valve element 21 in open position, the well fluids will "blow out" through the kelly joint 3 and subsequently to the mud pit thereby relieving the pressure in the drill string in the well. After the tong elements 5b and 6b pass just slightly below an outwardly protruding and encircling shoulder 20a on the tool joint 20, the kelly joint 3 is raised to permit the tong elements 5b and 6b to contract laterally and to permit the protruding grasping elements 24 to engage the shoulder 20a and thereby hold the apparatus A on the tool joint 20. In the event that there already is sufficient length of drill pipe in the well, mud can be pumped through the apparatus A and the drill string to kill the well. However, in the event that it is desirable to run additional length of drill pipe into the well, the valve element 21 can be left in open position and the kelly weight set down on the apparatus A. The valve 21 is reciprocated to closed position only after the kelly joint 3 and the apparatus A have been made into the drill string.
As shown in FIG. 3, flow of fluid through the blowout preventer apparatus A is prevented by valve port 22 of valve element 21 being in closed position, while the seal elements 23 or similar element 14 prevent flow of fluid between the inner main body 50 and the outer housing 40.
After locking the blowout preventer in place as described above and shown in FIG. 3, the kelly joint 3 and the blowout preventer apparatus A connected to the lower end thereof are rotated to permit the main body 50 of the apparatus A to be sealingly engaged with and made into the tool joint 20, as shown in FIG. 4. As the kelly joint 3 and the body 50 are rotated for threaded engagement of the body 50 into the tool joint 20, weight is applied to the kelly joint 3 resulting in the kelly 3 and the body 50 being completely integrated with the tool joint 20. The kelly joint 3 may then be rotated to unthread its lower end from the body 50.
After removal of the kelly joint 3 from the apparatus A, the outer housing 40 is removed therefrom so that the inner body 50 may be retained on the tool joint 20 and become an integral part of the drill string. With the valve element 21 still in closed position, the retainer cap member 19 is rotated by wrench or other tool and removed from the central housing 10 carrying the sectional elements 7a and 7b. Thereafter, the tool joint tong arms 5 and 6 can be removed from the body 50 over the top thereof by removing each of the elements of the split retainer ring 18, leaving only the body 50 in place over the tool joint 20.
After removal of the outer housing 40 from the body 50 of the apparatus A, a back pressure sub 44, which may or may not be affixed to the lower end of the kelly joint 3, is stabbed into and threadedly connected to the upper part of the body 50. The back pressure sub 44 may be of any conventional type and is not a part of the apparatus A, but is utilized in controlling the well. The back pressure sub 44 permits downward flow of fluid therethrough but prevents upward flow of fluid therethrough by means of flapper valve head 26 affixed to the sub 44 by means of a pin 28. The tool then is as shown in FIG. 5. With the back pressure sub 44 affixed as described, and the main body 50 of the apparatus A being affixed to the lower end thereof, the tool joint 20 being affixed to the lower end of the body 50, the valve element 21 may be rotated by means of the valve control 16 on the outer portion of the body 50 to allow the valve port 22 to be in open position with respect to passageway 60. The flapper valve head 26 will prevent flow of fluid above the valve head 26 and will contain the fluid within the passageway 60. The tool, may be run on the drill string to a desired depth in the well and fluid circulated downwardly through the passageway 60 to kill the well, if desired.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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A blowout preventer for the drill string of a subterranean well which is quickly and sealingly latchable to the upper tool joint of the string in the event of a well blowout. The blowout preventer basically comprises first and second tubular housing members, means defining a valve within one of said tubular housing members, means carried by one of said housing members for grasping a well tool joint, seal elements carried by said housing member for cooperation with said means defining a valve for containment of fluid within said apparatus, and means for selectively removing one of said housing members from the other of said housing members. A method of containing well and drilling fluids using the blowout preventer also is disclosed.
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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 to well boring in general and in particular to a method and apparatus for sensing a pipe joint within a well structure.
[0003] 2. Description of Related Art
[0004] In hydrocarbon production, a well may be formed by an outer casing located within a wellbore and may optionally be surrounded by cement. The well may then include a tool or production string therein for working or producing from the well. Due to the potentially high pressures within the well from hydrocarbons extracted from the hydrocarbon producing formation, numerous types of shut-off valves, spools and other fittings to isolate and control access to the well, such as, by way of non-limiting example a Christmas tree, as it is commonly known or a snubbing rig.
[0005] The well structure may include shut-off valves for closing off or otherwise completely or partially sealing the top of the well as desired by a user. In particular, one common design for such valves are pipe rams which utilize a pair of opposed rams which are movable along a plane perpendicular to the well bore. The rams may be moved along the plate by pistons or the like and are operable to be moved out of the central passage of the well or to be pressed together to seal the well. Rams may be of a blind or shear type to completely seal the well or of a pipe ram type in which the two rams each include a half-circle hole sized to pass a pipe therethrough when the two rams are pressed together. Such pipe rams are commonly utilized in snubbing rigs to seal around the drill or production string and isolate the well below the pipe ram from the environment while permitting the drill or production string to remain within the well or to be extracted or inserted into the well.
[0006] One difficulty that exists with common hydrocarbon wells is the difficulty of determining the location of the joints on the tool or production string. Such strings are commonly formed of a plurality of endwise connected pipes which are connected to each other by threaded connectors. Conventionally such threaded connectors are located at each end and provide enlarged portions of the pipe which are strengthened so as to provide a larger stronger section of the pipe to be grasped by tools and the like. Such tool joints present a larger cross-section than the remainder of the pipe. Disadvantageously, such enlarged diameters of tool joints may interfere with the proper operation of pipe rams should the pipe ram be attempted to be closed at the location of such a tool joint or when extracting or inserting the pipe when at least one of the rams is set to hold back the pressure. Such an event is commonly referred to as stripping which may create a risk of the tool joint being pulled or pushed into the closed piper ram thereby damaging the pipe and/or pipe ram.
SUMMARY OF THE INVENTION
[0007] According to a first embodiment of the present invention there is disclosed a system for sensing a pipe joint within a well structure bore. The system comprises a body connectable in line with the well structure. The body has a central bore therethrough along a central axis corresponding to a central bore of the well structure and an outer surface. The body includes a plurality of blind bores extending radially inwards from the outer surface. The system further includes at least one sleeve being locatable within one of the plurality of blind bores wherein each of the sleeves has a magnet located at an end thereof at least one sensor being locatable within one of the at least one sleeves. The at least one sensor is operable to output a signal representing the width of a metallic object located within the central bore.
[0008] The at least one sleeve may be formed of a ferromagnetic material. The body may comprise a spool. The spool may include a plurality of connection bores extending through the spool parallel to the central axis. The blind bores may be located between the connection bores. The spool may be formed of a substantially non-magnetic alloy. The spool may be formed of a nickel-chromium based alloy.
[0009] Each of the at least one sensors may comprise a hall effects sensor. At least one pair of blind bores may be connected to each other by a bridging bar. A first pair the blind bores may be located on opposite sides of the body. A second pair of blind bores may be located to one side of the first pair. The bridging bar may comprise a tubular member extending between the sleeves of the at least one pair of blind bores. The bridging bar may comprise a solid member extending between the sleeves of the at least one pair of blind bores. The bridging bar may be formed of a ferromagnetic material.
[0010] The system may further comprise a display operable to receive the output signal from the at least one sensor and to display an output to a user indicating the width of the metallic object within the central bore.
[0011] Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,
[0013] FIG. 1 is a cross-sectional view of a the top end of a wellbore having an outer casing and a production string located therein with an apparatus for sensing the location of a pipe joint.
[0014] FIG. 2 is a perspective view of the apparatus for sensing the location of a pipe joint according to a first embodiment of the present invention.
[0015] FIG. 3 is an exploded view of an apparatus for sensing the location of a pipe joint according to a first embodiment of the present invention.
[0016] FIG. 4 is a cross-sectional view of the apparatus of FIG. 3 as taken along the line 4 - 4 .
[0017] FIG. 5 is a cross-sectional view of the apparatus of FIG. 3 as taken along the line 5 - 5 .
[0018] FIG. 6 is an illustration of a display output showing voltage produced by a sensor of the apparatus of FIG. 3 as a tool joint is passed therepast.
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 , a well assembly located within a well bore 8 of a soil formation 6 is illustrated generally at 10 . The well assembly includes a well casing 12 having top flange 14 which is securable to a pipe ram 16 or any other desired well head device. It will be appreciated that the present apparatus may be located at any location within the well, such as, by way of non-limiting example, the casing, snubbing unit, blow out preventer or any other well apparatus. It will also be appreciated that the Although only a single pipe ram is illustrated in FIG. 1 for the sake of clarity, it will be appreciated that many installations will include more than one well head component. As illustrated in FIG. 1 , the well assembly includes an apparatus for sensing a pipe joint according to a first embodiment of the invention, shown generally at 20 and one or more top pipe, well component or other equipment 18 located thereabove. A production or tool string 15 is located within the casing and includes a plurality of tool joints 17 therealong.
[0020] The apparatus 20 senses the presence of the tool joint 17 and outputs a signal to a display 80 so as to indicate to a user that the tool joint 17 located within apparatus 20 so as to permit the user to advance the production or tool string 15 within the casing 12 by a predetermined distance so as to avoid having one of the pipe rams 16 or other well head devices engage upon the tool joint.
[0021] With reference to FIG. 2 , the apparatus 20 comprises a body 22 having a plurality of sensor bores 40 therein each adapted to receive a sleeve and a sensor therein. The body 22 comprises an annular or ring-shaped spool having inner and outer surfaces, 24 and 26 , respectively and extending between top and bottom surfaces, 28 and 30 , respectively. As illustrated in FIG. 1 , the inner and outer surfaces 24 and 26 are substantially cylindrical about a central axis 32 of the spool 22 . The inner surface 24 defines a central passage 34 extending therethrough which may be sized and shaped to correspond to the interior of the casing 12 . As illustrated in FIGS. 2 and 4 , the top and bottom surfaces are substantially planar along a plane normal to the axis 32 and may optionally include a seal groove 35 extending annularly therearound for receiving a seal as are commonly known in the art.
[0022] The spool 22 includes a plurality of bolt holes 36 extending therethrough between the top and bottom surfaces 28 and 30 along axis parallel to the central axis 32 . The bolt holes 36 are utilized to pass fasteners, such as bolts 38 as illustrated in FIG. 1 therethrough to secure the spool inline to the other components of the well assembly 10 according to known methods in the art.
[0023] The spool 22 also includes sensor bores 40 extending thereinto from the outer surface 26 . As illustrated herein, the sensor bores 40 are blind bores extending to a bottom depth within the spool by a distance less than the distance from the outer surface 26 to the inner surface 24 . In such a manner, the sensor bore 40 will maintain a barrier wall, generally indicated at 42 in FIG. 4 between the sensor bore 40 and the central passage 34 so as to maintain the seal provided by the spool 22 . The barrier wall 42 may have a thickness selected to provide adequate burst strength of the spool according to known methods. Optionally the sensor bore 40 may extend completely through the spool to the inner surface 24 . With reference to FIG. 5 , the bolt bores 36 may be located at regular intervals around the spool wherein the sensor bores extend through the spool at locations between the bolt bores. As illustrated in FIG. 5 , the sensor bores 40 may be arranged about the central passage 34 along a common plane normal to the axis 32 of the central passage although other orientations may be useful as well.
[0024] The spool 22 may have any depth between the top and bottom surfaces 28 and 30 as is necessary to accommodate the sensor bores 40 . By way of non-limiting example the spool may have a depth of between 3.5 and 24 inches (89 and 610 mm) with a depth of approximately 4 inches (102 mm) having been found to be particularly useful. Additionally, the spool will be selected to have an inner diameter of the inner surface 24 to correspond to the inner passage of the casing 12 for which it is to be used and an outer surface 26 diameter so as to provide a sufficient depth for the sensor bores 40 . In practice it has been found that an outer diameter of between 4 and 12 inches (102 and 305 mm) larger than the inner diameter has been useful. The spool 22 may be formed of a non-magnetic material, such as, by way of non-limiting example a a nickel-chromium based alloy, such as Inconel® manufactured by Special Metals Corporation. It will also be appreciated that other materials may be useful as well, such as, by way of non-limiting example duplex and super duplex stainless steels provided they do not interfere with the sensor operation as described below.
[0025] With reference to FIG. 3 , an exploded view of the apparatus is illustrated having sleeves 50 locatable within each of the sensor bores and sensors 70 locatable within the sleeves 50 . The sleeves 50 comprise tubular members extending between first and second ends, 52 and 54 , respectively, and having inner and outer surfaces, 56 and 58 , respectively. As illustrated in FIG. 4 , the outer surface 58 of the sleeves are selected to correspond closely to the sensor bores 40 in the spool 22 . The sleeves 50 are formed of a substantially ferromagnetic material, such as steel so as to conduct magnetic flux as will be more fully described below. The sleeves 50 are selected to have a sufficient outer diameter be received within the sensor bores 40 and an inner surface diameter sufficient to accommodate a sensor 70 therein. By way of non-limiting example it has been found that a diameter of the inner surface of between 0.5 and 1 inches (13 and 25 mm) has been useful. The sleeve 50 may also have a length sufficient to receive the sensor 70 therein, such as by way of non-limiting example, between 0.5 and 3 inches (13 and 76 mm). The outer diameter of the sleeve 50 may also optionally be selected to permit the sleeve to be secured within the sensor bore by means of an interference fit or with the use of adhesives, fasteners, plugs or the like. The sleeve 50 may also be selected to have an outer diameter of sufficient size to have an interference fit with the sensor bore 40 .
[0026] The sleeves 50 also include a magnet 60 located at the first end 52 thereof. The magnets 60 are selected to have strong magnetic fields. In particular, it has been found that rare earth magnets, such as, by way of non-limiting example, neodymium, or samarium-cobalt. Optionally, the magnets 60 may also be nickel plated. The magnets 60 are located at the first ends 52 of the sleeves 50 and retained in place by the magnetic strength of the magnets. Optionally, the sleeve 50 may include an air gap 51 between the magnet 60 and the barrier wall 42 of up to ½ inch (13 mm) although other distances may be useful as well.
[0027] The sensors 70 are inserted into the open second ends 54 of the sleeves and are retained within the sleeves by any suitable means, such as, by way of non-limiting example, adhesives, threading, fasteners or the like. The sensors 70 are selected to provide an output signal in response to the magnetic field in their proximity. By way of non-limiting example, the sensors 70 may comprise magnetic sensors, such as hall effect sensors although it will be appreciated that other sensor types may be utilized as well. As illustrated in FIG. 4 , the sensor may be located substantially at a midpoint of the sleeves 50 although it will be appreciated that other locations within the sleeve may be useful as well. The sensor includes an output wires 62 extending therefrom. The output wire 62 is wired or otherwise connected to the display and is therefore operable to provide an output signal representing the width of a metallic object located within the central passage 34 such as the drill string.
[0028] With reference to FIG. 6 , the output 70 may display the voltage signal outputted by the one or more sensors against time. During a first time period, the voltage signal will be at a first level, generally indicated at 84 , while a main portion of the pipe is drawn through the spool 22 . As the tool joint 17 is drawn through the spool 22 , the voltage output of the sensors 70 will be increased, generally indicated at 86 , due to the increased diameter of the metallic object within the central passage 34 . After the tool joint 17 passes the spool, the voltage will return to a lower level 88 . In such a manner, the display 80 will indicate to an operator when the tool joint 17 is located within the sleeve. Thereafter, the operator will be able to advance the production or tool string 15 by a known distance so as to ensure that the pipe rams 16 or other equipment avoids the tool joint 17 .
[0029] With reference to FIG. 2 , the apparatus may be provided with a bridging bars 90 extending between a pair of opposed sleeves 50 . The bridging bars 90 may be formed of a substantially ferromagnetic material and is adapted to be secured within the sensor bores 40 . The bridging bars 90 may be solid or hollow and are operably connected to the sleeves 50 within the sensor bores 40 . The bridging bars 90 serves to link the magnets and sensors on opposed sides of the spool 22 thereby increasing the field observed. As illustrated in FIG. 2 , the apparatus may include a central bridging bar 90 a extending between sensor bores 40 on opposed sides of the spool 22 and a pair of side bridging bars 90 b extending between a pair of sensor bores 40 located to one side of the central bridging bar 90 a. It will be appreciated that other arrangements may be useful as well, such as excluding the side or central bridging bars.
[0030] While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.
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A system for sensing a pipe joint within a well structure bore comprises a body connectable in line with the well structure. The body has a central bore therethrough and includes a plurality of blind bores extending radially inwards from the outer surface. The system further includes at least one sleeve being locatable within one of the plurality of blind bores wherein each of the sleeves has a magnet located at an end thereof at least one sensor being locatable within one of the at least one sleeves. The at least one sensor is operable to output a signal representing the width of a metallic object located within the central bore. The system may further include a display operable to receive the output signal from the at least one sensor and to display an output to a user indicating the width of the metallic object within the central bore.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 60/481,268 filed Aug. 20, 2003, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF INVENTION
This invention relates to locking devices in general and “lock-out” devices for deadbolts in particular.
Bolts or deadbolts are well known devices for locking a door shut for security purposes. In such well-known arrangements, the deadbolt or bolt is mounted in the body of the door and the deadbolt is operated by mechanical operating devices mounted on either side of the door. When the deadbolt is operated to a locked position it typically extends or projects from the side of the door into an opening in the door jam or wall to which the door is mounted. Thus, the deadbolt when operated to an extended position, “bolts” or “locks” the door in a closed position. The mechanical operating devices also can operate to retract the bolt into the side of the door to unlock the deadbolt or bolt.
In typical arrangements, one mechanical device used to operate a deadbolt may be a key cylinder into which a key is inserted. The key then can rotate the cylinder which, in turn, operates the deadbolt through various mechanical linkages. Another mechanical device that may be used to operate a deadbolt includes a knob that can be turned manually that, in turn, operates the deadbolt through various mechanical linkages.
It is known to use a key cylinder and knob device together to operate deadbolts. The key cylinder is normally mounted on the exterior side of the door so that a user can use a unique key to operate and lock the deadbolt from the exterior side of the door. The manual knob is typically mounted on the interior of the door and operates the deadbolt from the interior side of the door without a key. Thus, the user can easily lock and unlock the deadbolt from the interior of the door without using or locating a key.
It is sometimes desirable for users to disable the mechanical device for operating the deadbolt that is mounted on the exterior of the door. This can occur in situations in which the user does not wish to permit a person with a key to operate the deadbolt from the exterior side of the door such as, for example, a landlord/tenant situation in which the tenant does not wish the landlord to enter a rental property. Another important use of this feature is to prevent unauthorized access through the manipulation of the deadbolt by lock “picks” or the like. Mechanisms that disable the operation of a mechanical device used to operate a deadbolt are called “lock-out” devices.
Known lock-out devices for deadbolts are unreliable, difficult and clumsy to use and have safety concerns in that they do not signal to a user when a “lock-out” mechanism is in operation.
SUMMARY OF INVENTION
The invention provides a lock-out device for a locking mechanism that is reliable and simple to use and, in some embodiments, signals to the user that the lock-out mechanism has been activated. The invention may be comprised of a shaft upon which a knob or handle is mounted that has openings or channels in the wall of the shaft. The openings in the shaft correspond to protrusions or protuberances in the shaft housing. To operate the lock-out device, when the knob is turned to the locked position in which the deadbolt is extended, the handle or knob may be pulled which pulls the openings in the shaft into interlocking engagement with the protrusions in the shaft housing. As a result, a mechanical member that operates the locking mechanism is restrained, thus “locking out” the deadbolt bolt mechanism. Thus, the deadbolt can not be operated by a key through a key cylinder mounted on the exterior side of the door effecting a “lock-out” condition. In some embodiments, when the shaft is pulled into a lock-out position, a portion of the shaft becomes visible from the interior-side of the door. In some embodiments the visible portion of the shaft includes an indicator or warning mechanism to signal to the user that the deadbolt is now in “lock-out” condition.
BRIEF DESCRIPTION OF DRAWINGS
In the accompanying drawings, which are incorporated in and constitute a part of this specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below serve to illustrate the principles of this invention. The drawings and detailed description are not intended to and do not limit the scope of the invention or the claims in any way. Instead, the drawings and detailed description only describe embodiments of the invention and other embodiments of the invention not described are encompassed by the claims.
FIG. 1 is a partial cross-sectional view of the deadbolt lockout mechanism of the present invention.
FIG. 2 is a perspective view of the shaft used in the deadbolt lockout mechanism of the present invention.
FIG. 3 is a side view of the shaft shown in FIG. 2 .
FIG. 4 in an end view of the shaft shown in FIG. 2 .
FIG. 5 is a side view of the shaft shown in FIG. 2 , opposite from that shown in FIG. 3 .
FIG. 6 is an end view of the shaft shown in FIG. 2 , opposite from that shown in FIG. 4 .
FIG. 7 is an exploded view of the shaft, mounting plate and knob subassembly of the deadbolt locking mechanism of the present invention.
FIG. 8 is a plan view of the mounting plate shown in FIG. 7 .
FIG. 9 is a perspective view of the mounting plate shown in FIG. 7 .
FIG. 10 is a rear perspective view of the subassembly shown in FIG. 7 in the lockout position.
FIG. 11 is a front perspective view of the subassembly shown in FIG. 7 in the lockout position.
FIG. 12 is a side view of the subassembly shown in FIG. 7 in the lockout position.
FIG. 13 is a rear perspective view of the subassembly shown in FIG. 7 in the operational deadbolt position.
FIG. 14 is a front perspective view of the subassembly shown in FIG. 7 in the operational deadbolt position.
FIG. 15 is a side view of the subassembly shown in FIG. 7 in the operational deadbolt position.
FIG. 16 is an assembly view of the mounting plate and shaft subassembly in the lockout position.
FIG. 17 is an assembly view of the mounting plate and shaft subassembly in the operational deadbolt position.
FIG. 18 is a cross-sectional view of the mounting plate and shaft subassembly in lockout position.
FIG. 19 illustrates a device for operating a locking device that can be operated through the use of a combination dial or a key cylinder.
DETAILED DESCRIPTION
Referring now to FIG. 1 , a door 2 including one embodiment of the invention is shown. As can be seen, a deadbolt manipulation mechanism, such as a conventional key cylinder 4 is mounted on one side of the door 2 which permits the deadbolt mechanism 3 to be operated by a key 5 . The key cylinder 4 is normally mounted on the exterior side 6 of the door 2 in a protective housing 7 . The “exterior-side” of a door is the side which is on the outside wall of a dwelling or building or any space desired to be “locked” from unauthorized entry. However, this invention is not limited to such a configuration and the key cylinder may be mounted on the interior or exterior side of the door. A second deadbolt manipulation mechanism, such as a knob or handle 8 also for operating the deadbolt is mounted on the side of the door opposite the key cylinder 4 . The knob or handle 8 is mounted on a shaft 10 further described below. The shaft 10 is, in turn, mounted in an opening 12 in a shaft housing 14 .
The key cylinder 4 includes an elongated member 16 sometimes called a “tailpiece” that may be generally rectangular in cross-section, or may be adapted for other configurations. The elongated member 16 is connected to the rear of the key cylinder 4 . When the key cylinder 4 is rotated by key 5 , member 16 is also rotated. Member 16 is then connected by known mechanical linkages to a bolt or deadbolt (not shown). When member 16 is rotated in one direction the deadbolt is extended into a locked position. When member 16 is rotated in the opposite direction, the deadbolt is retracted into the door 2 into an unlocked position. This type of locking and unlocking action for a deadbolt through a key cylinder 4 is known.
As can be seen in FIG. 1 , shaft 10 is hollow in that it has a cavity 18 that extends along its entire length in a horizontal direction when shaft 10 is mounted in shaft housing 14 . Member 16 extends from key cylinder 4 into cavity 18 of shaft 10 . Thus, when knob 8 is rotated, shaft 10 rotates and then member 16 also rotates. Accordingly, the deadbolt can be operated through use of two different deadbolt manipulation mechanisms, such as handle 8 and key cylinder 4 . Thus, both handle 8 and key cylinder 4 may be used to operate the same deadbolt through the rotation of member 16 .
Referring now to FIGS. 2–6 , shaft 10 is shown. Shaft 10 is comprised of four different subsections along its length. The first subsection is the knob mounting portion 20 . Knob mounting portion 20 is generally rectangular or square in cross-section in one embodiment, but could be comprised of any cross-sectional shape. When shaft 10 is mounted in shaft housing 14 , knob mounting portion 20 extends from the exterior of shaft housing 14 . Knob 8 is then mounted on knob mounting portion 20 by fitting mounting portion 20 into a recess on knob 8 . Knob 8 is then secured to mounting portion 20 through the use of known connective methods, such as, for example, a set screw.
The second portion of shaft 10 is signal portion 30 . Signal portion 30 is circular in cross-section in one embodiment, but similar to mounting portion 20 , its construction is not limited to any particular cross-sectional shape. Signal portion 30 has two boundary walls 32 that form a recessed area 34 . An indication mechanism, such as, for example, a colored, circular plastic clip 36 is snap-fit around shaft 10 to fit into recessed area 34 between walls 32 . An alternative indication mechanism is direct application of color to the signal portion 30 of the shaft 10 . The indication mechanism can be of any color, but a visually distinct color typically used to give alerts or signals such as red, orange or yellow should be used. Alternatively, other indication mechanisms can be used, such as, for example, engravings, knurling, demarcations, recesses, or other physical marking or add on portion that would provide a visible indication to the user that the shaft 10 was pulled-out and the deadbolt mechanism 3 was in lockout position. Optionally, other indication mechanisms could be used, including electronic mechanisms or audible mechanisms.
The third portion of shaft 10 is camming portion 40 . Camming portion 40 has a cross-section that is not typical in that it is comprised of several cam surfaces 42 , 44 and 46 . Camming portion 40 is essentially comprised of eight different sides. Four sides 47 of camming portion 40 are comprised of four camming surfaces 46 . The other four sides 48 are each comprised of two camming surfaces 42 and 44 . Sides 47 and sides 48 alternate around the circumference of camming portion 40 .
The fourth subsection of shaft 10 is head portion 50 . Head portion 50 is generally circular in cross-section in one embodiment, but is not limited in any way to any particular cross-sectional shape. Head portion 50 has a diameter or cross-sectional width that is greater than any of the other three shaft portions 20 , 30 , 40 such that a ridge or lip 52 is formed between head portion 50 and camming portion 40 .
Head portion 50 has two grooves, openings or depressions 54 in its otherwise generally circular perimeter. These depressions 54 are on opposite sides of head portion 50 and are parallel to the horizontal axis of the shaft 10 when mounted in shaft housing 14 . Depressions 54 need not be of any particular shape, but in the embodiment shown in FIGS. 2 , 3 and 4 they are semi-circular in shape and form a groove-like depression. Depressions 54 could be located anywhere on head portion 50 in addition to the location shown in the embodiment depicted in FIGS. 2–6 .
Referring now to FIGS. 7–9 shaft housing 14 is described. Shaft housing 14 is comprised of an outer decorative plate 60 and a mounting plate 62 . Both plates 60 and 62 have an opening 64 and 66 , respectively, for accommodating shaft 10 . Decorative plate 60 covers the exterior surface of mounting plate 62 .
The interior or door facing side of mounting plate 62 includes a groove 80 . Groove 80 holds a spring or detent device 82 . Detent device 82 is a spring wire in the embodiment shown, but any type of known device that creates a spring, resilient or holding force can be used. The detent device 82 operates on cam surfaces 42 and 44 of shaft 10 as set forth below and serves to hold the shaft in, or urge it into, either a locked or unlocked position. The total shaft length can be of any dimension, but is preferably between 15 and 75 millimeters.
The mounting plate 62 also includes a collar 84 that extends from plate 62 around opening 66 except where biasing device 82 is located. In the embodiment shown in FIGS. 7–9 , collar 84 is circular or semi-circular in shape, but any shape that corresponds to the shape of head portion 50 of shaft 10 can be used. Collar 84 also has two protrusions or protuberances 86 that extend from the inside walls 83 of collar 84 . These protuberances 86 extend out from the wall of collar 84 approximately 2–3 millimeters to their tips and preferably can extend out from the inside walls of the collar anywhere from 1 millimeter to 2 centimeters. Protuberances 86 correspond to depressions 54 in shape and location, and, in this embodiment run parallel to the horizontal axis of shaft 10 when it is mounted in opening 66 .
Now referring to FIGS. 10–18 , the operation of one embodiment of the invention is described. As shown in FIG. 14 , the deadbolt mechanism 3 is in an unlocked position. As can be seen, head portion 50 extends beyond collar 84 . Thus, handle 8 can be rotated clockwise or counter clockwise to a locked position which would extend the deadbolt into a locked position. When handle 8 is rotated to the locked position, one of camming surfaces 46 operates against detent device 82 to “snap” the shaft 10 into the locked position.
Referring now to FIG. 10 , the shaft 10 is shown in the locked position. As can be seen, the depressions 54 correspond to and are “keyed” to protuberances 86 in the locked position. In this position, the deadbolt is extended from the door into the locked position.
To operate the “lock-out” function the handle 8 is pulled outwardly from the door 2 . This causes detent device 82 to act against camming surface 42 so that an adequate pulling force must be applied to handle 8 to overcome the spring or resilient force against the cam surface 42 . This tends to prevent accidental operation of the “lock-out” function.
As shaft 10 is pulled out by handle 8 , protuberances 86 fit into depressions 54 allowing the shaft 10 to continue to be pulled. When detent device 82 reaches the end of cam surface 42 it “snaps” or moves onto downward sloping cam surface 44 , effectively, pushing the head portion 50 into full interlocking engagement with the collar 84 , which is the “lock-out” position of the complete assembly.
In this “lock-out” position, the protuberances 86 and the depressions 54 are in an interlocking relationship such that the deadbolt can not be operated by key cylinder 4 and key 5 . This is the result of member 16 being held stationary by engagement between the shaft 10 and housing 14 . The engagement of the shaft 10 with the housing 14 is a result of the head portion 50 of the shaft nesting within the collar 84 of the housing 14 with the depressions 54 engaging the protuberances 86 on the collar.
In the lock-out position, the signal portion 30 of the shaft 10 and indication mechanism 36 becomes visible to the user indicating that the “lock-out” function is in operation and must be disengaged to operate the deadbolt. See FIGS. 11–12 .
To disengage the lock-out function, the user simply pushes on handle 8 . The same “snapping” camming surface operation will occur when the pushing force overcomes the spring force of detent device 82 on camming surface 44 . This will cause the lock-out function to disengage, thereby allowing handle 8 to be rotated which rotates member 16 and moves the deadbolt to the unlock position.
In an alternate embodiment, a person ordinarily skilled in the art would understand that the depressions 54 could be present in the collar 84 and the corresponding protuberances 86 could be present in the head portion 50 . It should also be understood that deadbolt manipulation mechanisms are not limited simply to a key cylinder and handle, but may take the form of various mechanical devices, such as, for example a combination dial. Neither is the invention limited to deadbolts or bolts, but can be used with any known locking mechanism.
The invention can be used with any mechanical device that can operate any locking mechanism, including a combination-type mechanical device or a device that can be operated by a combination dial or a key cylinder alternatively and interchangeably. In such a device, a user can operate a locking mechanism, including a deadbolt, by rotating a dial using an authorized numerical combination or by using the key cylinder. Such a device is depicted in FIG. 19 .
The invention has been described with reference to the preferred embodiment. Clearly, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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A deadbolt mechanism including a lock out mechanism that functions to disable the operation of the deadbolt from at least one side of the deadbolt mechanism. The deadbolt mechanism includes a deadbolt, key cylinder, housing, turn knob and a shaft that connects the key cylinder and turn knob. To place the deadbolt mechanism in lock out mode, the turn knob is moved to the locked positioned and then pulled outward away from the door. By pulling the knob outward, the shaft engages a portion of the housing which prevents rotation of the shaft and thereby prevents movement of the deadbolt from the locked position.
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CROSS REFERENCE TO RELATED APPLICATION
This is a divisional application of Ser. No. 324,608 filed Mar. 17, 1989, now U.S. Pat. No. 4,953,857, entitled "METHOD AND APPARATUS FOR INSTALLATION AND ALIGNMENT OF A SERIES OF POSTS".
TECHNICAL FIELD
The present invention relates generally to apparatus utilized to install posts in the ground, and more particularly to apparatus which will align and plumb a series of posts in equidistant spaced-apart relationship.
BACKGROUND OF THE INVENTION It is becoming a common occurrence to construct sound barrier walls alongside metropolitan interstate and highway systems in order to reduce the noise level attendant with such road systems. Sound barrier walls are typically constructed of a series of I-beam-shaped concrete posts, having concrete panels interposed therebetween. Because the concrete panels and posts are prefabricated and transported to the site, the location and alignment of the posts and panels is critical to form an effective sound barrier wall.
One of the most difficult problems encountered in constructing the sound barrier wall occurs after the first post has been located and mounted in the ground. Locating the next post and aligning it with the previously mounted post can be a tedious effort in trial and error. Once the additional post has been located, the next difficult task is in aligning the post with relation to the previous post such that the concrete panel fits exactly therebetween and in contact along the entire vertical edges of each end of the panel.
Once alignment has been accomplished, another problem is in providing a post hole of the exact depth necessary so that all posts are at the same height along the wall relative to ground level. In the prior art, this was accomplished by trial and error, removing the post so that the hole would be either partially filled or augered deeper.
It is therefore a general object of the present invention to provide a method and apparatus for locating and aligning a series of posts for a sound barrier wall or the like.
Another object is to provide a method and apparatus for aligning posts which will locate a series of equidistant posts.
A further object of the present invention is to provide a method and apparatus for aligning posts which quickly and easily plumbs a pair of spaced-apart posts in alignment to receive a panel therebetween.
Still a further object of the present invention is to provide a method and apparatus for aligning the height of a series of posts without resorting to trial and error.
Yet another object is to provide a method for locating and aligning posts which is simple to accomplish and quickly performed.
Yet a further object of the present invention is to provide an apparatus for aligning and locating posts which is simple in operation.
These and other objects of the present invention will be apparent to those skilled in the art.
SUMMARY OF THE INVENTION
An apparatus for locating and plumbing a series of posts is provided, which includes a generally vertical frame supported on three operable jacks. Two of the jacks are spaced transversely from one end of the frame and the third jack is connected to the opposite end of the frame, to form a three-point support for the frame. Each jack is operable to raise or lower that support and thereby align and plumb the frame.
The frame includes upper, intermediate and lower horizontal members, vertically spaced-apart and parallel, having ultra high molecular weight polyethylene pads attached at one end. The horizontal members are comprised of a pair of telescoping halves, so as to be selectively and adjustably extensible. A winch and strap is provided proximal to each end of each horizontal member, which is operable to hang a post against the ultra high molecular weight polyethylene pads on one end of the frame, and secure the post on the other end. A continuous series of alignment apparatus and posts may be continuously attached so as to form a completely aligned and plumbed series of posts.
The method for aligning a series of posts begins with providing a first alignment apparatus adjacent a first hole. A first post is attached to one end of the alignment apparatus and hung at the desired elevation in the post hole. A second alignment apparatus is then provided and one end is connected to the first post such that the alignment apparatus may be swung about the post like a door. Once the second alignment apparatus is positioned in the desired orientation, the support members are lowered to support the frame in that position. A second post is then provided and hung on the opposite end of the second alignment apparatus at the desired elevation within a second post hole. Subsequent alignment apparatus and posts may be attached in a similar fashion to create a series of aligned posts. Concrete or other material may then be inserted in the post holes to affixed the posts in their aligned positions. Once the posts are affixed, the alignment apparatus may be removed and the appropriate panels may be inserted between the aligned posts to form a wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention;
FIG. 2 is an elevational view of the right end of the post alignment apparatus shown in FIG. 1;
FIG. 3 is a front elevational view of the apparatus of FIG. 1, showing a post being located along one side thereof;
FIG. 4 is a front elevational view of a second alignment apparatus connected to the first alignment apparatus and post, showing the location and alignment of a second post;
FIG. 5 is a perspective view of a conventional post utilized with the invention;
FIG. 6 is a sectional view taken at lines 6--6 in FIG. 3;
FIG. 7 is a sectional view taken at lines 7--7 in FIG. 4;
FIG. 8 is a perspective view of a series of the alignment apparatus utilized in constructing a sound barrier wall; and
FIG. 9 is a perspective view of a completed sound barrier wall.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, in which identical or corresponding parts are identified by the same reference numeral, and more particularly to FIG. 1, the post alignment apparatus of this invention is designated generally at 10, and includes a generally vertically-oriented frame 12 affixed to a generally horizontally-oriented support frame 14.
Vertical frame 12 includes an upper 16, intermediate 18 and lower 20, horizontal member affixed in parallel relationship. Each horizontal member 16, 18 and 20 is comprised of a pair of telescoping right and left halves 16a and b, 18a and b, and 20a and b, respectively. Telescoping portions 22, 24 and 26 of upper 16, intermediate 18 and lower 20 horizontal members, respectively, are selectively secured together at the desired length using a pin and aperture combination 28, conventional in the art. A right vertical member 30 affixes right halves 16a, 18a and 20a in the appropriate vertically spaced-apart relationship, and a left vertical member 32 affixes left halves 16b, 18b and 20b in appropriate vertically spaced-apart position, as shown in the drawings.
A horizontally-oriented operable jack 34 includes a sleeve portion 36 and adjustable arm 38, sleeve portion 36 being mounted on intermediate member right half 18a. Adjustable arm 38 is extensible, and is pivotably connected at its free end to telescoping portion 18b of intermediate member 18. A rotatable pin 40 on jack 34, is operable by a handle 42, to selectively extend or retract telescoping portion 18b, for a purpose described in more detail hereinbelow.
Steel pads 44, 46 and 48 are affixed in a vertical plane on the ends of horizontal member right halves 16a, 18a and 20a, respectively, and will abut a vertical surface on a post as described in more detail hereinbelow. Ultra high molecular weight polyethylene pads 50, 52 and 54 are affixed in a vertical plane on the ends of horizontal member left halves 16b, 18b and 20b, respectively, and will abut a vertical surface on a post as described in more detail hereinbelow. A pair of buckle-type winches 56 are operably affixed at the upper end of right vertical member 30 (see FIG. 2), each winch 56 designed to receive and grip one end of a strap 58. Strap 58 is of a length which will reach around a vertical post, as shown in FIG. 6. A second and third pair of winches 60 and 62, respectively, are operably mounted on vertical member 30 in a similar fashion, adjacent horizontal members 18 and 20. Winch pairs 60 and 62 each have a strap 58 associated therewith.
Single winches 64, 66 and 68 are operably mounted along left vertical member 32, adjacent upper, intermediate and lower horizontal members 16, 18 and 20. Each winch 64, 66 and 68 has a strap 58 associated therewith, the straps 58 having one end thereof fastened opposite the winch 64, 66 or 68, as shown in FIGS. 1 and 3.
Support frame 14 includes a pair of left and right transverse members 70 and 72, respectively, affixed to right half 20a of horizontal member 20, in parallel relationship. Transverse members 70 and 72 include telescoping portions 70a and 72a, respectively, with their free ends affixed to rearward leg member 74, as shown in the drawings. A forward leg member 76 is affixed to the opposite ends of transverse members 70 and 72.
A forward structural ladder frame 78 is mounted diagonally between the upper end of right vertical member 30 and adjacent the forward end of transverse member 72. A rearward ladder frame 80 is affixed between the upper end of right vertical member 30 and the rearward end of transverse member 72. Ladders 78 and 80 structurally stabilize vertical frame 12 with respect to horizontal support frame 14, and also assist the user in operating strap 58 and winch 56 at the upper end of vertical member 30.
A vertical jack 82 is mounted to the extending end of forward leg 76, and a second vertical jack 84 is similarly affixed to rearward leg 74. A third vertical jack 86 is affixed to the left end of the right half 20a of lower horizontal member 20. In this fashion, jacks 82, 84 and 86 form three support points for supporting the entire alignment apparatus 10. A rotatable pin 88 on each jack 82-86 may be operated by handle 42 so as to raise or lower the foot 90 of the desired jack.
In order to allow for lateral adjustment of legs 74 and 76, second horizontal jack 92 is mounted on the telescoping portion 72a of transverse member 72. The adjustable arm 94 of jack 92 has its free end mounted to vertical member 30. Operation of rotatable pin 96 on jack 92 will thereby extend leg 74, and vertical jack 84, with respect to vertical frame 12.
Referring now to FIG. 9, the alignment apparatus 10 of the present invention is utilized to set and align a series of concrete posts 98, 98', 98", etc., so as to receive generally rectangular concrete panels 100, 100', 100", etc., therebetween. Location and alignment of posts 98 is critical, since panels 100 are precast, and cannot be easily changed to fit non-aligned posts.
The first step in constructing a sound barrier wall, is to auger the first post hole 102 to the required depth. A post alignment apparatus 10 is then placed adjacent hole 102 with steel pads 44, 46 and 48 vertically thereover, as shown in FIG. 3. FIG. 2 shows how horizontal jack 92 may be extended or retracted so as to align vertical member 30 and steel pads 44, 46 and 48 over post hole 102. Alignment apparatus 10 should then be plumbed vertically and horizontally utilizing jacks 82, 84 and 86.
Referring now to FIGS. 3, 5 and 6, a post 98 is lowered into post hole 102. Each post 98 is generally in the shape of an I-beam, and includes a pair of opposing valleys 104 and 106. Rectangular panels 100 (see FIG. 9) will have its vertical ends abutting the valleys between a pair of posts 98, for a close fit. Post 98 is lowered with valley 104 slidably abutting steel pads 44, 46 and 48, such that the post will be centered within post hole 102. Once post 98 is lowered to the proper elevation, straps 58 are wrapped around the post and tightened by the pairs of winches 56, 60 and 62 on vertical member 30. By tightening more or less on one winch, it is possible to "roll" post 98 about a vertical axis at the end of horizontal members 16a, 18a and 20a, as shown by arrows 108 in FIG. 6.
Once straps 58 are winched snug, the hoist 110 may be removed and the post allowed to hang by straps 58 on winch pairs 56, 60 and 62 at the right end of alignment apparatus 10. A pair of alignment bolts 112 are operably threaded through a bracket 114 mounted on lower horizontal member right half 20a adjacent steel pad 48, as shown in FIG. 6. Bolts 112 may be rotated in one direction or the other in order to move the lower end of post 98 as shown by arrows 116, for minute alignment and adjustment.
Once the first post 98 has been properly positioned and aligned, a second alignment apparatus 10' should be hoisted into position, as shown in FIG. 4. A hoist bracket 118 may be mounted at any convenient location on frame 12, to serve this purpose.
Second alignment apparatus 10' is positioned with ultra high molecular weight polyethylene pads 50', 52' and 54' on the left ends of upper, immediate and lower horizontal members 16', 18' and 20', in slidable abutting contact with valley 106 of post 98. Alignment frame 10' is then secured to post 98 utilizing straps 58' and winches 64', 66' and 68' along left vertical member 32'. Once alignment frame 10' is secured to post 98 by straps 58, alignment apparatus 10' may be pivotally swung about post 98 as shown by arrows 120 in FIG. 7 until the apparatus 10' is centered in the appropriate alignment for the continuation of the wall. Once aligned, jacks 82', 84' (not shown) and 86' are lowered to support the frame in position. The hoist may then be removed from hoist bracket 118' and moved to retrieve a second post 98'. Second post 98' is lowered into second hole 102', and is aligned and affixed to the second alignment apparatus 10', in a fashion similar to that previously described for post 98.
Concrete may be poured around the base of posts 98 and 98', etc. once they have been aligned by frames 10, 10', etc., as shown in FIGS. 8 and 9. Because the posts 98, 98', etc. are hung at the appropriate height at each end of alignment apparatus 10, 10', etc., it is not necessary to constantly auger or fill the post holes to correct the elevation of the posts. Once the concrete has hardened, the frames 10, 10', etc. may be removed, and panels 100, 100', etc. may be inserted.
Whereas the invention has been shown and described in connection with the preferred embodiment thereof, it will be understood that many modifications, substitutions and additions may be made which are within the intended broad scope of the claims. It can therefore be seen that the present invention fulfills at least all of the above-described objectives.
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A method for aligning a series of posts begins with providing a first alignment apparatus adjacent a first hole. A first post is attached to one end of the alignment apparatus and hung at the desired elevation in the post hole. A second alignment apparatus is then provided and one end is connected to the first post such that the alignment apparatus may be swung about the post like a door. Once the second alignment apparatus is positioned in the desired orientation, support members are lowered to support the frame. A second post is then provided and hung on the opposite end of the second alignment apparatus at the desired elevation within a second post hole. The second post is plumed and aligned with respect to the first post upon attachment to the second alignment apparatus. Subsequent alignment apparatus and posts may be attached in a similar fashion to form a series of aligned posts.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for use with soil/groundwater sampling equipment, and in particular, to an expendable protective sleeve and method for use to keep soil samplers and bore casings free from debris and other undesirable materials, and to prevent the development of negative pore pressure upon removal of the sampling device.
2. Background Art
It has become common to obtain groundwater and soil samples from various locations. The soil samples may be used to determine if an area is suitable for construction of buildings, roadways, etc. Soil and groundwater samples my be used to determine if groundwater and/or soil contamination may be present.
When analyzing an area, it is important to collect soil and groundwater samples which have not been disturbed or tainted. The collection of undisturbed soil samples is prerequisite for proper engineering analysis of samples which have not been cross-contaminated from overlying strata subsurface contamination.
When taking soil and groundwater samples, it is common to use an auger which bores a hole into the earth. As the auger is moved downwardly, samples may be taken for analysis to determine soil characteristics and in what zones contamination may be present. To facilitate such sampling, it is common to use an auger with a hollow cylindrical center which can be used to carry a sampling device.
During the collection of soil and groundwater samples from the various types of bore holes, saturated soils commonly invade the bore hole or the bore hole casing causing delays in the boring operation and then uncertainty as to the validity of the data attained from the sampling process. Those skilled in the art will appreciate that a disturbed or tainted sample is of little use. Thus, a variety of techniques have been used to prevent this phenomenon.
One common technique includes placing water within the bore hole to overcome external hydrostatic pressure. In collecting environmental samples, however, the placement of clean water into the bore hole can render the test results suspect and is often not practical. First, the water may dilute or spread the contaminants for which the sample is being taken, thereby giving an artificially low contamination reading when the soil is analyzed. Second, when drilling in very permeable or sandy soil, additional water must be added frequently to prevent the soil from entering into the auger. The large quantities of water raise the dilution concerns discussed above. In remote locations the requirement of additional water is often also impractical or sometimes impossible, as there is often not a convenient source of water which is known to be pure. Obviously, pumping water from a stream or other natural water source is not desirable, as the water itself may be contaminated, thereby increasing the chance of inaccurate results.
Another technique involves suspending a metal plug from a drill rod that is advanced concurrently with the auger in the bore hole. When the desired depth is obtained, the plug is removed from the auger to allow soil or groundwater sampling. Unfortunately, when the metal plug is removed from the auger, negative pressure is often developed. This is especially true in saturated soils. The negative pressures draws groundwater, sand and other debris into the bore hole plugging the auger and preventing sampling until the auger has been unplugged.
In an attempt to overcome this concern, yet another technique to inhibit the invasion of soil and groundwater into the sample collection device prior to reaching the desired sampling depth involves the placement of tape over the open end of the sample collection device. This technique tends to inhibit the invasion of soil and groundwater into the sample collection device. However, the technique does not inhibit the development of a negative pressure when the sampler is removed from the bore hole, thus allowing groundwater, sand, or other contaminants to be draw into the auger and thereby potentially taint any further samples.
Thus there is a need for an apparatus and method for preventing soils and water from being drawn into a hollow auger thereby plugging the auger. Such an apparatus should be inexpensive to use and expendable. Such an apparatus should also not interfere with subsequent drilling/sampling.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an apparatus and method for inhibiting sand and other debris from plugging the bore hole and auger during the collection of soil and groundwater samples.
It is another object of the present invention to provide an apparatus and method which inhibits the collapsing of bore hole sidewalls below the leading edge of the auger during collection of soil and groundwater samples.
It is an additional object of the present invention to provide an apparatus and method which increases the speed of the sample collection process.
It is yet another object of the present invention to facilitate the collection process by allowing suspension of the sample collection device in the bore hole during advancement of the auger until a desired sampling depth is obtained without allowing the bore hole to be contaminated by unwanted debris.
It is an additional object of the present invention to prevent the invasion of contaminated soil and groundwater into the sample collection device as the collection device is lowered to the desired sampling depth.
It is yet another object of the present invention to provide such an apparatus and method which is inexpensive and easy to use.
These and other objects and advantages will be apparent from the present invention wherein an expendable protective sleeve is disposed within the auger forming the bore hole so as to cover the sample collection device and inhibit the flow of sand, soil or groundwater between the auger and sample collection device. The sleeve comprises an elongate portion typically formed in the shape of a cylinder having first and second ends. The first end is closed by a solid covering member, while the second end remains open.
In use the sleeve is slid onto the lower end of a sample collection device by placing the collection device in the open second end of the sleeve and moving the collection device downwardly, adjacent to the first, closed end of the sleeve. The soil sample collection device may then be placed in the auger with the open end disposed at the bottom.
In accordance of one aspect of the invention the sleeve is made of a water resistant, yet destructible material such as polyethylene or polypropylene. When the sampling device is ready to be used, is pushed or driven so that its lower end penetrates through the solid covering member in the first end of the sleeve and into contact with the soil or groundwater at the desired sampling depth. The sampling device may then be withdrawn and the undisturbed soil or groundwater contained therein analyzed for soil characteristics or pollutants.
In addition to preventing soil from entering into the sample collection device while prior to positioning at the desired depth, and preventing soil or groundwater from entering between the sample collection device and the auger, the sleeve also helps to prevent a negative pressure from forming within the bore hole when the sampling device is withdrawn. With traditional drilling equipment, the withdrawal of the sample collection device was often accompanied by a negative pressure (suction) which caused the bore hole to collapse and cause soil and groundwater to enter and plug into the central bore of the auger. The soil in such a position prevents the collection of additional soil samples.
The sleeve, by remaining in place while the sample collection device is withdrawn, lessens the likelihood that a negative pressure will develop. The sleeve also helps resist any collapse of the bore hole below the leading edge of the auger.
If samples at different depths are desired, the first sample will be taken as indicated above. The auger will then be advanced down to a position just above the site of the next sample with a second sample collection device and sleeve mounted thereabout. As the auger drills further into the soil, the sleeve of the first sample holder is destroyed. Thus, it is beneficial to form the sleeve from a material which will not contaminate either the soil or the groundwater which is being tested.
In accordance with the principals of the present invention, the method of using the sleeve includes sliding the sleeve onto the sample collection device and positioning the collection device so that the sleeve is disposed between the collection device and the auger. In such a position, the sleeve prevents groundwater and soil from extending upwardly therein. Once the sample collection device and sleeve are disposed within the auger, drilling may begin. At the desired depth, the sample collection device is pushed through the sleeve and the sample obtained. The sample collection device is then removed. The auger is then withdrawn, or the auger is advanced to additional testing positions and a sample collection device with a sleeve moved into position to take another sample.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a auger casing which is made in accordance with the teachings of the prior art;
FIG. 2 shows a cross-sectional view of an auger with a rod and bit disposed therein in accordance with the teachings of the prior art;
FIG. 3 shows a cross-sectional view of the prior art auger of FIG. 1, with a prior art sample collection device and the sleeve of the present invention;
FIG. 3A shows a cross-sectional view of the auger of FIG. 3, with the sample collection device and protective sleeve extending down into the soil into a position common to soil sampling techniques; and
FIG. 4 shows a perspective view of an expendable protective sleeve for soil samples made in accordance with the teachings of the present invention.
DETAILED DESCRIPTION
Reference will now be made to the drawings in which the various elements of the present invention will be given numeral designations and in which the invention will be discussed so as to enable one skilled in the art to make and use the invention. It is to be understood that the following description is only exemplary of the principles of the present invention, and should not be viewed as narrowing the pending claims.
Referring to FIG. 1, there is shown a perspective view of a hollow-stem auger, generally indicated at 10. The auger 10 includes an elongate, cylindrical central shaft 14 defining a hollow portion (not shown). The cylindrical shaft 14 has an upper end 18 which attaches to a drilling shaft (not shown) so that the drilling shaft rotates the auger 10 as the drilling shaft rotates.
At an opposite end of the auger 10 is a receptacle 22 for receiving a cutter head, such as that generally indicated at 26. As the auger 10 rotates about its long axis A--A, the cutter head 26 cuts through the soil. As shown in FIG. 1, the cutter head 26 is the type commonly referred to as a finger type. The cutter head 26 gets its name from the elongate fingers 30 which extend downwardly and cut through the soil. Those skilled in the art will appreciate that there are several other types of cutter heads which may be used.
Disposed about the central shaft 14 of the auger 10 is a flighting 34 which lifts cut soil out of the bore hole formed by the auger. Thus, the flighting 34 helps to prevent the auger 10 from getting clogged with cut soil.
Referring now to FIG. 2, there is shown a cross-sectional view of the auger 10 and a rod 40 and bit 44 disposed therein. As the auger 10 rotates, the rod 40 and bit 44 are rotated in like directions to penetrate the soil. The bit 44 also helps to prevent the flow of fluids into the central hollow 50 where it may contaminate soil or groundwater samples to be taken further down in the bore hole.
When the appropriate depth has been reached within the soil, the rod 40 and bit 44 are removed from the central hollow 50 of the auger 10 to allow a soil/groundwater sample collection device (not shown) to be passed down through the central hollow 50 and into contact with the soil or groundwater to be sampled. Unfortunately, the withdrawal of the bit 44 often creates a negative pressure (suction) within the central hollow 50 of the auger 10. This is especially true when the auger 10 extends into soil which is below groundwater. Adhesion of the saturated soil creates an effective seal such that withdrawal of the bit creates suction.
The negative pressure within the central hollow 50 draws soil and water upwardly as represented by the shaded area 60. Once the water or soil has entered the auger 10, it must be removed. If it is not, subsequent soil and groundwater samples may not be reliable, as the sampling container will first be filled with the water or soil drawn in, rather than the undisturbed soil below the auger 10.
Referring now to FIG. 3, there is shown cross-sectional view of the prior art auger 10 of FIGS. 1 and 2. The auger includes the central shaft 14 with a flighting 34 disposed thereabout. Disposed in the central hollow 50 of the central shaft 14 is the rod 40 and a soil sample collection device 70. Those skilled in the art will appreciate that there are numerous different types of soil sample and groundwater collection devices 70. For example, FIG. 3 shows a collection device 70 which has a hemispherical spring 74 having a plurality of cuts formed therein so that a plurality of fingers 78 formed thereby can deflect out of the way as a soil sample (not shown) enters the soil sample collection device 70 from an open lower end 82. Once the soil sample has passed the hemispherical spring 74 and into a holding portion 86, the fingers 78 return to their original position and prevent the soil sample from falling out. Other common types of soil sample collection device include trap valve type and other similar arrangements.
Those skilled in the art will appreciate that the major problem with such sample collection devices 70 is the risk that soil will begin to accumulate in the holding portion 86 of the device as the auger 10 is driven downwardly. For this reason, those operating the equipment generally have avoided placing the collection device 70 into the auger 10 until the auger is disposed above the desired location. The collection device 70 is then forced downwardly by the rod 40 into the undisturbed soil below the auger 10.
In accordance with the principles of the present invention, it has been found that the auger 10 can be operated with the soil sample collection device 70 in place without collecting unwanted soil by using a protective sleeve 90. The sleeve 90 has first and second ends, 92 and 96 respectively, the first end being closed by a covering member 100. The second end 92 is open so that the soil sample collection device 70 can be slid into the sleeve 90.
When the protective sleeve 90 is nested about the soil sample collection device 70 soil is not able to work its way up into the collection device. By removing this risk, the samples taken with the collection device 70 are generally more reliable. Additionally, the sleeve 90 adds little extra work other than the few seconds necessary to place it about the collection device 70.
Referring now to FIG. 3A, there is shown a fragmented cross-sectional view of the invention as shown in FIG. 3, but with the soil sample collection device 70 deployed in a collecting position. Because it is important to obtain undisturbed soil samples, it is necessary to extend the soil sampling collection device 70 below the end of the auger 10. This is usually accomplished by applying a downward force with the rod 40 which is sufficient to drive the soil sample collection device 70 to penetrate the soil. Those skilled in the art will recognize that there are specific standards for the amount of force used and the number of impacts made when driving the device 70 into the ground.
As the soil sample collection device 70 is driven into the ground, the force causes it to puncture the covering member 100 at the first end 92 of the sleeve 90. Once the lower end 82 of the collection device 70 punctures the covering member 100, soil can freely move through the lower end and into the holding portion 86 as indicated by the arrow 104.
Once the soil sample collection device 70 has been driven to the desired depth, the device can be withdrawn from the bore hole and the sample removed. Another soil sampling device, with a sleeve disposed thereon, may then be moved down the central hollow 50 of the auger 10 and adjacent the cutter head 26.
Typically, the sleeve 90 will remain in the hole formed by the soil sample collection device 70. In such a position, the sleeve 90 serves several important functions. One of the major problems with such sampling devices is that they create a negative pressure as they are withdrawn from the soil. The negative pressure can cause the walls of the bore hole to collapse, and can even result in soil or water being drawn up into the auger 10. The sleeve 90, however, minimizes the risk of a negative pressure being developed. The sleeve also inhibits the ability of the walls of the bore hole to collapse as the sample collection device 70 is withdrawn, further reducing the potential of soil plugging the auger.
Once the sample collection device 70 is withdrawn and replaced (when additional sampling is desired), the auger 10 will generally shred the sleeve 90 as it advances down to the position of the next sample. Thus, the second or replacement sample collection device will have its own sleeve.
Referring now to FIG. 4, there is shown a perspective view of a sampling sleeve made in accordance with the principles of the present invention. The sleeve 90 includes the first end 92 which is closed by the cover member 100, and the open second end 96 for sliding about the soil sample or groundwater sample collection device shown in FIGS. 3 and 3A. To receive the soil sample collection device, the inner diameter of the sleeve 90 must be slightly larger than the outer diameter of the collection device. It is preferred that the fit of the sleeve 90 about the collection device be relatively snug to prevent water from collecting between the sleeve and the collection device, but not so tight that the sleeve 90 will cling to the collection device as it is withdrawn through the auger and up the bore hole.
Because the sleeve 90 must resist the tendency of soils to enter into the collection device, the sleeve should be made of a durable material. While polyethylene and polypropylene have been mentioned, many other durable materials could also be used. Additionally, because the soil sampling collection devices often pass through water saturated soils, the sleeve 90 is preferably made with water resistant or waterproof materials. Those skilled in the art will be familiar with many different materials and will be able to identify advantages and disadvantages to each in light of the present disclosure.
Thus there is disclosed an expendable protective sleeve and a method for using the same for soil and groundwater sampling. Those skilled in the art will recognize numerous modifications which can be made without departing from the scope and spirit of the present invention. The appended claims are intended to cover such modifications.
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A method for obtaining saturated soil samples includes conventional drilling equipment with a central hollow which receives a conventional soil sample collection device. An elongate sleeve with a closed end is nested about the sample collection device to prevent soil from entering the sample device before it is in position adjacent the soil to be sampled. Once in position, force is applied to the sample collection device to drive it into the soil. As the sample collection device is driven into the soil, it penetrates through the sleeve. The sample collection device is then withdrawn, leaving the sleeve in the hole formed by the collection device to help prevent collapse of the walls. The sleeve also helps to minimize any negative pressures which might develop as the sample collection device is withdrawn and which can result in soil plugging the central hollow of the auger.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of Invention
The invention relates generally to a riser assembly. More specifically, the invention relates to a string of tubular members and method of making, where a substrate is deposited onto the ends of the members after grooves have been formed in the ends, the ends are threaded, and the members are threaded together.
2. Description of Prior Art
Offshore drilling operations are typically performed through a drilling riser that extends between a subsea wellhead assembly at the seafloor and a drilling vessel. Drilling risers are usually made up of a number of individual tubulars attached to each other end to end to form a string. Ends of the tubulars are often threaded so that adjacent tubulars can be attached by engaging their respective threaded ends, where a smaller diameter pin end threadingly inserts into a larger diameter box end. Typically, the box ends diameters are increased by a separate upset forging process to provide material for machining threads thereon.
SUMMARY OF THE INVENTION
Provided herein is an example of a riser string and a method of forming a riser string. In one example described herein is a riser string having a first tubular with a box end and grooves on an outer surface proximate the box end. A metal cladding is on the grooves, and threads are on an inner surface of the box end. Also included is a second tubular with a pin end that is inserted into the box end with grooves on an outer surface proximate the pin end and cladding over the grooves. Threads on the outer surface of the pin end are engaged with the threads on the inner surface of the box end. The grooves on the first tubular may optionally each have a height that decreases with distance from a terminal end of the box end and a width that increases with distance from a terminal end of the box end. Grooves on the second tubular may each have a height that decreases with distance from a terminal end of the pin end and a width that increases with distance from a terminal end of the pin end. In an example, the grooves on the first tubular are shaped like a trapezoid with a bottom end distal from the outer surface of the box end, an opening at the outer surface of the box end having a length greater than the bottom end, and converging sides that extend from the opening to the bottom end. Optionally, the grooves on the second tubular are shaped like a trapezoid with a bottom end distal from the outer surface of the pin end, an opening at the outer surface of the pin end having a length greater than the bottom end, and converging sides that extend from the opening to the bottom end. Adjacent grooves on the first tubular may be separated by a space that increases with distance from a terminal end of the box end. In an alternative, adjacent grooves on the first tubular are separated by a space that decreases with distance from a terminal end of the box end.
Also described herein is a method of forming a riser string that includes forming grooves onto end portions of tubulars and depositing a layer of metal cladding onto the end portions of the tubulars and over the grooves. Threads are provided on an inner surface of an end of a tubular to form a box end along with threads on an outer surface of an end of a tubular to form a pin end. Threads on the pin end are engaged with threads on the box end to define a connection. In one example, the steps of forming the grooves, threads, and engaging the threads are repeated with additional tubulars. In an example, the step of forming the grooves involves forming a helical groove proximate an end of the tubular, the groove having a triangular shaped cross section. Optionally, the grooves are formed by forming a helical groove proximate an end of the tubular, the groove having a castellated shaped cross section. Forming the grooves may alternatively involve forming a series of trapezoidal shaped grooves that have a successively decreasing depth with distance from a terminal end of the tubular. The step of depositing a layer of metal cladding onto the end portions of the tubulars and over the grooves may use cuttings taken from one of the tubulars.
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 partial sectional view of an example of applying a metal spray to a tubular in accordance with the present invention.
FIG. 2 is a side sectional view of an example of the tubular of FIG. 1 and having a metal spray substrate in accordance with the present disclosure.
FIG. 3A is a side sectional view of an embodiment of tubulars having a metal spray substrate and threaded ends in accordance with the present invention.
FIG. 3B is a side sectional view of the tubulars of FIG. 3A in threaded engagement in accordance with the present invention.
FIG. 4 is a side sectional view of tubulars having profiled surfaces with the metal spray applied over the profiled surfaces in accordance with the present invention.
FIG. 5 is a side view of an alternate embodiment of a profiled surface on a tubular in accordance with the present invention.
FIG. 6 is a side view of an example of a riser connected between a subsea wellhead and a platform in accordance with the present invention.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
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 thorough 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 side view in FIG. 1 is an example of applying a cladding material to a tubular 20 where a spray 22 is directed from a spray gun 24 onto an outer surface of the tubular 20 . In the example of FIG. 1 , the tubular 20 is rotated while applying the spray 22 thereby forming a spray deposit 26 on the tubular 20 and in a designated location on the tubular 20 . In an embodiment, the spray deposit 26 onto the tubular 20 is applied using a metal spray process. One example of a metal spray process is found in Carter, U.S. Patent Application Publication No. US 2011/0193338, having application Ser. No. 12/702,340, which is assigned to the assignee of the present application and incorporated by reference herein in its entirety for all purposes. The spray 22 may be a metal spray, and in an example the metal spray can include cuttings or other debris removed from the tubular 20 during its machining.
FIG. 2 is a side sectional view of an example of the tubular 20 having a spray deposit 26 on the outer surface of the tubular 20 and adjacent an end 28 of the tubular 20 . Embodiments exist however, wherein the spray deposit 26 extends substantially the length of the outer surface of the tubular 20 . Referring now to FIG. 3A , tubulars 20 1,2 are shown each with spray deposits 26 1,2 formed on their respective ends 28 1,2 . Further illustrated in FIG. 3A are threads 30 1 formed on the outer surface of the spray deposit 26 1 thereby forming a pin end on the tubular 20 1 . Similarly, threads 30 2 are shown formed on an inner surface of the tubular 20 2 thereby forming a box end in tubular 20 2 . In the example of FIG. 3A , the machining forming the threads 30 1,2 may cut entirely through the spray deposits 26 1,2 in a radial direction and into the tubulars 20 1,2 along a portion of the length of the spray deposits 26 1,2 . As shown in the example of FIG. 3B , an advantage of the spray deposit method described herein is that tubulars 20 1,2 having substantially the same inner and outer diameters may be threaded together by interlocking threads 30 1,2 formed on the spray deposits 26 1,2 . This is an advantage over coaxially connecting tubulars with unions on an outer surface and/or an upset forging process.
In an optional embodiment as shown in side sectional view in FIG. 4 , outer surfaces of tubulars 20 A, 20 B are treated with grooves 32 A, 32 B so that when a spray 22 is deposited over the grooves 32 A, 32 B, the spray deposits 26 A, 26 B have increased adhesion properties over that with a surface of a tubular having little or no profile. More specifically, grooves 32 A are made up of a repeating series of adjacently positioned upwardly pointed teeth that resemble a saw tooth-like configuration. When the spray 22 ( FIG. 1 ) is deposited over the grooves 32 A, the lower portions of the spray deposit 26 A reside between adjacent teeth of the grooves 32 A. Grooves 32 B, which are shown as a repeating castellated configuration, may or may not have a consistent lengthwise distance between successive or adjacent teeth within the grooves 32 B. In one example embodiment, after initially applying spray 22 ( FIG. 1 ), an axial cross section of the spray deposit 26 is semi-elliptically shaped and can be machined to have a general planar upper surface with forward and aft surfaces extending generally perpendicular from an axis A X of tubular 20 A.
Referring now to FIG. 5 , a side sectional view of an example of grooves 32 C is shown wherein the groove members 34 1-n have a trapezoidal-like cross-section. In the example of FIG. 5 , the groove members 34 1-n are formed into an outer surface of the tubular 20 C and may each have a height and width that changes with respect to adjacent groove members. In the specific example of FIG. 5 , groove member 34 1 has a height greater than other groove members 34 2-n making up the grooves 32 C. The sequentially reduced heights between the groove members 34 1-n may follow a generally linear function, or may optionally be nonlinear as well. In the example of FIG. 5 , the groove members 34 1-n having the larger height and width are located proximate an end 28 C of the tubular 20 C. However, the order may be reversed so that groove members 34 1-n adjacent or more proximate the end 28 C may have a height exceeded by other groove members in the grooves 32 C. The shape of the grooves 32 C can be set with a more obtuse angle to improve density and adhesion of the metal spray, and also so that the metal spray contacts as much surface area as possible to prevent shadowing.
Referring now to FIG. 6 , an example of a riser 36 is shown deployed subsea, wherein the riser 36 is made up of a series of tubulars 20 1-n that extend from a wellhead assembly 38 subsea and up to a platform 40 . In the example of FIG. 6 , the wellhead assembly 38 is shown mounted on a sea floor 42 wherein the platform 40 is above sea surface, and may be floating or may have legs (not shown) mounted on the sea floor 42 .
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 exist 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 riser assembly and method of forming where the riser assembly is made up of tubular members joined together. A metal spray process applies a layer of cladding onto ends of the tubular members and the ends are threaded to form respective box and pin configurations. Grooves are provided onto the surface of the tubular members beneath where the metal spray is applied for enhancing adhesion of the cladding and tubular members. The layer of cladding provides sufficient material so that threads may be selectively formed on the outer or the inner surface of the tubular members.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 61/020,592 filed on Jan. 11, 2008, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The field of the invention relates generally to protective shields for isolating selected portions of construction and remodeling projects, and more specifically to a tool, a kit and methods for applying and adhering a protective film to a surface.
[0003] Protective films and covers, sometimes referred to as “shields” are widely utilized in the construction and remodeling industry to isolate, for example, finished elements and features on a job site that are proximate to, or in the midst of, unfinished elements and features on the job site. By virtue of such shields, some elements and features on the job site may be preserved and protected in good condition while work may be conducted in nearby locations. The shields prevent protected surfaces from being soiled, stained, marred, scuffed, scratched or otherwise adversely impacted by construction or remodeling activities. For certain items and surfaces, existing shield materials can be difficult to properly apply and install and improvements are desired.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one embodiment, an applicator tool for applying an elongated protective film material to a surface to be protected is disclosed. The protective film material comprises a sheet of solid film continuously wound upon itself in a roll for a plurality of turns. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The applicator tool comprises a film mounting portion adapted to engage the roll of protective film material and facilitate rotation of the roll of protective film material on the surface to be protected when the exposed tacky surface of the roll is in direct contact with the surface to be protected. A handle portion is coupled to the film mounting portion for moving the film mounting portion relative to the surface to be protected, thereby rotating the film mount and adhering the tacky surface to the surface to be protected when the handle is moved to advance the roll of protective film material in a predetermined direction.
[0005] Optionally, the film mounting portion may engage a central aperture in the roll of material. The film mounting portion may be adapted to support the roll from only one side of the roll. The surface to be protected may be selected from the group of a carpeted floor, a wood floor, a tile floor, a concrete floor, a laminate floor, a vinyl floor, a wall, a window, a step, a piece of furniture, and a countertop. The handle portion may be extendable and retractable to adjust an axial length of the handle.
[0006] In another embodiment, a hand held surface shield applicator tool is disclosed. The applicator tool comprises a handle portion configured to be gripped with a single hand of a user; a film mounting portion rotatably coupled to the handle portion; and an elongated protective film material continuously wound upon itself in a roll for a plurality of turns. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The roll is mounted on the film mounting portion to facilitate rotation of the roll when the exposed tacky surface of the roll is in direct contact with a surface to be protected, and the handle is movable relative to the surface to be protected to simultaneously rotate the roll and adhere the tacky surface to the surface to be protected, thereby providing an elongated shield on the surface to be protected. The shield has at least a length corresponding to a plurality of turns of the roll.
[0007] Optionally, the film mounting portion may be slidable into a central aperture in the roll of material. The film mounting portion may support the roll from only one side of the roll. The surface to be protected may be selected from the group of a carpeted floor, a wood floor, a tile floor, a concrete floor, a laminate floor, a vinyl floor, a wall, a step, a window, a piece of furniture, and a countertop. Only the tacky surface of the roll may engage the surface to be protected as the handle portion is moved. The surface to be protected comprises a substantially planar surface that is one of vertically oriented or horizontally oriented.
[0008] In another embodiment a kit for shielding a substantially planar surface is disclosed. The kit comprises an applicator tool having a handle portion defining a hand grip and a film mounting portion that is rotatable relative to the hand grip. At least one elongated protective material is provided that is continuously wound upon itself in a roll for a plurality of turns. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface, wherein the roll is removably mountable to the film mounting portion to simultaneously rotate the roll in direct engagement with the substantially planar surface to be protected and adhere the tacky surface to the substantially planar surface to be protected, thereby providing an elongated shield on the surface to be protected having at least a length corresponding to a plurality of turns of the roll.
[0009] Optionally, the film mounting portion may be slidable into a central aperture in the roll of material. The film mounting portion may extend from only one side of the roll. The tacky surface of the roll may engage the substantially planar surface, and the film mounting portion may not engage the substantially planar surface. The substantially planar surface may comprise one of a vertically oriented surface and a horizontally oriented surface. The substantially planar surface may comprise one of a floor, a wall, a step, a window, a countertop and a piece of furniture.
[0010] A method of shielding a surface to be protected on a construction or remodeling job site is also disclosed. The method comprises providing a roll of elongated protective film material continuously wound upon itself for a plurality of turns, the surface shield material having an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The method further comprises providing a hand-held applicator tool having a handle portion and a film mounting portion; mounting the roll to the film mounting portion; directly engaging the tacky surface of the roll to the surface to be protected; and guiding, using the handle portion, the tacky surface of the roll over the surface to be protected in a predetermined direction, thereby simultaneously rotating the roll and adhering the tacky surface to the surface to be protected, thereby providing an elongated shield over the surface to be protected.
[0011] Optionally, guiding the tacky surface of the roll comprises guiding the tacky surface of the roll along a substantially planar surface, the planar surface extending in one of a vertically oriented plane and a horizontally oriented plane.
[0012] In another embodiment, a shield for protecting a surface is disclosed. The shield comprises a carrier tube comprising a central aperture and an external surface and an elongate protective film material. The film material is continuously wound upon itself in a roll for a plurality of turns and an inner surface of the roll is coupled to the carrier tube external surface. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The protective film material is less than about 24 inches wide and is configured to separate from the roll and adhere to a surface to be protected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a known adhesive film and applicator for protecting a surface.
[0014] FIG. 2 is a perspective view of another type of protective film for protecting a surface.
[0015] FIG. 3 illustrates an applicator tool for the film shown in FIG. 2 in accordance with an exemplary embodiment of the invention.
[0016] FIG. 4 is a side elevational view of the applicator tool shown in FIG. 3 in use to apply the shield.
[0017] FIG. 5 is a perspective view of another embodiment of an applicator tool in a first operating condition.
[0018] FIG. 6 is an elevational view of the tool shown in FIG. 5 in a second operating position.
[0019] FIG. 7 is an exemplary flowchart of a method of shielding a surface with the applicator tool.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following detailed description illustrates embodiments of the invention by way of example and not by way of limitation. It is contemplated that the invention has general application to protective shields for isolating selected portions of construction and remodeling projects, and more specifically to a tool, kit and methods for applying and adhering a protective film to a surface.
[0021] Exemplary embodiments of applicator tools, kits and methods for applying adhesive protective films for selected surfaces on construction and remodeling job sites are described in detail below. The applicators, tools, kits and methods facilitate secure and reliable placement and application of the protective films with minimal time and by a single person. The tools, kits and methods are applicable to a variety of different sizes of films for protecting a wide variety of surfaces on a job site.
[0022] A. Introduction
[0023] It is often desirable to shield certain elements and features on a construction or remodeling site from potentially adverse effects while work is being conducted. As one example, it is often desirable to protect an existing floor, or a newly installed one, from construction traffic, dust, tools, paint and other construction materials that may otherwise soil, negatively impact or ruin a carpeted, wood, laminate, vinyl, or tiled surface. As another example, it is often desirable to shield and protect a newly installed countertop, or one in good condition, during construction and remodeling activities in the vicinity of the countertop.
[0024] Some protective films that are suitable to shield such surfaces are available in rolls wherein protective material is wound upon itself for compact storage and transport to a job site. When needed, the rolls may be placed on designated surfaces to be protected by unrolling the material on the designated surfaces to provide a protective barrier shield on the designated surfaces. The shields are removable when work is complete or when the shielding is no longer necessary.
[0025] Certain types of protective films are adhered to the surfaces to be protected on the job site so that their position can be maintained, and also to form a seal between the film and the surface being protected. While such adhesive shields are beneficial to protect such surfaces, they can be inconvenient, and sometimes difficult, to install.
[0026] FIG. 1 is a perspective view of a known adhesive film 100 and applicator 102 for protecting a surface 104 , such as, for example only, a carpeted floor on a job site. The film 100 is generally provided as a single, solid, and continuous sheet of material that is continuously wound upon itself in a roll 106 for a plurality of turns. The roll 106 provides for convenient and compact storage prior to use of the film 100 . When unrolled, the film 100 provides a strip of a thin skin or membrane on the surface to be protected 104 to shield and protect it from adverse effects of surrounding work in the area of the film 100 . Multiple strips of film 100 may be provided side-by-side or overlapping one another to shield larger areas of the surface 104 to be protected on the site. The film 100 may be fabricated from a variety of known materials and is generally available in a variety of sizes, such as 24 inch, 36 inch and even 48 inches in width W measured between lateral side edges 114 , 116 of the film 100 . The length of the film, measured generally perpendicular to the dimension W, may range from, for example, about 30 feet to 200 feet. The film 100 may be cut to any desired length by the user.
[0027] The film 100 is provided with opposing major surfaces 108 and 110 . The major surface 108 is provided with a pressure-sensitive adhesive that renders it tacky and adherent to the surface 104 to form a protective barrier seal with the surface 104 to be protected. The opposing major surface 110 of the film 100 does not include an adhesive and is not tacky. The roll 106 is wound such that the tacky surface 108 faces inwardly and the non-tacky surface 110 faces outwardly. That is, the non-tacky surface 110 is exposed on the outer surface of the roll 106 and the tacky surface 108 is not.
[0028] To assist with installing the film 100 , an applicator 102 has been provided that commonly includes a generally rectangular frame 112 that suspends the roll 106 above the surface 104 to be protected. A handle 120 extends from an upper portion of the applicator frame 112 , and the film 100 is partly unrolled from the roll 106 and drapes around a lower portion of the frame 112 such that the tacky surface 108 of the film passes under the lower portion of the frame 112 to engage it with the surface 104 to be protected. A person gripping the handle 120 may walk behind the frame 112 and push the frame 112 along the surface 104 to adhere the film 100 to the surface 104 . The lower portion of the frame 112 smoothly presses the tacky surface 108 to the surface 104 , and tension in the film 100 causes the suspended roll 106 to rotate in the direction of arrow B and release more of the tacky surface 108 for application to the surface 104 . Thus, the applicator 102 serves both to dispense the film 100 from the roll 106 and apply the film 100 to the surface 104 to be protected.
[0029] The applicator 102 presents a number of difficulties to certain users. The relatively large-sized rolls 106 (24 inch, 36 inch and 48 inch rolls) require a relative large and sturdy applicator 102 that can be costly, cumbersome to use, difficult to transport to a job site, and requires substantial storage space when not in use. The applicator 102 is convenient for large open settings such as industrial, commercial, and institutional facilities, but because of its size it is not well suited for smaller areas and settings, such as residential projects, having smaller areas and corners. The applicator 102 is therefore generally impractical for do-it-yourself projects and for occasional users of protective films.
[0030] The applicator 102 also is not well suited for certain applications. The size, weight, and bulk of the rolls 106 and applicator 102 renders it practically useless to apply film to vertical surface such as walls or windows, and also for some smaller horizontal floor surfaces and elevated horizontal surfaces from a floor, such as a countertop or stair step. It is not well suited for certain floor applications either, such as applying the film 100 to a floor that adjoins a wall that is to be painted, because the lateral edges 114 and 116 of the film 100 are inwardly spaced from the outer lateral edges of the applicator frame 112 , thereby leaving a small, and undesirable gap between one lateral edge 114 or 116 of the film 100 and the wall that is to be painted.
[0031] Still further, because of the size and bulk of the rolls 106 and the applicator frame 112 , it can be difficult for one person to properly install and suspend a roll 106 on the applicator frame 112 and to apply the distal end 118 of the film 100 to the surface 104 to be protected. That is, an assistant is often required to install and suspend a roll 106 of film 100 , drape it over the lower portion of the applicator frame 112 , and properly adhere the distal end 118 of the film 100 to the surface 104 and for an ensuing initial distance in the direction of arrow A until one operator can effectively push the applicator 102 alone to dispense and apply the film 100 for a desired distance. The need for multiple workers to install the film 100 consumes time and labor costs that may be more beneficially spent on other tasks.
[0032] For at least the above reasons, the rolls 106 and the applicator 102 are not very user friendly or practical to many potential users that desire to apply a protective film to surfaces on a job site. It would be desirable to provide an easier to use and more universally applicable applicator for a wider variety of applications of protective films on a job site.
[0033] FIG. 2 illustrates another type of protective film 130 for protecting a surface 132 on a job site. Like the film 100 described in relation to FIG. 1 , the film 130 in FIG. 2 is generally provided as a single, solid, and continuous sheet of material, such as polyethylene, that is continuously wound upon itself in a roll 134 for a plurality of turns for convenient and compact storage prior to use of the film 130 . When unrolled, the film 130 provides a strip of a thin skin or membrane on the surface to be protected 132 to shield and protect it from adverse effects of surrounding work in the area of the film 130 . Multiple strips of film 130 may be provided side-by-side or overlapping one another to shield larger areas of the surface 132 to be protected on the site. The film 130 is also available in a variety of sizes, such as 21 inch, 24 inch, 36 inch and even 48 inches in width W measured between lateral side edges 136 , 138 of the film 130 . The length of the film, measured generally perpendicular to the dimension W may range from, for example, about 30 feet to 200 feet. The film 130 may be cut to any desired length by the user.
[0034] Like the film 100 , the film 130 is provided with opposing major surfaces 140 and 142 . The major surface 140 is provided with a pressure-sensitive adhesive that renders it tacky and adherent to the surface 132 to form a protective barrier seal with the surface 132 to be protected. The opposing major surface 142 of the film 130 does not include an adhesive and is not tacky. Unlike the roll 106 shown in FIG. 1 , the roll 134 is wound such that the tacky surface 140 faces outwardly and the non-tacky surface 142 faces inwardly. That is, the tacky surface 140 is exposed on the outer surface of the roll 134 and the non-tacky surface 142 is not. That is, compared to the roll 106 of FIG. 1 , the roll 134 is reversed or oppositely wound with the tacky surface 140 exposed on the outer exterior surface of the roll 134 .
[0035] The reverse winding of the roll 134 is advantageous over the roll 106 in some aspects. The tacky surface 140 of the roll 134 may be directly engaged to the surface 132 to be protected, and the applicator 102 shown in FIG. 1 and its accompanying drawbacks may be avoided. That is, the roll 134 may be simply placed in surface engagement with the surface 132 to be protected, and rotated by the user about the axis 144 of the roll 134 in the direction of arrow B to unwind or unroll the film 130 on the surface 132 . The roll 134 is much more amenable to application by a single person than the roll 106 .
[0036] The roll 134 is not without drawbacks, however. The exposed tacky surface 140 on the outer surface of the roll 134 can make it somewhat difficult, or unpleasant, to rotate about the axis 144 by hand in an even manner. In floor installations, the roll 134 may be unrolled with a person's feet, but this can be difficult to do in an even manner, often resulting in undesirable voids and incomplete adherence and surface engagement of the film 130 with the surface 132 to be protected. Because of the size of the roll 134 , it may very well require more than one person to reliably and uniformly adhere the film 130 to the surface 132 to be protected, and the roll 134 is not very practical, if at all, for relatively small surfaces. It would be difficult, to say the least, to use the roll 134 on an inclined or vertically oriented surface on a job site.
[0037] B. Inventive Embodiments of Protective Film Applicators, Kits and Methods
[0038] Unique and advantageous embodiments of protective film applicators, tools, and methods of shielding surfaces that may be used more or less universally across a wide variety of different surfaces on a job site are disclosed hereinafter. The applicators and tools may be provided at relatively low cost to users, and the methods may be capably, easily, and quickly performed by a single person. The uniqueness, benefits and advantages of the tools, kits and methods will in part be apparent and in part will be pointed out in the discussion below.
[0039] FIG. 3 illustrates an exemplary applicator tool 150 that overcomes numerous disadvantages in the art, including but not limited to those discussed above. The applicator tool 150 generally includes a handle portion 152 , a film mounting portion 154 , and a roll 156 of protective film 160 that may be unrolled, using the applicator tool 150 as explained below, to cover and shield a substantially planar surface 162 on a construction or remodeling job site.
[0040] The handle portion 152 in the illustrative embodiment depicted in FIG. 3 defines a contoured hand grip 164 that may be conveniently gripped with one hand. The handle portion 152 may extend as shown in FIG. 3 in a generally perpendicular orientation to the longitudinal axis 166 of the roll 156 , although in other embodiments, the handle portion 152 may be oriented differently relative to the roll 156 , such as obliquely to the roll axis 166 or parallel to the axis 166 if desired. A variety of shapes, dimensions, and configurations of the handle portion 152 are possible in further and/or alternative embodiments without departing from the scope and spirit of the invention, and while still obtaining the benefits of the inventive concepts disclosed herein.
[0041] Also, as shown in FIG. 3 , the handle portion 152 is approximately centered along the longitudinal axis 166 of the roll 156 , although in another embodiment the handle could be positioned elsewhere as desired.
[0042] The film mounting portion 154 is rotatably mounted to the handle portion 152 such that the film mounting portion 154 may rotate about the roll axis 166 in the direction of arrow C when the handle portion 152 is moved relative to the surface 162 to be protected in the direction of arrow D. The film mounting portion 154 extends from and is supported by the handle portion 152 on only one lateral end 167 of the roll 156 , leaving the opposing end 168 of the roll 156 generally free and clear of any obstruction. As such, the film 160 can be applied with the applicator tool 150 to, for example, a horizontal surface at a location where it adjoins a vertical surface such as a wall or trim piece, without leaving a gap on the surface to be protected by abutting the free lateral end 168 of the roll 156 immediately proximal to or against the vertical surface.
[0043] The roll 156 , similar to the roll 134 described in relation to FIG. 2 , includes opposing major surfaces 170 and 172 . The surface 170 is provided with a known pressure sensitive adhesive rendering the surface 170 to be tacky, and the tacky surface 170 is exposed on the outer exterior surface of the roll 156 . The tacky surface 170 is appropriately formulated to be easily removed and peeled off the surface 162 to be protected when no longer needed without leaving any residue on the surface 162 . The surface 172 is not tacky and is outward facing and exposed when the film 160 is applied and adhered to the surface 162 to be protected. The non-tacky surface 172 may be finished with non-slip coatings and the like as desired. The film 160 is provided in a solid and substantially continuously extending sheet of material, such as a polyethylene blend or equivalent material that is tear resistant and puncture resistant. The film 160 may be transparent or opaque in different embodiments.
[0044] Like the roll 134 shown in FIG. 2 , the sheet of film material is wound upon itself for a plurality of turns about the roll axis 166 . The roll 156 may be provided on a carrier tube 174 fabricated from cardboard, for example, or another suitable material known in the art. Unlike the roll 134 , the roll 156 is substantially smaller and lighter. As an example, in one embodiment the roll 156 is approximately 9 and ⅛ inches wide and has an axial length of about 50 feet, thereby significantly reducing the size and weight of the roll 156 , and the complexity and difficulties of installing the film. Of course, other widths and lengths of film may be used, whether greater or smaller than those specifically identified above, in other embodiments. For example only, the roll 156 may vary from about one inch wide to about twenty-four inches wide with lengths ranging from about one foot to over fifty feet. Of course, other widths and lengths of film may be used, whether greater or smaller than those specifically identified above, in other embodiments.
[0045] The roll 156 , and more specifically a central aperture of the carrier tube 174 , may be fitted to the film mount portion 154 of the applicator tool 150 with slight interference and slip-fit engagement between the carrier tube 174 of the roll 156 and the film mounting portion 154 . Rotatable elements and mechanisms suitable for use as the film mounting portion 154 are well known and specific discussion thereof will be accordingly omitted. The roll 156 may be slip fit on the film mounting portion 154 with force applied along the roll axis 166 in the direction of arrow E, and removed with force applied along the roll axis 166 in the direction of arrow F opposite to the direction of arrow E.
[0046] Referring now to FIG. 4 , the handle portion 152 may be gripped by a user and the outer tacky surface 170 exposed on the outer exterior surface of the roll 156 may be directly engaged, with surface-to-surface engagement, with the surface 162 to be protected on a job site. With slight pressure to maintain the roll 156 in contact with the surface 162 to be protected, and with slight force applied to the handle portion 152 to move the applicator 150 in a direction parallel to the surface 162 to be protected (the direction of arrow D in FIG. 4 ), the roll 156 may be simultaneously rotated in the direction of arrow C and pressed into firm, substantially even and uniform adherence with the surface 162 to be protected. As such, the thin film 160 is rather easily unrolled into a planar orientation and reliably secured to the surface 162 to be protected.
[0047] The applicator tool 150 , including the roll 156 is lightweight and may be easily gripped and used by one person to apply the film 160 . The applicator tool 150 also is versatile and may be used to apply film 160 to a vertically oriented surface 180 (shown in phantom in FIG. 4 ). The tool 150 is also amenable to use on elevated surfaces such as countertops, table tops, other furniture pieces, and stair steps. The relatively small size of the applicator tool 150 allows for use in a variety of spaces large and small, including corner areas and intersections of vertical and horizontal surfaces.
[0048] Special formulations of film material may be provided in rolls 156 of various sizes in various embodiments for use on surfaces with different properties and textures, including but not limited to carpeted surfaces of varying piles, wood surfaces, laminate surfaces, vinyl surfaces, metallic surfaces, tile surfaces (e.g., glass, ceramic and stone), countertop surfaces (e.g., granite, marble, veneer, laminate), concrete and cement surfaces, painted surfaces, windows and doors of all types, and upholstery and fabrics. Still other surfaces could be protected with specifically formulated film materials optimal for specific attributes of the surfaces. An inventory of film materials may be maintained and universally applied with the same applicator tool 150 . The inventory may be color-coded, for example, to easily distinguish one type of roll for another. Alternatively, special purpose applicator tools having optimized shapes, sizes, and colors, but otherwise comparable functional features, may likewise be developed for use on specific surfaces and specific locations.
[0049] Cutting edges and the like may be provided in further alternative embodiments of the inventions to facilitate the film 160 being cut to length for a specific project. Otherwise, the film 160 may be cut with a utility knife or other tool separate from the applicator tool 150 .
[0050] Applicator tools 150 and protective film rolls 156 may be provided to users as kits in another aspect of the invention. For example, an applicator tool 150 may be packaged and sold together with, say, three film rolls 156 of the same or different types. The user may select a roll 156 for a project and mount it the applicator tool 150 for use, and when the roll is consumed the user may easily replenish the tool 150 with another roll 156 , or exchange one roll with another for protecting different surfaces.
[0051] FIGS. 5 and 6 illustrate another embodiment of an exemplary applicator tool 200 that in some aspects is similar to the applicator tool 150 shown in FIGS. 3 and 4 . Like features in FIGS. 3 and 4 are therefore designated with like reference characters in FIGS. 5 and 6 .
[0052] The applicator tool 200 includes the film mounting portion 154 and roll 156 of adhesive film as described above. Unlike the tool 150 having a relatively short and truncated handle portion 152 , the applicator tool 200 includes an extendible handle portion 202 having a first section 204 defining a hand grip for a user, a second section 206 that telescopes within the first section 204 , and a third section 208 that telescopes within the second section 206 so that the handle portion 202 can be extended ( FIG. 6 ) or retracted ( FIG. 5 ) to different lengths as desired by a user. Twist-type couplers 210 and 212 , familiar to those in the art, may be utilized to secure or release the telescoping sections 206 and 208 to obtain a user-selected length of the handle portion 202 appropriate for a given job. The extendible handle portion 202 may be particularly advantageous for applying the protective films to floor surfaces, wall surfaces, and windows, for example, to reduce the effort required by the user to install the film.
[0053] FIG. 7 is an exemplary flowchart of a method 220 of shielding a surface with an applicator tool, such as the tools 150 and 200 described above. The method includes providing 222 a roll of elongated protective film material, such as a roll 156 described above, that is continuously wound upon itself for a plurality of turns, and having an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The method also includes providing 224 a hand-held applicator tool having a handle portion and a film mounting portion. The steps of providing 222 and 224 the roll and the applicator tool may occur at the job site or at another location, may not involve a sale of either the roll or the applicator tool, and need not occur at the same time or in any particular order or sequence to perform the steps 222 and 224 .
[0054] Once provided, the user may mount 226 the roll to the film mounting portion of the applicator tool as previously described, and directly engage 228 the tacky surface of the roll to the surface to be protected. The user then may guide 230 , using the handle portion, the tacky surface of the roll over the surface to be protected in a predetermined direction, thereby simultaneously rotating the roll and adhering the tacky surface to the surface to be protected, and providing an elongated shield over the surface to be protected. After cutting 232 to a desired length to complete the shield, the user may choose another surface to be protected and return to step 228 .
[0055] If desired, the user may remove 234 the roll from the tool, select 236 another roll of film, and return to step 226 .
[0056] A variety of substantially planar surfaces, whether in horizontal planes, vertical planes or sloped planes that are oblique to vertical and horizontal planes, may be preserved and protected using the above-described methodology.
[0057] It is understood that additional steps, and omission and modification of the steps described are contemplated. For example, the tool may be provided with the roll mounted thereon so as to render the steps 222 , 224 , and 226 unnecessary. As another example, additional steps of extending and retracting the tool handle portion may be performed in connection with the method between any of the illustrated steps. Further additional steps that are contemplated include cleaning of the surface to be protected prior to installing the protective film to ensure optimal bonding of the film, and removing the film after construction or remodeling work is completed. If desired, more than one applicator tool may be provided so that more than one person can apply protective film.
[0058] The benefits of the invention are now believed to have been amply demonstrated along with how disadvantages in the art are overcome. The applicator tools, kits, and methodology disclosed may be provided and performed at relatively low cost with much appeal to professional contractors and workers, as well as lay people seeking to undertake home improvements and renovations on their own.
[0059] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A tool, kit, and method for applying an elongated protective film material to a surface. The tool includes a roll of sticky protective film wound so that the sticky surface is on the outside of the roll, a mounting portion to hold the roll while letting it rotate and a handle for ease of guiding the tool during use.
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FIELD OF THE INVENTION
The present invention relates to water distribution apparatus and more particularly to irrigation apparatus formed of two layers of thermoplastic material and forming both a liquid flow conduit and a pressure reducing path.
BACKGROUND OF THE INVENTION
Various types of drip irrigation apparatus are known to be formed of two or more layers of a thermoplastic material, bonded together by heat sealing. A common problem in such apparatus has been the provision of a communication path between the flow conduit and the pressure reducing path and between the pressure reducing path and the outside. According to one prior art technique, such communication paths are formed by laser aperturing. This method, however, requires significant accuracy and introduces complication into the manufacturing process, thus increasing the possibility of rejects and possibly increasing the costs of manufacture.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved two-layer water distribution apparatus.
In accordance with an embodiment of the invention there is provided irrigation apparatus comprising first and second layers of sheet material, at least one of the first and second layers being configured in relief and the first and second layers being bonded together at touching surfaces such that the bonding of the touching surfaces defines a liquid conduit, at least one pressure reducing path associated therewith and an exit port from each of the at least one pressure reducing paths.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood and appreciated from the following detailed description taken in conjunction with the drawings in which:
FIG. 1 is a schematic illustration of irrigation apparatus constructed and operative in accordance with an embodiment of the invention;
FIG. 2 is a schematic illustration of the irrigation apparatus of FIG. 1 in an alternative configuration;
FIG. 3 is a schematic illustration of the irrigation apparatus of FIG. 2 arranged for underground use;
FIG. 4 is a schematic illustration of irrigation apparatus constructed and operative in accordance with an alternative embodiment of the invention;
FIG. 5a is a sectional illustration of the apparatus of FIG. 1 taken along the line V--V.
FIG. 5b illustrates two-sided irrigation apparatus;
FIG. 6 is a sectional illustration of the apparatus of FIG. 1 taken along the lines VI--VI;
FIG. 7 is a schematic illustration of irrigation apparatus constructed and operative in accordance with still another embodiment of the invention; and
FIG. 8 is a schematic illustration of irrigation apparatus constructed and operative in accordance with still another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1, 5a and 6, there is seen a portion of drip irrigation apparatus constructed and operative in accordance with an embodiment of the present invention and formed of first and second layers 20 and 22 of sheet material such as PVC of thickness 0.1 mm or of any other suitable material. In accordance with a preferred embodiment of the invention, layer 22 is formed, as by embossing, vacuum deep drawing or any other suitable mechanism or technique to define in relief, a continuous elongate water supply channel 24, a pressure reducng path 28 and a narrow conduit 26 connecting channel 24 to pressure reducing path 28. Pressure reducing path 28 typically includes a large number of bends and turns and may be of any suitable configuration. An exit port 30 leads from the exit of the pressure reducing path 28 to the edge of the layers 20 and 22, for communication to the outside.
It is appreciated that a multiplicity of pressure reducing paths 28 and conduits 26 are associated with a single water supply channel 24 along its length to form a single irrigation unit which is coupled to a water supply source and disposed as desired.
In the preferred embodiment of the invention illustrated in the Figures layer 22 is flat except for the raised portions thereof and is bonded along its flat portions to a confronting flat layer 20, by heat sealing or any other suitable technique. It is to be noted that in accordance with alternative embodiments of the invention, layer 20 may be configured in relief or as a further alternative both layers 20 and 22 may be configured in relief.
It is envisioned that a plurality of units of the type shown in FIG. 1 may be manufactured simultaneously from sheets of plastic of width much greater than that of the apparatus of FIG. 1. It is a particular feature of the invention that the units can be arranged on the sheets of plastic such that the exit ports 30 of two adjacent units are connected, such that longitudinal cutting of the plastic sheets to separate the units also effectively opens the exit ports 30 to the atmosphere.
Reference is now made additionally to FIG. 2, which shows a possible alternative disposition of the irrigation apparatus described hereinabove. in which the pressure reducing path is angled with respect to the liquid conduit. It may be appreciated that the embodiment of FIG. 2 may be substantially identical to that of FIG. 1 except that a longitudinal slit is made where indicated in dashed lines 50 in FIG. 1, thus separating the pressure reducing paths from the remainder of the unit except at conduit 26.
The utility of the embodiment illustrated in FIG. 2 may be appreciated from a consideration of FIG. 3 which shows irrigation apparatus of the FIG. 2 type disposed below the soil surface. The pressure reducing paths 28 are arranged to lie generally perpendicularly to the liquid conduit 24 and extend to or adjacent the soil surface.
FIG. 5b shows a two-sided version of irrigation apparatus and comprises units arranged back to back with a single common intermediate wall.
Reference is now made to FIG. 4 which illustrates irrigation apparatus constructed and operative in accordance with an alternative embodiment of the invention. Here the pressure reducing path 28 is provided with a series of exit ports 25, 27 and 29. Exit ports 25, 27 and 29 are respectively located at the end of path 28, at a point before the end of path 28 and at a point even further from the end of path 28 than the other ports. The exit ports terminate at a distance from the outer edge 31 of the plastic sheets which increases sequentially according to the relative separation of the port from the end of the pressure reducing path 28.
It may thus be appreciated that a desired pressure reducing path length may be selected by opening a given exit port to the atmosphere. Thus if a maximum pressure reduction is desired, the unit should be slit along a line 33 such that port 25 is apertured but the remaining ports remain sealed. If less pressure reduction is required, a longitudinal cut is made along line 35, thus exposing port 27 to the atmosphere and producing a shorter effective pressure reducing path. If a continuous longitudinal cut is made along line 35, port 25 will also be slit, but this is immaterial, since the vast majority of the water will exit via port 27. Similarly if a cut is made along a line 37, exit port 29 will be opened, producing an even shorter effective pressure reducing path.
Reference is now made to FIG. 7 which shows irrigation apparatus also suitable for underground placement and having an elongated exit port 80 of length suitable for extending from the underground location to a desired watering location. The apparatus is manufactured by the techniques described above from two layers of sheet material and is formed to define a liquid conduit 24 which communicates with a pressure reducing path 28 of any suitable type or configuration. Longitudinal cuts are formed between the pressure reducing path 28 and the elongated exit port 80, typically along the dashed line 82.
Referring now to FIG. 8, there is seen a further alternative embodiment of irrigation apparatus comprising a liquid conduit 24 which communicates with a pressure reducing pathway 28, both of which are formed of two layers of sheet material by techniques substantially similar to those described above. Here, for example, the exit port 90 is configured to accomodate a pipe or tubing 100, which may be any suitable tubing of hard plastic or any other suitable material. The apparatus illustrated in FIG. 8 is thus suitable for underground disposition, and for greenhouse use.
It will be appreciated by persons skilled in the art that the above discussion and examples relate to illustrative embodiments of the invention and are not intended to be exhaustive of possible embodiments of the invention. The invention is not limited by the particular embodiments shown and described herein but rather is defined only by the claims which follow:
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Irrigation apparatus comprising first and second layers of sheet material, at least one of the first and second layers being configured in relief and the first and second layers being bonded together at touching surfaces such that the bonding of the touching surfaces defines a liquid conduit, at least one pressure reducing path associated therewith and an exit port from each of the at least one pressure reducing paths.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a slide door structure of an automobile, and more particularly to a slide door structure of an automobile which can slide and open both a front door and a rear door to a rear side of a vehicle body.
2. Description of the Related Art
A door of an automobile which open and closes to the right and left sides by a hinge mechanism is generally well-known. However, in the case of opening and closing the door mentioned above so as to get in and out of the vehicle, a space for which a passenger getting in and out can avoid any interference with the door so as to pass is necessary in a side of the vehicle. In the case that a sufficient width is not obtained even if the space is secured, it is necessary to pass through a narrow space in an unnatural posture, and many problems are generated for an aged person and a handicapped person. Further, in a road having a lot of traffic or the like, there is a risk that a person, a vehicle, a bicycle or the like comes into collision with the wide-open door and a great accident or the like is triggered, so that adequate care is necessary.
As one method for solving the problem mentioned above, there is a slide door. In the slide door, because the door is opened and closed by moving the door backward and forward, it is possible to completely leave open an opening portion in a side surface of the vehicle, which is different from the hinge type door, the slide door is user friendly and convenient in the case that the person comes in and out between inner and outer sides of a passenger room or the case that the person carries a load in and out. There is obtained an advantage that it is possible to get in and out of the vehicle parked in a narrow parking space without any difficulty, and the slide door is particularly convenient for the aged person and the handicapped person.
In this case, in the conventional slide door for the automobile, it is often the case that only one of the front door and the rear door is generally of the slide type, and it is often the case that the front door is of a type which must be moved forward to be opened, and the rear door is of a type which must be moved backward so as to be opened (for example, refer to patent document 1 and patent document 2).
However, in the case that only one door is of the slide type, it is not possible to completely make good use of the advantage of the slide type so as to obtain a wide opening, and there is left the problem that it is necessary to pay attention to open and close the other side door which is not of the slide type.
Further, a structure in which both the doors are slid backward and forward (for example, refer to patent document 3) becomes ungainly, and is better adapted to a particular intended use such as a camper or the like. However, there is generated a problem that a vehicle body design is not well thought out, in a passenger car.
Patent Document 1: Japanese Unexamined Patent Publication No. 2004-50877
Patent Document 2: Japanese Unexamined Patent Publication No. 2005-81878
Patent Document 3: Japanese Unexamined Patent Publication No. 2005-88811
SUMMARY OF THE INVENTION
As mentioned above, in the conventional slide type door, it is often the case that only one of the front door and the rear door is of the slide type, or the front door is slid forward and the rear door is slid backward, respectively even if both the doors are of the slide type. However, according to these methods, there is a problem that the advantage of the slide type door might not be sufficiently put to good use, a restriction is generated in a design of a vehicle body, and an outer appearance is degraded.
An object of the present invention is to provide a slide door structure of an automobile which can solve the problems mentioned above, can widely open a door by opening a front door and a rear door backward, can allow an occupant to get in and out without any difficulty even in a narrow parking space, and can reduce the number of restrictions on a design of a vehicle body.
In order to solve the problem mentioned above, according to the present invention, there is provided a slide door structure of an automobile supporting slide doors by a plurality of lower rail boards held by a link mechanism from a lower side of a vehicle body, wherein a forward side lower rail board exists in a lower portion of the vehicle body in a front side of a rear wheel house at a door closed time in a state in which the slide door is closed, and is drawn out toward a rear side in an outer side of the vehicle body from a front side of the rear wheel house, on the basis of a rotation of a forward link mechanism at a door open time in a state in which the slide door is opened, and a backward side lower rail board exists in the lower portion of the vehicle body in a rear side of the rear wheel house at a door contained time in a state in which the slide door is closed, and is drawn out toward a front side in the outer side of the vehicle body from the rear side of the rear wheel house on the basis of a rotation of a backward link mechanism at a door expanded time in a state in which the slide door is opened.
In order to solve the problem mentioned above, according to the present invention, a slide door structure of an automobile, the slide doors are formed of a front door and a rear door, the rear door being guided by a first slider sliding along a first upper guide rail provided in an upper side portion of the vehicle body, a second slider sliding along a first center guide rail provided in a side portion of the vehicle body, and a third slider sliding along a first lower guide rail provided in common in a front side lower rail board for the rear door and a rear side lower rail board for the rear door, and which slides backward at a time of being opened and forward at a time of being closed. The front door is guided by a fourth slider sliding along a second upper guide rail provided in an upper side portion of the vehicle body, a fifth slider sliding along a second center guide rail provided in the rear door side portion and a sixth slider sliding along a second lower guide rail provided in a front side lower rail board for the front door, and slides backward at a time of being opened and forward at a time of being closed.
In order to solve the problem mentioned above, according to the present invention, there is provided a slide door structure of an automobile, wherein the slider supports the slide door to a main body of the vehicle body via a support arm, and the support arm slides backward after being drawn out to an outer side from the vehicle body side portion at a predetermined distance from a position at which the slide door is closed, at a time of opening the slide door.
In order to solve the problem mentioned above, according to the present invention, there is provided a slide door structure of an automobile supporting a slide door from a lower side of a vehicle body by a lower rail board guided by a slide rail mechanism, wherein the lower rail board exists in a lower portion of the vehicle body in a front side of a rear wheel house at a door closed time in a state in which the slide door is closed, and is drawn out toward an outer side of the vehicle body by the slide rail mechanism, and a sub rail board provided in the lower rail board is drawn out to a rear side of the vehicle from the lower rail board so as to support the slide door.
In order to solve the problem mentioned above, according to the present invention, a slide door structure of an automobile is formed of a front door and a rear door, and driving wheels provided in a lower surface in a front side of both the doors are guided and moved by guide grooves provided in the lower rail board and the sub rail board so as to be opened and closed.
According to the slide door structure of the present invention, because both the front door and the rear door can slide to the rear side so as to be opened, it is possible to secure a wide opening, and it is possible to safely and easily get in and out from the vehicle parked in a narrow parking space. Further, because the slide rail does not get into an indoor side of a driver's seat and an assistant driver seat, it is possible to make the room inside wide and the slide rail does not form an obstacle to driving. Further, there are few restrictions on the design of an outer appearance of the vehicle and a freedom thereof is large, it is possible to improve an outer appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an outer appearance of a passenger car employing a first exemplary embodiment of a slide door structure according to the present invention;
FIG. 2 is a side elevational view of an outer appearance of a state in which a front door of the passenger car in FIG. 1 is open;
FIG. 3 is a side elevational view of an outer appearance of a state in which a rear door of the passenger car in FIG. 1 is open;
FIG. 4 is a side elevational view of an outer appearance of a state in which the front door and the rear door of the passenger car in FIG. 1 are open;
FIG. 5 is an explanatory view showing a structure of a lower rail board used in the slide door structure according to the present invention;
FIG. 6 is an explanatory view showing the structure of the lower rail board used in the slide door structure according to the present invention;
FIG. 7 is an explanatory view showing the structure of the lower rail board used in the slide door structure according to the present invention;
FIG. 8 is a plan view showing a positional relation at a time of opening and closing a slide door of a second exemplary embodiment of the slide door structure according to the present invention;
FIG. 9 is a plan view showing the positional relation at a time of opening and closing the slide door of the second embodiment of the slide door structure according to the present invention;
FIG. 10 is a plan view showing a state in which a lower rail board is drawn out of a vehicle body in the second embodiment;
FIG. 11 is a plan view showing the state in which the lower rail board is drawn out of the vehicle body in the second embodiment;
FIG. 12 is a plan view showing a structure of a guide groove on the lower rail board in the second embodiment;
FIG. 13 is a cross sectional view showing a driving portion of a supporting and driving mechanism in the second embodiment;
FIG. 14 is a cross sectional view showing a caster portion of the supporting and driving mechanism in the second embodiment; and
FIG. 15 is an explanatory view showing a rotation of a driving wheel of the driving portion shown in FIG. 13 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
A description will be given in detail of the present invention with reference to the accompanying drawings.
FIG. 1 shows a side elevational view of an outer appearance of a passenger car having a slide door according to an exemplary embodiment of the present invention. Further, FIGS. 2 , 3 and 4 are side elevational views of the outer appearance of the passenger car in a state in which the slide doors are open. In the present invention, the doors are structured such that both a front door and a rear door are opened by sliding them rearward, and are structured such that only the front door can be slid to be opened as shown in FIG. 2 , only the rear door can be slid so as to be opened as shown in FIG. 3 , and both the doors can be slid to a rear side so as to be opened, as shown in FIG. 4 . In FIGS. 1 to 4 , reference numeral 1 denotes a vehicle body, reference numeral 2 denotes a front door, reference numeral denotes a rear door, reference numeral 4 denotes a front wheel house, reference numeral 5 denotes a rear wheel house, reference numeral 6 denotes a front door handle, reference numeral 7 denotes a rear door handle, reference symbol 8 a denotes an upper guide rail for the front door, reference symbol 8 b denotes an upper guide rail for the rear door, reference symbol 9 a denotes a center guide rail for the front door, reference symbol 9 b denotes a center guide rail for the rear door, reference numeral 11 denotes a front side lower rail board for the rear door, reference numeral 12 denotes a rear side lower rail board for the rear door, and reference numeral 13 denotes a front side lower rail board for the front door.
Because both the front door 2 and the rear door 3 have the slide opening and closing structure as mentioned above, it is possible to widely open a side surface of the vehicle at a time of getting in and out of the vehicle, and there is an advantage that it is possible to get in and out of the vehicle parked in a narrow parking space without any difficulty. Particularly, safety and convenience can be obtained for an aged person and a handicapped person.
The structure mentioned above can be achieved by employing a structure for supporting the slide door from a lower side of the vehicle body by a plurality of lower rail boards held by a link mechanism, and by employing a two-stage traction structure in a supporting arm guiding the slide door to the guide rail.
FIGS. 5 , 6 and 7 are explanatory views showing a structure of the lower rail board according to the present invention. FIG. 5 shows a position of each of the lower rail boards in a state in which the front door 2 and the rear door 3 are closed, and FIG. 6 shows a position of each of the lower rail boards in a state in which the front door 2 and the rear door 3 are open. Further, FIG. 7 shows a position at a time when the front side lower rail board is opened and closed.
In FIGS. 5 , 6 and 7 , reference numeral 15 denotes a rotating arm of the rear door side lower rail board, reference numeral 16 denotes a rotating arm of the front door side lower rail board, and the other reference numerals are the same as those of FIGS. 1 to 4 .
A description will be given of an opening and closing motion of the door, a motion of the supporting arm together with the opening and closing motion and a motion of the lower rail board.
The front door 2 and the rear door 3 are supported by the main body of the vehicle body 1 on the basis of an engagement of a slider provided in a leading end of the supporting arm (not shown) with a guide rail, and the slider slides within the guide rail, thereby being opened and closed.
In a state in which the front door 2 is closed, a fourth slider existing at a leading end of the front door upper supporting arm provided in an upper side of the front door 2 is engaged with the upper guide rail 8 a for the front door, and a sixth slider existing at a leading end of the front door lower supporting arm provided in a lower side of the front door 2 is engaged with the lower guide rail for the front door provided in the front side lower rail board 13 for the front door.
In the case of opening only the front door 2 , the front door handle 6 of the front door 2 is first drawn out to a near side. Then, the front door 2 is drawn out against a spring provided in an inner portion of the front door upper supporting arm and the front door lower supporting arm in such a manner as to rise to the near side at a predetermined height. The front door upper supporting arm and the front door lower supporting arm are locked at the rising position.
Thereafter, if the front door 2 is slid to a rear side of the vehicle body, a fifth slider in a leading end of the front door center supporting arm provided at the midpoint of the front door 2 is engaged with the center guide rail 9 a for the front door provided in a side surface of the rear door 3 , and the fifth slider can slide in the center guide rail for the front door. Accordingly, the front door 2 is guided by a slider moving in three guide rails comprising the upper guide rail 8 a for the front door, the center guide rail 9 a for the front door and the lower guide rail for the front door so as to be slid, and is opened in a state as shown in FIG. 2 .
Next, a case that only the rear door 3 is opened is considered. In a state in which the rear door 3 is closed, a first slider existing in a leading end of the rear door upper supporting arm provided in an upper side of the rear door 3 is engaged with the upper guide rail 8 b for the rear door, and a third slider existing in a leading end of the rear door lower supporting arm provided in a lower side of the rear door 3 is engaged with the lower guide rail for the rear door provided in the front side lower rail board 11 for the rear door.
In the case of opening only the rear door 3 , the rear door handle 7 of the rear door 3 is first drawn out to a near side. Then, the rear door 3 is drawn out against a spring provided in an inner portion of the rear door upper supporting arm and the rear door lower supporting arm in such a manner as to rise to the near side. The rear door upper supporting arm and the rear door lower supporting arm are locked at the rising position.
Thereafter, if the rear door 3 is slid to the rear side of the vehicle body 1 , a second slider in a leading end of the rear door center supporting arm provided at the midpoint of the rear door 3 is engaged with the center guide rail 9 b for the rear door provided in the side portion of the vehicle body, and can slide in the center guide rail for the rear door. Accordingly, the rear door 3 is guided by a slider moving in three guide rails comprising the upper guide rail 8 b for the rear door, the center guide rail 9 b for the rear door and the lower guide rail for the rear door so as to be slid, and is opened in a state as shown in FIG. 3 .
Next, a case that both the front door 2 and the rear door 3 are opened to the rear side is considered. If the front door 2 is further moved to the rear side of the vehicle body from the state in which only the front door 2 in FIG. 2 is open, both the doors are locked to each other so as to be combined at a position where the front door 2 and the rear door 3 are overlapped. In a state in which the front door 2 and the rear door 3 are combined, it is possible to integrally control the front door 2 and the rear door 3 by the front door handle 6 of the front door 2 . In this state, if the front door handle 6 is drawn to the rear side, the front door 2 and the rear door 3 are integrally moved to the rear side.
The combination of the front door 2 and the rear door 3 is guided by five guide rails comprising the upper guide rail 8 a for the front door, the lower guide rail for the front door, the upper guide rail 8 b for the rear door, the center guide rail 9 b for the rear door and the lower guide rail for the rear door, at the beginning, and is guided by four guide rails from the midstream because the upper guide rail 8 a for the front door is disengaged as a result of its short length, thereby being slid.
In this case, a description will be given of a motion of the lower rail boards 11 , 12 and 13 , and the rotating arms 15 and 16 used for driving the lower rail boards 11 , 12 and 13 .
FIG. 5 shows a positional relation between the front side lower rail board 11 for the rear door, the rear side lower rail board 12 for the rear door and the front side lower rail board 13 for the front door in the state in which the front door 2 and the rear door 3 are closed.
In the state in which the front door 2 and the rear door 3 are closed, the rotating arms 15 and 16 are bent in a direction extending along the side surface of the vehicle body 1 , as shown in FIG. 5 , and the lower rail boards 11 , 12 and 13 are folded below the vehicle body 1 .
FIG. 6 shows a positional relation between the front side lower rail board 11 for the rear door, the rear side lower rail board 12 for the rear door and the front side lower rail board 13 for the front door, rotating arms 15 and 16 in the state in which the front door 2 and the rear door 3 are fully open as shown in FIG. 4 . In the state in which the doors 2 and 3 are fully open, the rotating arms 15 and 16 rise up in a vertical direction to the side surface of the vehicle body 1 .
If the rotating arms 15 and 16 are moved to the state in FIG. 6 from the state in FIG. 5 , the lower rail boards 11 and 13 are drawn out to a rear side surface from a front side of the vehicle body 1 , and the lower rail board 12 is drawn out to a front side surface from a rear side of the vehicle body 1 . Further, the front side lower rail board 11 for the rear door is brought into contact with the rear side lower rail board 12 for the rear door in an outer side of the rear wheel house 5 , and the lower guide rails for the rear door respectively provided on the lower rail boards 11 and 12 are connected to one.
FIG. 7 is a view showing a relation between the front side lower rail board 13 for the front door and the opened and closed state of the front door 2 . In the state in which the front door 2 is closed, the front side lower rail board 13 for the front door is folded below the vehicle body 1 , and the front door 2 exists at a position 2 . In this case, the front door handle 6 of the front door 2 is drawn out to the near side for opening only the front door 2 . Then, the front door 2 is drawn out to the near side in such a manner as to rise up at a predetermined height. In this state, if the front door 2 is slid to the rear side of the vehicle body, the front door 2 and the rear door 3 are fitted, and the front door 2 is finally opened to a state shown in FIG. 2 . The position of the front door 2 at this time is changed to a position 2 ′ indicated by a dotted line in FIG. 7 .
Further, in a state in which the front door 2 and the rear door 3 are integrally slid to the rear side and both the doors are fully open as shown in FIG. 4 , the front side lower rail board 13 is changed to a position 13 ′ indicated by a dotted line in FIG. 7 , and the front door 2 is changed to a position 2 ″.
As mentioned above, because the front door 2 and the rear door 3 of the slide door are structured such as to be supported by the lower guide rails provided in the lower rail boards 11 , 12 and 13 , both the front door 2 and the rear door 3 can be slid to the rear side of the rear wheel house so as to be opened, whereby it is possible to secure a wide opening. Accordingly, it is possible to safely and easily get in and out of the vehicle parked in a narrow parking space.
It is possible to make the room inside wide without the slide rail entering into the room inside of the driver seat and the assistant driver seat, and the slide does not form an obstacle to the driving.
Because a restriction of design of the outer appearance of the vehicle is small and a freedom thereof is large, it is possible to improve an appearance of the outer appearance.
Next, a description will be given of a second embodiment of the slide door structure according to the present invention with reference to FIGS. 8 to 15 .
In this second embodiment, the structure is made such that the lower rail board is drawn out to an outer side of the vehicle body by the slide rail mechanism, and the front door 2 and the second door 3 are supported from the below at the drawn position, and are moved along the rail or the guide groove so as to be opened and closed.
FIGS. 8 and 9 are plan schematic views showing a positional relation between lower rail boards 21 and 23 according to the second exemplary embodiment, and the front door 2 , the rear door 3 and the vehicle body. FIG. 8 shows a case of the narrow lower rail board 21 , and FIG. 9 shows a case of the wide lower rail board 23 . The narrow lower rail board 21 is structured such that a width of a portion drawn out to the outer side of the vehicle body is approximately equal to a width of the door 2 or 3 , and the wide lower rail board 23 is structured such that a width of a portion drawn out to the outer side of the vehicle body is approximately twice the width of the door 2 or 3 . In this case, positions of front wheels 51 and rear wheels 52 are simultaneously shown.
FIGS. 8A and 9A show a state in which both the doors 2 and 3 are closed, in which the lower rail boards 21 and 23 are accommodated below the vehicle body between the front wheel 51 of the front wheel house and the rear wheel 52 of the rear wheel house. FIGS. 8B and 9B show a state in which the lower rail boards 21 and 23 are drawn out to the outer side of the vehicle body, and the front door 2 is opened.
FIGS. 8C and 9C show a state in which the lower rail boards 21 and 23 are drawn out to the outer side of the vehicle body, sub rail boards 22 and 24 provided in the lower rain boards 21 and 23 are further drawn out to the rear side in a direction extending along the vehicle body, and the rear door 3 is opened while being guided along rails (guide grooves) on the sub rail boards 22 and 24 .
Further, FIGS. 8D and 9D show a state in which both the doors 2 and 3 are open.
FIGS. 10 and 11 show a state in which the lower rail board 21 is drawn out to the outer side of the vehicle body. The lower rail board 21 is accommodated between the front wheel 51 and the rear wheel 52 below the vehicle body as shown in FIG. 10 at a time of being accommodated. At a time of opening the doors 2 and 3 , the lower rail board 21 is slid to the side portion of the vehicle body by the slide rail 25 so as to be drawn out as shown in FIG. 11 . Further, the sub rail board 22 is drawn out along the vehicle body vertically to the lower rail board 21 after drawing out the lower rail board 21 , whereby the under supporting structure ef the doors 2 and 3 is structured.
In this case, the lower rail board 21 and the sub rail board 22 can be driven by a driving motor or the like (not shown).
Guide grooves 26 to 28 are provided, as shown in FIG. 12 , on the under supporting structure of the doors 2 and 3 constituted of the lower rail board 21 and the sub rail board 22 structured, as mentioned above.
FIG. 12A is a schematic view of a state in which the lower rail board 21 is accommodated below the vehicle body, and there are shown the guide groove 26 for the front door 2 provided in the lower rail board 21 and a part of the guide groove 27 for the rear door 3 . FIG. 12B shows a state in which the sub rail board 22 is drawn out after drawing out the lower rail board 21 , and there is shown a rear half portion 28 of the guide groove for the rear door 3 provided in the sub rail board 22 .
FIGS. 13 and 14 show an embodiment of a supporting and driving mechanism driving the front door 2 and the rear door 3 so as to move along the guide grooves 26 , 27 and 28 . In this case, in FIGS. 13 and 14 , cross sections of the guide grooves 26 , 27 and 28 are indicated by reference numeral 60 .
FIG. 13 is a cross sectional view of a driving portion 40 of the supporting and driving body provided in the front side lower surface of the doors 2 and 3 . The driving portion 40 is formed in such a manner that a width thereof is within a thickness of the doors 2 and 3 , a rotation of the motor 42 is connected to a driving wheel 41 via gears 43 and 44 , and the driving wheel 41 is rotated and moved within the guide grooves 26 , 27 and 28 indicated by the cross section 60 in FIG. 13 , thereby driving the doors 2 and 3 so as to open and close.
A movable portion constituted of the motor 42 , the gears 43 and 44 and the driving wheel 41 of the driving portion 40 is structured to be rotatable within a frame of the driving portion 40 . Accordingly, it is possible to rotate the driving wheel 41 to positions A, B and C in FIG. 15 with respect to the width of the doors 2 and 3 , and it is possible to move the doors 2 and 3 to the front side and the rear side while accurately following the guide grooves 26 , 27 and 28 so as to open and close.
FIG. 13 is a cross sectional view of a caster portion 45 of a supporting and driving body provided in a rear side of the doors 2 and 3 . The caster portion 45 is also formed in such a manner that a width thereof is within the thickness of the doors 2 and 3 .
A ball caster 46 is provided on a lower surface of the caster portion 45 in such a manner as to overstride the guide grooves 26 , 27 and 28 in which the cross sections are shown in FIG. 13 , and is structured such as to move while following to the motion of the driving portion 40 , thereby smoothly moving the doors 2 and 3 .
In this case, in the narrow lower rail board 21 , the front door 2 can be opened only to a position in FIG. 8B by the guide groove 26 , however, can be moved to a fully opened position in FIG. 8D by using guide rails provided at edges of the lower rail board 21 and the sub rail board 22 together.
The description is given above of the narrow lower rail board 21 and the sub rail board 22 , however, in the wide lower rail board 23 and the sub rail board 24 , the doors 2 and 3 can be guided by providing the same guide grooves.
As mentioned above, because the structure is made such that the front door 2 and the rear door 3 of the slide door are supported and guided by the guide grooves 26 , 27 and 28 provided in the lower rail boards 21 and 23 and the sub rail boards 22 and 24 , both the front door 2 and the rear door 3 can be slid to the rear side of the rear wheel house so as to be opened, and it is possible to secure the opening wide. Accordingly, there can be obtained the same effect as the first embodiment, such as the effect that it is possible to safely and easily get in and out of the vehicle parked in the narrow parking space.
INDUSTRIAL APPLICABILITY
Because the slide door structure according to the present invention is realized as mentioned above, the slide door structure can be used in the general passenger car, wagon type car and the like, in addition to the special type of automobile, and can be widely utilized in an automobile industry.
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A slide door structure of an automobile which enables occupants to get in and out with ease even in a narrow parking space because the door of the automobile can be largely opened and capable of reducing the constraints on the design of the body of the automobile. Forward lower rail boards ( 11, 13 ) are positioned on the lower part of the body ( 1 ) at the front of a rear wheel house ( 5 ) when the slide doors ( 2, 3 ) are closed and, when the slide doors ( 2, 3 ) are opened, extracted from the front side of the rear wheel house ( 5 ) to the outside rear side of the body ( 1 ) by the rotation of a front link mechanism, and a rear lower rail board ( 12 ) is positioned on the lower part of the body ( 1 ) at the rear of the rear wheel house ( 5 ) when the slide doors ( 2, 3 ) are closed and, when the slide doors ( 2, 3 ) are opened, extracted from the rear side of the rear wheel house ( 5 ) to the outside front side of the body ( 1 ) by the rotation of a rear link mechanism.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] The present invention relates to an apparatus for supporting vertical steel reinforcement bar (re-bar) of various diameters during the pouring of a concrete foundation for a wall using a base board with holders attached to the base board. The holders holding the re-bars are positioned in such a way that the re-bars would allow the hollow concrete blocks to fit over them during the construction of the wall.
[0002] In a typical wall construction project, a ditch must be dug out. The ditch is then filled with concrete cement forming the foundation for the wall. Hollow blocks are then set on the foundation, and cemented. Concrete is poured into the hollow block to provide strength. However, in order for the wall to be structurally sound, re-bars originating from the foundation and extending upwards into the wall, must be placed. Typically, the steps taken to construct a block wall is as follows:
[0003] A ditch extending into the ground is dug to house the foundation of the wall. Re-bars are suspended off the ground and are individually wired to a wooden board by steel tie wires. The re-bars extend into the ditch and are spaced and aligned in such a way that the apertures on the hollow blocks allow the re-bars to go through the interior of the hollow blocks which form the wall. With the re-bars hanging from the wooden board, concrete is poured into the ditch. A foundation is formed when the concrete hardens. The wooden board is removed by first cutting the steel tie wires. As the concrete hardens around the re-bars, they become firmly held by the foundation. Hollow blocks are lowered down over the vertical re-bars, cemented and set upon the foundation to create a wall. Concrete is poured down the hollows blocks to reinforce and form a strong wall and the re-bars in the blocks provides the additional strength for the wall. The traditional way of constructing a wall using the steel tie wire requires a person to hold the re-bar while it is being tied to the wooden board. The positions of the re-bars have to be measured and marked on the wooden board. This process is time consuming. An improved way of avoiding the steel tie wires is disclosed in U.S. Pat. No. 5,688,428. While this method did away with the use of steel tie wires, it still requires the traditional wooden board and measurements for the re-bar holders on the wooden board. Another method as shown in U.S. Pat. No. 6,161,360 requires a penetrable cover for the re-bars. U.S. Pat. No. 5,371,991 propose the use of C-shaped holders on a wooden board to avoid using the steel tie wires.
[0004] It is therefore an objective of this invention to provide a simple device, where one worker can quickly suspend and hold the re-bars in place while concrete is poured into the ditch to create a foundation. It is also an objective of this invention to provide an easy way for a worker to either slide or snap the re-bar into a re-bar holder. It is a further object of this invention to provide a way to interconnect several re-bar support devices to cover the desired length of the foundation of the wall.
SUMMARY OF THE INVENTION
[0005] The present invention is a device designed to help a construction worker to efficiently suspend re-bars over a ditch at the precise locations where the hollow blocks are to be lowered to form a block wall.
[0006] This device comprises a base board preferably but not necessarily hollow, with re-bar holders attached to the base board. The hollow base board has a top surface, a first wall, a bottom surface, a second wall, a first end and a second end, the top and bottom surface having a top and bottom apertures aligned to accommodate a stake through said top and bottom apertures; a plurality of re-bar holders attached to one or a combination of the walls of the base board; and, means for connecting the stake to the base board. The stake has two ends with one bottom end being sharp to penetrate into the ground and connects to the base board through a pin. Several stakes are usually needed to support and to suspend the hollow base board horizontally. The pin penetrates through a hole of a side surface of the base board, the hole on the stake and through another hole on the other side surface of the base board.
[0007] One unique feature of this device is the provision of connectors on the lateral ends of the base board to connect one base board of one re-bar support device to another base board of a re-bar support device if more than one base board is needed to cover a desired length of a foundation for a block wall.
[0008] Another unique feature of this apparatus is in its re-bar holders. The re-bar holder has a body, a top aperture, a bottom aperture and a side aperture. A guide may be attached to the bottom aperture of the body of the re-bar holder, the guide having a first diameter the same as the diameter of the bottom aperture and a second diameter bigger than that of the bottom aperture with a side cut off to attach or protrude from the first wall of the base board. The guide may also have a guide aperture cut out from the side of the guide facing away from and opposite the first wall.
[0009] The body of the re-bar holder, to form a stronger grip of the re-bar, may have a plurality of saw-tooth blades extending into the top of the body of the re-bar holder or may have an array of buttons embedded into the inside wall of the body. The re-bar holder may also incorporate a side guide shaped like an elongated half circular cylinder extending along the side aperture, the side aperture being cut off by the body with adequate spacing to easily snap a re-bar into the re-bar holder.
[0010] A process of constructing a foundation for a wall having a re-bar for reinforcement using the above device comprises digging a ditch having enough space to accommodate a foundation for a wall; installing a stake at each lateral end of a base board extending over a desired length of the foundation; suspending the base board on the stakes through a pin connecting each lateral end of the base board to the stake; sliding or snapping a required number of re-bar into a series of re-bar holder; pouring concrete into the ditch and allowing the concrete to harden to form the foundation; and, removing the base board off the re-bars. If the length of the desired foundation is longer than one base board, several base boards may be connected in series to each other to cover the desired length of the foundation before or after suspending the lateral ends of the base board corresponding to each end of the foundation on their respective stakes through the pin. The base board of the re-bar support device are suspended prior to putting the re-bars on the re-bar holders.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a perspective view of the re-bar support device.
[0012] [0012]FIG. 2 is a perspective view of a stake.
[0013] [0013]FIG. 3 is a perspective view of the first re-bar holder.
[0014] [0014]FIG. 4 is a side view of the re-bar holder of FIG. 3.
[0015] [0015]FIG. 5 is a perspective view of the second re-bar holder.
[0016] [0016]FIG. 6 is a perspective view of the third re-bar holder.
[0017] [0017]FIG. 7 is a perspective view of the fourth re-bar holder.
[0018] [0018]FIG. 8 is a perspective view of the fifth re-bar holder.
[0019] [0019]FIG. 9 is a perspective view of the spade female and male connectors on the base board.
[0020] [0020]FIG. 10 is a perspective view of another connector with the spade female and male connectors of FIG. 9 rotated by 90 degrees.
DETAILED DESCRIPTION OF THE INVENTION
[0021] [0021]FIG. 1 illustrates the re-bar support device 20 on a base board 30 . The base board 30 is hollow, preferably but not essentially made of plastic material, having a top surface 31 , a first wall 32 , a bottom surface 33 , and a second wall 34 . On the top surface 31 and the bottom surface 33 are apertures 35 and 36 , usually but not essentially of rectangular shape, carved out to allow a stake 40 shown in FIG. 2 to go through these apertures. The stake 40 has a top end 41 and a sharp bottom end 42 and its shape conforms with the shape of apertures 35 and 36 . Commercially available stakes are usually made of metal and are 1½ inches wide and ⅜ inch thick having a plurality of holes or apertures along the length of the stake. However, only one aperture 39 is sufficient to hold one stake to the re-bar support device 20 . The aperture 39 approximately 1¼ inch from the top end 41 of the stake as shown in FIG. 2 is usually chosen for the device 20 described. The stake illustrated herein only has one aperture. The stake 40 is placed through the top surface 31 and the bottom surface 33 of the device 20 through apertures 35 and 36 . On the first wall 32 and the second wall 34 are apertures 37 and 38 , usually round, aligning with each other to allow a pin 55 (not shown) to pass through the first round aperture 37 through the aperture 39 on the stake 40 and then through the second round aperture 38 . The pin 55 attaches the base board 30 to the stake 40 . The base board 20 has two lateral ends, a first end 21 and a second end 22 . The bottom 42 of the stake penetrates into the ground. One stakes 40 is used for each lateral ends, 21 and 22 of the base board 30 for support. Re-bar holders 43 of different sizes are attached on or protrudes from one wall or a combination of the walls of the base board 30 . A plurality of these re-bar holders are at pre-measured positions so as to fit the apertures on the blocks used to construct a wall. The re-bar holder may extend through the width of the wall to which it is attached (not shown) or may be shorter as shown in FIGS. 1, 9 and 10 . The base board 30 may have the re-bar holders attached at fixed position to fit a particular sized hollow blocks or may have a plurality of holes through which a re-bar holder may attach to depending upon the type and size of the hollow blocks to be used. The latter will allow the use of the same base board for different types of hollow blocks. The re-bar holders can be attached to the holes on the base board by several means known in the art.
[0022] [0022]FIGS. 3 through 8 illustrate the various shapes of the re-bar holders. All the re-bar holders have a geometric shape conforming with the shape of the re-bar, herein shown as cylindrical for a cylindrically shaped re-bar. The re-bar holder 43 has a body 45 , a top aperture 50 , a bottom aperture 44 , and a side aperture 51 . The internal diameters of the top aperture 50 of the re-bar holders 43 are varied and selected to correspond to the outside diameters of the various re-bars. The re-bar holders 43 are preferably made of a plastic material or a resilient metal to frictionally hold and suspend the re-bar during the concrete pouring stage. The side aperture 51 of the body 45 is sized so that a re-bar can be snapped into the re-bar holder. The re-bar illustrated in FIG. 3 has a guide 46 , preferably conical in shape. The conical guide 46 has two diameters. The first diameter of the conical guide 46 is the same as the diameter of the bottom aperture 44 of the body of the re-bar holder 43 and is attached to the bottom of the body of the re-bar holder 43 . The second diameter 56 of the re-bar conical guide 46 is slightly bigger than those of the re-bar apertures 44 and 50 of the re-bar holder 43 to allow a re-bar to easily slide into the re-bar holder 43 from the bottom aperture 44 and upwards toward the body 45 of the re-bar holder 43 . The conical guide 46 is attached to or protrudes from the base board 30 and is cut off by the first wall 32 of the base board 30 as shown in FIG. 4.
[0023] [0023]FIG. 5 illustrates a plurality of saw-tooth blades 49 extending into the top of the body 45 of the re-bar holder covering part of the top aperture 50 of the re-bar holder 43 . The purpose of the plurality of saw-tooth blades 49 is to provide more friction to the re-bar holder 43 , to keep the re-bar from sliding downward once it is inside the re-bar holder.
[0024] [0024]FIG. 6 illustrates a modification of the re-bar holder shown in FIG. 3 where a guide aperture 52 is cut out from the side of the conical guide 46 facing away from the first wall 32 .
[0025] [0025]FIG. 7 shows a re-bar holder without the conical guide 46 but incorporates a side guide 47 attached to the body 45 of the re-bar holder 43 through the side aperture 51 . The re-bar side guide 47 is shaped like an elongated half circular cylinder extending along the side aperture 51 , the side aperture being cut off by the body 45 with adequate spacing so that a re-bar, when placed into the side guide 47 , would be easily snapped into the re-bar holder.
[0026] [0026]FIG. 8 illustrates a modification of FIG. 7 whereby an array of buttons 48 is embedded into the inside wall of the body 45 of the re-bar holder 43 . The buttons may have different geometric shapes, cubical, partial sphere, a 3 dimensional square, a 3 dimensional rectangle or a pyramid. The purpose of the array of buttons 48 is to create more friction so that the re-bar would be suspended and held firmly once it is slid or snapped into the re-bar holder.
[0027] [0027]FIG. 9 illustrates the re-bar support device 20 having a spade female connector 53 and a male connector 54 attached to the two respective ends 21 and 22 of the base board 30 . A second re-bar support device 20 may be connected by fitting the male connector 54 of one re-bar support device into the female connector 53 of another re-bar support device. A third re-bar support device or more support devices may be connected in the same manner depending upon the length of the wall desired. Other connecting mechanisms aside from that shown in FIG. 9 may be used such as rotating male connector 54 and the female connector of 53 of the connecting mechanism by 90 degrees. The rotated female connector 57 and the rotated male connector 58 are shown in FIG. 10.
[0028] Unless specifically stated, the re-bar support device 20 is preferably made of a rigid plastic material.
[0029] In operation, a ditch having enough space to accommodate the volume of the foundation for a wall is dug. Two stakes are pounded into the ground preferably above the ditch with the distance of the stakes determined by the length of the wall plus approximately half a foot of distance to each end of the wall. A base board 30 is then suspended on the two stakes by fitting the base board into the stakes through the aligned apertures 35 and 36 on the top surface 31 and the bottom surface 33 respectively. One lateral end 21 of the base board is connected to the first stake by using a pin 55 , which is structurally sound to support the weight of the base board 30 and the re-bar holders 43 . The pin is introduced through the aperture 37 on the first wall 32 , the aperture 39 of the stake 40 and the aperture 38 of the second wall 34 . The second lateral end 22 of the base board 30 is suspended on a second stake 40 using the same method. If the wall is longer than the length of the re-bar support device, several support devices can be connected to each other to cover the lenght of the wall. The re-bars, extending into the ditch, are then either slid or snapped into the holders 43 attached to the base board at predetermined positions to conform with the holes of the hollow block. Concrete is poured into the ditch and allowed to harden. After the concrete has hardened, the base board 30 is removed by removing the two pins 55 and stakes 40 and then either sliding the base board off the re-bars or un-snapping the base board holders from the re-bars.
[0030] While the embodiments of the present invention have been described, it should be understood that various changes, adaptations, and modifications may be made therein without departing from the spirit of the invention and the scope of the claims.
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A re-bar support device comprising a base board and re-bar holders to hold a plurality of re-bars spaced to fit into the holes of the hollow blocks used to build a block wall. The re-bar support device attaches to vertically standing stakes. Several re-bar support devices may be interconnected to cover the desired length of the foundation of the wall. The re-bar support device proposes several methods for easily introducing a re-bar to a re-bar holder and also discloses modifications on the internal side of the body of the re-bar support device to allow a better grip on the re-bars while concrete is poured around them during the formation of the foundation for the wall.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] The present invention relates to a retractable and extensible step assembly, and more particularly, to a retractable and extensible step assembly with minimal parts that can be stored under a cabinet without taking storage space from the cabinet.
[0002] There are prior art steps including, for example, steps that are stored in a cabinet and complicated steps that are stored under the cabinet with many moving parts. U.S. Pat. No. 3,311,190, for example, is directed to a child aid for lavatories and the like. The invention is a rigid step unit having two steps in a base portion in the form of a drawer. However, the step unit must be pivoted upward and the supporting rails must be moved forward and into abutment with the drawer. This requires the user to bend over and physically move step up and into place. The user must also reverse the process and lower the step before closing the drawer.
[0003] U.S. Pat. No. 3,481,429 also discloses a drawer step. The drawer step has a frame and a step, legs hingedly affixed to the step, and a foldable support structure secured to the frame. As with the previous step, this drawer step also requires that the user either bend down or use a foot to pull the step upward into usable position. If the folding legs of the step are not appropriately positioned, the step could collapse, possibly injuring the user.
[0004] U.S. Pat. No. 5,005,667 is directed to an extensible and retractable step assembly for a cabinet standing on a floor. The step assembly has an open rectangular base with a step therein. The step must be raised and pulled forward to engage cross pins on the lower ends of linkage arms in downwardly offset notches at the ends of slots in the base. However, if the cross pins come out of the notches through bumping the step or otherwise, the step will collapse, possibly injuring the user.
[0005] Similarly, the collapsible and retractable step apparatus in U.S. Pat. No. 5,341,897 may also be prone to instability and requires considerable effort in setting up for use.
[0006] Accordingly, the present invention is directed to a retractable and extensible step that substantially obviates one or more of the problems and disadvantages in the prior art. Additional features and advantages of the invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the apparatus particularly pointed out in the written description and claims, as well as the appended drawings.
SUMMARY OF THE INVENTION
[0007] To achieve these and other advantages and in accordance with the purpose of the invention as embodied and broadly described herein, the invention is directed to a a retractable and extensible step assembly to be disposed within a cabinet on the floor, the step assembly includes a base, a step hingingly connected to a first end of the base, the step having a first stepping surface and a second stepping surface, the first stepping surface being disposed on a first side of the step and the second stepping surface being disposed on a second side of the first step, the first and second sides being opposite one another, and a cabinet engagement means disposed on the base to slidingly engage the cabinet.
[0008] In another aspect, the invention provides for a retractable and extensible step assembly to be added to a cabinet after the cabinet has been installed at a location, the step assembly includes a sliding element to attach the step assembly in a hole in the cabinet, a retractable and extensible step assembly, the step assembly including a base, a step hingingly connected to the base, the step having a first stepping surface and a second stepping surface, the first stepping surface being disposed on a first side of the step and the second stepping surface being disposed on a second side of the first step, the first and second sides being opposite one another.
[0009] It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
[0010] The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of the specification. The drawings illustrate several embodiments of the invention and together with the description serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a front perspective view of a floor cabinet and a wall cabinet with one embodiment of a step assembly according to the present invention;
[0012] [0012]FIG. 2 is a perspective view of the step assembly with the cabinets of FIG. 1 in a second configuration;
[0013] [0013]FIG. 3 is an enlarged view of the step assembly separated from the cabinets;
[0014] [0014]FIG. 4 is an enlarged view of the step assembly separated from the cabinets and in the second configuration;
[0015] [0015]FIG. 5 is a front view of the of the step assembly of FIG. 4;
[0016] [0016]FIG. 6 is a cross sectional view of the step assembly along the line 6 - 6 in Fig. FIG. 3;
[0017] [0017]FIG. 7 is a front, fragmentary view of the step assembly of FIG. 1 in the floor cabinet; and
[0018] [0018]FIG. 8 is perspective front view of the front face of another embodiment of a step assembly according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] A step assembly 10 according to the present invention is illustrated in FIG. 1 in use with a floor cabinet 12 and upper cabinet 14 . The cabinets 12 , 14 could be of any configuration and type mounted in any location, including the kitchen, bathroom, storage/laundry room, or even the garage. As best seen in FIGS. 3 and 4, the step assembly 10 has a step 16 connected to a first end 18 of a base 20 by hinges 22 . The step assembly 10 is typically stored under the floor cabinet 12 in kick space 24 . The step assembly 10 is shown in FIGS. 1 & 3 in a first configuration. The step 16 has a first stepping surface 26 on a first side 28 . The first stepping surface 26 is positioned for use when the step assembly 10 is in the first configuration. The step assembly 10 has a first height H1 that generally corresponds to the height of the kick space 24 (typically about 4 inches), but the height H1 could also be less than the height of the kick space 24 is so desired. The step assembly 10 is shown to have a width that is about the width of one side of the floor cabinet 12 . However, the width of the step assembly 10 could be smaller or larger than shown, depending on a user's needs or desires. Similarly, while the step assembly 10 is shown in the middle of floor cabinet 12 , it could be positioned anywhere in the floor cabinet the user would like it.
[0020] The step assembly 10 is shown in a second configuration in FIGS. 2 and 4. The step 16 is rotated about the hinges 22 to rest on top of the base 20 . The step 16 and base 20 are separated from one other along a plane P (see FIG. 6) that forms an angle α that is about 45° relative to the floor. The angle a may be greater or smaller, depending on a user's preference. With the angle α at about 45°, the side rails 30 are typically out of the way of the user if the user must step off or on to the step assembly 10 from either side. Also, the side rails 30 also present less of a tripping hazard to the user and others when the step assembly 10 is being used.
[0021] In the second configuration, the step assembly 10 has a second stepping surface 32 on a second side 34 for the user to step on. The second stepping surface 32 is hidden from view and use when the step assembly 10 is in the first configuration. However, the second stepping surface 32 does assist in this configuration by providing rigidity to the step assembly 10 . In the second configuration, the step assembly 10 has height H2, which is about twice the height of the base 20 (height of H1, which is about 4 inches). While the height of the base 20 and the step 16 are illustrated to be the same, they may be of different heights, with either one being higher than the other. Obviously, they should be not larger than the kick space 24 .
[0022] Two hinges 22 are shown, one on each of the side rails 30 . However, a single piano hinge may also be used to provide more stability and ruggedness if so desired. The support bar 36 may be moved forward to the plane P, where the step 16 and the base 20 are connected, to provide a surface for attaching the piano hinge. Similarly, the first stepping surface 26 may be extended backwards to allow the piano hinge to be mounted thereon.
[0023] The step assembly 10 is preferably mounted in the kick space 24 below the storable space in the floor cabinet 12 . The step assembly 10 is preferably mounted in the floor cabinet 12 by drawer rails 38 , which allows the step assembly to be withdrawn from the floor cabinet 12 by a predetermined amount. Similarly, the step assembly 10 will only travel the predetermined distance so that the front face 40 of the step assembly is flush with the cabinet in the kick space 24 . While drawer rails 38 are shown, the step assembly 10 could be mounted to the cabinet with any appropriate mechanism, including for example, a tongue and groove system, or the step assembly 10 could be mounted on wheels to engage and roll along the floor to allow the step assembly to be rolled out from under the floor cabinet 12 .
[0024] Also, while a handle 42 that extends outward from the front face of the step assembly 10 is illustrated in the figures, the handle could be integral with the drawer, not extending beyond the front face, thereby not being a tripping hazard or drawing attention to the step assembly. Additionally, a tab 44 could replace the handle 42 , as shown in FIG. 8. The tab 44 could be mounted on the top of the front face 40 as shown, or along one side of the front face 40 . If the tab 44 were mounted on a side edge of the front face, it would accessible to the user's foot, and the user could use their foot to pull the step assembly 10 out from the floor cabinet 12 and to rotate the step 16 around the hinges 22 and into the second configuration. Similarly, the user could use their foot and tab 44 to move the step 16 from the second configuration back to the first configuration without having to bend over.
[0025] The step assembly 10 also has skid elements 46 mounted to the second stepping surface or the side rails 30 on the step 16 . Preferably the skid elements 46 assist in keeping the step 16 in the same plane as the base 20 . While the step 16 is held in position by the hinges 22 and by the engagement of the step 16 with the base 20 along the plane P, the skid elements 46 keep the step 16 from engaging the floor directly in front of the step assembly 10 and from also putting undue stress on the drawer rails 38 or other engagement elements 38 when the step assembly 10 is pulled out from the floor cabinet 12 .
[0026] It should also be noted that the step assembly 10 can be attached to the cabinet during its manufacture or even mounted in the floor cabinet after the floor cabinet has been installed.
[0027] It will be apparent to those skilled in the art that various modifications and variations can be made in the step assembly of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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An extensible and retractable step assembly is provided that has a base and a first step. The step is attached to one end of the base and rotates up on the base. The step has first and second stepping surfaces for reaching different heights. The step assembly may be inserted before or after the cabinet is installed.
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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 a roof construction and, more particularly, to a roof construction for converting a ventilated roof to a thermally insulated, non-ventilated roof without tearing off the existing roof sheathing of, for example, asbestos cement which is carried by roof beams.
BACKGROUND OF THE INVENTION
Ventilated roof constructions which already exist and are still being used, can no longer be used, or can be used only in a very limited manner in view of new heat-protection regulations in certain countries. Where one wishes to adjust these existing roofs to meet the new heat-protection regulations, a layer of insulating material which is at least 8 cm thick would have to be built in below the underside of the roof. A disadvantage of such a restoration of an existing roof is that the temperature drop to the wave crest of the corrugated asbestos cement roof, which wave crest lies thereabove, is very small. Through this, the warm air current which is needed for ventilation is too small to remove all moisture, so that physical damage must necessarily occur, as has also been the case when such roof constructions were used for gymnastic and sports halls, even though with a lesser amount of thermal insulation.
A basic purpose of the invention is to change an existing corrugated asbestos roof to a nonventilated roof, namely to a warm roof, with as little expense as possible and without removing the old roof sheathing.
SUMMARY OF THE INVENTION
This purpose is attained by providing holes in the existing sheathing over the length of each roof beam at approximately equal intervals, through which extend posts which are secured on the roof beams and project above the old roof sheathing. An insulating intermediate carrier is secured on the posts, has a U-shaped or a hat-shaped profile, and extends above the posts which are arranged in a row. The new roof sheathing is secured on the U-shaped or hat-shaped profile, and the space between the old sheathing and new sheathing is filled with an insulating layer.
The conversion of an existing ventilated, corrugated asbestos cement roof into a nonventilated warm roof is thus done by providing, along the roof beams which carry the old roof sheathing and at predetermined distances which correspond with the static requirements, holes in the old roof sheathing through which extend posts which are connected to the roof beams. These posts are advantageously constructed as Z-angles, wherein two Z-angles are arranged side by side with opposed orientations and have flanges secured on the roof beam. Through this, one achieves a substantially moment-free force transfer. An insulating intermediate carrier is then screwed onto the posts, which project upwardly beyond the old roof sheathing, on which intermediate carrier is secured a U-shaped or hat-shaped profile which extends over the entire length or width of the roof construction. The insulating intermediate carrier can either include individual insulating pieces which are secured on the individual posts, or can include a through-going thermo-roof beam which in itself forms a space-stable grid carrier, as will be described in greater detail hereinafter. The space between the old roof sheathing and the new roof sheathing, the latter advantageously being made of sheet metal, can then be filled either with a polyurethane foam or with mineral wool. The use of mineral wool will always be preferred when the surrounding temperatures and the moisture are not suitable for the use of polyurethane foam or the demand for a nonburnable roof construction exists.
In the case of roofs with a greater slope, the posts are preferably Z-angles and are not designed with legs arranged at 90° to the center web thereof, but at an angle which corresponds to the roof slope and is greater than 90°, the two legs being parallel to one another in order to meet the existing roof slope. Through this, the load is applied to the roof beam in such a direction that no moment, or only a very small moment, is applied onto the roof beam.
BRIEF DESCRIPTION OF THE DRAWINGS
Two exemplary embodiments of the invention will be described in greater detail hereinafter in connection with the drawings, in which:
FIG. 1 is a longitudinal sectional side view of an inventive roof construction;
FIG. 2 is a sectional view taken along the line II--II of FIG. 1;
FIG. 3 is a top view of posts which, according to the invention, are connected to the roof beam of an existing roof;
FIG. 4 is a sectional view similar to FIG. 2 of a further embodiment according to the invention;
FIG. 5 is a longitudinal sectional view of the inventive roof construction of FIG. 4; and
FIG. 6 is a view similar to FIG. 4 which shows a further alternative embodiment having an inclined post.
DETAILED DESCRIPTION
In the exemplary embodiment which is illustrated in FIGS. 1 to 3, an existing roof has sheathing 1, for example of corrugated asbestos cement, which is carried by a roof beam 2 which is in turn supported on supports which are not further illustrated. Round holes 3 are cut into the sheathing 1, as can be seen in the top view in FIG. 3. A post 4 is inserted through each hole 3, which post in the exemplary embodiment is two Z-shaped pieces 5 and 6 (FIG. 2) which are screwed alternately onto the roof beam 2. This has the advantages that, on the one hand, relatively small holes are sufficient and, on the other hand, the load distribution onto the roof beam occurs symmetrically.
The free legs 7 and 8 of the profile pieces 5 and 6 extend over the sheathing 1 and are screwed to an intermediate carrier 9 (FIG. 2) at the points 10 and 11. The intermediate carrier 9 is, in the exemplary embodiment according to FIGS. 1 to 3, a space-sturdy intermediate carrier and has minimal capability for conducting heat from the post to new roof sheathing 12 which is secured thereon. The intermediate carrier 9 has a lower rail 13, which is U-shaped in cross section and has legs 14 and 15 which are directed upwardly. A respective round bar 16 is welded into each corner of the rail 13, which causes the rail 13 to be statically reinforced and to be able to be manufactured of a thin material.
V-shaped rods 17 are welded to each round bar 16 and extend the entire length of the carrier. A longitudinally extending further rod 18 is disposed between and welded to the bends of the rods 17, and extends the entire length of the intermediate carrier 9. The distance between the V-shaped rods 17 is reduced in a side view (FIG. 1), so that through the resulting rectangular support the space-stable intermediate carrier 9 is obtained, which is generally gridlike. The intermediate carrier 9 is distinguished by a high stability in all directions of stress application and by a minimum use of material, wherein the connections of the rail 13 which lies on the bottom to the rod 18 which lies on top occur through relatively small cross sections in comparison to the longitudinal extent of the intermediate carrier. Through this, it is achieved that the carrier, viewed in a building or vertical direction, suffices with only a few relatively small heat bridges. This is of a great advantage for roof constructions which place high demands on thermal insulation.
A U-shaped member 22 is connected to the rod 18 of the intermediate carrier 9 by means of a clamping device which includes screws 19 and 20 and a plate 21. The legs 23 of the member 22 extend downwardly and form abutments for the fastening of the new roof sheathing 12, which in the simplest case is secured by means of clips 24 on the member 22.
The screws 19 and 20 have heads which are accessible from the outside of the member 22, and engage tapholes in the plate 21. Two insulating pieces 25 and 26 are arranged between the member 22 and the plate 21, which insulating pieces 25 and 26 are pressed against the profile rod 18 by the clamping device. Through this, a further insulation of the member 22 relative to the post 4 is obtained and, furthermore, this arrangement permits angular adjustment of the inclination of the member 22 to correspond with the desired slope of the roof with respect to the intermediate carrier 9. Through this, adjustment to various possible slopes of the roof is possible without great difficulty.
The space between the old roof sheathing 1 and the new roof sheathing 12, which in the exemplary embodiment according to FIGS. 1 to 3 is equal to the height of the intermediate carrier, is filled with an insulating layer, which layer can be a polyurethane foam or a mineral fiber insulating material.
It is possible with the inventively constructed roof to set up, without great expense and in particular without removing the existing roof sheathing, a new thermally insulated and unventilated roof construction. Aside from the technical advantages of this construction, in which above the old roof sheathing there is arranged an insulating layer, this construction is effected with simple means and, moreover, the advantage is achieved that activities in the building are not influenced during the reconstruction of the roof.
In the exemplary embodiment according to FIGS. 4 and 5, parts corresponding to those in FIGS. 1-3 are provided with the same reference numerals. The exemplary embodiment according to FIGS. 4 and 5 differs from the one according to FIGS. 1 to 3 substantially in that the post 4, which in FIGS. 4 and 5 also includes two Z-shaped profile pieces 5 and 6 connected to the beam 2 by screws 27, is designed taller, so that the legs 7 and 8 extend farther above the roof sheathing 1 than in the exemplary embodiment according to FIGS. 1 to 3. The intermediate carrier 9 is reduced to two insulating pieces 39 and 40, on which is placed a rail 28 which extends the entire length of the roof beam 2 and has a hat-shaped profile. Holes 31 are provided in the laterally angled ends 29 and 30 of the rail 28, through which extend the screws 19 and 20 which are in turn screwed into tapholes in the legs 7 and 8. The screwheads of the screws 19 and 20 engage further insulating pieces 32 and 33, which are each provided with a shoulder 34 or 35 which engages and corresponds in size to the holes 31, so that the screws are not directly connected to the rail 28 and thus cannot form a thermal bridge. The height of the shoulders 34 and 35 is slightly less than the available space so that, during tightening of the screws 19 and 20, the ends 29 and 30 of the cap-shaped rail 28 are tightly clamped in. The new roof sheathing 12 is then clipped onto the cap-shaped rail, after which the space between the old roof sheathing and the new roof sheathing is filled with an insulating material.
With respect to the roof sheathing 12, it preferably includes sheets of metal which, at their edges 36, are angled upwardly and in a conventional manner can be moved one over the other, so that a tight connection between both is obtained. It is also conceivable to place an intermediate plate 37 onto the old roof sheathing 1 when the insulating layer 38 is supposed to have a defined lower end which does not correspond with the wavy surface of the old roof sheathing.
The further exemplary embodiment which is illustrated in FIG. 6 is substantially identical to that according to FIGS. 4 and 5, with the single change that the post 4, which is again formed of two Z-shaped profile pieces 5 and 6, has angles between its legs which are greater than 90°. Through this, it is achieved that, in the case of more strongly sloped roofs, the force introduction extends through the center of the roof beam 2 and not at a location spaced therefrom, so as to avoid applying a moment onto same. The angle of the legs of the Z-shaped profile pieces can be chosen to correspond to the slope of the roof and to the height of the new roof structure. With this, the otherwise automatic application of force onto the subconstruction with a moment does not exist.
For the inventive roof construction, it is sufficient when using Z-angles to create a hole of 70 mm through the old roof sheathing to the roof beam which lies therebelow. By overcoming the symmetrical load application, for example using Z-shaped angles which are mounted alternately, one achieves a symmetrical load delivery onto the roof beams which lie therebelow. The connection of intermediate carriers, posts and roof beams is done using screw connections, which preferably are rust-free. The new roof sheathing, which preferably includes metal sheets, is applied by means of holding clips to the intermediate carrier. Through the construction of the posts, which if desired can be inclined, it is always assured that the application of forces onto the roof beam occurs in a torque-free manner, namely, symmetrically. In an economical aspect, it has proved to be particularly advantageous that the entire roof structure can be made of premanufactured parts without an influence of the space which is to be provided with the new roof construction occurring.
Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
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Conversion of a ventilated roof to a thermally insulated, nonventilated roof without tearing off an existing roof sheathing which is, for example, made of asbestos cement and is carried by roof beams, includes the provision of holes in the old roof sheathing over the length of each roof beam at approximately equal intervals; and the provision of posts which are secured on the roof beams, extend through the holes, and project above the old roof sheathing. A heat-insulating intermediate structure is secured on the posts, has a U-shaped or hat-shaped profile, and extends over the posts which are arranged in a row, on which U-shaped or hat-shaped profile is secured the new roof sheathing. The space between the old and new roof sheathings is filled with an insulating layer.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application is a continuation of application Ser. No. 08/305,901, filed Sep. 14, 1994, and now issued as U.S. Pat. No. 5,617,795.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for assisting in maintenance of rail roadbeds. More specifically, it relates to an apparatus for guiding new ties into the roadbed and for holding tie plates against rails when ties are being replaced.
In order to maintain railroad tracks in safe operating condition, it is necessary to replace the ties periodically. The ties (made of wood, metal or concrete) underneath the rails tend to wear out after an extended period of use. Various machines have been developed for removing and/or inserting the ties.
Among problems encountered in use of such machines are the handling of the tie plates when old ties are removed. Manual handling of the tie plates slows down the process and increases costs and safety risks. Absent intervention, the tie plates simply drop to the roadbed when the old ties are removed.
Another problem is getting a new tie to slide into the cavity left by removal of the old tie without catching on the rails (which rails are lifted during removal and insertion), any tie plates held against the rails, and other obstructions.
The following U.S. patents, assigned to the assignee of the present application and hereby incorporated by reference, show various such machines:
______________________________________U.S. Pat. No. Inventor Issue Date______________________________________4,951,573 Madison August 28, 19905,048,424 Madison et al September 17, 19915,197,389 Glomski et al March 30, 1993______________________________________
Madison '573 discloses a tie remover/inserter using the structure of a modified backhoe.
Madison and Newman '424 discloses a tie replacer including a tie guide structure to help guide the new tie into proper position without catching on obstructions. It uses electromagnets to hold tie plates against the uplifted rails.
Glomski, Newman, and Madison '389 discloses a tie replacer with a tie guide assembly and air-cylinder operated magnets to hold the tie plates against the rails.
U.S. Pat. No. 4,241,663 issued Dec. 30, 1980 to Lund et al. discloses use of electromagnets to hold tie plates to rails.
Although those and various other devices for tie plate handling and/or tie guiding have been generally useful, they have been subject to one or more disadvantages.
Those devices using magnets or electromagnets for holding tie plates often pick up metal parts (such as loose tie plate spikes) other than tie plates. Such other metal parts may prevent the devices from securely holding the tie plates against the rails. Further, even non-metallic debris, such as ballast, may get between the tie plates and the magnets or electromagnets and cause tie plates to drop free of the rails.
The guide assemblies or structures for guiding ties into place often still have problems with debris blocking ties as they go into place. Further, it often requires great force to overcome friction and to get the ties into place using such tie guides. Finally, such tie guides often allow or cause wandering of the tie as it is inserted. In other words, the tie doesn't maintain its orientation perpendicular to the rails during insertion.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a new and improved tie guide and tie plate holding assembly.
A more specific object of the present invention is to provide a tie guide which eases insertion of ties and reduces the amount of force required to insert a new tie.
A further object of the present invention is to provide a tie plate holder which avoids or minimizes problems from debris.
Yet another object of the present invention is to provide a tie plate holder and tie guide which are highly efficient and reliable.
The above and other features of the present invention which will be more readily understood when the following detailed description is considered in conjunction with the accompanying drawings are realized by an apparatus for aiding in tie replacement operations including: a frame; and first and second side clamp assemblies supported by the frame. Each of the first and second clamp assemblies have a pair of opposing field side mechanical grip elements and a pair of opposing gauge side mechanical grip elements, the pairs of field side and gauge side mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced. The pairs of field side and gauge side mechanical grip elements are self-centering such that when gripping a tie plate each pair of mechanical grip elements will automatically center about the tie plate prior to gripping the tie plate and without moving the tie plate. The first and second clamp assemblies further include respective corresponding first and second grip hydraulic cylinders. Each pair of mechanical grip elements are attached for movement with opposing rod and cylinder ends of one of the first and second hydraulic cylinders.
Each of the first and second clamp assemblies further include at least one spring corresponding to each hydraulic cylinder and operably connected to the corresponding mechanical grips for self-centering thereof. More preferably, each of the first and second clamp assemblies further includes two springs corresponding to each hydraulic cylinder and operably connected to the corresponding mechanical grips for self-centering thereof.
The frame is an apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame. There are first and second clamp assembly lifters for vertically moving the respective first and second clamp assembly lifters relative to the apparatus frame.
The apparatus further includes a tie guide supported by the frame, the tie guide having a plurality of rollers on an underside thereof, the rollers operable to minimize friction between the tie guide and a new tie being inserted under the tie guide. A first sweeper supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted.
The apparatus is combined with a tie replacer vehicle.
The present invention may alternately be described as an apparatus for aiding in tie replacement operations including: a apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame; and a first side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder (i.e., under the first side clamp assembly) are removed and replaced. The first side clamp assembly includes a pair of opposing field side mechanical grip elements and a pair of opposing gauge side mechanical grip elements, the pairs of field side and gauge side mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
The apparatus further includes a second side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced, and wherein the second side clamp assembly includes a pair of opposing field side mechanical grip elements and a pair of opposing gauge side mechanical grip elements, the pairs of field side and gauge side mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced. The mechanical grip elements include a pair of self-centering mechanical grip elements such that when gripping a tie plate the pair of mechanical grip elements will automatically center about the tie plate prior to gripping the tie plate and without moving the tie plate. The first side clamp assembly further includes at least one spring operably connected to self-center the pair of mechanical grip elements. More specifically, the mechanical grip elements are pairs of self-centering field side and gauge side mechanical grip elements such that when gripping a tie plate each pair of mechanical grip elements will automatically center about the tie plate prior to gripping the tie plate and without moving the tie plate.
A second side clamp assembly is supported by the apparatus frame on a side opposite the first side clamp assembly and has mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
A tie guide is supported by the apparatus frame, the tie guide having a plurality of rollers on an underside thereof, the rollers operable to minimize friction between the tie guide and a new tie being inserted under the tie guide. A first sweeper is supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted.
The present invention may alternately be described as an apparatus for aiding in tie replacement operations including: an apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame; and a tie guide supported by the apparatus frame, the tie guide having a plurality of rollers on an underside thereof, the rollers operable to minimize friction between the tie guide and a new tie being inserted under the tie guide. A tie guide lifter operably connects the tie guide to the apparatus frame for causing relative vertical movement therebetween. A first side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
The present invention may alternately be described as an apparatus for aiding in tie replacement operations including: an apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame; a tie guide supported by the apparatus frame; a first side tie plate holder supported by the apparatus frame and operable to grip tie plates when ties thereunder are removed and replaced; and a first sweeper supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted. A second sweeper is supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted. A tie guide lifter operably connects the tie guide to the apparatus frame for causing relative vertical movement therebetween. The tie plate holder includes a first side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention will be more readily understood when the following detailed description is considered in conjunction with the accompanying drawings wherein like characters represent like parts throughout the several views and in which:
FIG. 1 shows a schematic side view of a vehicle according to the present invention;
FIG. 2 shows a perspective view of an apparatus for aiding in tie replacement operations according to the present invention;
FIG. 3 shows an end view of the apparatus of FIG. 2;
FIG. 4 shows a perspective view, with some parts removed for ease of illustration, of a portion of the apparatus;
FIG. 5 is a side view of portions of the apparatus;
FIG. 6 is a top view of a tie and a portion of a sweeper of the apparatus; and
FIG. 7 is a simplified cross sectional view along lines 7--7 of FIG. 6.
DETAILED DESCRIPTION
With reference initially to FIG. 1, a tie replacing vehicle 10 has a main frame 10M and front and back pairs of rail engagement wheels 10W (only one of each pair visible). A tie replacer apparatus 12 is depicted schematically, as are rail clamps 14 and a tie guide/plate holding apparatus 16.
The vehicle 10, tie replacer 12, rail clamps 14, and various other (unshown) parts of the vehicle may be constructed in the fashion shown and described in the above mentioned and incorporated by reference U.S. Patents Madison et. al '424 and/or Glomski et. al '389. However, the tie guide/plate holder 16 is constructed differently from arrangements of those patents and will be discussed in detail below.
Turning now to FIGS. 2 and 3, the tie guide/plate holder 16 is an apparatus for assisting in the replacement of ties. This guide/holder apparatus 16 serves to hold tie plates P against rails R when an old tie T is being removed and a new tie (not shown) is being inserted. The vehicle 10 will lift the rails R to allow removal of the old tie T and its replacement by a new tie in the manner discussed in Madison '424 and Glomski '389. In addition to holding the tie plates P against the rails R during the tie removal and insertion process, apparatus 16 will guide a new tie in place without it binding against the rails R or other possible obstacles.
The apparatus 16 includes an apparatus frame 18 attached to main or vehicle frame 10M (FIG. 3 only) by front and back scissor linkages 20. The linkages 20 are controlled by hydraulic cylinders 22 which extend to lift apparatus frame 18 into an upper, inoperative or travel position relative to vehicle frame 10M and retract to extend linkages 20 and lower apparatus frame 18 into a lower, operative or working position relative to vehicle frame 10M. Linkages 20 and cylinders 22 together serve as a frame lifter for vertically moving apparatus frame 18. When lowered into its illustrated working position, apparatus frame 18 has front and back pair of flanged wheels 24 (not all 4 are visible) in contact with the rails R. The apparatus frame 18 has plates 26 and 28 (momentarily view FIG. 5) which are fixed respectively to members 30 and 32 of frame 18.
As best shown in FIG. 2, frame 18 includes right and left pairs of plates 34 to which links 36 are pivotably attached at axles 36A. Plate clamp assemblies 38 have plates 40 pivotably attached at points 40P to ends of the links 36. Hydraulic actuators or cylinders 42 have rod ends secured to plates 44, which are part of apparatus frame 18. The barrel or cylinder ends of actuators 42 are pivotably attached to plates 46 which in turn are mounted to shafts 48. (As will be apparent, the apparatus 16 is symmetric with respect to its right and left sides corresponding to the rails R.) Right and left actuators 42 extend to lift corresponding right and left assemblies 38 by lifting shafts 48 and plates 40 with pivoting at points 40P and axles 36A. Retracting an actuator 42 would lower the corresponding assembly 38 including plates 40 and other parts discussed below.
When lifted into their upper positions, the assemblies 38 are raised such that the vehicle may be indexed or moved until the assemblies 38 are over a tie to be replaced. Assemblies 38 may then be lowered into an operative position for plate clamping as will be discussed. Links 50 (only one visible, right side of FIG. 2, but there is right field side, right gauge side, left field side, and left gauge side of these links) connect to blocks 52 (only one visible, would be right and left side such blocks). The blocks 52 are fixed to corresponding plates 40 and are part of the assemblies 38. The links 50 maintain the proper orientation for assemblies 38 as they are lifted and lowered, links 50, links 36, plates 40, and portions of assemblies 38 collectively constituting a four bar linkages.
Continuing to view FIG. 2, but also referring to FIG. 4, the details of the plate clamp assembly 38 will be discussed. For ease of illustration, the field one of the plates 40 is removed from FIG. 4. It should be appreciated that, not only is there identical right and left side of the plate holding assemblies or holders 38, but the field and gauge side of holding assemblies 38 are identical.
Above the field block 52 (FIG. 4) is a center plate 54 connecting it to a corresponding, not visible, gauge block, all of which are fixed to plates 40. The center plate 54 has a mount 56 to which shaft 58 is fixed with springs 60 movably capturing mounts 62 at opposite ends thereof. The mounts 62 are trapped by lock nuts or rings (not shown) at ends of shaft 58 such that shaft 58 does not slip out of the holes in mounts 62. Mounts 62 are part of end plates 64 which, like center plate 54, extend between identical field and gauge components. End plates 64 have blocks 66 fixed to them and are retracted/extended by operation of jaw cylinder 67. Blocks 66, captured to slide on shaft 69, in turn have jaws or grip elements 68 secured to them. It will therefore be readily appreciated that the grip elements 68 are attached or mounted for sliding movement in a straight line corresponding to movement along shaft 69, with direction of movement is parallel to an extension/retraction direction for the hydraulic cylinder 67. The jaws 68 have contact surfaces 68C which are inclined from vertical. Specifically, in the view of FIG. 4, the right contact surface 68C would be inclined rightwardly at its upper end and left contact surface 68C would be inclined leftwardly at its upper end. In that fashion, opposing jaws 68 may firmly wedge tie plate P against the rail R. The jaws 68 of FIG. 4 are the field jaws on one side of the track, it being understood that identical gauge jaws would hold the gauge side of the plate P and that identical field and gauge side jaws would be mounted on the other side of the vehicle. There would be 4 jaws 68 associated with each rail R for a total of 8 jaws 68 on the apparatus 16.
Turning to FIGS. 2, 3, and 5 in conjunction, a tie guide 70 is movable up and down by tie guide lifter actuators 72 which have their barrel ends pivotably attached to plates 74. The plates 74 are fixed to member 32 of apparatus frame 18. The rod ends of actuators 72 are pivotably attached to member 76 connected to the remainder of tie guide 70 by members 78.
As best shown in FIG. 5, tie guide 70 is also attached to the member 30 of apparatus frame 18 by four bar linkages made of links 80 and adjustable links 82 (only one of each visible in FIG. 5), which maintain the orientation of tie guide 70 when it is moved up and down by actuators 72. Plates 84 are fixed to member 76 to move up and down with tie guide 70. Bolts 86 are mounted thereon to serve as an adjustable stop by hitting a portion of plate 88 fixed to member 32 when the tie guide 70 is dropped to a lower guiding position relative to the apparatus frame 18. A central portion 90 of tie guide 70 includes a series of rollers 92 free to rotate about axes perpendicular to the lengthwise direction of tie T and front and back side plates 94 at each side, the side plates 94 having wide mouths and being tapered inward to direct the tie T into the space therebetween without binding. The space between side plates 94, which serve as side members, is considered as a tie channel extending transversely to a rail direction and into which a tie is channeled when it is inserted, as clearly shown in FIG. 5. Rollers 92 are mounted to chains 92C (see visible one in FIG. 3) which are unpowered, but help minimize friction between the bottom of tie guide 70 and the top of a tie T being inserted (see FIG. 5). As with the other portions of apparatus 18, the tie guide 70 is symmetric about a central axis (not shown) extending lengthwise between and parallel to rails R.
With reference to FIGS. 3, 6, and 7 in conjunction, a hydraulic sweeper 96 on each side has nine sweep paddles 96P (shown schematically in FIG. 7, left out of FIG. 3 for ease of illustration) which turn about central axis 96A. They may follow a circular pattern, an oval pattern with major axis horizontal, or, as shown, an oval pattern with major axis being vertical. In any case, the paddles 96P sweep ballast or other debris off new ties as they are inserted. The top view of FIG. 6 shows that the paddle 96P sweeping over the top of tie T in direction 96M is inclined to push debris leftwardly, off the tie and towards the unshown central axis between the two rails R. By having the sweep elements or paddles 96P sweep towards the central axis, debris is kept away from the rails R. The paddles 96P are 1/4 inch steel mounted to parallel hydraulically powered chain drives 98 (FIG. 3). The chain drives 98 are supported by the members 100 which are part of tie guide 70.
The operation of the apparatus 18 will now be described. The vehicle 10 moves to the tie to be removed. During this movement, the hydraulic valves (not shown) controlling the apparatus frame lifter actuators 22 are in the floating mode such that apparatus frame 18 can freely move up or down as it rolls on rails R. When the tie guide 70 and plate holders 38 are over a tie to be removed, actuators 22 cause frame 18 to press downwardly. At the same time, plate holder actuators 42 move plate holders 38 from their upper positions to their lower positions. Jaw actuators 67 are then retracted to bring four grip elements or jaws 68 against each of the two tie plates corresponding to the tie being replaced. The springs 60 insure that, when beginning to grip a tie plate, each pair of mechanical grip elements will automatically center about the tie plate prior to securely gripping the tie plate and without moving the tie plate. In other words, the springs 60 cause jaws to float at opposite ends of shaft 69 and tend to equalize force on both opposed jaws 68. Frame lifters 22 are returned to the floating mode and reduced pressure is supplied to tend to lift plate holders 38 which now hold the plates P. When the rail is lifted using the process described in the incorporated by reference patents, the plate holders 38 hold the tie plates P against the bottoms of the rails R. Floating of the frame lifter actuators 22 at this time avoids hindering removal of the old tie.
Before the new tie is inserted, pressure is applied to guide lifters or actuators 72 which lowers tie guide 70 into its lower or tie guiding position. Tie guide 70 is moved down to the position determined by the bolts 86. Tie sweepers 96 are activated to sweep and prevent ballast from getting between the tie T and tie plates P. The new tie T is now inserted.
After the new tie is inserted, plate hold or clamp actuators 67 are extended such the jaws 68 release the plates P. Before that happens, the plates P are automatically centered relative to tie guide 70 by operation of springs 60. Therefore, they will be centered relative to the central axis of the new tie being inserted and best positioned for attachment to the new tie. After jaws 68 release the plates, plate holder lift actuators 42 are extended to lift plate holders 38 and tie guide lift actuators 72 are retracted to lift tie guide 70 such that the vehicle may move to the next tie to be replaced.
When the vehicle is to travel long distances without replacing ties, actuators 22 are extended to lift the frame 18 relative to the vehicle frame 10M.
When moving between ties to be replaced, an operator may manually control the position of the vehicle. Alternately, a sensing system (not shown) may index or move the vehicle between ties. Such a sensing system is shown and described in U.S. Patent application of Newman et. al, Ser. No. 08/265,834, filed on Jun. 27, 1994, assigned to the assignee of the present application, and hereby incorporated by reference.
Although specific constructions have been presented herein, it is to be understood that these are for illustrative purposes only. Various modifications and adaptations will be apparent to those of skill in the art. In view of possible modifications, it will be appreciated that the scope of the present invention should be determined by reference to the claims appended hereto.
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An apparatus grips tie plates and guides new ties during replacement of worn out ties in the road bed of a railroad track. Mechanical grip elements grip tie plates and secure them against the rail, while an old tie is removed and a new tie is inserted. A spring arrangement automatically self-centers opposing pairs of grip elements. That is, when beginning to grip a tie plate, each pair of mechanical grip elements will automatically center about the tie plate prior to securely gripping the tie plate and without moving the tie plate. The grip elements are supported by an apparatus frame. A frame lifter moves the apparatus frame vertically between an upper and a lower position relative to a vehicle frame of a tie replacer vehicle. A tie guide includes rollers on the underside thereof for minimizing friction between ties being inserted and the tie guide. Sweepers are mounted to the apparatus frame to clean off a tie as it is being inserted.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a continuation of application Ser. No. 740,185, filed May 31, 1985 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to pipe connectors for connecting pipes particularly but not exclusively for use in conveying pressurized fluids, for example steam, gas or oil, for example in oil or gas exploration or production.
2. Description of the Prior Art
One of the main types of connector presently used for such purposes comprises a female member having an internal circumferential surface provided with a thread and a male member having a corresponding external circumferential surface also provided with a thread which is threadedly received within the female member. Seals are required between the members and frequently one such seal is provided by abutment between an axially facing surface on the free end of one of the members, generally the male member, and a corresponding surface provided on the other member, the surfaces being abutted under compression when the members are fully engaged together. To obtain seals which will withstand conditions of use, the surfaces need to be abutted under triaxial compression, i.e. compressive forces in axial, radial and circumferential directions. To obtain this the abutted surfaces are directed radially as well as axially. In one connector the free end of the male member is provided with two oppositely directed frusto-conical surfaces being a radially outer surface the apex of the cone of which is directed outwardly of the male member and a radially inner surface the apex of the cone of which is directed inwardly of the member, such that the free end of the male member has a generally V-shaped section in a radial plane. Corresponding surfaces are provided on a shoulder in the female member and the two members are relatively dimensioned so that the radially inner surface on the male member comes into contact with the corresponding surface on the female member first and is then deformed to bring the radially outer surface on the male member into contact with the corresponding surface on the female member. However in this connector, when the two members are fully engaged together, a very high stress concentration may occur along the line joining the two frusto-conical surfaces of the male member and this can cause part of the shoulder of the female member extending from this line of high stress concentration to shear off, totally destroying the seal.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide improved pipe connectors which eliminate all the disadvantages of the prior art above described and which do not cause the stress concentration and are able to keep complete seal with the aid of triaxial compression.
It is a further object of the invention to provide pipe connectors which are simple in construction and inexpensive and are able to keep the seal in the connectors even if being subjected to high internal pressures and external forces.
In order to achieve these objects, the pipe connector according to the present invention comprising a female member having an internal circumferential surface provided with a thread and a male member having an external circumferential surface corresponding to the internal circumferential surface of the female member, to be received within the female member, and provided with a thread for engagement with the thread of the female member, wherein, when the members are fully engaged together, a generally axially directed annular surface at the free end of one of the members makes abutting sealing contact with a corresponding oppositely generally axially directed annular surface on the other member, the abutted surfaces of the members comprising portions which are directed radially outwardly and inwardly of the members and which are continuously curved.
Advantageously the abutted surfaces of the members are relatively dimensioned so that they are a radial force fit such as to cause deformation of the end portion of the free end of the one member away from the other member as the members are fully engaged together.
According to another aspect of the present invention there is provided a pipe connector comprising a female member having an internal circumferential surface provided with a thread and a male member to be received within the female member and having an external circumferential surface corersponding to the internal circumferential surface of the female member provided with a thread to be engaged with the thread of the female member, wherein, when the members are fully engaged together, a generally axially facing annular surface at the free end of the one of the members makes abutting sealing contact with a corresponding oppositely generally axially facing annular surface on the other member, the annular surface at the free end of the one member comprising a first radially outwardly and axially facing annular surface portion having a first radius of curvature, a second radially inwardly and axially facing annular surface portion having a second radius of curvature, and a third annular surface portion having a third radius of curvature which interconnects and merges with the first and second surface portions, the third radius of curvature being less than the first and second radii of curvature, and the other member having corresponding first, second and third annular surface portions having substantially the same radii of curvature as the first, second and third annular surface portions of the one member, the relative dimensions of the abutted surfaces being arranged so that the portion of the free end of the one member provided with the annular surface portions is a radial force fit relative to the other member such as to cause radial deformation of the end portion of the free end of the one member in a direction away from the other member as the members are fully engaged together.
Advantageously where the third surface portion merges with the first and second surface portions of the members respectively, the surface portions have common tangents.
According to one embodiment, the one member is the male member, a generally axially directed annular surface at the free end of the male member making abutted sealing contact with a corresponding oppositely generally axially directed annular surface on the female member, and the dimensions of the annular surface portions of the members are arranged so that the first surface portions come into contact and are deformed before the second surface portions come into contact.
Advantageously the surface portions are arranged so that, while the third surface portions may come into contact when the members are fully engaged together, the compressive stress thereacross is less than that across the first and second surface portions of the members.
Preferably, where the one member is the male member, the first radius of curvature of the first surface portion of the male member is less than the second radius of curvature of the second surface portion and the radius of curvature of the third surface portion is substantially less than both the first and second radii of curvature.
For example, the first radius of curvature may be about one half the second radius of curvature and the third radius of curvature may be about one tenth of the second radius of curvature.
Preferably, where the one member is the male member, the first surface portion of the male member merges with a cylindrical peripheral surface portion and the first surface portion of the female member merges with a frusto-conical surface portion, the maximum diameter of which is greater than that of the cylindrical surface portion of the male member so that the frusto-conical surface portion of the female member serves to guide the free end of the male member towards its final position relative to the female member. The minimum diameter of the frusto-conical surface portion of the female member is preferably less than that of the cylindrical surface portion.
Where the one member is the male member, the second surface portion of the male member may terminate at the internal surface of the male member or may merge with a fourth annular frusto-conical surface portion which then terminates at the internal surface of the member. In the latter event, the female member is also provided with a corresponding fourth annular surface portion having substantially the same conicity as the fourth surface portion of the male member. Advantageously the fourth frusto-conical surface portions form tangents to the second surface portions.
According to another embodiment of the invention, the one member is the female member, a generally axially directed surface at the free end of the female member making abutted sealing contact with a corresponding oppositely generally axially directed annular surface on the male member, and the dimensions of the annular surfaces of the members are arranged so that the second surface portions come into contact and are deformed before the first surface portions come into contact.
Preferably the second radius of curvature is less than the first radius of curvature and the third radius of curvature is substantially less than both the first and second radii of curvature. For example the second radius of curvature may be about one half the first radius of curvature and the third radius of curvature may be about one tenth the second radius of curvature.
Embodiments according to the present invention will now be described, by way of example only, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial sectional view through an embodiment of pipe connector according to the present invention;
FIGS. 2 and 3 are enlarged axial sectional views of parts of the connector of FIG. 1;
FIGS. 4 and 5 show the parts of FIGS. 2 and 3 during interengagement of the members of the pipe connector of FIG. 1; and
FIGS. 6 and 7 are axial sectional views of other embodiments of the pipe connectors according to the present invention.
FIGS. 8 and 9 are enlarged sectional views of parts of the connector of FIG. 1, illustrating the radii of curvature of the annular surfaces of the male and female members, respectively.
FIG. 10 shows the parts of FIGS. 8 and 9 during interengagement of the members of the pipe connector of FIG. 1, illustrating the clearance between the members on an exaggerated scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a connector which comprises a male member 1 and a female member 2. In this embodiment the female member 2 is provided by part of a sleeve 3 which also provides a second female member 2a for connection with a second male member 1a. Each of the male members 1, 1a is provided at the end of a pipe section 4, 4a and may, as shown, be formed integrally with the pipe section or may be made separately and welded or otherwise fixed thereto.
As shown, each male member 1, 1a has a generally frusto-conical outer peripheral surface 5, 5a which is provided with a thread and each female member 2, 2a has a corresponding frusto-conical inner peripheral surface 6, 6a which is also provided with a thread for receiving and engaging the corresponding male member. The members may be conventionally threaded or for example may be provided with threads as described in any of co-pending UK Applications Nos. 8421540, 8421541 and 8421615. The threads on the peripheral surfaces terminate short of the free ends 7, 7a of the male members and the corresponding inner ends of the surfaces 6, 6a of the female member and, when the members are fully engaged together, a generally axially directed surface on the free end of each male member is brought into sealing abutment with a corresponding oppositely generally axially directed surface on a shoulder 8 of the female member, as will be described more fully in relation to FIGS. 2 to 5, which show only the free end 7 of male member 1 and the corresponding portion of shoulder 8 and the adjacent internal surface of the female member 2.
As shown in FIG. 2, the free end 7 of the male member 1 is provided with a first radially outwardly and axially directed annular surface portion 9 which has a radius of curvature R1, and a second radially inwardly and axially directed annular surface portion 10 having a radius of curvature R2. The surface portions 9, 10 are interconnected by a third annular surface portion 11 having a radius of curvature R3, which surface portion 11 merges with surface portions 9 and 10 at lines 12 and 13 where the adjacent surface portions have common tangents to remove any discontinuity in the curvature of the surface portions 9, 10, 11. The third surface portion 11 extends over the apex or crest of the end surface of the male member and has a substantially smaller radius of curvature than those of the first and second surface portions. For example, the radius of curvature R1 may be about one half of the radius of curvature R2 and the radius of curvature R3 may be about one tenth of the radius of curvature R2.
The first surface portion 9 merges with a cylindrical peripheral surface portion 14 which forms a tangent to surface portion 9 at line 15. The second surface portion 10 may terminate at 16 at the inner surface of the male member. Alternatively the surface portion 10 may merge at 16 with a fourth frusto-conical surface portion 17, shown in broken lines, which forms a tangent to surface portion 10 at line 16. Surface portion 17 then terminates at the inner surface of the male member.
As shown in FIG. 3, the female member 2 is provided with surface portions 19, 20, 21 and optionally 27 corresponding to surface portions 9, 10, 11 and 17 of the male member and with substantially the same radii of curvature R1, R2 and R3 and with lines of merging 22, 23 and 26 corresponding to lines 12, 13 and 16. However in the female member, the first surface portion 19 merges at 28 with a frusto-conical surface portion 29, which may for example extend at between about 5° and 30° to the axis, and which is followed by a cylindrical surface portion 30. The maximum diameter of surface portion 29 is greater than the diameter of surface portion 14 of the male member so that surface portions 14 and 30 are slightly spaced even with full interengagement of the members. However the minimum diameter of surface portion 29 is less than the diameter of surface portion 14 and the maximum dimensions of portions 9, 10, 11 are greater than those of portions 19, 20, 21. Thus as the members are screwed together, the free end of the male member is guided toward its final position by the frusto-conical surface portion 29 of the female member and initially makes contact with the female member in the region of line 28. Surfaces 9 and 19 then progressively come into contact as shown in FIG. 4 with an increasing degree of deformation, which is initially elastic and finally plastic, so that these surfaces 9, 19 are subject to triaxial stresses due to both axial compression and radially inward deflection or deformation of the end portion of the free end 7 of the male member which is caused by the contact between the surfaces 9 and 19. As surfaces 9 and 19 become fully engaged, surfaces 10 and 20, and 17 and 27 if provided, come into abutment are compressed together, as shown in FIG. 5.
The surfaces 9, 10 and 11, and 19, 20 and 21 are dimensioned and arranged so that, when surfaces 9 19 and 10, 20 are fully engaged together and under the designed compressive stress, surfaces 11 and 21 may be slightly spaced apart or in contact, but they will in any even experience substantially less compressive stress than surfaces 9, 19 and 10, 20.
The tolerancing of the radii of curvature of the surfaces 9, 10 and 11 and 19, 20 and 21 in such that the radii of curvature of surfaces 19 and 20 of the female member are at least equal to or slightly greater than the radii of curvature of surfaces 9, 10, and the radius of curvature of surface 21 is at most equal to or slightly less than the radius of curvature of surface 11.
The radii of curvature of annular surfaces 9, 10, and 11 of the male member are specifically illustrated and shown in FIG. 8, as MR1, MR2, and MR3. The radii of curvature of annular surfaces 19, 20, and 21 of the female member are specifically illustrated in FIG. 9, as FR1, FR2, and FR3.
The clearance between the male and female members during the interengagement thereof, is illustrated on an exaggerated scale in FIG. 10. This Figure also illustrates the two line contacts, namely, a seal contact and a torque contact.
When radii of curvature FR1 and FR2 are slightly larger than the radii of curvature MR1 and MR2, and radius of curvature FR3 is slightly smaller than the radius of curvature MR3, the following relationship therebetween may be expressed:
FR2>MR2>FR1>MR1>MR3>FR3 (1)
While the invention has been described in the context of a connector in which the female member is provided by a sleeve, it will be appreciated that it is equally applicable to a pin and box connector, for example as shown in FIG. 6, where the male and female members 31, 32 are formed integrally with or fixed, for example as shown by welding, or otherwise to the ends of pipe sections 4, 4a, a generally axially directed surface, e.g. as described with reference to FIG. 2, at the free end 37 of the male member 31 making abutting sealing contact with a corresponding generally axially directed surface, e.g. as described with reference to FIG. 3, provided on shoulder 38 on the female member 32.
Additionally, while the invention has been described in terms of sealing abutment between a generally axially directed surface on the free end of the male member and an internal surface on the female member, it will be appreciated that it is equally applicable to a connector where sealing is required between a generally axially directed surface on the free end of the female member and a corresponding surface on the male member, for example as shown in FIG. 7. As shown in FIG. 7 an axially directed surface on the free end 38 of the female member 32 makes abutting sealing contact with a surface provided on a shoulder 39 of the male member 31. Surface portions corresponding to surface portions 9, 10, 11 are provided on the free end 38 and surface portions corresponding to surface portions 19, 20, 21 are provided on the shoulder 39 as described above except that the surface portions corresponding to portions 9 and 19 are radially inwardly, rather than radially outwardly, directed (and are therefore herein termed second surface portions) and the surface portions corresponding to portions 10, 20 are radially outwardly, rather than radially inwardly, directed (and are therefore herein termed first surface portions). The female member may also be provided with surface portions corresponding to portions 14 and 17 and the male member may be provided with surface portions corresponding to portions 29, 30 and 27.
In a specific embodiment of a pipe connector as described above in relation to FIGS. 1 to 5, the radii of curvature R1, R2 and R3 of the male member are 0.2 inches, 0.4 inches and 0.04 inches, and the axial distance between the centers of the circles radius R1 and R2 is 0.287 inches.
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A pipe connector comprises an internally threaded female member and an externally threaded male member for threaded engagement in the female member. When the members are fully engaged together, an axially and radially directed surface at the free end of one of the members, e.g. the male member, is abutted against a corresponding surface on the other member, e.g. the female member. The surface comprises radially inwardly and outwardly curved surface portions which are relatively dimensioned to be a radial force fit such as to cause deflection of the end portion of the free end of the male member away from the female member as the members are brought into full engagement to bring the surfaces into full engagement.
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BACKGROUND OF THE INVENTION
The concept of providing large, open work areas which are then subdivided into individual work areas by means of movable and rearrangable partitions has become popular in recent years. The panels used to subdivide the area and form the separation walls are normally manufactured in a variety of modular widths, such as 12, 18, 24, 30, 36, 40, 48 or 60 inches. A number of manufacturers of these panels have entered the market utilizing different modular widths. These panels are normally provided at each edge with means for detachably hanging a variety of accessory items, such as storage bins, shelving, work surfaces, bulletin boards and racks for storing or organizing various work materials such as paper. These accessories are supported by brackets designed to detachably engage and lock to slotted standards at the vertical edges of the panels.
As these type of panels have been manufactured in a variety of widths, accessories adapted to mate with the mounting brackets of one size panel will not necesssarily be adaptable to the brackets on a different size panel, requiring that numerous accessories having mounting brackets of various widths be purchased. A further complication arises from the fact that different manufacturers use different designs for the bracket supports. A system which provides for adaptability of different accessories to panels having different widths and bracket support designs, is disclosed in U.S. patent application Ser. No. 269,417, by Douglas F. Wolff, which has a common assignee as the present application. That system provides a beam which can be adapted to hook into the detachable means of various panel widths. The beam provides a plurality of identical pockets spaced along its length, and an accessory construction having a hook or hooks which are received into these pockets to support the accessory. Thus, this system allows an accessory to be used on panels of various widths.
As such panels are used in a variety of work environments, it is desirable to provide accessories that can perform a variety of functions. Although some storage devices provide for permanent storage, a desirable function is to provide temporary article support and organization for use during a particular project or daily routine. Particularly desirable would be to fulfill this function with a device which is both lightweight and inexpensive and can be adapted to a variety of work settings.
SUMMARY OF THE INVENTION
The invention provides article supports for use with a beam structure that is detachably secured to the vertical standards of panels in a space divider system. The article supports provide an organizer for work materials and the like having a number of substantially horizontal arms which are secured to the beam so as to extend outward from the wall panel. These arms are spaced along the beam and are grouped in pairs, having flexible material supported between the arms to thus form an article receiving pocket therebetween.
In one embodiment of the invention, a number of pairs of arms are spaced along the beam with one arm of each pair above the other, with the flexible material extending between alternating upper and lower arms to form an organizer including a number of article receiving pockets. In other embodiments crosspieces extend between the arms, to either form a rack for supporting numerous flexible articles or from which the flexible material depends in order to form the article receiving pocket.
In certain embodiments of the invention, the article supports have a detachable connector which can be used to connect a variety of accessories to a beam so that each article support can be used with beams having different pocket sizes or configurations.
Thus, the invention provides organizer pieces for temporary article storage while short term use is being made of the articles, such as a daily or weekly work project divider. The organizer article supports of the present invention can be supported on various widths of divider panels and replace other bulky storage items, such as file cabinets, which are hard to move should a work area be desired to be rearranged. Additionally, with storage devices of the present invention only that amount of storage area that is required need be provided. Unlike free standing file cabinets and the like, temporarily unused organizer storage devices of the present invention can easily be removed from the work area and compactly stored, since the supports nearly nest or stack for storage. Although other storage devices which are hung from movable panels can also be removed for storage, the bulky and noncollapsible structure of some, such as cupboards, do not allow for compact storage. The article supports of the present invention can be inexpensively yet sturdily made to provide a more flexible approach to work material organization.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an oblique view of a portion of a space divider panel wall system illustrating embodiments of the invention installed thereon;
FIG. 2 is an oblique view of a beam and a frame for a divider organizer of this invention with the flexible webbing omitted;
FIG. 3 is a front elevational view of the divider organizer of FIG. 2 with the flexible webbing attached;
FIG. 4 is an oblique view of an individual web supporting arm pair;
FIG. 5 is a fragmentary end elevation view of the arm pair of FIG. 4 illustrating the beam in section;
FIG. 6 is an exploded, oblique view of a rack and support unit embodying the present invention;
FIG. 7 is a fragmentary, sectional view illustrating the attachment of the accessory of FIG. 6 to the beam;
FIG. 8 is an oblique view of a modified construction for the frame illustrated in FIG. 1;
FIG. 9 is a sectional view taken along plane IX--IX of FIG. 8;
FIG. 10 is an exploded, oblique view of the support bracket for the structure illustrated in FIG. 8;
FIG. 11 is an oblique view of a further modified construction for one of the accessory units;
FIG. 12 is a broken, side view of the accessory shown in FIG. 11;
FIG. 13 is an oblique view of a stand for the accessories of this invention; and
FIG. 14 is a fragmentary sectional view taken along the plane XIV--XIV of FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The numeral 10 indicates a portion of a space divider panel structure illustrating four, individual panels 11 which have been locked together to form a wall unit. The opposite vertical ends of each of the panels are provided with a slotted standard 12 of conventional construction. The slotting of the standards 12 provides the means by which various accessories such as shelving, storage cabinets, work surfaces and the like can be detachably hooked to and supported from the panels 11. This is conventional practice in this type of movable panel or partition-type, space divider construction. The width of panels 11 varies from one manufacturer to another and each particular manufacturer normally manufactures panels in several modular widths. Supported on panels 11 by beams 20 are work units or organizers such as pocket dividers 30, a computer printout rack 50 and a pouch 60. It is to be understood that the invention is not limited to these three types of work units or racks.
One embodiment of the present invention includes a pocket forming divider 30 (FIGS. 2 and 3). Divider 30 has a plurality of U-shaped brackets 31 each having a pair of vertically spaced, generally horizontal arms 32 which extend outwardly from panel 11. A vertical bar 33 connects the two arms of each bracket, so that each set has an overall U-shape oriented on its side. Vertical bar 33 portion of each bracket is secured to beam 20 by being clamped between and welded to the inner and outer rails 21 and 22 of both the upper and lower members of beam 20, preferably at uniform spacings.
Flexible element or webbing 34 is passed over and around arms 31 to provide compartments or pockets 35. Flexible element 34 can be made of numerous materials, such as textile fabric, plastic or any other material which is both flexible and strong, with the strength of the material dictated by the articles to be supported. The opposite ends of the webbing 34 are looped over to form an envelope or sleeve to receive one of the arms 31. The webbing 34 is passed vertically between adjacent vertically spaced arms 31 to create generally V-shaped pockets which are open at both the top and outer ends. It is passed over the upper arms and under the lower arms. It is preferably pulled taut so the pockets will retain their shape when loaded. It will be recognized that a different arrangement of the webbing can be utilized which will change the configuration of the pockets.
Flexible webbing 34 can have enough elasticity that it can be passed over the free ends of arms 31 for removal. This allows both for the alteration of the configuration of webbing 34 on the arms and also allows dividers 30 to be nested when removed from panels 11 during storage. Plastic caps 35 (only one of which is illustrated) can be used to cover the ends of arms 31 to eliminate any sharp edges (FIG. 2).
In another embodiment, shown in FIG. 4, each bracket 31a is independently secured to beam 20. Each bracket 31a is equipped with its own individual connector 36. Connector 36 has two downward convergent legs 37 which are joined at the bottom to form a V-shaped configuration corresponding in shape and size to the pockets 27 of the supporting beam. Horizontal portions 38 extend toward each other from the tops of the legs 37 and terminate in parallel outward extensions 39. Connector 36 therefore has a triangular shape which is spaced from the back face of the vertical bar portion 32a to provide a gap to receive the front rods or rails of the beam when the bracket is installed (FIG. 5).
Beam 20 is utilized to either mount the individual brackets 31a or the pocket divider 30 and other accessories to panel 11 (FIG. 1). Beam 20 has inner and outer rails 21 and 22 (FIG. 6). The inner rail 21 has upper and lower rods 23 and 23a and the outer rail 22 has upper and lower rods 24 and 24a (FIG. 5). The rails are spaced apart and supported by intermediate members 25. The beam has a height adequate to stabilize racks or accessories mounted on them. The intermediate members 25 are arranged to form V-shaped pockets 27 of identical size and shape. The lower ends of adjacent segments preferably are spaced apart to provide a gap or opening through the bottom of each of the pockets 27. It will be recognized that while beam 20 preferably utilizes a wedge of V-shaped pocket 27, the pockets could be of a different shape, although the pocket sides should retain a limited degree of downwardly convergent inclination to provide positive seating of the brackets.
Each end of the beam 20 is supported by a suitable end bracket 28 (FIG. 1). Each end bracket 28 has extending therefrom a pair of hooks 29 of a size and spacing to be received in a pair of vertically spaced slots of one of the standards 12. The construction of beam 20 is more fully described in United States patent application Ser. No. 269,417, having Douglas F. Wolff as the named inventor, which application is assigned to the same assignee as the present application, the contents of which application is expressly incorporated herein by reference.
To mount each individual bracket 31a on beam 20, connector 36 is seated in a pocket 27. After the desired number of individual brackets 31a have been secured to the beam, flexible webbing is installed in the same manner as used to install it on bracket 30. In doing so, by making the webbing taut it forms panels between the arms which will hold their basic shape when loaded with work material. The use of individual brackets permits the user to select the size and number of pockets or compartments desired.
FIGS. 6 and 7 illustrate a detachable connector 40 for securing accessories such as racks to the beam. Detachable or releasable connect 40 has pair of spaced, downwardly extending V-shaped hooks or legs 41 sized and shaped to seat in a pair of the pockets 27 in the beam. The hooks 41 are joined by a horizontal member 42, which is of a length to space the hooks to match the spacing of the pockets 27. At each end of the releasable connector an extension 43 projects forward from the top of the hook. Although it is preferable that extension 43 rests upon upper rod 24 of the beam to provide additional support for the accessory when the connector is seated in the beam, contact between the intermediate members 25 and the hooks 41 alone is sufficient to provide positive support for the device. The terminal end of each extension 43 is bent downwardly into an eyelet 44, with extension 43 being of sufficient length that the upper rail or rod 24 can pass between the hooks 41 and eyelets 44 when connector 40 is seated on beam 20, as shown in FIG. 7. Preferably, horizontal member 43 rests on the top of the rail 24 with the eyelets 44 hanging over the front face of the beam.
Detachable connector 40 is formed from suitable steel rod. While the connector 40 must be of relatively stiff stock, it must permit the eyelets 44 to be slightly separated to mount the main body 45 of the accessory.
The main body 45 of the rack used with the detachable connector 40 includes a frame 46. The frame 46, preferably, is a generally horizontal closed loop extending outwardly from the panel. The inner ends of frame 46 terminate in laterally extending pegs 47. An inner cross piece 48 connects the sides of the frame adjacent the pegs 47 completing the loop and preventing lateral deflection of the pegs. Welded to the bottom of the frame 46 is a brace 49, which prevents frame 46 from pivoting downwardly relative to the panel when frame 46 is secured to the beam. The brace 49 is shaped such that its lower leg portion 52 seats against the front face of the beam 20, positively supporting the frame 46 against downward pivotal movement. It will be recognized that the brace can have a number of different configurations and perform the same function.
The frame 46 is secured to the connector 40 by spreading the eyelets 44 sufficiently to pass over the ends of the pegs 47. Upon release of the eyelets, they will seat over the pegs. This must be done while the connector is separated or at least partially separated from the beam 20 so that the entire hook portion of the connector is available to permit flexing. Once the hooks are seated in the pockets, they are supported against spreading by the intermediate members 25.
The article supporting means of the frame can take several forms. For example, it can be formed by a plurality of parallel cross bars 53 (FIG. 6) to form a surface or to serve as rods over which materials such as computer printout sheets can be draped. As an alternative, the cross bars 53 can be omitted and a pocket forming, flexible web 54 can be suspended between the back and front lateral members of the frame 46 to form the pouch-like accessory 60 (FIG. 1). By the addition of one or more intermediate cross members the webbing can be made to form multiple pockets or pouches.
FIGS. 8 and 9 illustrate a modified construction for an accessory article support frame or rack. In this construction, the spaced brackets 31 of the accessory support 30a are rigidly interconnected by a rod 61 welded to their front faces a short distance below the top of the frame. They are also rigidly interconnected by a lower rod 62 welded to their back faces. The tops of the brackets are also welded to the angle member 63.
The ends of the rod 61 project beyond the adjacent brackets 31 and are turned down to form ears 64 (FIG. 10). These are clamped between the inner and outer plates 65 and 66 of the support bracket 28a when the plates are secured by the screws 67. The design of the bracket 28a may be such that the lower rod 62 bears against the panel surface when the arms of the brackets 31 are horizontal. This, however, is not essential.
FIGS. 11 and 12 illustrate a further modification in which the rack 80 is a basket-type of structure having, at opposite ends, downwardly projecting legs 81 and 82. The legs project below the bottom of the rack so the accessory 80 can be detached from the beam and placed on a surface such as a desk. The accessory 80 has a hook 83 at its rear end so it can be hung from the beam. The lower portion of the rear leg 82 is offset rearwardly to provide a panel engaging brace 84 to better support the unit. The intermediate article supporting wires 85 are secured to the stabilizing rod 86 to increase the rigidity of the basket.
The beam can have uses other than being suspended from the panels of a space divider system. As illustrated in FIGS. 13 and 14 it can be mounted on legs 90 secured to its ends by appropriate end caps 91. The upper ends of the legs 90 are inserted between the front and rear rods of the beam 20 and are secured by tightening the screws 92 which threadedly engage the legs. This causes the front rods of the beam to be clamped between the cap and the leg. The legs are provided with long, forwardly extending feet 93 to stabilize the structure against the cantilevered loads applied by the accessory racks. This permits the beam to by supported on a suitable surface 94 such as a table or credenza.
From the above description it is apparent that the article supports incorporating this invention can perform a variety of functions. The flat rack can store flexible, hanging items such as computer printout sheets, or can be used in the manner of a conventional shelf. The pouch can store bulky items while the dividers can be used both to sort and store different groups of items. Due to the angled surface provided by the dividers, papers stored therein will stand at an angle and the top sheet will therefore be displayed. All of the article supports are manufactured of preferably steel, metal rods and abrasion and tear resistant fabric so that additional storage units are easy to erect and compact to store, while being sturdy in use.
The provision of a surface supported stand permits the units to be temporarily detached from the wall panels, moved to an active work zone and returned when no longer needed. The provision of legs on the units provides the same advantages.
From the above description and drawings of the preferred embodiment, it will be recognized that other variations or modifications can be made without departing from the principal or spirit of the invention. Such modifications are to be considered as included in the hereinafter appended claims unless these claims by their language expressly state otherwise.
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The invention provides accessories for suspension from beams mounted on either space divider panels or a stand with the individual accessory units being readily movable from one support to another or in some cases being capable of being temporarily placed on a supporting surface while their content is being actively utilized.
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This application relies for priority on U.S. Provisional Patent Application Ser. No. 60/416,534, filed on Oct. 8, 2002, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to snow grooming vehicles that use winches to assist in climbing steep inclines. The invention is also directed to level winding systems for winch assemblies.
2. Description of Related Art
Tracked vehicles used in rugged terrain often employ winch assemblies to assist in maneuvering steep inclines. Snow grooming vehicles, for example, are sometimes equipped with winches that have cables that attach to fixed points on the incline to allow the vehicle to be anchored to the fixed point while sweeping up or down the slope. The cable anchor prevents the vehicle from turning over or sliding down the slope, which could occur on very steep inclines.
A winch-equipped vehicle typically carries a cable that extends outwardly through a rotatable boom. The boom is an elongated metal arm that guides the cable through a series of pulleys. Depending on the direction of intended travel, the boom is rotated to extend forwardly over the cab or to extend rearwardly away from the cab. The cable is typically carried on a drum, preferably a grooved drum, that is driven to control outlay and intake of the cable. A guide, preferably a level winder, is provided at the base of the boom to assist in aligning the cable as it is fed to and from the drum to prevent twisting of the cable.
Most prior art winches use vertical guides and worm gears that follow a linear path parallel to the drum's axis of rotation to align the cable with the drum grooves. As the load on the cable in such a system can be up to 10,000 lbs., the guide assembly must be constructed to accommodate such forces. These assemblies require a large degree of maintenance to prevent the guides and gears from rusting and breaking. However, constant lubrication is necessary. Additionally, these guide assemblies consume a large amount of space, which leaves limited space for the pulleys and rollers associated with the cable system. As a result, the diameter of the pulleys and rollers are often smaller than the minimum recommended cable bending radius. Bending cable about a radius less than the recommended bending radius shortens the life and reliability of the cable.
Some prior art systems use capstan systems to address the problems associated with the prior art guide assemblies described above. FIG. 5 illustrates a capstan system 100 that utilizes a linear guide system 110 . The torque applied to the guide system 110 is reduced by winding cable 120 around a capstan 130 . As a result, the force at the exit of the capstan 130 is a fraction, 1,000 lbs. for example, of the force in a conventional guide system. The cable 120 is guided from the capstan 130 through a sliding component 140 to a drum 150 . However, the capstan 130 itself occupies a great deal of space and is complex, due in large part to the motors required for driving the capstan. Further, maintenance for a capstan is complicated as changing a cable requires a large investment of labor. Moreover, the sliding component 140 must be constantly lubricated.
Thus, there is a need for a less complex and more compact guide assembly associated with such a winch, especially a level winder assembly.
SUMMARY OF THE INVENTION
An aspect of embodiments of the invention is to provide a winch assembly that has a relatively compact and simple design.
Another aspect of embodiments of the invention is to provide a winch assembly suitable for use on a snow grooming vehicle and further to provide a snow grooming vehicle equipped with such a winch.
A further aspect of embodiments of the invention is to provide a winch that is relatively easy to operate, may allow an operator to observe operation, and may extend the useful life of the wound cable.
Among other things, the invention is directed to a winch assembly that includes a drum, a driver, and a level winder. The drum carries a length of cable. The driver is coupled to the drum and rotates the drum to wind and unwind the cable. The level winder is disposed adjacent to the drum to guide the cable with respect to the drum, and is supported to move in an arc shaped path.
The invention is also directed to a winch assembly that includes a drum, a driver, and a level winder. The drum carries a length of cable. The driver is coupled to the drum and rotates the drum about a generally horizontal axis to wind and unwind the cable. The level winder is disposed adjacent to the drum to guide the cable with respect to the drum. The level winder is also supported to pivot about a generally vertical axis.
The invention is also directed to vehicle that includes a frame, an engine that is supported by the frame, a drive mechanism that is operatively connected to the engine, and a winch assembly that is supported by the frame. The winch assembly includes a drum that carries a length of cable. A driver is coupled to the drum for rotating the drum to wind and unwind the cable. A level winder is disposed adjacent to the drum to guide the cable with respect to the drum. The level winder is supported to move in an arc shaped path.
These and other aspects of embodiments of the invention will become apparent when taken in conjunction with the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Features of the invention are shown in the drawings, which form part of this original disclosure, in which:
FIG. 1 is a partial view of a tracked vehicle having a winch assembly in accordance with embodiments of the invention;
FIG. 2 is an enlarged side view of the level winder illustrated as a part of the tracked vehicle shown in FIG. 1 ;
FIG. 3 is a top schematic view of the level winder of FIG. 2 ;
FIG. 4 is a side perspective view of the level winder of FIG. 2 ; and
FIG. 5 is a view of a prior art capstan cable winding system.
DETAILED DESCRIPTION OF THE INVENTION
This invention is described for use on a tracked vehicle, particularly a snow grooming vehicle, for purposes of illustration only. However, the winch and level winder in accordance with embodiments of this invention may be used in any cable winding system. Further, the winch may be used on any type of vehicle, especially vehicles driven by rotatable tracks that may be driven over rugged terrain, such as steep inclines on mountains or ravines.
Throughout this description, reference is made to vertical and horizontal axes. It is understood that these axes are intended to refer to a vehicle position in which the vehicle is supported on a substantially horizontal surface.
FIG. 1 illustrates a vehicle 10 of the present invention. The vehicle 10 includes a frame 12 , an engine 14 supported by the frame 12 , a drive mechanism 16 operatively connected to the engine 14 , a winch assembly 24 supported by the frame 12 , and a boom 18 supported by the frame 12 . A cab 15 for having an operator and vehicle control elements is also supported by the frame 12 . In the illustrated embodiment, the engine 14 is not illustrated, but its location is indicated on the frame 12 . As would be appreciated by those skilled in the art, the engine 14 need not be positioned in the area indicated. Instead, the engine 14 may be located on the vehicle 10 in any alternative, suitable location.
The frame 12 can be fabricated from materials well known in the art, including but not limited to steel. Fabrication techniques well known in the art can be used to form and assemble the frame 12 .
The engine 14 can be any engine typically used in such vehicles. The size of the engine 14 will depend on the size and specific demands of the vehicle 10 . Preferably, the engine 14 is an internal combustion engine that can generate a high horse power.
The drive mechanism 16 is operatively connected to the engine 14 so as to move the vehicle 10 across a surface. The drive mechanism 16 allows for the vehicle 10 to move across land, ice, or water. The drive mechanism 16 may comprise an endless track, as illustrated by FIG. 1 , wheels, or any component that will allow the vehicle 10 to travel.
The winch assembly 24 is supported on a winch frame 19 that is coupled to the frame 12 . The winch assembly 24 includes a drum 26 that carries a length of cable 28 , a driver 30 coupled to the drum 26 for rotating the drum 26 to wind and unwind the cable 28 , and a level winder 32 disposed at a base portion of the boom 18 and adjacent to the drum 26 to guide the cable 28 with respect to the drum 26 .
It is contemplated that the driver 30 is a hydraulic motor that is operatively connected to the engine 14 via a suitable hydraulic system. Of course, as would be appreciated by those skilled in the art, the driver 30 may be mechanically driven by the engine. Alternatively, the driver 30 my be an electrically-driven motor. It should be understood that the driver 30 may be of any type suited for this purpose without departing from the scope and spirit of the invention.
The boom 18 has a guide system that guides the cable 28 outward from (or inward to) the vehicle 10 . The guide system includes a series of pulleys 20 , a series of rollers 22 , or any combination of pulleys 20 and rollers 22 . The pulleys 20 are disposed on the boom 18 , and the cable 28 is fed around the pulleys 20 . The rollers 22 are disposed on the boom 18 , and the cable 28 is fed over the rollers 22 . The boom 18 is preferably formed of metal and may comprise a pair of parallel beams with the guide system supported therebetween. Alternatively, the boom 18 may be formed of a series of rigid members fixed together as an integral cantilever support. It is noted that the boom 18 may have any other suitable construction without departing from the invention.
As seen in FIG. 1 , the boom 18 is supported for movement on a support platform 21 that is supported by the vehicle frame 12 , at least in part, via the winch frame 19 . Preferably, the boom 18 is supported for rotatable movement with respect to the platform 21 on the winch frame 19 . With this arrangement, the boom 18 can be oriented at various directions with respect to the drive mechanism 16 to accommodate different directions of travel. The direction of the boom 18 may be controlled by the operator or may be preset. Alternatively, other mounting structures may be implemented that allow for directional adjustment. It is also possible to use a fixed boom depending on the intended use of the vehicle 10 .
The cable 28 is typically metal, such as steel, but may be any material suitable for the intended purpose of the invention. Any known cable 28 capable of withstanding a large load is suitable. The diameter of the cable 28 and type of material are chosen to ensure that the load requirements of the vehicle 10 may be tolerated.
The drum 26 is mounted on the winch frame 19 such that it rotates about a longitudinal axis. The longitudinal axis is generally horizontal (when the vehicle 10 is supported on a horizontal surface). The drum 26 is sized to ensure that the appropriate amount of cable 28 can be completely wound onto the drum 26 . The cable 28 is wound across an outer circumferential surface of the drum 26 . The outer circumferential surface of the drum 26 may be smooth or grooved. In the preferred embodiment, the drum 26 is grooved, as illustrated in FIG. 3 .
Grooves with the appropriate radius may be formed in the circumferential surface of the drum 26 so that when the cable 28 wraps around the drum, the cable 28 lies in what is essentially one continuous groove. The grooves may be added to the drum 26 by standard fabrication techniques, including but not limited to machining. Spaced grooves around the circumference of the drum 26 allow the cable 28 to be retained in the grooves during winding and unwinding. The grooves provide a tighter, neater, and more compact wind as compared to drums with a smooth surface. This provides for smoother operation and may enhance the life of the cable 28 .
The driver 30 is coupled to the drum 26 and rotates the drum 26 . The drum 26 rotates in one direction to wind the cable 28 and in the opposite direction to unwind the cable 28 . As mentioned above, the driver 30 may be an electric or hydraulic motor, for example. The driver 30 may be operatively connected to the vehicle engine 14 and/or electrical system or may be an independent component. The driver 30 preferably is sized to handle the load created by the drum 26 and the cable 28 .
The level winder 32 is disposed adjacent to the drum 26 to guide the cable 28 from the boom 18 with respect to the drum 26 . The level winder 32 is supported to move in an arc shaped path and is preferably supported to pivot about a generally vertical axis. The arc shaped path is largely defined by the pivoting of the level winder 32 about the generally vertical axis.
As illustrated in FIG. 2 and FIG. 3 , the level winder 32 includes a rotatable support 34 , a cable support frame 36 that is connected to the rotatable support 34 , and a pair of rotatable pulleys 38 carried by the cable support frame 36 . The cable support frame 36 pivots with the rotatable support 34 . By this, the pair of pulleys 38 pivot with respect to the drum 26 .
The rotatable support 34 is mounted on the winch frame 19 . The rotatable support 34 is preferably operatively connected to a pair of rotatable support bearings 58 . The rotatable support bearings 58 are fixedly attached to the winch frame 19 . The rotatable support bearings 58 are connected to opposite ends of the rotatable support 34 so that the rotatable support 34 can freely rotate about a generally vertical axis, while being fixed in the other two directions. The rotatable support 34 is substantially the shape of a hollow cylinder with at least one slot 35 along the longitudinal length of the cylinder. Of course, any suitable support assembly may be used to allow the level winder 32 to pivot with respect to the drum 26 .
The winch assembly 24 further includes a rotatable pulley 60 that is disposed adjacent to the rotatable support 34 such that an outer edge of the rotatable pulley 60 lies within the slot 35 of the rotatable support 34 . The rotatable pulley 60 is disposed between two substantially parallel support plates 37 . The support plates 37 are fixedly attached to the rotatable support 34 such that the support plates 37 rotate with the rotatable support 34 about a generally vertical axis. The rotatable pulley 60 is mounted to the support plates 37 such that the rotatable pulley 60 can freely rotate about its generally horizontal axis. The rotatable pulley 60 directs the cable 28 from the boom 18 to the level winder 32 . The rotatable pulley 60 has a radius greater than or equal to the minimum recommended bending radius of the cable 28 .
The level winder 32 further includes at least one actuator 40 that is coupled to the rotatable support 34 . In the preferred embodiment, one upper bracket 39 is mounted to each support plate 37 , preferably above the axis of the rotatable pulley 60 . One end of the actuator 40 is pivotally attached to the upper bracket 39 . The opposite end of the actuator 40 is pivotally attached to the winch frame 19 , as seen in FIG. 1 , and is in communication with a proximity switch 56 . Preferably, the actuator 40 is a hydraulic or pneumatic cylinder. Upon activation, the actuator 40 extends or retracts to push or pull the support plates 37 , which in turn rotates the rotatable pulley 60 , the rotatable support 34 , and the cable support frame 36 . As will be discussed below, this causes the pair of pulleys 38 to pivot with respect to the drum 26 to maintain the cable 28 in a predetermined position relative to the drum 26 . The desired predetermined position relative to the drum 26 is generally perpendicular, in this case.
Referring to FIGS. 2-4 , the cable support frame 36 includes an upper plate 41 and a lower plate 43 that are substantially parallel to one another. The cable support frame 36 has a longitudinal centerline CL that extends in a direction from the rotatable support 34 towards the drum 26 . Each support plate 37 further includes a pair of lower brackets 45 that are fixedly attached to the support plate 37 below the axis of the rotatable pulley 60 . The lower brackets 45 in each pair are spaced such that the cable support frame 36 can be disposed therebetween. A pair of level winder ball bearings 62 are disposed within the cable support frame 36 on opposite sides of the longitudinal centerline CL. The level winder ball bearings 62 are mounted and oriented in such a way as to create a generally horizontal axis. The level winder ball bearings 62 allow the cable support frame 36 to rotate within a fixed range about a generally horizontal axis.
A biasing mechanism 42 is coupled between the cable support frame 36 and the top of the support plates 37 , preferably at the upper brackets 39 . The biasing mechanism 42 maintains the cable support frame 36 in a predetermined position relative to the rotatable support 34 . The predetermined position relative to the rotatable support 34 is generally perpendicular. The biasing mechanism 42 can include a spring that retains the cable support frame 36 in a relatively horizontal position. Of course, any biasing mechanism can be used, including a resilient cable or hydraulic or pneumatic cylinder. By this construction, the cable support frame 36 can move slightly up or down with respect to the surface of the drum 26 to accommodate the thickness of the cable 28 wound on the drum 26 .
At the opposite end of the cable support frame 36 , the pair of pulleys 38 are disposed between the upper plate 41 and the lower plate 43 on opposite sides of the longitudinal centerline CL of the cable support frame 36 . The pair of pulleys 38 are connected to the cable support frame 36 with pulley bearings 47 . The pulleys 38 are generally oriented in the same plane and are spaced so that the cable 28 can pass between them. The centers of the pulleys 38 are aligned on an axis that is generally perpendicular to the longitudinal centerline CL of the cable support frame 36 .
The level winder 32 further includes a feeding mechanism 44 that is pivotally supported by the cable support frame 36 . The feeding mechanism 44 controls the tension and direction of the cable 28 as the cable 28 is fed from the pulleys 38 to the drum 26 . An embodiment of the feeding mechanism 44 is illustrated in detail in FIG. 4 . The feeding mechanism 44 includes a pivot arm 55 , a pair of guiding rollers 46 , and a pair of tensioning rollers 49 .
In the preferred embodiment, the pivot arm 55 is disposed above the upper support plate 41 of the cable support frame 36 such that the pivot arm 55 and the cable support frame 36 extend in substantially parallel planes to one another. The pivot arm 55 is pivotally connected to the cable support frame 36 with a bearing 59 and a fastener 61 at a position along the longitudinal centerline CL of the cable support frame 36 . The pivot arm 55 has a first end and a second end. The first end of the pivot arm 55 extends beyond the cable support frame 36 in the direction towards the drum 26 .
The guiding rollers 46 are attached between a pair of roller support brackets 53 with bearings and fasteners. The roller support brackets 53 are fixedly attached to the first end of the pivot arm 55 and extend generally downward in such a manner that they do not interfere with the pair of pulleys 38 . The guiding rollers 46 are generally aligned in a vertical plane and are spaced and shaped such that the cable 28 can fit snugly between them.
The pair of tensioning rollers 49 are disposed at one end of a pair of cantilever brackets 51 . The cantilever brackets 51 each have a first end and a second end. The first ends of the cantilever brackets 51 are pivotally connected to the first end of the pivot arm 55 with bushings and fasteners. The second ends of the cantilever brackets 51 extend away from the pivot arm 55 and cable support frame 36 towards the drum 26 . The tensioning rollers 49 are connected to the second ends of the cantilever brackets 51 with bearings and fasteners. Preferably, the tensioning rollers 49 and the guiding rollers 46 are oriented such that their axes of rotation are perpendicular to one another. For example, in the preferred embodiment, the guiding rollers 46 rotate about generally horizontal axes and the tensioning rollers 49 rotate about generally vertical axes (when the vehicle 10 is supported on a horizontal surface). Alternatively, the guiding rollers 46 may rotate about generally vertical axes and the tensioning rollers 49 may rotate about generally horizontal axes (when the vehicle 10 is supported on a horizontal surface).
The feeding mechanism 44 further includes a pressure controller 48 . The pressure controller 48 is coupled to the tensioning rollers 49 to control the pressure between the tensioning rollers 49 to control feeding of the cable 28 . Preferably, the pressure controller 48 includes a hydraulic cylinder. Alternatively, the pressure controller 48 may include a pneumatic cylinder or any other resilient device. In the preferred embodiment, the pressure controller 48 includes a pair of hydraulic cylinders, as illustrated in FIG. 4 .
The feeding mechanism 44 further includes a sensitivity controller 50 . The sensitivity controller 50 is coupled to the tensioning rollers 49 to adjust the distance between the tensioning rollers 49 . Preferably, the sensitivity controller 50 includes a first plate 64 mounted to one of the cantilever brackets 51 and a second plate 66 mounted to the other cantilever bracket 51 . A third plate 68 is disposed in between the cantilever brackets 51 and is fixedly attached to the pivot arm 55 . The sensitivity controller 50 further includes a pair of adjustment screws 52 . The adjustment screws 52 are used to set a gap between the first plate 64 and the third plate 66 and a gap between the second plate 68 and the third plate 66 .
As the adjustment screws 52 are tightened, the cantilever brackets 51 are pushed away from each other, thereby increasing the gap between the tensioning rollers 49 , which decreases the sensitivity to changes in the position of the cable 28 . Conversely, as the adjustment screws 52 are loosened, the cantilever brackets 51 will by drawn towards each other due to the pressure exerted by the pressure controller 48 . This in turn will decrease the gap between the tensioning rollers 49 , which increases the sensitivity to changes in the position of the cable 28 .
The feeding mechanism 44 further includes a position actuator 54 that is operatively coupled to the proximity switch 56 that activates the actuator 40 to pivot the level winder 32 . A first end of the position actuator 54 is pivotally connected to the pivot arm 55 . A second end of the position actuator 54 is pivotally connected to the proximity switch 56 . When the feeding mechanism 44 pivots beyond a certain predetermined position, the position actuator 54 signals the proximity switch 56 . The proximity switch 56 activates movement of the level winder 32 along the arc shaped path by signaling the actuator 40 . Any known type of proximity switch or position detector may be used.
In operation, the cable 28 starts in a fully wound position on the drum 26 . The cable 28 is fed from the drum 26 through the level winder 32 , through the rotatable support 34 , through the guide system within the boom 18 , and out one end of the boom 18 . The cable 28 is secured to a predetermined anchor point located on the terrain and the vehicle 10 moves away from the anchor point via the drive mechanism 16 . In order for the vehicle 10 to move away from the anchor point, the cable 28 must be lengthened or “played out” from the drum 26 . The driver 30 rotates the drum 26 such that the cable 28 unwinds from the drum 26 , thereby allowing the cable 28 to lengthen.
As the cable unwinds from the drum 26 , it releases from the drum at a release point 57 . The release point 57 moves parallel to the longitudinal axis of the drum 26 as the drum 26 rotates. The level winder 32 pivots in an arc such that the feeding mechanism 44 is substantially aligned with the release point 57 . This ensures that the cable 28 is generally perpendicular to the drum 26 at the release point 57 so that the cable does not twist or kink.
After the cable 28 releases from the drum 26 , the cable 28 passes in between the pair of tensioning rollers 49 . As the location of the release point 57 changes, the cable 28 exerts a greater pressure against one of the tensioning rollers 49 . When the resulting pressure on the pressure controller 48 exceeds a predetermined value, the pivot arm 55 pivots just enough to keep the cable 28 perpendicular to the drum 26 . When the pivot arm 55 reaches a maximum pivot point, the position actuator 54 activates the proximity switch 56 . The proximity switch 56 then signals the actuator 40 . The actuator 40 rotates the level winder 32 along an arc shaped path in the direction that the cable 28 is extending toward the drum 26 . As the level winder 32 rotates, the pivot arm 55 is drawn by the cable 28 to rotate independently to ensure the cable 28 remains perpendicular to the drum 26 . These adjustments by the feeding mechanism 44 are constantly repeated while the winch assembly 24 is in operation.
After the cable 28 passes through the tensioning rollers 49 , the cable 28 passes in between the guiding rollers 46 . The guiding rollers 46 ensure that the cable 28 is properly lined up to pass in between the pair of pulleys 38 , regardless of the amount of tension in the cable 28 . Once the cable 28 passes the pair of pulleys 38 , it travels through the cable support frame 36 and onto the rotatable pulley 60 . The rotatable pulley 60 feeds the cable 28 though the rotatable support 34 to the pulleys 20 and rollers 22 located in the guide system in the boom 18 .
To drive the vehicle 10 in a reverse direction towards the anchor point, the rotation of the drum 26 must be reversed by the driver 30 so that any slack in the cable 28 can be tightened. In other words, the cable 28 must be rewound onto the drum 26 . Further, the vehicle 10 may need the power of the winch assembly 24 help pull the vehicle 10 back towards the anchor point. The level winder 32 operates in the same manner as was described above, only the cable 28 moves in the opposite direction and the pulleys 20 , 60 , 38 and rollers 22 , 46 , 49 rotate in the opposite direction.
Due to the relatively compact design of the level winder 32 , the operator of the vehicle 10 can watch the winding process to ensure that the cable 28 is being properly unwound and wound, because the level winder 32 does not obstruct the view of the drum 26 .
It will be understood that the invention encompasses various modifications and alterations to the precise operating systems. For example, although the system is described for use in a heavy duty cable winding assembly, other windable materials may be used in the device, and the device may be adapted for use in smaller manufacturing environments.
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A level winder is provided for winding cable in a winch system. The winch is suitable for use on a tracked vehicle, such as a snow grooming vehicle, to assist the vehicle in maneuvering on steep inclines. The level winder uses a pivoting pulley assembly to feed cable onto and off of a drum.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional patent application Ser. No. 61/068,274 filed on Mar. 6, 2008.
BACKGROUND OF THE INVENTION
The present application is directed to a new design of architectural concrete structure and to a wall system formed by a plurality of such structures. Concrete blocks are used extensively in building construction in a wide variety of designs. Prior art blocks and block systems for forming walls include the following U.S. Pat. Nos. 2,647,392; 2,701,464; 4,018,018; 4,075,808; 4,514,949; 4,854,097; 6,032,424; and 6,223,491.
Concrete blocks are heavy to handle and do not provide good insulating characteristics. U.S. Pat. No. 4,854,097 discloses a building block having improved insulating characteristics in which at least a part of the volume within the concrete is filled with highly insulating foam.
It is an object of the present invention to provide a an architectural concrete structure and a system for forming walls or other structures in which the components have good insulating characteristics and has a large central, open passageway to provide a structure having lower weight than would be expected for the size of the component formed and having good insulating characteristics.
Other objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description of the preferred embodiments and the accompanying drawings.
SUMMARY OF THE INVENTION
The invention is directed to an architectural concrete structure and a wall system formed with a plurality of architectural concrete structure wherein each block has first and second cement sections spaced apart and joined together with steel reinforcing bars and tubular members filled with cement. The first and second sections have parallel outer wall surfaces and inner wall surfaces which taper outwardly in an upward direction. Foam insulation is secured to each of the tapering wall surfaces, which insulation members define a tapered passageway extending through the length of the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing two architectural concrete structures of the present invention with the upper structure resting upon the lower structure.
FIG. 2 is a side elevational view partially in section.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings there is shown in FIG. 1 two architectural concrete structures 10 of the present invention including an upper structure stacked upon a lower structure 10 . The structure 10 extends along a longitudinal path from a first end 34 to a second end 36 and includes a first section 12 of poured Portland cement or concrete and a second section 14 of Portland cement or concrete. The first section 12 and second section 14 are spaced apart from one another and each has an upper surface 16 and a lower surface 18 extending between the first end 34 and second end 36 . The first section 12 includes a flat outer wall surface 20 extending longitudinally along a path parallel to axis A from the first end 34 to the second end 36 and extending in height from the lower surface 18 to the upper surface 16 . The second section 14 has an outer wall surface 20 which also extends from the first end 34 to the second end 36 and in height from the lower surface 18 to the upper surface 16 . Axis A defines the central longitudinal axis of the concrete 10 . The outer wall surfaces 20 are parallel to each other.
As can be seen in FIG. 1 , the first section 12 and the second section 14 each has an inner wall surface 22 , each of which is disposed at an angle flaring away from one another as they extend upwardly from the lower surface 18 toward the upper surface 16 . The included angle between the respective inner wall surfaces 22 and the lower surface 18 is approximately 75°±10°. Such inner wall surfaces 22 extend between the first end 34 and second end 36 of their respective first section 12 and second section 14 . Preferably the respective inner wall surfaces 22 extend upwardly from their respective lower surfaces 18 , flaring outwardly away from each other but do not extend completely to the respective upper surfaces 16 .
Positioned in interfacial contact with each of the inner wall surfaces 22 is a flat sheet of rigid foam material for providing insulation for the block 10 . The first flat insulation member 28 and the second flat insulation member 30 each extends upwardly from the lower surfaces 18 of their respective first section 12 and second section 14 to an upper edge 51 slightly below the respective upper surfaces 16 at the termination of their respective adjacent inner wall surfaces 22 . With this construction, there is provided a ledge 40 of cement or concrete between the top edges 51 of each of the first flat insulation member 28 and second flat insulation member 30 . The presence of the respective ledges 40 assists in retaining the first and second flat insulation members 28 and 30 snuggly against their respective inner wall surfaces 22 and prevents direct contact against such upper edges 51 of the first and second flat insulation members 28 and 30 by the structure 10 positioned above it, as shown in FIG. 1 .
The foam material could be one of a number of well known plastics but preferably is one having an R-value in the range of R5.6 to R8 per inch of thickness such as polyisocyanurate or polyurethane, for example. Foam polystyrene could also be used for those situations in which a lower R-value is acceptable.
As can be seen in FIG. 1 , the first and second flat insulation members 28 , 30 define an open passageway 32 which is wider in the area adjacent the upper surface 16 than in the area adjacent the lower surface 18 . The passageway 32 extends from the first end 34 to the second end 36 .
A pair of ⅜ inch reinforcing bars 38 extends across the passageway 32 and through apertures 42 in the respective first and second flat insulation members 28 , 30 slightly below the ledges 40 . The reinforcing bars 38 extend into the cement or concrete of the respective first and second sections 12 , 14 and have down turned elbows 45 for secure engagement to such sections 12 , 14 .
Also, spanning the passageway 32 in an area approximately midway between the upper surfaces 16 and lower surfaces 18 is a length of polyvinylchloride (PVC) pipe 44 having a diameter (for example about 3″) sufficiently large to receive therein cement as it is being introduced into a mold for forming the block 10 . The PVC pipe 44 extends through apertures 46 in the respective first and second flat insulation members 28 , 30 and extends a short distance into each of the respective first and second sections 12 , 14 . The reinforcing bars 38 and the PVC pipe 40 are positioned in the respective apertures 42 and 46 of the first and second flat insulation members prior to pouring cement or concrete in the mold used for forming the architectural concrete structure 10 . Upon pouring the cement into the mold cavity, the elbows 45 of the reinforcing bar 38 will be encased by the cement and the open ends of the PVC pipe 44 will receive cement sufficiently to completely fill the PVC pipe 44 as shown in the breakaway section of the pipe in FIG. 1 .
As will be appreciated, in addition to providing reinforcing, the reinforcing bars 38 maybe used for gripping and lifting the blocks 10 .
There is also provided reinforcing mesh 48 and wires for supporting the mesh during the step of pouring concrete in the mold as shown in FIG. 2 . For example, the reinforcing mesh 48 could be 18 gauge wire and spaced apart 6″ vertically and horizontally.
If desired, the first section 12 could be poured with concrete of one color and the second section 14 could be poured with a different color thereby permitting a decorative pattern to be formed when constructing a wall simply by having some blocks 10 laid with the first section 12 facing outwardly and other blocks 10 laid with the second section 14 facing outwardly. In addition, various designs or architectural features can be molded or formed on the first section 12 and second section 14 . Also grout or mortar can be positioned in the joint between adjacent structures to peal the interface and to provide for a fluid tight use between the structures.
The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not a limitative sense, the scope of the invention being defined solely by the appended claims.
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An architectural concrete structure and a wall system formed with a plurality of architectural concrete structure wherein each block has first and second cement sections spaced apart and joined together with steel reinforcing bars and tubular members filled with cement. The first and second sections have parallel outer wall surfaces and inner wall surfaces which taper outwardly in an upward direction. Foam insulation is secured to each of the tapering wall surfaces, which insulation members define a tapered passageway extending through the length of the structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/788,873 filed Mar. 15, 2013, and U.S. patent application Ser. No. 14/207,110 filed Mar. 12, 2014, both of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a swimming pool pressure cleaner, and, more specifically to a swimming pool pressure cleaner that is capable of switching between bottom and top cleaning modes, as well as automatically switching into a reverse mode.
[0004] 2. Related Art
[0005] Swimming pools generally require a certain amount of maintenance. Beyond the treatment and filtration of pool water, the walls of the pool should be scrubbed regularly. Further, leaves and various debris can float on the surface of the pool water, and should be removed regularly. This means that a pool cleaner should be capable of cleaning both the walls of the pool as well as the surface of the pool water.
[0006] Swimming pool cleaners adapted to rise proximate a water surface of a pool for removing floating debris therefrom and to descend proximate to a wall surface of the pool for removing debris therefrom are generally known in the art. These “top-bottom” cleaners are often pressure-type or positive pressure pool cleaners that require a source of pressurized water to be in communication therewith. This source of pressurized water could include a booster pump or pool filtration system. Generally, this requires a hose running from the pump or system to the cleaner head. In some instances, a user may have to manually switch the pool cleaner from a pool wall cleaning mode to a pool water surface cleaning mode.
[0007] Additionally, swimming pool cleaners can utilize jet nozzles that discharge pressurized water to generate a vacuum or suction effect. This suction effect can be utilized to dislodge debris that is on a pool wall and to pull the debris and water through a filtering arrangement or filter bag. The jet nozzles can be placed inside a vacuum tube such that the debris and pool water are directed through the tube. The jet nozzles can be grouped and/or arranged to discharge the pressurized water stream in general alignment with the flow of water through the vacuum tube, e.g., parallel flow. However, this alignment of flow can result in areas of concentrated water flow, e.g., “hot areas,” and areas with significantly reduced flow.
[0008] Accordingly, there is a need for improvements in pool cleaners that are capable of cleaning both the pool water surface and the pool walls, and jet nozzles that create more uniform distribution of water flow through a vacuum tube.
SUMMARY OF THE INVENTION
[0009] The present disclosure relates to a swimming pool pressure cleaner that is capable of switching between bottom and top cleaning modes, as well as automatically switching into a reverse mode. The cleaner includes a top housing having a retention mechanism attached thereto, a chassis, and a plurality of wheels rotationally connected to the chassis. The chassis houses a drive assembly that is connected with a water distribution manifold. The drive assembly includes a timer assembly, a reverse/spinout mode valve assembly, and a top/bottom mode valve assembly. The water distribution manifold includes a reverse/spinout mode manifold chamber, a top mode manifold chamber, and a bottom mode manifold chamber. An external pump provides pressurized water to the cleaner, which is provided to the timer assembly and to the reverse/spinout mode valve assembly. The timer assembly includes a turbine that is rotated by the pressurized water, and drives a gear reduction stack that drives a Geneva gear. The Geneva gear rotates a valve disk positioned within the reverse/spinout mode valve assembly. The valve disk includes a window that allows the provided pressurized fluid to flow there through to either a reverse drive chamber or a forward drive chamber of a reverse/spinout mode valve body. When the window is adjacent the reverse drive chamber, the pressurized fluid flows into the reverse drive chamber and to the reverse/spin-out mode manifold chamber, which in turn directs the pressurized fluid to a reverse/spinout jet nozzle. The reverse/spinout jet nozzle propels the cleaner rearward or offsets the general path of the cleaner. When the window is adjacent the forward drive chamber, the pressurized fluid flows into the forward drive chamber and to the top/bottom mode valve assembly. The top/bottom mode valve assembly includes a top/bottom mode valve body and a top/bottom mode valve disk that has a window. The top/bottom mode valve disk window directs the pressurized fluid into either a top mode chamber or a bottom mode chamber of the top/bottom mode valve body. When the window is adjacent the top mode chamber, the pressurized fluid flows into the top mode chamber and to the top mode manifold chamber, which in turn directs the pressurized fluid to at least one skimmer jet nozzle and a thrust/lift jet nozzle. The thrust/lift jet nozzle discharges the pressurized fluid to propel the cleaner generally toward a pool water surface and along the pool surface, while the at least one skimmer jet nozzle discharges the pressurized fluid into the debris retention mechanism. When the window is adjacent the bottom mode chamber, the pressurized fluid flows into the bottom mode chamber and to the bottom mode manifold chamber, which in turn directs the pressurized fluid to a forward thrust jet nozzle, and a suction jet ring. The forward thrust jet nozzle discharges the pressurized fluid to propel the cleaner along a pool wall surface. The suction jet ring is positioned adjacent a suction head provided on the bottom of the cleaner and a suction tube that extends from the suction jet ring toward the top housing. The suction jet ring directs the pressurized fluid to at least one vacuum jet nozzle that discharges the pressurized fluid through the suction tube and into the debris retention mechanism.
[0010] The present disclosure further relates to a fluid distribution system for controlling the operation of a device for cleaning a swimming pool. The distribution system includes an inlet body having an inlet for receiving a supply of pressurized fluid, a valve assembly body including first and second inlet openings and first and second outlet openings and defining a first valve chamber extending between the first inlet opening and the first outlet opening, and a second valve chamber extending between the second inlet opening and the second outlet opening, and a valve subassembly. The valve subassembly includes a turbine rotatably driven by a supply of pressurized fluid, a cam plate including a cam track and which is operatively engaged with the turbine such that the cam plate is rotationally driven by the turbine, the cam track having a first section and a second section, and a valve seal including a sealing member and a cam post, wherein the valve seal is rotatably mounted adjacent the cam plate and the valve assembly body with the cam post engaged with the cam track. The valve seal is rotatable between a first position where the sealing member is adjacent the first inlet opening and a second position where the sealing member is adjacent the second inlet opening. The valve assembly body is adjacent the inlet body such that the inlet is in fluidic communication with the first and second valve chambers. When the cam post is engaged with the first section of the cam track the valve seal is placed in the first position where the valve seal prevents fluid from flowing through the second inlet opening and across the second valve chamber. When the cam post is engaged with the second section of the cam track the valve seal is placed in the second position where the valve seal prevents fluid from flowing through the first inlet opening and across the first valve chamber.
[0011] The present disclosure further relates to a fluid distribution system for controlling the operation of a device for cleaning a swimming pool. The distribution system includes an inlet body having an inlet for receiving a supply of pressurized fluid, a valve assembly body including first and second inlet openings and first and second outlet openings and defining a first valve chamber extending between the first inlet opening and the first outlet opening, and a second valve chamber extending between the second inlet opening and the second outlet opening, a timer assembly, and a valve subassembly. The timer assembly and valve subassembly includes a turbine rotatably driven by a supply of pressurized fluid, a cam wheel including first and second cam tracks and which is operatively engaged with the turbine such that the cam wheel is rotationally driven by the turbine, and a rocker seal including first and second sealing member and a cam post, wherein the rocker seal is pivotally mounted adjacent the cam wheel and the valve assembly body with the cam post engageable with the first and second cam tracks. The rocker seal is pivotal between a first position where the first sealing member seals the first inlet opening and a second position where the second sealing member seals the second inlet opening. The valve assembly body is adjacent the inlet body such that the inlet is in fluidic communication with the first and second valve chambers. When the cam post is engaged with the first cam track the rocker seal is placed in the first position where the first sealing member prevents fluid from flowing through the second inlet opening and across the second valve chamber. When the cam post is engaged with the second cam track the rocker seal is placed in the second position where the second sealing member prevents fluid from flowing through the first inlet opening and across the first valve chamber.
[0012] The fluid distribution system could be incorporated into a swimming pool cleaner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing features of the invention will be apparent from the following Detailed Description of the Invention, taken in connection with the accompanying drawings, in which:
[0014] FIG. 1 is a schematic representation of a positive pressure pool cleaner of the present disclosure in a pool;
[0015] FIG. 2 is a first perspective view of the pool cleaner of the present disclosure;
[0016] FIG. 3 is a second perspective view of the pool cleaner of the present disclosure;
[0017] FIG. 4 is a third perspective view of the pool cleaner of the present disclosure;
[0018] FIG. 5 is a left side view of the pool cleaner of the present disclosure;
[0019] FIG. 6 is a right side view of the pool cleaner of the present disclosure;
[0020] FIG. 7 is a front view of the pool cleaner of the present disclosure;
[0021] FIG. 8 is a rear view of the pool cleaner of the present disclosure;
[0022] FIG. 9 is a top view of the pool cleaner of the present disclosure;
[0023] FIG. 10 is a bottom view of the pool cleaner of the present disclosure;
[0024] FIG. 11 is an exploded perspective view of the pool cleaner of the present disclosure;
[0025] FIG. 12 is a sectional view of the pool cleaner of the present disclosure taken along line 12 - 12 of FIG. 5 ;
[0026] FIG. 13 is a cross-sectional view of the pool cleaner of the present disclosure taken along line 13 - 13 of FIG. 5 ;
[0027] FIG. 14 is a schematic diagram of the water distribution and timing system of the pool cleaner of the present disclosure;
[0028] FIG. 15 is a first perspective view of the drive assembly and flow manifold of the pool cleaner of the present disclosure;
[0029] FIG. 16 is a second perspective view of the drive assembly and flow manifold of the pool cleaner of the present disclosure;
[0030] FIG. 17 is an exploded perspective view of the drive assembly and flow manifold of the pool cleaner of the present disclosure;
[0031] FIG. 18 is a right side view of the drive assembly of the present disclosure;
[0032] FIG. 19 is a left side view of the drive assembly of the present disclosure;
[0033] FIG. 20 is a top view of the drive assembly of the present disclosure;
[0034] FIG. 21 is a bottom view of the drive assembly of the present disclosure;
[0035] FIG. 22 is a front view of the drive assembly of the present disclosure;
[0036] FIG. 23 is a rear view of the drive assembly of the present disclosure;
[0037] FIG. 24 is an exploded perspective view of the drive assembly of the present disclosure;
[0038] FIG. 25 is a sectional view of the drive assembly of the present disclosure take along line 25 - 25 of FIG. 22 ;
[0039] FIG. 26 is a sectional view of the drive assembly of the present disclosure take along line 26 - 26 of FIG. 20 showing a turbine;
[0040] FIG. 27 is a sectional view of the drive assembly of the present disclosure take along line 27 - 27 of FIG. 20 showing a Geneva gear;
[0041] FIG. 28 is an exploded view of the reverse/spin-out mode assembly of the present disclosure;
[0042] FIG. 29 is a front view of the reverse/spinout mode valve body of the present disclosure;
[0043] FIG. 30 is a sectional view of the reverse/spin-out mode assembly of the present disclosure take along line 30 - 30 of FIG. 20 showing the fluid chambers;
[0044] FIG. 31 is an exploded view of the top/bottom mode assembly of the present disclosure;
[0045] FIG. 32 is a front view of the top/bottom mode valve body of the present disclosure;
[0046] FIG. 33 is a sectional view of the top/bottom mode assembly of the present disclosure take along line 33 - 33 of FIG. 20 showing the fluid chambers and ports;
[0047] FIG. 34 is a first perspective view of the flow manifold and suction jet ring of the present disclosure;
[0048] FIG. 35 is a second perspective view of the flow manifold and suction jet ring of the present disclosure;
[0049] FIG. 36 is a right side view of the flow manifold and suction jet ring of the present disclosure;
[0050] FIG. 37 is a left side view of the flow manifold and suction jet ring of the present disclosure;
[0051] FIG. 38 is a front view of the flow manifold and suction jet ring of the present disclosure;
[0052] FIG. 39 is a rear view of the flow manifold and suction jet ring of the present disclosure;
[0053] FIG. 40 is a top view of the flow manifold and suction jet ring of the present disclosure;
[0054] FIG. 41 is a bottom view of the flow manifold and suction jet ring of the present disclosure;
[0055] FIG. 42 is a cross-sectional view of the flow manifold and suction jet ring of the present disclosure taken along line 42 - 42 of FIG. 38 ;
[0056] FIG. 43 is a sectional view of the flow manifold and suction jet ring of the present disclosure taken along line 43 - 43 of FIG. 40 showing the bottom mode flow path;
[0057] FIG. 44 is a cross-sectional view of the pool cleaner of the present disclosure taken along line 44 - 44 of FIG. 9 ;
[0058] FIG. 45 is a perspective view of a hose connection of the present disclosure;
[0059] FIG. 46 is a top view of a hose connection of the present disclosure;
[0060] FIG. 47 is a sectional view of the hose connection of the present disclosure taken along line 47 - 47 of FIG. 46 ;
[0061] FIG. 48 is a perspective view of a hose swivel of the present disclosure;
[0062] FIG. 49 is a top view of the hose swivel of the present disclosure;
[0063] FIG. 50 is a cross-sectional view of the hose swivel of the present disclosure taken along line 50 - 50 of FIG. 49 ;
[0064] FIG. 51 is a perspective view of a filter of the present disclosure;
[0065] FIG. 52 is an exploded perspective view of the pool cleaner of the present disclosure showing another embodiment of the drive assembly;
[0066] FIGS. 53-54 are partial sectional views of the pool cleaner of the present disclosure, illustrating the drive assembly of FIG. 52 ;
[0067] FIG. 55 is a schematic diagram of the water distribution and timing system of FIG. 52 ;
[0068] FIG. 56 is a first perspective view of the drive assembly and water distribution manifold of FIG. 52 ;
[0069] FIG. 57 is a second perspective view of the drive assembly and water distribution manifold of FIG. 52 ;
[0070] FIG. 58 is an exploded perspective view of the drive assembly and water distribution manifold of FIG. 52 ;
[0071] FIG. 59 is a right side view of the drive assembly of FIG. 52 ;
[0072] FIG. 60 is a left side view of the drive assembly of FIG. 52 ;
[0073] FIG. 61 is a top view of the drive assembly of FIG. 52 ;
[0074] FIG. 62 is a bottom view of the drive assembly of FIG. 52 ;
[0075] FIG. 63 is a front view of the drive assembly of FIG. 52 ;
[0076] FIG. 64 is a rear view of the drive assembly of FIG. 52 ;
[0077] FIG. 65 is an exploded perspective view of the drive assembly of FIG. 52 ;
[0078] FIG. 66 is a sectional view of the drive assembly taken long line 66 - 66 of FIG. 64 ;
[0079] FIG. 67 is a sectional view of the drive assembly taken along line 67 - 67 of FIG. 61 and showing a turbine;
[0080] FIG. 68 is a sectional view of the drive assembly taken along line 68 - 68 of FIG. 61 and showing a cam track in a reverse/spin-out position;
[0081] FIGS. 69-70 are exploded views of the reverse/spin-out mode cam assembly, the reverse/spin-out mode valve assembly, and the top/bottom mode valve assembly of the drive assembly of present disclosure;
[0082] FIGS. 71-73 are front, rear, and sectional views, respectively, of the reverse/spinout mode valve body of the drive assembly of the present disclosure;
[0083] FIGS. 74-75 are exploded perspective and sectional views, respectively, of the top/bottom mode valve assembly of the drive assembly of present disclosure;
[0084] FIGS. 76-78 are perspective, left side, and sectional views, respectively, of the water distribution manifold of the pool cleaner of the present disclosure;
[0085] FIG. 79 is a side view of a jet nozzle assembly and vacuum suction tube of the present disclosure;
[0086] FIG. 80 is a perspective view of the jet nozzle assembly of FIG. 79 ;
[0087] FIG. 81 is a top view of the jet nozzle assembly and vacuum suction tube of FIG. 79 ;
[0088] FIG. 82 is a cross-sectional view of the jet nozzle assembly and vacuum suction tube taken along line 82 - 82 of FIG. 81 showing the vortex angle of a jet nozzle;
[0089] FIG. 83 is a cross-sectional view of the jet nozzle assembly and vacuum suction tube taken along line 83 - 83 of FIG. 81 showing the convergence angle of a jet nozzle;
[0090] FIG. 84 is a top view of the jet nozzle assembly and vacuum suction tube with the jet nozzle assembly having one jet nozzle;
[0091] FIG. 85 is a top view of the jet nozzle assembly and vacuum suction tube with the jet nozzle assembly having two jet nozzles;
[0092] FIG. 86 is a top view of the jet nozzle assembly and vacuum suction tube with the jet nozzle assembly having four jet nozzles; and
[0093] FIG. 87 is a perspective view of another reverse/spin-out mode cam and reverse/spin-out mode valve assembly of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0094] The present invention relates to a positive pressure top/bottom pool cleaner, as discussed in detail below in connection with FIGS. 1-87 .
[0095] Referring initially to FIG. 1 , a positive pressure pool cleaner 10 of the present disclosure is shown operating in a swimming pool 12 . The cleaner 10 is configured to switch between two cleaning modes, a bottom cleaning mode and a top/skim cleaning mode. When the cleaner 10 is in the bottom mode, it will traverse the pool walls 14 , including side walls and bottom floor wall, cleaning them with a suction operation that removes debris. When the cleaner 10 is in the top mode, it travels across and skims the pool water line 16 , trapping any floating debris proximate the pool water line 16 . The cleaner 10 is capable of being switched between the bottom mode and the top mode by a user, as discussed in greater detail below. The cleaner 10 is also adapted to occasionally switch from a forward motion to backup/spin-out mode whereby the cleaner reverses direction and/or moves in a generally arcuate sideward path to prevent the cleaner 10 from being trapped and unable to move, e.g., by an obstruction or in the corner of the pool 12 . A discussion of the backup/spin-out mode is provided below.
[0096] As shown in FIG. 1 , the pool cleaner 10 is connected to an external pump 18 by a hose connection 20 and a segmented hose 22 . The segmented hose 22 is connected to a rear inlet of the pool cleaner 10 and extends to the hose connection 20 , which is connected to the external pump 18 . This connection allows the external pump 18 to provide pressurized water to the pool cleaner 10 to both power locomotion of the cleaner 10 as well as the cleaning capabilities of the cleaner 10 . The segmented hose 22 may include one or more swivels 24 , one or more filters 26 , and one or more floats 28 installed in-line with the segmented hose 22 . As such, the pressurized water flowing through the segmented hose 22 can also flow through the one or more swivels 24 , one or more filters 26 . The swivel 24 allows the segmented hose 22 to rotate at the swivel 24 without detaching the cleaner 10 from the external pump 18 . As such, when the cleaner 10 travels about the pool 12 , the segmented hose 22 will rotate at the one or more swivels 24 , thus preventing entanglement. The one or more filters 26 may provide a filtering functionality for the pressurized water being provided to the cleaner 10 .
[0097] With reference to FIGS. 2-11 , the cleaner 10 includes a top housing 30 and a chassis 32 . The top housing 30 includes a body 34 and a cross member 36 . The cross member 36 connects to and spans across sidewalls of the body 34 , forming a skimmer opening 38 , a channel 40 , and a rear opening 42 . The skimmer opening 38 is an opening generally at the front of the cleaner 10 formed between the body 34 and the cross member 36 such that the skimmer opening 38 allows the flow of liquid and debris between the body 34 and the cross member 36 , along the channel 40 , and exiting the rear opening 42 . The body 34 includes a deck 44 , first and second sidewalls 46 , 48 extending generally upward from the deck, and a rounded front wall 50 . As discussed, the cross member 36 spans across and connects to the sidewalls 46 , 48 . The deck 44 , the sidewalls 46 , 48 , and the cross member 36 provide the structure that forms the channel 40 .
[0098] A debris bag retention mechanism 52 is provided at the rear of the top housing 30 generally adjacent the rear opening 42 . The retention mechanism 52 is adapted to have a debris bag 54 attached thereto. When the debris bag 54 (see FIG. 1 ) is attached to the retention mechanism 52 the rear opening 42 is adjacent the opening to the debris bag 54 such that any debris that passes through the rear opening 42 , flows into, and is deposited in the debris bag 54 . In operation, when the cleaner 10 is in top mode debris that floats along the water line 16 of the pool 12 would travel through the skimmer opening 38 , across the channel 40 , e.g., along the deck 44 , and out through the rear opening 42 into the debris bag 54 .
[0099] The rounded front wall 50 includes a plurality of removed portions 56 adapted for a plurality of diverter wheels to extend therethrough and past the rounded front wall 50 . The deck 44 includes a debris opening 58 that traverses through the deck 44 . The debris opening 58 allows debris removed from the pool walls 14 to be moved through the deck 44 of the top housing 34 and into the debris bag 54 .
[0100] A plurality of skimmer/debris retention jets 60 are positioned on each of the first and second sidewalls 46 , 48 of the top housing body 34 to spray pressurized water rearward toward the debris bag 54 . The skimmer/debris retention jets 60 are in fluidic communication with a fluid distribution system, discussed in greater detail below, such that the skimmer/debris retention jets 60 spray pressurized water when the cleaner 10 is in the skim/top mode of operation. The skimmer/debris retention jets 60 function to force water and any debris that may be in the channel 40 rearward into the debris bag 54 . Furthermore, the jetting of water rearward causes a venturi-like effect causing water that is more forward than the skimmer/debris retention jets 60 to be pulled rearward into the debris bag 54 . Thus, the skimmer/debris retention jets 60 perform a skimming operation whereby debris is pulled and forced into the debris bag 54 . Furthermore, the skimmer/debris retention jets 60 prevent debris that is in the debris bag 54 from exiting.
[0101] The chassis 32 includes a first wheel well 62 , a second wheel well 64 , a front wheel housing 66 , a rear wall 68 , and a bottom wall 70 . The first wheel well 62 functions as a side wall of the chassis 32 and a housing for a first rear wheel 72 . The second wheel well 64 functions as a second side wall of the chassis 32 and a housing for a second rear wheel 74 . The first and second rear wheels 72 , 74 are each respectively rotationally mounted to the first and second wheel wells 62 , 64 . The front wheel housing 66 extends outwardly from the front of the chassis 32 and functions to rotationally secure a front wheel 76 to the chassis 32 . The front wheel 76 , and the first and second rear wheels 72 , 74 , which are freely rotatable, support the cleaner 10 on the pool walls 14 and allow the cleaner 10 to traverse the pool walls 14 .
[0102] The rear wall 68 includes an inlet port 78 , a top/bottom mode adjustment aperture 79 , a forward (bottom mode) thrust jet nozzle aperture 80 , and a top mode jet nozzle aperture 81 . The rear wall 68 also includes a forward (bottom mode) thrust jet nozzle 82 extending through the forward thrust jet nozzle aperture 80 , and a top mode jet nozzle 83 extending through the top mode jet nozzle aperture 81 , which are discussed in greater detail below. The inlet port 78 includes an external nozzle 84 and an internal nozzle 86 , each respectively have a barb 88 , 90 that facilitates connection of a hose thereto. The external nozzle 84 allows a hose, such as the segmented hose 22 , to be connected to the cleaner 10 , putting the cleaner 10 in fluidic communication with the external pump 18 . The external nozzle 84 is generally a fluid inlet, while the internal nozzle 86 is generally a fluid outlet. That is, the external nozzle 84 is connected to and in fluidic communication with the internal nozzle 86 such that water provided to the external nozzle 84 travels to and exits the internal nozzle 86 . The internal nozzle 86 is connected to a hose 87 , 403 a (see FIGS. 11 and 54 ) which is connected, and in fluidic communication, with a drive assembly, discussed in greater detail below. The forward (bottom mode) thrust jet nozzle 82 extends through the rear wall 68 , and includes an internal nozzle 94 , and a barb 96 , and is discussed in greater detail below.
[0103] The bottom wall 70 includes a suction head 98 and a suction aperture 100 . The suction head 98 is formed as a pyramidal recess or funnel disposed in the bottom wall 70 and extending to the suction aperture 100 , which extends through the bottom wall 70 . As shown in FIGS. 4 and 10 , the suction head 98 may include a rectangular perimeter that extends generally across the width of the bottom wall 70 of the cleaner 10 . A suction tube 102 is positioned adjacent the suction aperture 100 and extends from the suction aperture 100 to the debris opening 58 of the top housing 30 . A plurality of suction jet nozzles 104 are mounted adjacent the suction aperture 100 and oriented to discharge a high velocity stream of water through the suction tube 102 , creating a venture-like suction effect. The high velocity discharge from the suction jet nozzles 104 removes debris from the pool walls 14 when the cleaner 10 is in bottom mode. In such an arrangement, the suction head 98 functions to direct loosened debris into the suction aperture 100 , this debris is forced through the suction tube 102 by the suction jet nozzles 104 . The plurality of suction jet nozzles 104 may be three nozzles arranged in a triangular orientation, four nozzles arranged in a rectangular orientation, or various other orientations. Furthermore, the plurality of suction jet nozzles 104 may be oriented to direct their respective stream of water parallel to the central axis of the suction tube 102 , or may be oriented to direct their respective stream of water at an angle to the central axis of the suction tube 102 to cause a helical flow, which also results in increase performance/efficiency of the cleaner.
[0104] The chassis 32 includes a front rim 106 having a plurality of cut-outs receiving diverter wheels 108 . The front rim 106 and cut-outs define an upper frontal perimeter of the chassis 32 . The plurality of diverter wheels 108 are rotatably mounted to the chassis 32 adjacent the front rim 106 such that the diverter wheels 108 extend through the cut-outs. The diverter wheels 108 function as rotatable bumpers so if the cleaner 10 approaches a pool wall 14 the diverter wheels 108 contact the pool wall 14 instead of the top housing 30 or the chassis 32 . When in contact with the pool wall 14 , the diverter wheels 108 rotate, allowing the cleaner 10 to be continually driven and moved along, and/or diverted away from, the pool wall 14 . Thus, the diverter wheels 108 protect the cleaner 10 from damage due to contact with the pool wall 14 . Vice versa, the wheels 108 protect the pool walls from damage due to the cleaner 10 , e.g., scuffing, scratching, etc.
[0105] The chassis 32 includes a reverse/spin-out thrust jet nozzle housing 110 located at a frontal portion generally adjacent the front wheel housing 66 . The jet nozzle housing 110 includes a removed portion 111 providing access to a reverse/spin-out thrust jet nozzle 112 . The reverse/spin-out thrust jet nozzle 112 is secured within the jet nozzle housing 110 and includes an outlet 114 and an inlet 116 having a barb 118 . The barb 118 facilitates attachment of a hose 119 a to the inlet 116 . Water provided to the inlet 116 is forced out the outlet 114 under pressure causing a jet of pressurized water directed generally forward. This jet of pressurized water causes the cleaner 10 to move in a rearward direction. Alternatively, the reverse/spin-out thrust jet nozzle 112 may be positioned at an angle to the chassis 32 such that it causes an angular movement of the cleaner 10 , e.g., a “spin-out,” instead of rearward movement of the cleaner 10 . In either configuration, the reverse/spin-out thrust jet nozzle 112 functions to occasionally cause the cleaner 10 to move in a reverse motion or spin-out motion so that if it is ever stuck in a corner of the pool 12 , or stuck on an obstruction in the pool 12 , such as a pool toy or pool ornamentation, it will free itself and continue to clean the pool 12 .
[0106] FIG. 12 is a sectional view of the pool cleaner 10 taken along line 12 - 12 of FIG. 5 . As illustrated in FIG. 12 , the chassis 32 forms a housing for a drive assembly 120 , a water distribution manifold 122 , and the suction tube 102 .
[0107] FIGS. 14-17 illustrate the drive assembly 120 and the water distribution manifold 122 , which are in fluidic communication with one another. The drive assembly 120 includes a timer assembly 124 , a back-up/spin-out mode valve assembly 126 , and a top/bottom mode valve assembly 128 , each discussed in greater detail below. The water distribution manifold 122 includes a manifold body 130 and a jet ring 132 . The manifold body 130 includes a plurality of chambers that function to direct water flow amongst the various jet nozzles of the cleaner 10 . The suction tube 102 includes a bottom end 134 and a top end 136 . The jet ring 132 is connected with the bottom end 134 of the suction tube 102 and includes the plurality of suction jet nozzles 104 .
[0108] FIGS. 17-27 show the drive assembly 120 in greater detail. Particular reference is made to FIG. 24 , which is an exploded view of the drive assembly 120 showing the components of the timer assembly 124 , the inlet body 138 , the back-up/spin-out mode assembly 126 , and the top/bottom mode assembly 128 . The timer assembly 124 includes a turbine housing 140 , a gear box 142 , a Geneva gear lower housing 144 , and a Geneva gear upper housing 146 . The drive assembly 120 is configured such that the backup/spin mode assembly 126 is adjacent the inlet body 138 , the inlet body 138 is adjacent the Geneva gear upper housing 146 , the Geneva gear lower housing 144 is adjacent the Geneva gear upper housing 146 , the gear box 142 is adjacent the Geneva gear lower housing 144 , and the turbine housing 140 is adjacent the gear box 142 .
[0109] The inlet body 138 includes an inlet nozzle 148 having a barbed end 150 . The inlet nozzle 148 provides a flow path from the exterior of the inlet body 138 to the interior. The inlet body 138 defines an annular chamber 152 that surrounds a central hub 154 . The inlet nozzle 148 is in communication with the annular chamber 152 such that fluid can flow into the inlet nozzle 148 and into the annular chamber 152 . The annular chamber 152 includes a closed top and an open bottom. An outlet nozzle 156 having a barbed end 158 is provided on the inlet body 138 generally opposite the inlet nozzle 148 . The outlet nozzle 156 provides a path for water to flow out from the inlet body 138 . As such, water flowing into the inlet nozzle 148 flows through the annular chamber 152 and exits the inlet body 138 through the outlet nozzle 156 . The inlet body 138 is generally closed at an upper end, e.g., the end adjacent the Geneva gear upper housing 146 , and open at a lower end, e.g., the end adjacent the backup/spin-out mode assembly 126 .
[0110] The turbine housing 140 includes an inlet nozzle 160 having a barbed end 162 , and a turbine 164 . A hose 159 is connected at one end to the barbed end 158 of the inlet body outlet nozzle 156 and at another end to a the barbed end 162 of the turbine housing inlet nozzle 160 . Accordingly, water flows out from the inlet body 138 through the outlet nozzle 156 and to the turbine housing inlet nozzle 160 by way of the hose 159 . The turbine 164 includes a central hub 166 , a plurality of blades 168 , a boss 170 extending from the central hub 166 and having an output drive gear 172 mounted thereto, a central aperture 174 . The central hub 166 , boss 170 , and output drive gear 172 are connected for conjoint rotation. Accordingly, rotation of the blades 168 causes rotation of the central hub 166 , boss 170 , and output drive gear 172 . The central aperture 174 extends through the center of the turbine 164 , e.g., through the output drive gear 172 , the boss 170 , and the central hub 166 . A first shaft 176 extends through the central aperture 174 and is secured within a shaft housing 178 that is provided in a top of the turbine housing 140 . The first shaft 176 extends from the shaft housing 178 , through the turbine 164 , and into the gear box 142 . The turbine housing 140 also includes one or more apertures 180 in a sidewall thereof that allow water to escape the turbine housing 140 . When pressurized water enters the turbine housing 140 through the inlet nozzle 160 it places pressure on the turbine blades 168 , thus transferring energy to the turbine 164 and causing the turbine 164 to rotate. However, once the energy of the pressurized water is transferred to the turbine 164 it must be removed from the system, otherwise it will impede and place resistance on new pressurized water entering the turbine housing 140 . Accordingly, new pressurized water introduced into the turbine housing 140 forces the old water out from the one or more apertures 180 . FIG. 26 is a sectional view of the turbine housing 140 taken along line 26 - 26 of FIG. 20 further detailing and showing the arrangement of the turbine 164 within the turbine housing 140 . The turbine housing 140 is positioned on the gear box 142 .
[0111] The gear box 142 includes a turbine mounting surface 182 having an aperture 184 extending there through. The turbine housing 140 is positioned on, and covers, the gear box turbine mounting surface 182 , such that the turbine 164 is adjacent the turbine mounting surface 182 and the turbine output drive gear 172 extends through the aperture 184 and into the gear box 142 . The gear box 142 houses a reduction gear stack 186 that is made up of a plurality of drive gears 188 , some of which include a large gear 190 connected and coaxial with a smaller gear 192 (see FIG. 25 ) for conjoint rotation therewith. The conjoint rotation of the large gear 190 with the smaller gear 192 causes for a reduction in gear ratio. As can bee seen in FIG. 25 , which is a sectional view of the drive assembly 120 , the gear reduction stack 186 includes two series of coaxial gears 188 that both include a central aperture 194 extending through the gears 188 . One of the series gear 186 is coaxial with the turbine 164 such that the first shaft 176 extends through the gears 188 , and into a first shaft bottom housing 218 of the Geneva gear upper housing 146 , discussed in greater detail below. Thus, the first series of gears 188 rotates about first shaft 176 . A second series of gears 188 is positioned to engage the first series of gears 188 and have a second shaft 196 extending through the central aperture 194 thereof. The second shaft 196 is parallel to the first shaft 176 and is secured within a second shaft top housing 198 that is positioned in a top wall of the gear box 142 . The second shaft 196 extends through the Geneva gear lower housing 144 . The turbine output drive gear 172 engages a large gear 190 of the first gear 188 that rotates about the second shaft 196 . The smaller gear 192 of the first gear 188 engages another gear 188 that rotates about the first shaft 176 . A series of such gears are positioned within the gear reduction stack 186 with particular gear ratios, and engaged with one another in the above-described fashion, so that rotation of the turbine 164 , and subsequent rotation of the turbine output drive gear 172 , causes each gear 188 of the gear reduction stack 186 to rotate with each subsequent gear rotating at a different speed. The gear reduction stack 186 includes a final gear stack output gear 200 that rotates about the first shaft 176 . The gear stack output gear 200 includes a drive gear 202 and a Geneva drive gear 204 extending from the drive gear 202 for conjoint rotation therewith. The gear stack output drive gear 202 engages and is driven by one of the smaller gears 192 of a gear 188 of the gear stack 186 . Accordingly, rotation of the turbine blades 168 causes rotation of the central hub 166 , boss 170 , and output drive gear 172 , which output drive gear 172 causes rotation of the gears 188 of the gear reduction stack 186 , and ultimately rotation of the gear stack output gear 200 . As shown in FIG. 27 , the Geneva drive gear 204 includes a central hub 206 , a central aperture 208 , and a post 210 , which all extend from the drive gear 204 , thus having conjoint rotation therewith. The central hub 206 includes a remove section 212 . The function of the Geneva drive gear 204 is discussed in greater detail below in connection with FIG. 27 .
[0112] Referring now to FIG. 27 , the Geneva gear lower housing 144 is positioned between the gear box 142 and the Geneva gear upper housing 146 . The Geneva gear lower housing 144 includes an aperture 214 that the Geneva drive gear 204 extends through. The Geneva gear upper housing 146 includes the first shaft bottom housing 218 and a Geneva output aperture 230 (see FIG. 25 ). The Geneva gear lower and upper housings 144 , 146 house a Geneva gear 220 . The Geneva gear 220 includes a second shaft bottom housing 221 , a plurality of cogs 222 , a plurality of slots 224 between each cog 222 , and a socket 228 (see FIG. 25 ). The second shaft 196 (see FIG. 25 ) extends through the Geneva gear lower housing 144 and is secured within the shaft bottom housing 221 . The Geneva gear 220 shown in FIG. 27 includes eight cogs 222 separated by eight slots 224 . The slots 224 extend radially inward from the periphery of the Geneva gear 220 . Each of the cogs 222 include an arcuate portion 226 on the peripheral edge thereof. The socket 228 extends from the Geneva gear 220 and through the upper housing Geneva output aperture 230 , which generally have mating geometries so that the Geneva gear socket 228 can rotate within the Geneva output aperture 230 , but is restricted from planar translation. The Geneva gear socket 228 generally has a circular outer geometry, for rotation within the Geneva output aperture 230 , and a non-circular inner geometry, here square.
[0113] In operation, rotation of the drive gear 202 (see FIG. 25 ) results in rotation of the Geneva drive gear 204 (see FIG. 25 ). Accordingly, because the Geneva gear central hub 206 and the Geneva gear post 210 are a part of the Geneva drive gear 204 , and thus attached to the underside of the drive gear 202 , they rotate about the first shaft 176 . The Geneva gear post 210 is positioned radially and at a distance from the central hub 206 so that it can engage the Geneva gear 220 . Similarly, the Geneva gear 220 is sized so that each of the cogs 222 can be positioned adjacent the Geneva dive gear central hub 206 . Additionally, the Geneva gear 220 is sized so that the Geneva gear post 210 can be inserted into the slots 224 . When the Geneva drive gear 204 is rotated, the post 210 orbits the central aperture 208 , while the central hub 206 rotates adjacent an arced removed portion 226 of an adjacent cog 222 . Accordingly, the central hub 206 does not engage the cogs 222 . Continued rotation of the Geneva drive gear 204 results in the post 210 making a full orbit about the central aperture 208 until it reaches a point where it intersects a cog slot 224 . Further rotation of the post 210 causes the post 210 to enter a slot 224 and engage a side wall of a cog 222 , pushing the cog in the rotational direction of the post 210 . To facilitate this rotation, the removed portion 212 of the central hub 206 allows any extraneous portions of the cogs 222 that would otherwise contact the central hub 206 to instead move within the removed portion 212 . Thus, the central hub 206 does not restrict the Geneva gear 220 from rotating. As the post 210 rotates while engaging the cog 222 it pushes the cog 222 and causes the entire Geneva gear 220 to rotate in an opposite direction than the rotational direction of the post 210 . The post 210 does not continually rotate the Geneva gear 220 for the entirety of the rotational cycle of the post 210 , but instead acts as an incremental rotation device that “clicks” a cog 222 over one position while it engages the cog 222 . As such, the Geneva gear 220 has a series of distinct positions, with the number of distinct positions being based on the number of cogs 222 . Here, there are eight cogs 222 , so there are eight distinct positions, e.g., each position being at 45°. Therefore, the entire Geneva gear 220 is rotated, or “clicked” over, 45° per rotational cycle of the post 210 , as opposed to continuous rotation if this were a standard gear. Accordingly, the Geneva gear 220 does not gradually switch positions, but is instead more quickly “clicked” over to a new position. The Geneva gear 220 can be altered to accommodate different scenarios that could require lesser or greater angular positioning of the Geneva gear 220 , for example if it is required for there to be 20° positioning, then the Geneva gear could include eighteen cogs and eighteen slots.
[0114] Referring back to FIG. 25 , rotation of the Geneva gear 220 causes conjoint rotation of the Geneva gear socket 228 within the upper housing Geneva output aperture 230 . The Geneva gear socket 228 rotationally engages a drive head 260 of a reverse/skim-out valve selector 238 , which will be discussed in greater detail.
[0115] FIGS. 28-30 show the reverse/spin-out mode assembly 126 in greater detail. FIG. 28 is an exploded view of the reverse/spin-out mode assembly 126 , and the inlet body 138 . The reverse/spin-out mode assembly 126 includes a reverse/spin-out mode valve body 236 and a reverse/skim-out mode valve selector 238 . The reverse/spin-out mode valve body 236 includes an opening 240 , an internal forward drive chamber 242 , an internal reverse drive chamber 244 , and a plurality of dividers 246 that separate the internal forward drive chamber 242 and the internal reverse drive chamber 244 . As can be seen, internal structural support ribs are provided within the chamber 242 , as shown in FIG. 28 .
[0116] The reverse/spin-out mode valve selector 238 includes a valve disk 254 , a shaft 256 , an enlarged section 258 , a drive head 260 , and an o-ring 262 . The valve disk 254 is generally circular in geometry and sized to match the reverse/spin-out mode valve body opening 240 . The valve disk 254 includes a window 264 that is positioned on the outer periphery of the valve disk 254 . The window 264 extends through the valve disk 254 , and generally spans an angular distance about the circumference equal to a single position of the Geneva gear cog 222 . More specifically, in the current example, there are eight cogs 222 at eight distinct positions, e.g., each position being at 45°. Accordingly, the window 264 extends an angular distance of 45° about the circumference of the valve disk 254 , which matches the expanse of a single cog 222 , and the distance a single cog 222 travels during a single rotational cycle of the Geneva gear 220 . The shaft 254 extends from the center of the valve disk 254 to an enlarged section 258 . The enlarged section 258 is generally circular in shape and sized to be inserted into, and rotate within, the central hub 154 of the inlet body 138 . The enlarged section 258 can include an o-ring 262 about the periphery for creating a seal radially against the central hub 154 . The drive head 260 extends from the enlarged section 258 and includes a generally square geometry. Particularly, the drive head 260 is configured to engage the Geneva gear socket 228 , such that rotation of the Geneva gear socket 228 rotationally drives the drive head 260 . Accordingly, the drive head 260 and the Geneva gear socket 228 include mating geometries. Rotation of the drive head 260 results in rotation of the valve disk 254 , and thus the window 264 . The window 264 provides a pathway for water to flow through and into either the internal forward drive chamber 242 or the internal reverse drive chamber 244 . Specifically, water enters the inlet body 138 at the inlet 148 and flows to the annular chamber 152 . When in the annular chamber 152 , the water flows in two directions, i.e., out through the outlet 156 and toward the opening 240 of the reverse/spin-out mode valve body 236 . However, the water is restricted from entering the opening 240 of the reverse/spin-out mode valve body 236 by the reverse/spin-out valve selector 238 . Accordingly, the water must flow through the window 264 of the reverse/spin-out valve selector 238 , and into the reverse/spin-out valve body 236 (see FIG. 25 ).
[0117] FIG. 29 is a top view of the reverse/spin-out mode valve body 236 , and FIG. 30 is a sectional view of the reverse/spin-out mode valve body 236 taken along line 30 - 30 of FIG. 20 . The window 264 generally includes eight different positions, which are based on the eight cog 222 positions. One of these positions is adjacent the internal reverse drive chamber 244 , and seven of these positions are adjacent the internal forward drive chamber 242 . The Geneva gear 220 drivingly rotates the valve disk 254 , and the window 264 , 45° at a time so that the window 264 switches between the eight different positions for each rotation of the Geneva drive gear 204 . As shown in FIG. 30 , the internal forward drive chamber 242 encompasses approximately seven of the eight sections, while the internal reverse drive chamber 244 encompasses a single section. Accordingly, the window 264 will be positioned adjacent the internal forward drive chamber 242 for approximately ⅞ ths of the time, and will be positioned adjacent the internal reverse drive chamber 244 for approximately ⅛ th of the time. As mentioned previously, the Geneva gear 220 functions to quickly rotate 45° at a time so that the window 264 swiftly rotates from one position to the next, instead of gradually moving from one position to the next. Accordingly, the time spent by the window 264 adjacent both the internal reverse drive chamber 244 and the internal forward drive chamber 242 when the window 264 is switching between these two chambers is minimized.
[0118] The internal reverse drive chamber 244 is in fluidic communication with a reverse/spinout outlet port 250 that can include an o-ring 252 . The reverse/spinout outlet port 250 is connected with the water distribution manifold 122 , and is discussed in greater detail below. The internal forward drive chamber 242 is connected with the open bottom of the reverse/spin-out mode valve body 236 for the water to flow to the top/bottom mode valve body 270 . Each of the inlet body 138 , turbine housing 140 , gear box 142 , Geneva gear upper housing 146 , reverse/spin-out mode valve body 236 , and top/bottom mode valve body 270 can include a plurality of coaxially aligned mounting brackets 232 that allow connection by a plurality of bolts 234 .
[0119] FIGS. 31-33 show the top/bottom mode assembly 128 in greater detail. FIG. 31 is an exploded view of the top/bottom mode assembly 128 . The top/bottom mode assembly 128 includes a top/bottom mode valve body 270 and a top/bottom mode valve selector 272 . The top/bottom mode valve body 270 includes and upper opening 274 , an internal bottom mode chamber 276 , an internal top mode chamber 278 , and a plurality of dividers 280 that separate the internal bottom mode chamber 276 and the internal top mode chamber 278 . The top/bottom mode valve body 270 is closed at the bottom. The internal bottom mode chamber 277 is connected, and in fluidic communication, with a bottom mode outlet port 282 that can include an o-ring 284 . The internal top mode chamber 278 is connected, and in fluidic communication, with a top mode outlet port 286 that can include an o-ring 288 . The top/bottom mode valve body 270 also includes a central hub 290 that is positioned within and is coaxial with the top/bottom mode valve body 270 . The central hub 290 is hollow and extends from the upper opening 274 through the bottom of the top/bottom mode valve body 270 . The central hub 290 is connected with the dividers 280 . The internal bottom mode chamber 276 and the internal top mode chamber 278 extend about the circumference of the central hub 290 .
[0120] The top/bottom mode valve selector 272 includes a valve disk 292 , a shaft 294 , an enlarged section 296 , an engageable drive head 298 , and an o-ring 300 about the enlarged section 296 . The drive head 298 is configured to be engaged by a user, such that a tool can be used to engage the head 298 and rotate the top/bottom mode valve selector 272 to select a desired mode of operation. The valve disk 292 is generally circular in geometry and sized to match the top/bottom mode valve body upper opening 270 . The valve disk 292 includes a window 302 that is positioned on the outer periphery of the valve disk 292 . The window 302 extends through the valve disk 292 . The shaft 294 extends from the center of the valve disk 292 to the enlarged section 296 . The enlarged section 296 is generally circular in shape and sized to be inserted into, and rotate within, the central hub 290 . The enlarged section 296 can include the o-ring 262 about the periphery for creating a seal radially against the central hub 290 . The drive head 298 extends from the enlarged section 296 , and includes a geometry that facilitates engagement. For example, the drive head 298 can include a square or hexagonal geometry, or alternatively can include a flat slot for engagement with a flat-head screwdriver, or a crossed slot for engagement with a Phillips-head screwdriver. Rotation of the drive head 298 results in rotation of the valve disk 292 , and thus the window 302 . The window 302 provides a pathway for water to flow through and into either the internal bottom mode chamber 276 or the internal top mode chamber 278 . Specifically, water that flows through the internal forward drive chamber 242 of the reverse/spin-out mode valve body 236 can pass through the window 302 to enter the top/bottom mode valve body 270 . The top/bottom mode valve body 270 chamber that the water enters, e.g., the internal bottom mode chamber 276 and the internal top mode chamber 278 , depends on the positioning of the window 302 . That is, when the window 302 is positioned adjacent the internal bottom mode chamber 276 , due to engagement of the drive head 298 and rotation of the valve disk 292 , water will flow into the internal bottom mode chamber 276 . On the other hand, if the window 302 is positioned adjacent the internal top mode chamber 278 , water will flow into the internal top mode chamber 276 .
[0121] FIG. 32 is a top view of the top/bottom mode valve body 128 , and FIG. 33 is a sectional view of the top/bottom mode valve body 128 taken along line 33 - 33 of FIG. 20 . As can be seen, the internal bottom mode chamber 276 and the internal top mode chamber 278 are generally divided by the central hub 290 and the plurality of dividers 280 . The internal bottom mode chamber 276 is connected with the bottom mode outlet port 282 , while the internal top mode chamber 278 is connected with the top mode outlet port 286 . Accordingly, water that flows into the internal bottom mode chamber 276 will flow out from the bottom mode outlet port 282 , while water that flows into the internal top mode chamber 278 will flow out from the top mode outlet port 286 . The bottom mode outlet port 282 and the top mode outlet port 286 are connected with the water distribution manifold 122 , which will be discussed in greater detail.
[0122] FIGS. 34-43 show the water distribution manifold 122 in greater detail. Specific reference is made to FIGS. 34-35 , which are perspective views of the water distribution manifold 122 . The water distribution manifold 122 includes a manifold top 308 , the manifold body 130 , and the jet ring 132 . The manifold top 308 includes three inlets, a reverse/spinout inlet 312 , a top mode inlet 314 , and a bottom mode inlet 316 . The manifold top 308 also includes a plurality of mounting tabs 318 for engagement with the manifold body 130 , and a plurality of mounting risers 320 for engagement with the mounting brackets 232 of the top/bottom mode valve body 270 . The reverse/spinout inlet 312 is generally connected with the reverse/spinout outlet port 250 of the reverse/spinout mode valve body 236 , such that the reverse/spinout outlet port 250 is inserted into the reverse/spinout inlet 312 and the o-ring 252 creates a seal radially against a wall of the reverse/spinout inlet 312 . The top mode inlet 314 is generally connected with the top mode outlet port 286 of the top/bottom mode valve body 270 , such that the top mode outlet port 286 is inserted into the top mode inlet 314 and the o-ring 288 creates a seal radially against a wall of the top mode inlet 314 . The bottom mode inlet 316 is generally connected with the bottom mode outlet port 282 of the top/bottom mode valve body 270 , such that the bottom mode outlet port 282 is inserted into the bottom mode inlet 316 and the o-ring 284 creates a seal radially against a wall of the bottom mode inlet 316 . The manifold top 308 is positioned on top of the manifold body 130 .
[0123] FIG. 42 is a sectional view of the manifold body 130 taken along section line 42 - 42 of FIG. 38 . The manifold body 130 defines a reverse/spinout mode chamber 326 , a top mode chamber 328 , and a bottom mode chamber 330 . The reverse/spinout mode chamber 326 , the top mode chamber 328 , and the bottom mode chamber 330 are separated by a plurality of internal divider walls 332 . The manifold body 130 includes a bottom wall 334 than includes an aperture 336 extending through a portion of the bottom wall 334 that forms the bottom mode chamber 330 . The aperture 336 extends through the bottom wall 334 to a flow channel 338 . The flow channel 338 is located on the bottom 339 of the manifold body bottom wall 334 and sealed with the channel 105 that is located on the bottom wall 70 of the chassis 32 . Accordingly, a fluid-tight pathway is formed between the flow channel 338 and the chassis bottom wall channel 105 . A gasket may be provided between the flow channel 338 and the chassis bottom wall channel 105 to facilitate formation of a seal.
[0124] The chassis body 130 also includes a reverse/spinout outlet 340 having a barbed end 342 , two top mode skimmer outlets 344 each having a barbed end 346 , a top mode jet nozzle housing 348 , and a bottom mode outlet 350 having a barbed end 352 . The reverse/spinout outlet 340 is in fluidic communication with the reverse/spinout mode chamber 326 . Accordingly, water that flows into the reverse/spinout mode chamber 326 flows out from the reverse/spinout outlet 340 . A first hose 119 a (see FIG. 11 ) is connected to the reverse/spinout outlet 340 at one end, and to the reverse/spin-out thrust jet nozzle inlet 116 (see FIG. 11 ) at the other end. The barbed end 342 facilities attachment of the first hose 119 a to the reverse/spinout outlet 340 while the inlet barb 118 facilitates attachment of the first hose 119 a to the inlet 116 . Water provided from the reverse/spinout outlet 340 to the inlet 116 is forced out the outlet 114 under pressure causing a jet of pressurized water directed generally forward. This jet of pressurized water causes the cleaner 10 to move in a rearward direction. Alternatively, the reverse/spin-out thrust jet nozzle 112 may be positioned at an angle to the chassis 32 such that it causes an angular movement of the cleaner 10 , e.g., a “spin-out,” instead of rearward movement of the cleaner 10 . In either configuration, the reverse/spin-out thrust jet nozzle 112 functions to occasionally cause the cleaner 10 to move in a reverse motion or spin-out motion so that if it is ever stuck in a corner of the pool 12 , or stuck on an obstruction in the pool 12 , such as a pool toy or pool ornamentation, it will free itself and continue to clean the pool 12 .
[0125] The top mode skimmer outlets 344 and the top mode jet nozzle housing 348 are in fluidic communication with the top mode chamber 328 . The top mode jet nozzle housing 348 houses the skim mode jet nozzle 83 . Accordingly, water that flows into the top mode chamber 328 flows out from the top mode skimmer outlets 344 , and the top mode jet nozzle 83 . A second hose 119 b (see FIG. 13 ) is connected to one of the top mode skimmer outlets 344 at one end, and a third hose 119 c (see FIG. 13 ) is connected to the other top mode skimmer outlet 344 at one end. The barbed ends 346 facilitate attachment of the second and third hoses 119 b , 119 c to the top mode skimmer outlets 344 . The second and third hoses 119 b , 119 c are each respectively connected at their second end to one of the plurality of skimmer/debris retention jets 60 , such that the skimmer/debris retention jets 60 spray pressurized water when water is provided to them by way of the top mode skimmer outlets 344 . The skimmer/debris retention jets 60 function to force water and any debris that may be in the channel 40 rearward into the debris bag 54 . Furthermore, the jetting of water rearward causes a venturi-like effect causing water that is more forward than the skimmer/debris retention jets 60 to be pulled rearward into the debris bag 54 . Thus, the skimmer/debris retention jets 60 perform a skimming operation whereby debris is pulled and forced into the debris bag 54 . Further, the skimmer/debris retention jets 60 prevent debris that is in the debris bag 54 from exiting. Additionally, water provided from the top mode chamber 328 to the top mode jet nozzle 83 is forced out the top mode jet nozzle 83 under pressure, causing a jet of pressurized water directed generally rearward and downward. This jet of pressurized water propels the cleaner 10 toward the pool water line 16 for skimming of the pool water line 16 . When the cleaner 10 is skimming the pool water line 16 , the top mode jet nozzle 83 propels the cleaner 10 forward along the pool water line 16 .
[0126] FIG. 43 is a sectional view of the manifold body 130 taken along line 43 - 43 of FIG. 40 showing the bottom mode chamber 330 in greater detail. The bottom mode outlet 350 is in fluidic communication with the bottom mode chamber 330 . Additionally, as mentioned above, the bottom mode chamber 330 is in fluidic communication with the flow channel 338 through the aperture 336 . The flow channel 338 extends across the bottom 339 of the manifold body 130 and to the jet ring 132 . Accordingly, water that flows into the bottom mode chamber 330 flows out from the bottom mode outlet 350 , and through the aperture 336 . One end of a fourth hose 119 d (see FIG. 13 ) is connected to the bottom mode outlet 350 , and the second end is connected to the internal nozzle 94 of the forward thrust jet nozzle 82 . The barbed end 352 and the internal nozzle barb 96 facilitate attachment of the fourth hose 119 b to the bottom mode outlet 350 and the forward thrust jet nozzle 82 , respectively. The fourth hose 119 d provides water from the bottom mode outlet 350 to the forward thrust jet nozzle 82 , such that the forward thrust jet nozzle 82 sprays pressurized water when water is provided thereto. The pressurized water is forced through the forward thrust jet nozzle 82 and out the forward thrust jet nozzle 82 under pressure, causing a jet of pressurized water directed generally rearward. This jet of pressurized water propels the cleaner 10 across the pool wall 14 , e.g., the bottom of the pool, so that the cleaner 10 can clean the pool wall 14 . In this regard, water that flows through the bottom mode chamber 330 also flows across the flow channel 338 and to the jet ring 132 .
[0127] The jet ring 132 defines an annular flow channel 354 and includes a plurality of protrusions 356 extending from a top surface 358 of the jet ring 132 . The bottom end 134 of the suction tube 102 can be positioned on the top surface 358 of the jet ring 132 . The plurality of protrusions 356 can be inserted into the bottom end 134 of the suction tube 102 , such that the protrusions 356 secure the suction tube 102 to the jet ring 132 and restrict the suction tube 102 from detaching from the jet ring 132 . Accordingly, when the water distribution manifold 122 is secured within the chassis 32 , the suction tube 102 extends from the jet ring 132 to the debris opening 58 of the top housing body 34 . The annular flow channel 354 is in fluidic communication with the flow channel 338 and is sealed with the channel 105 that is located on the bottom wall 70 of the chassis 32 . Accordingly, a fluid tight pathway is formed between the annular flow channel 354 , the flow channel 338 , and the chassis bottom wall channel 105 . A gasket may be provided between the annular flow channel 354 and the flow channel 338 , and the chassis bottom wall channel 105 to facilitate formation of a seal.
[0128] FIG. 44 is a sectional view taken along line 44 - 44 of FIG. 9 showing the flow channel 338 connected with the channel 105 of the bottom wall 70 . The jet ring 132 is positioned within the chassis 32 adjacent the suction aperture 100 , and includes the plurality of suction jet nozzles 104 that are in fluidic communication with the annular flow channel 354 and positioned to discharge water through the suction tube 102 . Accordingly, the suction jet nozzles 104 spray pressurized water when water is provided to them by way of the flow channel 338 and the annular flow channel 354 . The suction jet nozzles 104 discharge pressurized water upward through the suction tube 102 toward the debris opening 58 , forcing any loose debris through the suction aperture 100 , across the suction tube 102 , out the debris opening 58 , and into the debris bag 54 . Furthermore, the jetting of water upward through the suction tube 102 causes a venturi-like suction effect causing the suction head 98 to loosen debris from the pool walls 14 and direct the loosened debris into the suction aperture 100 . This debris is forced through the suction tube 102 by the suction jet nozzles 104 .
[0129] FIGS. 45-47 show the hose connection 20 in greater detail. The hose connection 20 includes a connector portion 400 , a body 402 , and a nozzle 404 . The connector portion 400 includes a radially protruding inclined track 406 to engage a mating member of a hose, e.g., segmented hose 22 , for mounting with a caming action. This engagement can be characterized as a bayonet mount. FIG. 47 is a sectional view taken along line 47 - 47 of FIG. 46 , showing the hose connection 20 in greater detail. The body 402 includes a rotatable ball valve 408 , and a plurality of seals 410 . The rotatable ball valve 408 includes a ball 411 positioned within the body 402 . The seals 410 extend circumferentially about the ball 411 , and are positioned between the ball 411 and an internal wall of the body 402 . Accordingly, the seals 410 create a seal radially against the body 402 . A stem 412 extends from the ball 411 and through the body 402 , where it is attached with a handle 414 . Rotation of the handle 414 , results in rotation of the ball 411 within the body 410 . When in a first position, water can flow through the ball 411 . When in a second position, water is sealed off from flowing through the ball 411 . Accordingly, the hose connection 20 can be used to control flow therethrough. The nozzle 404 includes a barb 416 that facilitates attachment of a hose to the nozzle 404 .
[0130] FIGS. 48-50 show the swivel 24 in greater detail. The swivel includes a first body 418 and a second body 420 . The first body 418 includes a tubular section 422 having a barb 424 and a radial extension 426 . A locking ring 428 extends from the radial extension and includes an annular wall 430 and an inwardly extending shoulder 432 . The second body 420 includes a tubular portion 434 having a barb 436 and a radial shoulder 438 . The radial shoulder 438 includes an annular protrusion 440 . The radial shoulder 438 of the second body 420 is positioned within the annular wall 430 of the first section locking ring 438 , such that a first chamber 442 is formed between the first section locking ring 438 , and the inwardly extending shoulder 432 . A plurality of bearing balls 444 , which could be acetal balls, can be positioned within the first chamber 442 . A second chamber 446 is formed between the radial extension 426 of the first body 418 , the annular wall 430 , and the radial shoulder 438 . An annular sealing washer 448 and an annular seal 450 may be positioned and compressed within the second chamber 446 , with the annular protrusion 440 contacting the annular sealing washer 448 . Accordingly, the first and second bodies 418 , 420 can rotate with respect to one another, such that the bearing balls 444 facilitate rotation, and the annular sealing washer 448 and the annular seal 450 seal the first and second bodies 418 , 420 from leakage. Accordingly, water can flow through the first and second bodies 418 , 420 .
[0131] FIG. 51 is a perspective view of a filter 26 . The filter 26 includes a body 452 , a filter assembly 454 partially positioned within the body 452 , and a nut 456 . The body includes a nozzle 458 having a barb 460 . The filter assembly 454 includes a filter 462 and a nozzle 464 having a barb 466 . The nut 456 secures the filter assembly 454 with the body 452 . Accordingly, water can flow into the body nozzle 458 , into the body 452 , through the filter 462 where it is filtered, and out the filter nozzle 464 .
[0132] Operation of the cleaner 10 is summarized as follows. In operation, the pump 18 provides pressurized water through the segmented hose 22 , any connected swivels 24 , filters 26 , and floats 28 , and to the cleaner 10 . The segmented hose 22 is connected to the inlet port external nozzle 84 . The barb 88 facilitates attachment of the segmented hose 22 to the inlet port external nozzle 84 . Additionally, the nut 92 can be utilized to secure the segmented hose 22 to the inlet port external nozzle 84 in embodiments where the segmented hose 22 includes a threaded end for engagement with the nut 92 . The pressurized water flows through the inlet port 78 of the cleaner 10 and out through the inlet port external nozzle 86 , where it flows through the hose 87 and to the drive assembly inlet 148 . The pressurized water flows through the drive assembly inlet 148 and into the inlet body 138 . When in the inlet body 138 , the water diverges into two flows. A first flow flows to the outlet 156 and a second flow flows through the reverse/skim-out mode valve disk window 264 .
[0133] The first flow flows out of the outlet 156 , through the hose 159 and to the turbine housing inlet 160 . The first flow enters the turbine housing 140 through the inlet 160 , and places a force on the turbine blades 168 . This force causes the turbine 164 to rotate about the first shaft 176 . The first flow then exits the turbine housing 140 through the apertures 180 . Rotation of the turbine 164 causes the output drive gear 172 to drive the reduction gear stack 186 , resulting in rotation of the plurality of drive gears 188 . The plurality of drive gears 188 engage one another, with one of the drive gears 188 engaging, and rotationally driving, the gear stack output gear 200 . Rotation of the gear stack output gear 200 causes rotation of the Geneva drive gear 204 , including rotation of the post 210 about the first shaft 176 . The post 210 continually orbits the first shaft 176 while water drivingly engages the turbine 164 . During each rotation, the post 210 slides into a slot 224 of the Geneva gear 220 , and “pushes” an adjacent cog 222 . This engagement, e.g., the post 210 “pushing” the cog 222 , results in sequential rotation of the Geneva gear 220 , wherein, for example, the Geneva gear 220 rotates 45° for each orbit of the post 210 . Rotation of the Geneva gear 220 results in the Geneva gear socket 228 engaging and rotating the reverse/spin-out valve selector drive head 260 , thus rotationally driving the reverse/spin-out valve selector 238 and associated valve disk window 264 . Accordingly, Geneva gear 220 causes the valve disk window 264 to move between different positions adjacent the internal forward drive chamber 242 , and adjacent the internal reverse drive chamber 244 . While the first flow is causing the Geneva gear 220 to rotate the valve disk 254 , the second flow flows through the valve disk window 264 and into the reverse/spin-out mode valve body 236 chamber that it is adjacent to at that moment. For example, when the valve disk window 264 is adjacent the internal forward drive chamber 242 , into the internal forward drive chamber 242 . However, when the valve disk window 264 is adjacent the internal reverse drive chamber 244 , the second flow flows into the internal reverse drive chamber 244 . Thus, the Geneva gear 220 continuously and automatically determines which chamber the second flow of water flows into.
[0134] When the pressurized water of the second flow flows into the internal reverse drive chamber 244 , it flows out of the internal reverse drive chamber 244 through the outlet port 250 , into the reverse/spinout inlet 312 of the water distribution manifold 122 , into the reverse/spinout mode chamber 326 , out through the reverse/spinout outlet 340 , through the first hose 119 a , and to the reverse/spin-out thrust jet nozzle 112 , where it is discharged. Alternatively, when the pressurized water of the second flow flows into the internal forward drive chamber 242 , it flows through the valve disk window 302 of the top/bottom mode valve selector 272 . The valve disk window 302 is rotatable by a user by inserting a tool through the top/bottom mode adjustment aperture 79 extending through the cleaner rear wall 68 and rotationally engaging the drive head 298 . Accordingly, the valve disk window 302 can be positioned adjacent the internal bottom mode chamber 276 or the internal top mode chamber 278 .
[0135] When the valve disk window 302 is positioned adjacent the internal top mode chamber 278 , the pressurized water of the second flow flows into the internal top mode chamber 278 , out of the internal top mode chamber 278 through the top mode outlet port 286 , into the top mode inlet 314 of the water distribution manifold 122 , into the top mode chamber 328 , and out through the top mode skimmer outlets 344 and the top mode jet nozzle 83 . The portion of the flow that exits through the top mode skimmer outlets 344 flows through the respective second and third hose 119 b , 119 c and to the respective skimmer/debris retention jet 60 where it is discharged.
[0136] When the valve disk window 302 is positioned adjacent the internal bottom mode chamber 276 , the pressurized water of the second flow flows into the internal bottom mode chamber 276 , out of the internal bottom mode chamber 276 through the bottom mode outlet port 282 , into the bottom mode inlet 316 of the water distribution manifold 122 , into the bottom mode chamber 330 , and out through the bottom mode outlet 350 and the aperture 336 . The flow portion that flows through the bottom mode outlet 350 flows through the fourth hose 119 d and to the forward thrust jet nozzle 82 where it is discharged. The flow portion that flows through the aperture 336 , flows across the flow channel 338 , into the annular flow channel 354 , and is discharged through the plurality of vacuum jet nozzles 104 .
[0137] FIGS. 52-78 show another embodiment of the drive mechanism of the pool cleaner 10 . Particularly, the pool cleaner 10 of FIGS. 52-78 includes a drive assembly 500 and water distribution manifold 502 for providing water to the various nozzles. The drive assembly 500 is connected with an inlet tube 503 a , reverse/spin-out tube 503 b , and bottom mode tube 503 c , while the water distribution manifold 502 is connected with first and second skimmer tubes 503 d , 503 e , each of which are discussed in greater detail below. FIG. 52 is an exploded perspective view of the pool cleaner 10 of the present disclosure including the drive assembly 500 . FIG. 53 is a sectional view of the pool cleaner 10 taken along line 53 - 53 of FIG. 5 showing the drive assembly 500 . As illustrated in FIG. 53 , the chassis 32 forms a housing for the drive assembly 500 , the water distribution manifold 502 , and the suction tube 102 . The pool cleaner 10 of FIGS. 52-78 is similar in structure as described in connection with FIGS. 1-44 , however, the drive assembly 500 and the water distribution manifold 502 replace the drive assembly 120 and the water distribution manifold 122 of FIGS. 1-44 .
[0138] FIGS. 55-58 illustrate the drive assembly 500 and the water distribution manifold 502 , which are in fluidic communication with one another. The drive assembly 500 includes a timer assembly 504 , a reverse/spin-out mode cam assembly 506 , a reverse/spin-out mode valve assembly 508 , and a top/bottom mode valve assembly 510 , each discussed in greater detail below. The water distribution manifold 502 includes a top mode manifold body 512 and a jet ring 514 . The manifold body 512 includes a plurality of chambers that function to direct water flow amongst the various jet nozzles of the cleaner 10 . The suction tube 102 includes a bottom end 134 and a top end 136 . The jet ring 514 is connected with the bottom end 134 of the suction tube 102 and includes a plurality of suction jet nozzles 720 .
[0139] FIGS. 55-75 show the drive assembly 500 in greater detail. Particular reference is made to FIG. 65 , which is an exploded view of the drive assembly 500 showing the components of the timer assembly 504 , the reverse/spin-out mode cam assembly 506 , the reverse/spin-out mode valve assembly 508 , and the top/bottom mode valve assembly 510 . The timer assembly 504 includes a turbine housing 518 , a gear box 520 , a gear box upper housing 522 , and a socket housing 524 . The reverse/spin-out mode cam assembly 506 includes a cam upper housing 526 and a cam plate 596 . The reverse/spin-out mode valve assembly 508 includes an inlet body 516 , a cam lower housing 528 , a reverse/spin-out mode valve body 529 , and a reverse/spinout seal 624 . The drive assembly 500 is configured such that the inlet body 516 is connected with the cam lower housing 528 , the reverse/spin-out mode valve body 529 , and the reverse/spin-out seal 624 to form the reverse/spin-out mode valve assembly 508 , with the top/bottom mode valve assembly 510 being adjacent to the reverse/spin-out mode assembly 508 , the cam lower housing 528 adjacent the cam upper housing 526 , the timer cover 524 adjacent the cam upper housing 526 , the gear box 520 is adjacent the timer cover 524 , and the turbine housing 518 is adjacent the gear box 520 . The inlet body 516 includes an inlet nozzle 530 having a barbed end 532 . The inlet nozzle 530 provides a flow path from the exterior of the inlet body 516 to the interior. The inlet nozzle 530 is connectable with the inlet tube 503 a , which is connectable with the internal nozzle 86 , such that water can flow to the cleaner 10 and through the inlet tube 503 a to the inlet body 516 . The inlet body 516 defines an internal chamber 534 . The inlet nozzle 530 is in communication with the internal chamber 534 such that fluid can flow into the inlet nozzle 530 and into the internal chamber 534 . The inlet body 516 further includes a top opening 536 that is adjacent cam lower housing 528 , which will be discussed in greater detail below. An outlet nozzle 538 having a barbed end 540 is provided on the inlet body 516 . The outlet nozzle 538 provides one path for water to flow out from the inlet body 516 . As such, water flowing into the inlet nozzle 530 flows into the interior chamber 534 and into the outlet nozzle 538 . Accordingly, a portion of the water exits the inlet body 516 through the outlet nozzle 538 . The inlet body 516 is generally closed at an upper end, e.g., the end adjacent the cam lower housing 528 , but for the opening 536 , and is open at a lower end, e.g., the end adjacent the reverse/spin-out mode valve assembly 508 .
[0140] FIG. 67 is a sectional view of the turbine housing 518 showing the components thereof in greater detail. The turbine housing 518 includes an inlet nozzle 542 having a barbed end 544 , and a turbine 546 . A hose 547 is connected at one end to the barbed end 540 of the inlet body outlet nozzle 538 and at another end to a the barbed end 544 of the turbine housing inlet nozzle 542 . Accordingly, water flows out from the inlet body 516 through the outlet nozzle 538 and to the turbine housing inlet nozzle 542 by way of the hose 547 . The turbine 546 includes a central hub 548 , a plurality of blades 550 , a boss 552 extending from the central hub 548 and having an output drive gear 554 mounted thereto, and a central aperture 556 . The central hub 548 , boss 552 , and output drive gear 554 are connected for conjoint rotation. Accordingly, rotation of the blades 550 causes rotation of the central hub 548 , boss 552 , and output drive gear 554 . The central aperture 556 extends through the center of the turbine 546 , e.g., through the output drive gear 554 , the boss 552 , and the central hub 548 .
[0141] A first shaft 558 extends through the central aperture 556 and is secured within a shaft housing 560 that is provided in a top of the turbine housing 518 . The first shaft 558 extends from the shaft housing 560 , through the turbine 546 , and into the gear box 520 . The turbine housing 518 also includes one or more apertures 562 in a sidewall thereof that allow water to escape the turbine housing 518 . When pressurized water enters the turbine housing 518 through the inlet nozzle 542 it places pressure on the turbine blades 550 , thus transferring energy to the turbine 546 and causing the turbine 546 to rotate. However, once the energy of the pressurized water is transferred to the turbine 546 it must be removed from the system, otherwise it will impede and place resistance on new pressurized water entering the turbine housing 518 . Accordingly, new pressurized water introduced into the turbine housing 518 forces the old water out from the one or more apertures 562 . FIG. 67 is a sectional view of the turbine housing 518 taken along line 67 - 67 of FIG. 61 further detailing and showing the arrangement of the turbine 546 within the turbine housing 518 . The turbine housing 518 is positioned on the gear box 520 .
[0142] The gear box 520 includes a turbine mounting surface 564 having an aperture 566 extending there through. The turbine housing 518 is positioned on, and covers, the gear box turbine mounting surface 564 , such that the turbine 546 is adjacent the turbine mounting surface 564 and the turbine output drive gear 554 extends through the aperture 566 and into the gear box 520 . The gear box 520 houses a reduction gear stack 568 that is made up of a first and second gear stack 570 a , 570 b , each gear stack 570 a , 570 b including a plurality of large gears 572 connected and coaxial with a smaller gear 574 (see FIG. 66 ) for conjoint rotation therewith. The conjoint rotation of the large gear 572 with the smaller gear 574 causes for a reduction in gear ratio. As can bee seen in FIG. 66 , which is a sectional view of the drive assembly 500 , the first and second coaxial gear stack 570 a , 570 b each include a central aperture 576 . The first gear stack 570 a is coaxial with the turbine 546 such that the first shaft 558 extends through the gears 572 , 574 of the gear stack 570 a , and into the timer cover 524 where it is secured. Thus, the first gear stack 570 a rotates about the first shaft 558 . The first gear stack 570 a includes a final gear stack output gear 582 as the bottom most gear of the stack 570 a . The final gear stack output gear 582 includes a small drive gear 584 . The second gear stack 570 b is positioned such that the gears 572 , 574 that make up the second gear stack 570 b engage the gears 572 , 574 that make up the first gear stack 570 a . Additionally, the second gear stack 570 b has a second shaft 578 extending through the central aperture 576 thereof. The second shaft 578 is parallel to the first shaft 558 and is secured within a second shaft top housing 580 that is positioned in a top wall of the gear box 520 . The small gear 574 of the second gear stack 570 b engages a large gear 572 of the first gear stack 570 a that rotates about the first shaft 558 . Similarly, a conjoint small gear 574 of the first gear stack 570 a engages a large gear 572 of the second gear stack 570 b that rotates about the second shaft 578 . A series of such gears are positioned within the gear reduction stack 568 with particular gear ratios, and engaged with one another in the above-described fashion, so that rotation of the turbine 546 , and subsequent rotation of the turbine output drive gear 554 , causes each gear 572 , 574 of the gear stacks 570 a , 570 b to rotate with each subsequent gear rotating at a different rotational speed. The second gear stack 570 b includes an output drive gear 586 as the bottom most gear. The output drive gear 586 includes a large drive gear 588 and a socket 590 extending from the large drive gear 588 for conjoint rotation therewith. The large drive gear 588 engages the small drive gear 584 of the final gear stack output gear 582 . The output drive gear 586 engages and is driven by the small drive gear 584 of the final gear stack output gear 582 . Accordingly, rotation of the turbine blades 550 causes rotation of the boss 552 , and output drive gear 554 , which output drive gear 554 causes rotation of the gears 572 , 574 of the gear reduction stack 568 , and ultimately rotation of the output drive gear 586 .
[0143] As shown in FIG. 66 , the output drive gear 586 is positioned between the gear box upper housing 522 and the timer cover 524 . The timer cover 524 engages the gear box 520 creating a sealed compartment that contains the reduction gear stack 568 , including the cam drive gear 586 . The timer cover 524 includes a socket aperture 592 that receives the output drive gear socket 590 . Accordingly, the socket 590 is accessible from the exterior of the timer cover 524 .
[0144] Positioned adjacent to the timer cover 524 is the cam upper housing 526 , which is also positioned adjacent to the cam lower housing 528 . Accordingly, the cam upper housing 526 is between the timer cover 524 and the cam lower housing 528 . The cam upper housing 526 includes a central aperture 594 . The cam plate 596 is positioned between the cam upper housing 526 and the cam lower housing 528 . The cam plate 596 includes a body 598 having a bottom side 600 and a top side 602 . A shaft 604 extends from the center of the top side 602 of the body 598 . The shaft 604 includes a shaped head 606 at the end thereof, and a circumferential notch 608 . The circumferential notch 608 includes an o-ring positioned therein. The shaft 604 extends from the body cam 598 and through the cam upper housing 526 , which generally have mating geometries so that the shaft 604 can rotate. The shaped head 606 engages the socket 590 of the output drive gear 586 , which generally have mating geometries so that they can rotate conjointly. That is, the socket 590 and the shaped head 606 have matching geometries such that rotation of the socket 590 will drivingly rotate the shaped head 606 , and thus the entirety of the cam plate 596 . A central hub 612 extends from the center of the bottom side 600 of the body 598 . The central hub 612 includes an aperture 614 with a post 616 positioned therein. The post 616 is secured in the aperture 614 at one end, and in an aperture 622 of the cam lower housing 528 at another end, such that the cam plate 596 can rotate about the post 616 . The bottom side 600 of the cam body 598 further includes a cam track 618 that encircles the central hub 612 . The cam track 618 is generally circular shaped with a uniform radius, except for a radially extended portion 620 that has a greater radius. FIG. 68 is a sectional view of the cam plate 596 , showing elements thereof in greater detail, e.g., the cam track 618 and the radially extended portion 620 .
[0145] The cam track 618 is configured to operate a rotatable reverse/spin-out seal 624 , which the majority of is positioned in the inlet body 516 . The rotatable reverse/spin-out seal 624 is shown in detail in FIGS. 68 and 69 . FIG. 69 is a top exploded view of the reverse/spin-out mode cam assembly 506 , the reverse/spin-out mode valve assembly 508 , and the top/bottom mode valve assembly 510 . The rotatable reverse/spin-out seal 624 includes an body 626 , an arched portion 628 , a sealing member 630 , a stationary post 632 , and a cam track post 634 . The stationary post 632 is secured to a top surface of the reverse/spin-out mode valve assembly 508 such that the reverse/spin-out seal 624 can rotate about the stationary post 632 . The reverse/spin-out seal 624 is positioned on a top surface of the reverse/spin-out mode valve assembly 508 , and within the internal chamber 534 of the inlet body 516 such that the cam track post 634 extends through the opening 536 of the inlet body 516 and extends into the cam track 518 .
[0146] In operation, rotation of the output drive gear 586 (see FIG. 66 ) results in rotation of the cam plate 596 by way of the engagement between, and mating geometries of, the socket 590 and the shaped head 606 . The cam track post 634 of the reverse/spin-out seal 626 is positioned within the cam track 618 such that they are in engagement. Thus, as the cam plate 596 rotates, the cam track post 634 rides in the cam track 618 . As described above, the cam track 618 includes a majority portion having a first radius and a radially extended portion 620 that has a greater radius. As the cam plate 596 rotates, the cam track post 634 will transition between the majority portion and the radially extended portion 620 . When the cam track post 634 transitions into the radially extended portion 620 of the cam track 618 , the cam track 618 pushes the cam track post 634 radially outward, which causes the reverse/spin-out seal 624 to rotate clockwise about the stationary post 632 and into a reverse/spin-out position. Similarly, when the cam track post 634 transitions into the majority portion of the cam track 618 , e.g., out from the radially extended portion 620 and into the lesser radius portion, the cam track 618 pulls the post 624 radially inward, which causes the reverse/spin-out seal 624 to rotate counter-clockwise about the stationary post 632 and into a forward position. Discussion of the reverse/spin-out position and the forward position is provided below.
[0147] FIGS. 69-73 show the reverse/spin-out mode valve assembly 508 in greater detail. FIG. 69 is a top exploded view of the reverse/spin-out mode cam assembly 506 , the reverse/spin-out mode valve assembly 508 , and the top/bottom mode valve assembly 510 , while FIG. 70 is a bottom exploded view of the same. The reverse/spin-out mode valve assembly 508 is positioned adjacent the inlet body 516 and generally defines a forward chamber 636 and a reverse/spin-out chamber 638 separated from the forward chamber 636 and defined by a chamber wall 639 (see FIG. 70 ). The reverse/spin-out mode valve assembly 508 includes a reverse/spin-out chamber opening 640 and a reverse/spin-out chamber nozzle 642 having a barbed end 644 . The reverse/spin-out chamber 638 is in fluidic communication with the reverse/spin-out chamber opening 640 and the reverse/spin-out chamber nozzle 642 , such that fluid can flow through the reverse/spin-out opening 640 , into the reverse/spin-out chamber 638 and out the reverse/spin-out chamber nozzle 642 without entering the forward chamber 636 . The reverse/spin-out valve assembly 508 further includes a forward chamber opening 646 (see FIG. 72 ) and an open end 648 , such that the forward chamber opening 646 , forward chamber 636 , and the open end 648 are in fluidic communication. Accordingly, fluid flows into the forward chamber opening 646 , through the forward chamber 646 , and out the open end 648 . FIG. 73 is a cross-sectional view of the reverse/spin-out mode valve assembly 508 showing the forward chamber 636 and the reverse/spin-out chamber 638 in greater detail.
[0148] FIGS. 69-70 and 74 - 75 show the top/bottom mode valve assembly 510 in greater detail. FIGS. 69-70 are top and bottom perspective view, respectively, showing the top/bottom mode valve assembly 510 . The top/bottom mode valve assembly 510 includes a body 649 and a sealing plate 692 . The body 649 defines a top/bottom mode main chamber 652 and includes a top opening 650 , a bottom mode opening 654 , and a top mode opening 660 . The top opening 650 provides access to the top/bottom mode main chamber 652 , while the top/bottom mode valve body 649 is closed at the bottom. FIG. 74 is a perspective view of the top/bottom mode valve assembly 510 with the sealing plate 692 not shown in order to illustrate the bottom mode opening 654 and the top mode opening 660 . The bottom mode opening 654 connects with a bottom mode outlet chamber 656 that is defined by a bottom mode outlet port 658 and a bottom mode nozzle 666 . The bottom mode outlet port 658 and the bottom mode nozzle 666 extend from the top/bottom mode valve body 649 . The bottom mode nozzle 666 includes a barbed end 668 (see FIG. 75 ). The top mode opening 660 connects with a top mode outlet chamber 662 that is defined by a top mode outlet port 664 . The top mode outlet port 664 extends from the top/bottom mode valve body 649 . As can be seen in FIG. 74 , a hub 670 extends from the top/bottom mode valve assembly body 649 and defines a chamber 672 . The hub 670 connects with the body 649 , which includes an opening 674 that places the top/bottom mode main chamber 652 in connection with the chamber 672 . The hub 670 allows the sealing plate 692 to be rotated by a source external to the top/bottom mode valve assembly 510 , which is discussed in greater detail below.
[0149] A top/bottom mode selector 676 is connected to the top/bottom mode valve assembly 510 . The top/bottom mode selector 676 includes a lever arm 678 having a first arm 680 and a second arm 682 , a fulcrum 684 , a user-engageable tab 686 , and a plate 688 . The fulcrum 684 engages the lever arm 678 between the first arm 680 and the second arm 682 , such that the lever arm 678 can rotate about the fulcrum 684 . The user-engageable tab 686 is positioned at the end of the first arm 680 and is positioned adjacent a wall of the pool cleaner 10 , as shown in FIG. 53 . Accordingly, a user can push the user-engageable tab 686 up or down to rotate the lever arm 678 about the fulcrum 684 . The user-engageable tab 686 can include a plurality of ridges to facilitate use by a user. The second arm 682 includes a pin 689 that extends from an end of the second arm 682 . The plate 688 is connected with a central shaft 690 (see FIG. 75 ) and includes an aperture 691 located near the periphery of the plate 688 . The central shaft 690 extends through the hub 670 , e.g., is positioned within the chamber 672 , and engages the sealing plate 692 . The pin 689 engages the aperture 691 of the plate 688 , such that the pin 689 can rotate the plate 688 , along with the central shaft 690 and the sealing plate 692 , while itself rotating within the aperture 691 . Accordingly, the tab 686 can be engaged by a user to rotate the top/bottom mod selector 676 clockwise or counter-clockwise to rotate the sealing plate 692 between two positions. In a first position, e.g., the position shown in FIG. 69 also referred to as the bottom mode position, the sealing plate 692 is positioned adjacent the top mode opening 660 , thus sealing the top mode outlet chamber 662 . In such a configuration, fluid can flow through the bottom mode opening 654 , through the bottom mode outlet chamber 656 , and out the bottom mode outlet port 658 and the bottom mode nozzle 666 . In a second position, e.g., a top mode position, the sealing plate 692 is positioned adjacent the bottom mode opening 654 , thus sealing the bottom mode outlet chamber 656 . In such a configuration, fluid can flow through the top mode opening 660 , through the top mode outlet chamber 662 , and out the top mode outlet port 664 . The bottom mode outlet port 658 and the top mode outlet port 664 are connected with the water distribution manifold 502 , which will be discussed in greater detail.
[0150] FIGS. 76-78 show the distribution manifold 502 in greater detail. FIG. 76 is a perspective view of the distribution manifold 502 . The distribution manifold 502 includes the top mode manifold 512 and the jet ring 514 . The top mode manifold 512 includes a manifold body 696 , inlet port 698 , first top mode skimmer outlet 700 having a barbed end 702 , second top mode skimmer outlet 704 having a barbed end 706 , and a top mode jet nozzle housing 708 that houses a top mode jet nozzle 710 . The top mode manifold inlet port 698 is generally connected with the top mode outlet port 664 of the top/bottom mode valve assembly 510 , such that the top mode manifold inlet port 698 is inserted into the top mode outlet port 664 . The jet ring 512 includes a body 714 , a bottom mode inlet port 716 , a plurality of upper protrusions 718 that secure the suction tube 102 , and a plurality of suction jet nozzles 720 . The bottom mode inlet port 716 is connected with the bottom mode outlet port 658 of the top/bottom mode valve assembly 510 , such that the bottom mode inlet port 716 is inserted into the bottom mode outlet port 658 .
[0151] FIG. 78 is a sectional view of the distribution manifold 502 taken along line 78 - 78 of FIG. 77 . The top mode manifold body 696 defines a top mode inner chamber 712 , while the jet ring 512 defines a bottom mode inner chamber 722 . The top mode inner chamber 712 is in fluidic communication with the inlet port 698 , the first and second top mode skimmer outlets 700 , 704 , and the top mode jet nozzle housing 708 including top mode jet nozzle 710 . Accordingly, fluid can flow through the top mode outlet port 664 of the top/bottom mode valve assembly 510 , into the top mode manifold inlet port 698 , through the top mode inner chamber 712 , and out through the first and second top mode skimmer outlets 700 , 704 and the top mode jet nozzle 710 . The first and second top mode skimmer outlets 700 , 704 are connected with the first and second skimmer tubes 503 e , 503 d (see FIGS. 53-54 ), which are each in turn connected to the skimmer/debris retention jets 60 (see FIGS. 7 and 53 - 54 ). The engagement of the top mode jet nozzle 710 with the top mode jet nozzle housing 708 can be a ball-and-socket joint such that the jet nozzle 710 can be rotated within the housing 708 . Fluid provided from the top mode inner chamber 712 to the top mode jet nozzle 710 is forced out the top mode jet nozzle 710 under pressure, causing a jet of pressurized water directed generally rearward and downward. This jet of pressurized water propels the cleaner 10 toward the pool water line 16 for skimming of the pool water line 16 . When the cleaner 10 is skimming the pool water line 16 , the top mode jet nozzle 710 propels the cleaner 10 forward along the pool water line 16 .
[0152] The bottom mode inner chamber 722 is in fluidic communication with the bottom mode inlet port 716 and the plurality of suction jet nozzles 720 . Accordingly, fluid can flow through the bottom mode outlet port 658 of the top/bottom mode valve assembly 510 , into the bottom mode inlet port 716 , through the bottom mode inner chamber 722 , and out through the plurality of suction jet nozzles 720 . The suction jet nozzles 720 function in accordance with the suction jet nozzles 104 discussed in connection with FIGS. 1-44 . Accordingly, the suction jet nozzles 720 spray pressurized water when water is provided to them by way of the bottom mode inner chamber 722 . The suction jet nozzles 720 discharge pressurized water upward through the suction tube 102 toward the debris opening 58 , forcing any loose debris through the suction aperture 100 , across the suction tube 102 , out the debris opening 58 , and into the debris bag 54 (see FIG. 4 ). Furthermore, the jetting of water upward through the suction tube 102 causes a venturi-like suction effect causing the suction head 98 to loosen debris from the pool walls 14 and direct the loosened debris into the suction aperture 100 . This debris is forced through the suction tube 102 by the suction jet nozzles 720 .
[0153] Operation of the cleaner 10 utilizing the drive assembly 500 (discussed above in connection with FIGS. 52-78 ) is summarized as follows. In operation, the pump 18 provides pressurized water through the segmented hose 22 , any connected swivels 24 , filters 26 , and floats 28 , and to the cleaner 10 . The segmented hose 22 is connected to the inlet port external nozzle 84 . The barb 88 facilitates attachment of the segmented hose 22 to the inlet port external nozzle 84 . Additionally, the nut 92 can be utilized to secure the segmented hose 22 to the inlet port external nozzle 84 . In such embodiments, the nut 92 bites into the soft material of the segmented hose 22 to restrain the hose 22 . The pressurized water flows through the inlet port 78 of the cleaner 10 and out through the inlet port external nozzle 86 , where it flows through the hose 503 a and to the inlet body inlet nozzle 530 . The pressurized water flows into the inlet body 516 . When in the inlet body 516 , the water diverges into two flows. A first flow flows to the outlet nozzle 538 and a second flow flows toward the reverse/spin-out mode valve assembly 508 .
[0154] The first flow flows out of the outlet nozzle 538 , through the hose 547 and to the turbine housing inlet 542 . The first flow enters the turbine housing 518 through the inlet 542 , and places a force on the turbine blades 550 . This force causes the turbine 546 to rotate about the first shaft 558 . The first flow then exits the turbine housing 518 through the apertures 562 . Rotation of the turbine 546 causes the output drive gear 554 to drive the first large gear 572 of the second gear stack 570 b , which is in engagement of the first gear stack 570 a , resulting in rotation of the plurality of large diameter gears 572 and small diameter gears 574 . The first and second gear stacks 570 a , 570 b engage one another, with the final gear stack out 582 being rotated such that the small drive gear 584 thereof engages and rotates the output drive gear 586 . Rotation of the output drive gear 586 causes rotation of the socket 590 , and thus rotation of the cam plate 596 due to the mating relationship of the socket 590 and the shaped head 606 of the cam plate 596 . As the cam plate 596 rotates, the reverse/spin-out seal post 634 rides within the cam track 618 to affect the position of the reverse/spin-out seal 624 .
[0155] As discussed above, the reverse/spin-out seal 624 is configured to rotate about the stationary post 632 according to the position of the cam track post's 634 position in the cam track 618 . When the cam track post 634 is positioned in the first radius portion of the cam track 618 , e.g., the lesser radius portion, the reverse/spin-out seal 624 is positioned such that the sealing member 630 is adjacent the reverse/spin-out opening 640 , thus sealing the reverse/spin-out chamber 638 and allowing fluid to flow through the forward chamber opening 646 and into the forward chamber 636 . Conversely, when the cam track post 634 is positioned in the radially extended portion 620 of the cam track 618 , the reverse/spin-out seal 624 is positioned such that the sealing member 630 is adjacent the forward chamber opening 646 , thus sealing the forward chamber 636 and allowing fluid to flow through the reverse/spin-out opening 640 and into the reverse/spin-out chamber 638 . Accordingly, the cam plate 596 determines what position the reverse/spin-out seal 624 is in, and rotates the seal between a forward position and a reverse/spin-out position. The length of time that the reverse/spin-out seal 624 stays in either position is determined by the length, e.g., circumferential length, of the radially extended portion 620 . A greater length radially extended portion 620 results in a greater amount of time that the reverse/spin-out seal 624 will be positioned adjacent the forward chamber opening 646 . Similarly, a lesser length radially extended portion 620 results in a lesser amount of time that the reverse/spin-out seal 624 will be positioned adjacent the forward chamber opening 646 . If the radially extend portion 620 makes up one eighth (⅛ th ) of the cam track 618 circumference, then the reverse/spin-out seal 624 will be positioned adjacent the forward chamber opening 646 one eighth (⅛ th ) of the time. The circumferential length of the radially extended portion 620 can be determined based on a user's need, and a different cam plate 596 can be provided for different situations.
[0156] When the cam track post 634 is positioned in the radially extended portion 620 of the cam track 618 , forcing the reverse/spin-out seal 624 to seal the forward chamber opening 646 and the forward chamber 636 . When in such a position, water flows to the cleaner 10 , through the inlet port 78 , through the inlet tube 503 a , into the inlet nozzle 530 , into the inlet body internal chamber 534 , into the reverse/spin-out chamber 638 , out the reverse/spin-out chamber nozzle 642 , through the reverse/spin-out tube 503 b , and to the reverse/spin-out thrust jet nozzle 112 where it is discharged under pressure. Alternatively, when the cam track post 634 is not positioned in the radially extended portion 620 of the cam track 618 , the reverse/spin-out seal 624 is adjacent the reverse/spin-out chamber opening 640 , thus sealing the reverse/spin-out chamber 638 . This allows water to enter the inlet body internal chamber 534 and flow into forward main chamber 636 . From there, the water flows through the forward main chamber 636 and into the top/bottom mode valve assembly body 649 .
[0157] Once in the top/bottom mode valve assembly body 649 , the flow of the water is dictated by the position of the sealing plate 692 . As discussed above, the sealing plate 692 can be positioned adjacent the bottom mode opening 654 to seal the bottom mode outlet chamber 656 , or adjacent the top mode opening 660 to seal the top mode outlet chamber 662 .
[0158] When the sealing plate 692 is positioned adjacent the bottom mode opening 654 , the water flows through the top mode opening 660 , through the top mode outlet chamber 662 , out the top mode outlet port 664 of the top/bottom mode valve assembly 510 , into the top mode manifold inlet port 698 , through the top mode inner chamber 712 , and out through the first and second top mode skimmer outlets 700 , 704 and the top mode jet nozzle 710 . The first and second top mode skimmer outlets 700 , 704 are connected with the first and second skimmer tubes 503 e , 503 d (see FIGS. 53-54 ), which are each in turn connected to the skimmer/debris retention jets 60 (see FIGS. 7 and 53 - 54 ).
[0159] When the sealing plate 692 is positioned adjacent the top mode opening 660 , the water flows through the bottom mode opening 654 , across the bottom mode outlet chamber 656 , and out the bottom mode outlet port 658 and the bottom mode nozzle 666 of the top/bottom mode valve assembly 510 . The flow out from the bottom mode outlet port 658 flows into the bottom mode inlet port 716 , through the bottom mode inner chamber 722 , and out through the plurality of suction jet nozzles 720 . The bottom mode nozzle 666 is connected with the bottom mode tube 503 c , which is also connected with the forward thrust jet nozzle 82 where the water is discharged. Discharge of the water through the forward thrust jet nozzle 82 results in the cleaner 10 being driven forward.
[0160] FIGS. 79-86 show a jet nozzle assembly 1000 and a vacuum suction tube 1002 of the present disclosure that can be utilized in a pressure or robotic pool cleaner such as the pool cleaner illustrated in FIGS. 1-44 and 52 - 78 and the accompanying disclosures thereof. FIG. 79 is a side view of the jet nozzle assembly 1000 and the vacuum suction tube 1002 . The jet nozzle assembly 1000 is similar to the jet ring 132 described in connection with FIGS. 1-44 , and the jet ring 514 described in connection with FIGS. 52-78 . That is, the jet nozzle assembly 1000 can be used in place of the jet ring 132 and/or the jet ring 514 . Similarly, the vacuum suction tube 1002 is similar to the suction tube 102 described in connection with FIGS. 1-44 and 52 - 78 . The vacuum suction tube 1002 is a tubular component having a first open end 1002 a and a second open end 1002 b , and is positioned adjacent the jet nozzle assembly 1000 . FIG. 80 is a perspective view of the jet nozzle assembly 1000 and FIG. 81 is a top view showing the jet nozzle assembly 1000 and the vacuum suction tube 1002 . The jet nozzle assembly 1000 includes an annular body 1004 having a top opening 1004 a and a bottom opening 1004 b , and also includes first, second, and third jet nozzles 1006 a , 1006 b , 1006 c positioned on an interior wall of the annular body 1004 (see FIG. 81 regarding the third jet nozzle 1006 c ). The jet nozzles 1006 a , 1006 b , 1006 c each include a body 1008 a , 1008 b , 1008 c and an outlet 1010 a , 1010 b , 1010 c . The jet nozzles 1006 a , 1006 b , 1006 c are positioned and arranged on the interior wall of the annular body 1004 such that water discharged therethrough is directed towards the top opening 1004 a of the annular body 1004 .
[0161] As shown in FIGS. 79 and 81 , the vacuum suction tube 1002 is positioned with one of its ends, e.g., the first open end 1002 a , adjacent the top opening 1004 a of the jet nozzle assembly body 1004 such that the jet nozzles 1006 a , 1006 b , 1006 c discharge water through the jet nozzle assembly body top opening 1004 a and into the vacuum suction tube 1002 . The discharged water exits the vacuum suction tube 1002 at the end opposite the jet nozzle assembly 1000 , e.g., the second open end 1002 b , which can be positioned adjacent an attached filter, filter bag, etc., which can be used to filter or trap any debris that is discharged through the vacuum suction tube 1002 . Particularly, the jet nozzle assembly 1000 can be incorporated into a pressure or robotic pool cleaner such that the jet nozzle assembly body bottom opening 1004 b is positioned at a bottom of the pool cleaner and open to the pool water, e.g., atmosphere. The pressurized discharge of water through the jet nozzles 1006 a , 1006 b , 1006 c generates a venturi or suction effect at the bottom opening 1004 b such that pool water is suctioned into the bottom opening 1004 b from the pool and discharged through the vacuum suction tube 1002 . This also results in any debris that may be on the pool floor or wall to also be suctioned through the vacuum suction tube 1002 , and discharged therethrough and into an attached filter or filter bag.
[0162] FIG. 82 is a cross-section view of the jet nozzle assembly 1000 and vacuum suction tube 1002 taken along line 82 - 82 of FIG. 81 . FIG. 83 is a cross-section view of the jet nozzle assembly 1000 and vacuum suction tube 1002 taken along line 83 - 83 of FIG. 81 . As can be seen in FIGS. 82 and 83 , the jet nozzle assembly body 1004 includes an internal channel 1012 that is in fluidic communication with each of the jet nozzles 1006 a , 1006 b , 1006 c . As illustrated in FIG. 83 , the outlets 1010 a , 1010 b , 1010 c of the jet nozzles 1006 a , 1006 b , 1006 c are in fluidic communication with the internal channel 1012 such that pressurized fluid flowing through the internal channel 1012 can be discharged through each of the jet nozzles 1006 a , 1006 b , 1006 c through the respective outlet 1010 a , 1010 b , 1010 c . The internal channel 1012 is also in fluidic communication with a source of pressurized fluid, such as a pump that can be internal to the pool cleaner (e.g., for a robotic pool cleaner) or a pump that is external to the pool and provides positive pressure to the pool leaner (e.g., for a positive-pressure pool cleaner). Accordingly, pressurized fluid is provided from a source of pressurized fluid to the internal channel 1012 , where it travels along the internal channel 1012 and is discharged through each of the jet nozzles 1006 a , 1006 b , 1006 c.
[0163] Configuration of the nozzles 1006 a , 1006 b , 1006 c will now be discussed in greater detail. It is noted that the nozzles 1006 a , 1006 b , 1006 c are constructed and configured the same, and simply spaced apart from one another. Accordingly, reference hereinafter may be made with respect to a single nozzle and it should be understood that these statements hold true for the remaining nozzles. Each of the nozzles 1006 a , 1006 b , 1006 c is configured to discharge fluid at a vortex angle α (see FIG. 82 ) and a convergence angle β (see FIG. 83 ). As shown in FIG. 82 , the nozzle 1006 a discharges fluid in the direction of arrow A, which is at an angle α (e.g., vortex angle) in a first plane with respect to the centerline CL of the vacuum suction tube 1002 when the centerline CL is aligned with the nozzle outlet 1010 a . Essentially, this means that the direction of water discharged from the nozzle 1006 a is not in alignment with the direction of water flow across the vacuum suction tube 1002 , e.g., along the centerline CL of the vacuum suction tube 1002 from the first open end 1002 a to the second open end 1002 b , but instead the water is discharged to flow in a helical path about the centerline CL and not in a straight line. This arrangement creates a vortex flow through the vacuum suction tube 1002 . As mentioned previously, this holds true for the remaining nozzles 1006 b , 1006 c . Additionally, as shown in FIG. 83 , the fluid discharged by the nozzle 1006 a is also discharged in the direction of arrow B, which is at an angle β (e.g., convergence angle) in a second plane with respect to the centerline CL of the vacuum suction tube 1002 when the centerline CL is not aligned with the nozzle outlet 1010 a . Essentially, this means that the water discharged from the nozzle 1006 a is directed toward the centerline CL, and not parallel to the centerline CL. As mentioned previously, this holds true for the remaining nozzles 1006 b , 1006 c . Thus, the water being discharged by all of the nozzles 1006 a , 1006 b , 1006 c converges at the centerline CL. This arrangement creates a convergent flow through the vacuum suction tube 1002 . Accordingly, the water discharged through the nozzles 1006 a , 1006 b , 1006 c flow in helical paths that converge with one another. By angling the nozzles 1006 a , 1006 b , 1006 c at a vortex angle α and/or a convergence angle β, the volumetric flow of water being suctioned into the jet nozzle assembly 1000 and through the vacuum suction tube 1002 is increased, creating a more efficient machine as no additional energy needs to be introduced in order to effect this increased volumetric flow rate. Additionally, the flow characteristics through the vacuum suction tube 1002 is smoothed, thereby providing a more uniform distribution of water flow.
[0164] It should be understood that it is not necessary to utilize both a vortex angle and a convergence angle at the same time; instead, each of a vortex angle and a convergence angle can be implemented absent the other, or can be utilized together. It should also be understood that the jet nozzle assembly 1000 can be provided with more or less than three nozzles as illustrated, e.g., the jet nozzle assembly 1000 can have one nozzle (see FIG. 84 ), two nozzles (see FIG. 85 ), four nozzles (see FIG. 86 ), etc.
[0165] Table 1 below shows simulated testing results illustrating how volumetric flow rate is affected by various configurations of the number of nozzles, vacuum tube diameter, nozzle convergence angle β, nozzle vortex angle α, nozzle diameter, and flow per nozzle. The column “Volume Flow Rate 1” indicates the volumetric flow rate at a point prior to the nozzles, e.g., upstream of the nozzles, and thus represents that volumetric flow rate of fluid that is being suctioned into the jet nozzle assembly. The column “Volume Flow Rate 2” indicates the volumetric flow rate at a point that is at the top of the tube, e.g., downstream of the nozzles, and thus represents that volumetric flow rate of fluid that is being discharged through the vacuum tube. As can be seen from Table 1, when the number of nozzles, vacuum tube diameter, nozzle outlet diameter, and flow per nozzle are kept constant, the greatest increase in flow rate results from a nozzle convergence angle β of 30° and a nozzle vortex angle α of 30°. In this configuration, a volumetric flow rate of 26.255 gallons per minute through the vacuum tube is achieved while only discharging 1.02 gallons per minute through each nozzle.
[0000]
TABLE 1
Convergence and Vortex Angle Analysis
Flow per
Vacuum
Nozzle
Nozzle
Nozzle
nozzle
Volume
Volume
Number
Tube
Convergence
Vortex
outlet
(gallons
Flow Rate 1
Flow Rate 2
of
diameter
Angle β
Angle α
diameter
per
(gallons per
(gallons per
nozzles
(in.)
(°)
(°)
(in.)
minute)
minute)
minute)
3
2.5
30
0
0.095
1.02
19.1014231
22.1614116
3
2.5
20
20
0.095
1.02
17.1452074
20.2051716
3
2.5
20
30
0.095
1.02
19.4976677
22.5576560
3
2.5
30
30
0.095
1.02
23.1946716
26.2546880
3
3.125 ×
30
30
0.095
1.02
22.8158551
25.8758734
2.00
ellipse
3
2.000
0
0
0.110
1.33
3.94641192
7.93642269
grouped
3
2.750
0
0
0.110
1.33
19.1217895
21.7818559
[0166] Table 2 below shows simulated testing results illustrating how volumetric flow rate is affected by various configurations of the number of nozzles, vacuum tube diameter, nozzle convergence angle β, nozzle diameter, and flow per nozzle. The column “Volume Flow Rate 1” indicates the volumetric flow rate at a point prior to the nozzles, e.g., upstream of the nozzles, and thus represents that volumetric flow rate of fluid that is being suctioned into the jet nozzle assembly. The column “Volume Flow Rate 2” indicates the volumetric flow rate at a point that is at the top of the tube, e.g., downstream of the nozzles, and thus represents that volumetric flow rate of fluid that is being discharged through the vacuum tube. As can be seen from Table 2, when the number of nozzles, nozzle outlet diameter, and flow per nozzle are kept constant, the greatest increase in flow rate results from a nozzle convergence angle β of 30° and a vacuum tube diameter of 2.75″. In this configuration, a volumetric flow rate of 23.242 gallons per minute through the vacuum tube is achieved while only discharging 1.02 gallons per minute through each nozzle.
[0000]
TABLE 2
Convergence Angle Analysis
Flow per
Vacuum
Nozzle
nozzle
Volume Flow
Volume Flow
Number
Tube
Nozzle
outlet
(gallons
Rate 1
Rate 2
of
diameter
Convergence
diameter
per
(gallons per
(gallons per
nozzles
(in.)
Angle β
(in.)
minute)
minute)
minute)
3
2.000
0
0.095
1.02
11.9752825
15.0353494
3
2.375
0
0.095
1.02
9.59365171
12.6536792
3
2.500
0
0.095
1.02
13.1455821
16.2056329
3
2.625
0
0.095
1.02
15.466108
18.5261497
3
2.750
0
0.095
1.02
14.3846266
17.4446835
3
2.000
30
0.095
1.02
18.8003332
21.8603464
3
2.375
30
0.095
1.02
16.9372863
19.9973027
3
2.500
30
0.095
1.02
17.5032121
20.5632155
3
2.625
30
0.095
1.02
17.767893
20.8279138
3
2.750
30
0.095
1.02
20.1816962
23.2416961
3
2.750
0
0.110″
1.33
19.12178957
21.78185593
3
2.000
0
0.110″
1.33
3.946411925
7.936422691
grouped
[0167] FIG. 87 is a perspective view of an alternative reverse/spin-out mode cam wheel 1100 , reverse/spin-out mode valve assembly body 1102 , and reverse/spin-out rocker seal 1104 of the present disclosure that can be utilized in the pressure cleaner 10 described previously. The reverse/spin-out mode cam wheel 1100 , reverse/spin-out mode valve assembly body 1102 , and reverse/spin-out rocker seal 1104 provide an alternative mode of switching the pressure cleaner 10 between reverse and spin-out modes. Particularly, the reverse/spin-out mode cam wheel 1100 can be utilized in place of the cam plate 596 of, for example, FIG. 69 , the reverse/spin-out mode valve assembly body 1102 can be utilized in placed of the reverse/spin-out mode valve assembly 508 of, for example, FIG. 69 , and the reverse/spin-out rocker seal 1104 can be utilized in place of the reverse/spinout seal 624 of, for example, FIG. 69 .
[0168] The reverse/spin-out mode cam wheel 1100 can be positioned between the cam upper housing 526 and the cam lower housing 528 of FIG. 65 , in place of the cam plate 596 . The reverse/spin-out mode cam wheel 1100 includes a body 1106 , a radial wall 1108 , a shaft 1110 extending from the body 1106 , and first and second cam tracks 1112 , 1114 extending radially from the radial wall 1108 . The shaft 1110 extends from the center of the body 1106 and includes a shaped head 1116 at the end thereof, and a circumferential notch 1118 . The circumferential notch 1118 can include an o-ring positioned therein. The shaft 1110 from the reverse/spin-out mode cam wheel 1100 and through the cam upper housing 526 , where it engages the socket 590 . The shaped head 1116 and the socket 590 have matching geometries such that rotation of the socket 590 will drivingly rotate the shaped head 1116 , and thus the entirety of the reverse/spin-out mode cam wheel 1100 . Accordingly, rotation of the reverse/spin-out mode cam wheel 1100 is achieved in the same fashion as that of the cam plate 596 described above in connection with FIGS. 52-75 , which need not be repeated in its entirety. The first cam track 1112 extends radially from an upper portion of the radial wall 1108 of the reverse/spin-out mode cam wheel 1100 and along a portion of the circumference of the radial wall 1108 , for example, along ⅞ ths of the radial wall 1108 . The first cam track 1112 includes a cam ramp 1112 a that levels out into a flat portion 1112 b . The cam ramp 1112 a extends from a top of the radial wall 1108 to the center of the radial wall 1108 . The second cam track 1114 extends radially from a lower portion of the radial wall 1108 of the reverse/spin-out mode cam wheel 1100 and along a portion of the circumference of the radial wall 1108 where the first cam track 1112 is missing, for example, along ⅛ th of the radial wall 1108 . The second cam track 1114 includes a cam ramp 1114 a . The cam ramp 1114 a extends from a bottom of the radial wall 1108 to the center of the radial wall 1108 .
[0169] The reverse/spin-out mode valve assembly body 1102 is positioned adjacent the inlet body 516 and generally defines a forward chamber and a reverse/spin-out chamber 1116 separated from the forward chamber and defined by a chamber wall 1119 . The reverse/spin-out mode valve assembly body 1102 includes a reverse/spin-out chamber opening 1120 and a reverse/spin-out chamber nozzle 1122 having a barbed end 1124 . The reverse/spin-out chamber 1116 is in fluidic communication with the reverse/spin-out chamber opening 1120 and the reverse/spin-out chamber nozzle 1122 , such that fluid can flow through the reverse/spin-out opening 1120 , into the reverse/spin-out chamber 1116 and out the reverse/spin-out chamber nozzle 1122 without entering the forward chamber. The reverse/spin-out valve assembly body 1102 further includes a forward chamber opening 1126 and an open end 1128 , such that the forward chamber opening 1126 and the open end 1128 are in fluidic communication. Accordingly, fluid flows into the forward chamber opening 1126 , through the forward chamber, and out the open end 1128 . The reverse/spin-out mode valve assembly body 1102 also includes a pivot assembly 1130 that secures the reverse/spin-out rocker seal 1104 to the reverse/spin-out mode valve assembly body 1102 and permits the reverse/spin-out rocker seal 1104 to pivot.
[0170] The reverse/spin-out rocker seal 1104 includes a first seal 1132 , a second seal 1134 , a pivot 1136 extending between the first and second seals 1132 , 1134 , and a cam post 1138 extending from the first seal 1132 . The reverse/spin-out rocker seal 1104 is placed on top of the reverse/spin-out mode valve assembly body 1102 with the pivot 1136 being placed within the pivot assembly 1130 , and with the first seal 1132 adjacent the reverse/spin-out opening 1120 and the second seal 1134 adjacent the forward chamber opening 1126 . The first seal 1132 is configured to engage and seal the reverse/spin-out opening 1120 , while the second seal 1134 is configured to engage and seal the forward chamber opening 1126 . The reverse/spin-out rocker seal 1104 is configured so that only one of the first and second seals 1132 , 1134 engages the respective reverse/spin-out opening 1120 and forward chamber opening 1126 at a time.
[0171] The reverse/spin-out mode cam wheel 1100 , reverse/spin-out mode valve assembly body 1102 , and reverse/spin-out rocker seal 1104 are arranged such that the cam post 1138 of the reverse/spin-out rocker seal 1104 extends to the reverse/spin-out mode cam wheel 1100 and can engage the first and second cam tracks 1112 , 1114 . As the reverse/spin-out mode cam wheel 1100 rotates counter-clockwise, the cam post 1138 alternates between engaging the first cam track 1112 and the second cam track 1114 . More specifically, as the reverse/spin-out mode cam wheel 1100 rotates, e.g., is driven through rotation of the socket 590 , the cam post 1138 will engage the cam ramp 1112 a of the first cam track 1112 and ride therealong until it is at the bottom of the radial wall 1108 and kept in that position by the flat portion 1112 b of the first cam track 1112 . This results in the reverse/spin-out rocker seal 1104 being rotated about the pivot 1130 such that the reverse/spin-out mode rocker seal 1104 is placed in a first position. In the first position, the first seal 1132 engages the reverse/spin-out opening 1120 , thus sealing the reverse/spin-out opening 1120 and preventing water from entering the reverse/spin-out chamber 1116 , and the second seal 1134 disengages from the forward chamber opening 1126 , thus allowing water to enter the forward chamber through the forward chamber opening 1126 . Further, in the first position, the cleaner 10 is in a forward mode where water flows through the open end 1128 of the reverse/spin-out mode valve assembly body 1102 and to the top/bottom mode valve assembly 510 , such as that illustrated in FIG. 69 , whereby the fluid flow is utilized to propel the cleaner 10 in a forward direction. Continued rotation of the reverse/spin-out mode cam wheel 1100 results in the first cam track 1112 ending and the cam post 1138 engaging the second cam track 1114 . Upon completion of the first cam track 1112 , the cam post 1138 engages the cam ramp 1114 a of the second cam track 1114 , which the cam post 1138 rides along until it is at the top of the radial wall 1108 . This results in the reverse/spin-out rocker seal 1104 being rotated about the pivot 1130 such that the reverse/spin-out mode rocker seal 1104 is placed in a second position. In the second position, the first seal 1132 disengages from the reverse/spin-out opening 1120 , thus allowing water to enter the reverse/spin-out chamber 1116 through the reverse/spin-out opening 1120 , and the second seal 1134 engages the forward chamber opening 1126 , thus preventing water from entering the forward chamber through the forward chamber opening 1126 . Further, in the second position, the cleaner 10 is in a reverse/spin-out mode where water flows through the reverse/spin-out chamber nozzle 1112 of the reverse/spin-out mode valve assembly body 1102 and to the reverse/spin-out thrust jet nozzle 112 , such as that illustrated in FIG. 53 , whereby the fluid flow is utilized to propel the cleaner 10 in a reverse/spin-out direction. Continued rotation of the reverse/spin-out mode cam wheel 1100 results in the second cam track 1114 ending and the cam post 1138 once again engaging the first cam track 1112 . This rotation is continued ad infinitum.
[0172] One of ordinary skill in the art should understand that since the first cam track 1112 is longer than the second cam track 1114 , the cleaner 10 will stay in forward mode for a longer period of time than the reverse/spin-out mode. Accordingly, the time that the cleaner 10 stays in each one of these modes can be altered by changing the length of the first and second cam tracks 1112 , 1114 .
[0173] Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit or scope thereof. It will be understood that the embodiments of the present invention described herein are merely exemplary and that a person skilled in the art may make any variations and modification without departing from the spirit and scope of the invention. All such variations and modifications, including those discussed above, are intended to be included within the scope of the invention.
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A fluid distribution system for an underwater pool cleaner comprises an inlet body having an inlet for receiving a supply of pressurized fluid, a valve assembly body in fluid communication with the inlet of the inlet body and including a plurality of fluid outlets, a first one of the outlets provides fluid for propelling the underwater pool cleaner in a forward direction and a second one of the outlets provides fluid for propelling the underwater pool cleaner in a reverse direction, and a valve subassembly including a cam wheel that is fluidicly driven by the supply of pressurized fluid and periodically switches the supply of pressurized fluid from the first one of the outlets to the second one of the outlets to periodically change direction of propulsion of the underwater pool cleaner.
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CROSS REFERENCE TO RELATED APPLICATIONS
The invention claims benefits of Provisional Application Ser. No. 61/241,083, filed on Sep. 10, 2009. This provisional application is incorporated by reference in its entirety.
BACKGROUND
1. Technical Field
The present application relates generally to perforating and more particularly to shaped charges having cases made with sintered metal powders.
2. Background Art
To complete a well for purposes of producing fluids (such as hydrocarbons) from a reservoir, or to inject fluids into the reservoir, one or more zones in the well are perforated to allow for fluid communication between the wellbore and the reservoir. Normally, perforation is accomplished by lowering a perforating gun string that has one or more perforating guns to the desired intervals within the well. Activation of the one or more guns in the perforating gun string creates openings in any surrounding casing and extends perforations into the surrounding formation.
A perforating gun typically includes a gun carrier and a number of shaped charges mounted to the gun carrier. The gun carrier can be a sealed gun carrier that contains the shaped charges and that protects the shaped charges from the external wellbore environment. Alternatively, the gun carriers can be on a strip carrier onto which capsule shaped charges are mounted. A capsule shaped charge is a shaped charge whose internal components are sealably protected against the wellbore environment.
One of the major problems facing designers of perforating guns for use in oil and gas wells may be the issue of gun survivability, especially, in guns, where charges are used in high shot densities. The causes of gun failure include the initiation of cracks on the interior gun wall caused by the impact of the shaped charge case fragments traveling at high speed and as a result of the high gas pressure generated by the explosion within the case.
Combination of the multiple impact sites and the high interior gas pressure can form centers of damages and initiate cracks in the gun wall, thereby compromising the integrity of the gun wall. Such a failure may rupture the gun and lead to costly retrieval of the destroyed gun from the well.
Another issue associated with the use of the conventional perforating guns is that the fragments, generated from the detonated cases, may damage the fluid circulation pumps or interfere with completion equipment. Furthermore, these fragments may restrict the flow of hydrocarbons through the perforations inside the wellbore casing.
Therefore, better shaped charges are needed to enhance gun survivability and protect downhole equipment.
SUMMARY
One aspect of preferred embodiments relates to shaped charges. A shaped charge in accordance with one embodiment includes a casing defining an interior volume, wherein the casing is prepared by sintering a metal powder or a mixture of metal powders; a liner located in the interior volume; and an explosive between the liner and the casing.
Another aspect relates to methods for manufacturing a shaped charge casing. A method in accordance with one embodiment includes the steps of: mixing a metal powder or a metal powder mixture with a binder to form a pre-mix; pressing the pre-mix in a mold to form a casing green body; heating the casing green body to a first temperature to vaporize the binder; raising the temperature to a second temperature in an inert or reducing atmosphere to sinter the metal powder or the metal powder mixture to produce the shaped charge casing.
Another aspect relates to methods for perforating a well. A method in accordance with one embodiment includes the steps of: disposing a perforating gun to a selected zone in a wellbore, wherein the perforating gun comprises at least one shaped charge, wherein the shaped charge comprises: a casing defining an interior volume, wherein the casing is prepared by sintering a metal powder or a mixture of metal powders, a liner located in the interior volume, and an explosive between the liner and the casing; and detonating the at least one shaped charge.
Other aspects and advantages of preferred embodiments will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a perforating gun with shaped charges disposed in a wellbore in accordance with one embodiment.
FIG. 2 shows a shaped charge in accordance with one embodiment.
FIG. 3 shows a capsule shaped charge in accordance with one embodiment.
FIG. 4 shows a method of manufacturing a sintered metal powder shaped charge casing in accordance with one embodiment.
FIG. 5 shows (A) the powder debris of a shaped charge casing after explosion in accordance with one embodiment; and (B) the debris and fragments of a conventional shaped charge casing after explosion.
FIG. 6 shows the effects of detonation of shaped charges in accordance with embodiments of the invention, as compared with conventional shaped charges.
DETAILED DESCRIPTION
Embodiments relates to shaped charges having casings made of sintered metal powders. Embodiments also relate to methods for designing and manufacturing sintered powder metal casings for shaped charges and the use thereof.
FIG. 1 illustrates a tool string 102 deployed in a wellbore 104 . The tool string 102 includes a perforating gun 106 that has a carrier 108 having various shaped charges 110 (e.g., perforator charges or other explosive devices that form perforating jets) attached thereto. The perforating gun 106 is carried by a carrier line 116 , which can be a wireline, slickline, coiled tubing, production tubing, and so forth. The carrier 108 may be an expendable carrier that is designed to shatter as a result of detonation of the shaped charges 110 . An example of such an expendable carrier is a strip carrier, such as a carrier formed of a metal strip. In a different implementation, instead of mounting the shaped charges 110 on a strip carrier, the carrier can be a seated housing that has an inner chamber in which the shaped charges are located, with the chamber being sealed against external wellbore fluids in the wellbore 104 .
In the embodiment shown in FIG. 1 , the shaped charges 110 are provided in a sealed chamber of a carrier housing. Therefore, the shaped charges 110 are non-capsule shaped charges. In alternative embodiments, when the shaped charges 110 are mounted to the carrier strip 108 such that the shaped charges 110 would be exposed to wellbore fluids, the shaped charges 110 are capsule shaped charges that have a capsule to provide a fluid seal to protect internal components of the shaped charges 110 against the wellbore fluids.
The shaped charges 110 in the example of FIG. 1 are ballistically connected to a detonating cord 112 . The detonating cord 112 is connected to a firing head 114 . When activated, the firing head 114 initiates the detonating cord 112 , which in turn causes detonation of the shaped charges 110 .
In a different implementation, the detonating cord 112 can be replaced with one or more electrical wires connecting the firing head 114 to the shaped charges 110 . Electrical signal(s) can be sent by the firing head 114 over the one or more electrical wires to activate the shaped charges 110 . For example, the shaped charges 110 can be associated with electrically-activated initiators (e.g., electrical foil initiators or EFIs), which when activated by an electrical signal causes initiation of a detonator or explosive to detonate the corresponding shaped charge 110 .
In accordance with some embodiments, a shaped charge 110 has an outer casing that is formed of sintered metal powders. When exploded, the sintered metal powder casing would produce finer particles or debris, which would cause less damages to a perforating gun.
FIG. 2 shows an example shaped charge 110 that has a casing 200 . The outer casing 200 defines an inner chamber 202 to receive a main explosive 204 . Also, a liner 206 is provided inside the outer casing 202 , where the liner 206 generally has a generally conical shape. The conical shape of the liner 206 provides for a deeper perforation hole. Alternatively, the liner 206 can have a different shape, such as a general bowl shape, which would allow for creation of larger holes. The main explosive 204 is provided between the liner 206 and the inside of the casing 200 .
As further depicted in FIG. 2 , an opening 208 at the rear of the casing 200 allows for an explosive material portion 210 to be provided, where the explosive material portion 210 is ballistically coupled to the detonating cord 112 to allow for the detonating cord 112 to cause the explosive material portion 210 to detonate, which in turn causes the main explosive 204 to detonate. Detonation of the main explosive 204 causes the liner 206 to collapse such that a perforating jet is formed and projected away from the shaped charge 110 . The perforating jet is directed towards the structure (e.g., casing and/or surrounding formation) in which a corresponding perforation tunnel is to be formed.
Upon detonation of the main explosive 204 , a large amount of heat and pressure is generated in a very short period of time. This sudden surge of pressure and heat may cause the casing 200 to disintegrate, generating fragments and debris. Such fragments or debris would be hurled with high speed to impact the perforating gun housing.
FIG. 3 shows an alternative embodiment of a shaped charge, identified as 110 A. The shaped charge 110 A is identical in construction with the shaped charge 110 of FIG. 2 , except that a cap 300 is also provided in the shaped charge 110 A to sealably engage with the casing 200 , where the cap 300 allows for the internal components of the shaped charge (liner and explosive material) to be protected from the external wellbore environment.
Effectively, the cap 300 and casing 200 form a capsule that sealably defines a sealed inner chamber containing the internal components of the shaped charge. The shaped charge 110 A is a capsule shaped charge, whereas the shaped charge 110 of FIG. 2 is a non-capsule shaped charge.
In accordance with embodiments, the casing 200 , as shown in FIGS. 2 and 3 , can be formed of a sintered metal power, using suitable sintering techniques. In general, the metal powders, together with one or more binders, are first formed into a green body having the desired casing shape. Then, the green body is heated at a suitable temperature to vaporize the binder materials and volatile materials. Finally, the temperature is raised to a temperature high enough to cause sintering of the metal powders.
FIG. 4 shows a method 40 for manufacturing a sintered metal powders casing of a shaped charge in accordance with one embodiment. A forming die of a shaped charge casing may be used to make a “green body” of sufficient strength to withstand normal handling in the manufacturing processes. This may be accomplished by mixing a metal powder (or a mixture of metal powders) with one or more binders to form a pre-mix and then pressing the pre-mix in the die under high pressure (step 41 ). The mixing of the metal powder (or the mixture of metal powders) may be performed in the die (or mold).
The metal powders may be steel powders or a mixture formulated to provide a unique combination of strength, density, and/or fracturability. For example, carbon may be incorporated into steel powder to achieve high fracturability. In accordance with other embodiments, copper or other metals, including (but not limited to) tin, zinc, tungsten, may be added to the steel powder to achieve high density.
The green body of the shaped charge casing may then be placed in an inert or reducing atmosphere (step 42 ), such as nitrogen/hydrogen, which may be a stream flowing over the green body. The green body may be gradually heated to a modest temperature, e.g., ˜300-500° C., to slowly vaporize the binders and/or other volatile components (step 43 ). These binders and/or other volatile components are used to provide sufficient strength to the green body for easy handling. After the binders and/or other volatile components are vaporized, the temperatures may be raised to a suitable temperature for a proper duration to cause the metal powders to be sintered together. One skilled in the art would appreciate that the temperatures and durations for sintering would depend on the compositions of the powders and/or the shapes and sizes of the green bodies. Typical sintering temperature for steel powders may be around 1000° C. or higher, e.g., ˜1150° C. The duration may range from minutes to many hours, typically round a few hours (step 44 ). Once the metal powder is sintered, a strong solid body (shaped charge casing) would be formed. At the end of the sintering process, the shaped charge casing may be allowed to cool in an inert atmosphere to room temperature (step 45 ). Finally, the shaped charge casing made of sintered metal powders may then be loaded with explosives and liners according to the techniques known in the art.
EXAMPLES
In accordance with embodiments, a steel powder mixture, for example, may include powdered steel (such as Ancorsteel® 1000B from Hoeganaese Corporation, Riverton, N.J.), a suitable amount of carbon (such as ˜0.01-5% or more of graphite, depending on the desirable characteristics of strength/brittleness), one or more binders (such as a wax, for example, 0.25-2.75% of Acrawax® C from Lonza, Basel, Switzerland), and, if necessary, ˜0.05-1.5% of mineral oils, which may be used as a binder and dust suppressant.
In one example, a powder steel mixture may include steel powders and tin powders, zinc powders, or a mixture of copper with tin and/or zinc (i.e., bronze or brass alloy). In another example, a steel powder mixture may include 80-90% steel powder and 10-20% of the tin, zinc, brass and/or bronze.
In accordance with some embodiments, a steel powder mixture may also include other metals, for example, to increase the density of the steel casing to produce increased confinement of the explosive charges. A sintered metal powder casing typically has a normal density of around ˜6.8 gm/cc, comparable to that of a solid steel machined case (7.8 gm/cc). If desired, the density of a sintered steel powder casing may be increased to above 7.8 gm/cc by adding materials, such as tungsten, copper, and other metals. A higher density casing may provide a high degree of confinement to enhance shaped charge performance, e.g., enhanced penetration tunnel sizes and/or lengths into the formation. Such casings may be used for special applications, such as small high performance casing or ultra-deep penetrators.
In addition, the properties of a sintered metal powder casing can be easily altered. For example, the hardness of sintered metal powder casings can be altered by steam treatments with an impervious coating of bluish-black iron oxide to seal the pores of the cases.
In accordance with embodiments, these steel powders or mixtures may be pressed in a mold (or die) to form a shaped charge casing “green body.” After the casing green body is formed, the green body may be removed from the die. The “green casing” may then be gradually heated to a suitable temperature, e.g., ˜300-500° C., in an inert reducing atmosphere, to vaporize the minor components, such as binders and/or mineral oils. The temperatures may then be raised to a temperature high enough to cause the metal powders to sinter, e.g., ˜1150° C. (or other suitable temperature), in an inert reducing atmosphere, which may comprise a flow of, for example, ˜90% nitrogen and 10% hydrogen.
Sintering causes the steel powder particles and/or other metal powders or particles to bind (fuse) together. The sintering temperatures may vary depending on the type of metals used. One skilled in the art would appreciate that the sintering points may be estimated from phase diagrams. Finally, the shaped charge casings may be allowed to cool to room temperature and loaded with an explosive and liner using any conventional techniques.
Being made of sintered metal powders, shaped charge casings in accordance with embodiments are expected to produce finer particle debris. For example, FIG. 5A shows that the debris produced by shaped charge casings according to preferred embodiments after detonation are fine powders or fine particles. In contrast, FIG. 5B shows that the debris produced by detonation of a conventional shaped charge casing, which is a machined steel casing, comprise much large fragments.
Because debris from shaped charge casings are fine particles, they will impact the gun wall with less damaging force. As a result, use of these casings can improve perforating gun survivability.
FIG. 6 shows, with flash X-Ray, the debris clouds 61 , 62 produced by sintered metal powder casings in accordance with embodiments. The debris clouds 61 , 62 contain fine particles. In contrast, the debris clouds 63 , 64 and shards of metal are produced by a conventional machined steel casing.
FIG. 6 also shows shrapnel damage 67 on plywood 65 caused by detonation of a conventional machined steel casing. The damages manifest themselves as significant indentations distributed over the plywood. In contrast, the damages caused by a sintered metal powder casing show more evenly distributed powder spray pattern 66 .
The powder-spray damages 66 are shallower indentations distributed over the surface of the plywood. It is apparent that these minor indentations are less likely to form damage centers that can lead to cracks of the object. In addition, the spray of fine particles produced by a sintered metal powder casing may attenuate the outgoing shock wave generated from the explosion. Together, these properties suggest that a sintered metal powder casing would cause less damages to a perforating gun than would a conventional machined steel casing.
Consistent with the above predictions, gun swell tests have shown a similar correlation, i.e., sintered metal powder casings cause less swell to perforating guns than their machined steel counterparts would at equivalent shot densities.
Advantages of the powder metal casings in accordance with the embodiments may include one or more of the following. Debris produced by a sintered metal powder casing are finer particles. This would avoid the formation of damage centers that might lead to cracks on perforating gun wall. The density of a sintered metal powder casing can be easily altered by mixing in proper metals. This would reduce the production costs and make such casings more readily available. From a manufacturing perspective, only a sufficient amount of metal powders is used. This would reduce the costs, as compared to the making of machined steel cases, because no waste or secondary machining is involved. In addition, the properties of a sintered metal powder casing can be easily altered. For example, the hardness of sintered metal powder casings can be altered by steam treatments with an impervious coating of bluish-black iron oxide to seal the pores of the cases. This would have an advantage over the traditional zinc plating of a machined casing because iron oxide is non-reactive and not easily worn off.
While preferred embodiments have been described herein, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the inventive scope of the application as disclosed herein.
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A shaped charge includes a casing defining an interior volume, wherein the casing is prepared by sintering a metal powder or a mixture of metal powders; a liner located in the interior volume; and an explosive between the liner and the casing. A method for manufacturing a shaped charge casing includes the steps of mixing a metal powder or a metal powder mixture with a binder to form a pre-mix; pressing the pre-mix in a mold to form a casing green body; heating the casing green body to a first temperature to vaporize the binder; raising the temperature to a second temperature in an inert or reducing atmosphere to sinter the metal powder or the metal powder mixture to produce the shaped charge casing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119(e) to provisional application, Attorney Docket No. 45800/CAG/P501, filed Oct. 19, 2001, the contents of which is expressly incorporated herein by referenced as though fully set forth in full.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates generally to storage containers, and more particularly, to storage containers for recorded media.
[0004] 2. Background
[0005] In recent years, optical discs have emerged as one of the most popular mediums for storing audio, video and computer information. To accommodate the wholesale and retail distribution of the disc, numerous storage containers have been developed. These storage containers typically include a base supporting a central hub to engage an aperture in the center of the disc. The base is generally hinged to a lid so as to open and close the storage container like a book. This design is well suited for use by the consumer, but may pose certain security risks in the retail environment. In the recent years, retailers have reported numerous incidents of theft involving the unauthorized removal of discs from the their storage containers. Labels and shrink wrap have been proposed in the past as a way to deal with this problem. However, these proposals have had limited success because of the ease at which labels and shrink wrap can be opened with a sharp item. Accordingly, there is a need for a storage container which is designed to discourage theft in the retail environment.
SUMMARY
[0006] In one aspect of the present invention, a storage container includes a lid having a lid panel and an arm extending from the lid panel, the arm including a detent having a first surface parallel to the lid panel and a second surface having a taper extending at least a portion between the first surface and a distal end of the arm, and a base configured to receive a disc, the base having a base panel and a member extending from the base panel, the member having an opening defined by an interior surface having a portion thereof parallel to the base panel, the first surface of the detent engaging the interior surface portion of the member when the storage container is closed.
[0007] In another aspect of the present invention, a storage container includes a lid, a base configured to receive a disc, and means for latching the lid to the base to close the storage container.
[0008] In yet another aspect of the present invention, a storage container includes a lid, a base having an annular wall configured to support an outer periphery of a disc, means for latching the lid to the base to close the storage container, means for clamping the outer periphery of the disc to the annular wall when the storage container is closed, and means, coupled to the lid, for preventing the disc from sliding out of the storage container.
[0009] It is understood that other aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein is shown and described only exemplary embodiments of the invention, simply by way of illustration. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings in which like reference numerals refer to similar elements:
[0011] [0011]FIG. 1 is a perspective view of an exemplary storage container;
[0012] [0012]FIG. 1A is a blow up of a portion of the exemplary storage container of FIG. 1 illustrating the detail of a tab;
[0013] [0013]FIG. 1B is a blow up of a portion of the exemplary storage container of FIG. 1 illustrating the details of a catch;
[0014] [0014]FIG. 2 is a cross-section view of the exemplary storage container of FIG. 1 taken along line 2 with a disc shown prior to engagement with a hub;
[0015] [0015]FIG. 3 is a cross-section view of the exemplary storage container of FIG. 1 taken along line 2 with a disc shown in engagement with the hub;
[0016] [0016]FIG. 4 is a perspective view of an exemplary storage container in the closed position;
[0017] [0017]FIG. 5 is a cross-section view of the exemplary storage container of FIG. 4 taken along lines 5 ;
[0018] [0018]FIG. 6 is a perspective view of a portion of an exemplary storage container illustrating the details of a tab and catch latching mechanism;
[0019] [0019]FIG. 7 is a cross-section view of the tab and catch latching mechanism of FIG. 6 taken along line 7 showing the tab just prior to engagement with the catch;
[0020] [0020]FIG. 8 is a cross-section view of the tab and catch latching mechanism of FIG. 6 taken along line 7 showing the tab engaged with the catch;
[0021] [0021]FIG. 9 is a perspective view of a portion of an exemplary storage container illustrating the details of a break away tab hinged to the storage container; and
[0022] [0022]FIG. 10 is an exploded perspective view of the exemplary storage container of FIG. 9 illustrating the insertion of the break away tab into the exemplary storage container after the hinge connection is broken.
DETAILED DESCRIPTION
[0023] The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments of the present invention and is not intended to represent the only embodiments in which the present invention can be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description sets forth the inventive concepts in terms of construction and function of the exemplary storage containers. It is to be understood, however, that the same, equivalent, and alternative constructions and functions may be accomplished with other storage containers which are also intended to be encompassed within the spirit and scope of the invention.
[0024] As used herein, the term “optical disc” or “disc” means any compact disc (CD), compact disc read only memory (CD-ROM), recordable compact disc (CD-R), rewriteable compact disc (CD-RW), digital video disc or digital versatile disc (DVD), recordable digital video disc or recordable digital versatile disc (DVD-R), digital video disc random access memory or digital versatile disc random access (DVD-RAM), as well as other similar media which is used for storing information.
[0025] A perspective view of an exemplary storage container is shown in FIG. 1. The exemplary storage container includes several security features that are particularly useful for these types of containers in the retail environment. However, as those skilled in the art will appreciate, these security features are equally applicable to any type of storage container regardless of the contents. In the described exemplary embodiment, the storage container comprises a housing 12 including a lid 14 and a base 16 . The lid 14 may include a pair of clips 15 to hold pamphlets, brochures, booklets, or other printed media. The lid 14 can be attached to the base 16 in a variety of ways. By way of example, a hinge panel 18 can be attached to the lid 14 with a first living hinge 20 and attached to the base 16 with a second living hinge 22 . Various other means for attaching the lid 14 to the base 16 will be readily apparent to those skilled in the art.
[0026] The base 16 includes a base panel 24 with a peripheral base wall 26 extending along the three sides of the base panel not attached to the living hinge 22 . The base panel 24 includes an annular wall 28 to support the disc away from the base panel 24 . The annular wall 28 can be designed with a seat 30 that supports the unrecorded outer edge of the disc. The annular wall 28 may further be equipped with any number of finger holes to facilitate the removal of the disc from the storage container. In the described exemplary embodiment, there are four finger holes 32 equally spaced from one another along the circumference of the annular wall 28 . However, as those skilled in the art will readily appreciate, any number of finger holes can be used depending on the particular design requirements and manufacturing specifications. The finger hole design can take on various forms. By way of example, convex or semi-circular recesses in the annular wall 28 can be used to provide easy access to the periphery of the disc during the removal process.
[0027] A retaining member 34 extending upward from base panel 24 can be used to engage the central aperture of the disc. The retaining member 34 can be designed in any fashion that sufficiently retains the disc in the storage container. One such design includes an annular ring 36 which supports the unrecorded inner edge of the disc adjacent the central aperture. The annular ring 36 and the annular wall 28 cooperate to maintain the disc in the storage container away from the base panel 24 . Cantilevered from the annular ring 36 are six inwardly extending radial arms 38 which collectively form a hub. As best seen in FIGS. 2 and 3, the hub includes an upper surface 40 with an outwardly extending lip 42 which overlies the unrecorded inner edge of the disc when retained by the hub.
[0028] To engage the disc with the retaining member 34 , the disc is placed inside the storage container with its outer edge over the seat 30 of the annular wall 28 and its center aperture over the upper surface 40 of the hub (see FIG. 1). The placement of the disc over the hub prior to engagement is shown in FIG. 2. The disc 44 can be manually pressed by the user toward the base panel 24 until the inner edge of the disc 44 defining the center aperture slides over the lip 40 and into engagement with the hub as shown in FIG. 3. Referring to FIG. 3, the disc 44 can be removed from the retaining member 34 by applying a downward force to the upper surface 40 of the hub to force the lip 40 downward through the center aperture of the disc to free the disc from the retaining member 34 . An attractive feature of the retaining member design is that the annular ring 36 prevents the downward movement of the inner edge of the disc 44 despite any downward movement of the hub. This approach prevents the disc 44 from being damaged due to undesirable flexing of the disc 44 during removal.
[0029] Referring back to FIG. 1, the lid 14 includes a lid panel 46 with a peripheral lid wall 48 extending along the three sides of the lid panel 46 not attached to the living hinge 20 . A lip 50 can be formed at a distal end of an interior portion of the peripheral lid wall 48 on each side of the storage container. A rail 52 can be positioned on each side of the storage container along the base panel 24 each which cooperates with the peripheral base wall 26 to form a nesting slot for a respective one of the lips 50 . In at least one embodiment of the storage container, the lips 50 can be configured with a concave design that extends close to or all the way to the base panel 24 when the storage container is in the closed position. This arrangement may prevent the disc from sliding out of the storage container should the disc become dislodged. The concave design of the lips 50 may also make it more difficult for one to remove the disc from the storage container through a gap between the peripheral base and lid walls when the storage container is in the closed position. These attendant benefits may be achieved with other lip designs without departing from the inventive concepts described herein. By way of example, the lips 50 can be rectangular, triangular, or any other design which covers at least a portion of the gap formed between the peripheral base and lid walls when the storage container is in the closed position.
[0030] The storage container may be equipped with additional features that maintain the disc in engagement with the hub during transportation and handling of the closed storage container. The lid 14 may include tabs 54 which engage the outer edge of the disc when the storage container is in the closed position. Each tab can be supported by the lid panel 46 and includes a surface which extends inwards toward the center of the lid 14 and away from the peripheral lid wall 48 . Alternatively, each tab can be configured as a flat member extending directly from the front portion of the peripheral lid wall 48 inward toward the center of the lid 14 .
[0031] The tabs 54 can be designed to work alone, or alternatively, in combination with other structures to maintain the disc in engagement with the hub when the storage container is in the closed position. By way of example, the hinge panel 18 can be configured with a reinforcing rib 56 that not only increases the structural strength of the hinge panel 18 , but can be used to further maintain the disc in engagement with the hub when the storage container is in the closed position. This can be accomplished with a variety of rib designs depending on the aesthetic criteria for the storage container. By way of example, the reinforcing rib 56 can extend inwardly from the hinge panel 18 a sufficient length such that, when the storage container is in the closed position, the reinforcing rib 56 extends over the annular wall 28 and engages the unrecorded upper surface of the disc. The reinforcing rib 56 can be designed with a semi-circular recess or convex configuration for alignment with the seat 30 of the annular wall 28 to avoid placing undue stress on portions of the disc unsupported by the seat 30 .
[0032] [0032]FIG. 4 is a perspective view of an exemplary storage container in the closed position. FIG. 5 is a cross-section view of the exemplary storage container of FIG. 4 taken along line 5 . The manner in which the reinforcing rib 56 cooperates with the tabs 54 of the lid 14 to effectively clamp the outer edge of the disc to the seat 30 of the annular wall 28 is shown in FIG. 5. In at least one embodiment of the storage container, the tab 54 can be formed with a 58 at its distal end. As shown in FIG. 5, with the storage container in the closed position, the tab 54 extends over the annular wall 28 of the base panel 24 such that the ridge 58 engages the unrecorded upper surface of the disc to securely lodge the disc between the ridge 58 and the seat 30 of the annular wall 28 . In a similar manner to the reinforcing rib 56 , the ridge 58 can be formed with an arc shape that is aligned with the seat 30 of the annular wall 28 when the storage container is in the closed position to avoid flexing the disc by placing a downward force on a portion of the disc unsupported by the seat 30 . The ridge design minimizes surface contact between the tabs and the disc. In addition, the ridge design may provide for a tighter grip on the disc since the tabs have to be located sufficiently above the disc when the storage container is in the closed position to clear the annular wall 28 . Alternatively, the tabs can be used to directly to secure the disc to the seat 30 of the annular wall 28 .
[0033] The storage container may also be equipped with a latching mechanism to discourage the unauthorized removal of the disc from the storage container during retail distribution. The latching mechanism may take on various forms depending on the overall design constraints and security objectives. By way of example, the latching mechanism can be designed in a manner that requires a significant amount of force to open the storage container. Numerous techniques may be employed to implement this type of latching mechanism. These techniques can range from a single latch to any number of latches working together to achieve a storage container which cannot be easily open without exerting considerable force.
[0034] An exemplary latching mechanism for a storage container is shown in FIG. 1. The exemplary latching mechanism includes tabs 60 supported by the lid 14 in combination with catches 62 supported by the base 16 . The tabs 60 can be designed in various fashions depending on the design specifications and other relevant factors. In the described exemplary embodiment, the tabs 60 are fairly rigid members supported by the lid panel 46 . Increased rigidity may be achieved with a pair of reinforcing ribs 61 on each of the tabs 60 . As best seen by FIG. 1A, a detent 64 can be located at the distal end of the tab 60 . The detent 64 includes a tapered surface 65 with an undercut wall 67 . The catches 62 are also fairly rigid members extending from the base panel 24 (see FIG. 1). As best seen in FIG. 1B, the catch 62 includes a catch member 64 with an aperture 66 formed therein for catching the detent 64 of the tab 60 when the storage container is being closed. A support member 68 extending upward from the base panel between the aperture 66 and the peripheral base wall 26 is used to maintain rigidity of the catch 62 when the storage container is being opened and closed.
[0035] [0035]FIG. 6 is a perspective view of the tab and catch just prior to engagement as the exemplary storage container is being closed. FIG. 7 is a cross-section view of the exemplary storage container of FIG. 6 taken along line 7 . As shown in FIGS. 6 and 7, when the storage container is being closed by the user, the tapered upper surface of the detent 65 comes into contact with the upper portion of the catch member 64 . Since the tab 60 and the catch 62 are fairly rigid, the user must increase the force applied to the base and lid to bring them together to cause either the tab 60 to flex slightly backward and/or cause the catch member 64 to flex slightly forward against the support member 68 to allow the tapered upper surface of the detent 65 to slide past the exterior upper portion of the catch member 64 and snap into the aperture 66 with the undercut wall 67 facing the interior upper portion of the catch member 64 as shown in FIG. 8. FIG. 8 is a cross-section view of the exemplary storage container of FIG. 6 taken along line 7 with the exemplary storage container in the closed position. Because of the undercut wall 67 of the detent 60 , the force to open the storage container is even greater than that required to close the storage container. To open the container, the user applies a force to the base and lid to separate them from one another. In a manner similar to that described in connection with the closing of the storage container, the applied force to the storage container must be sufficient to cause either the tab 60 to flex slightly backward and/or cause the catch member 64 to flex slightly forward against the support member 68 . However, in this case, since the undercut wall 67 of the detent 64 is not tapered, the force required to flex the tab 60 backward and/or the catch member 64 forward against the support member 68 to allow the detent 64 to clear the catch member 64 and release it from the aperture is much greater. This increased force to open the storage container may discourage the unauthorized opening of the storage container in the retail environment.
[0036] The amount of force required to open and close the storage container can be varied by altering the design the reinforcing ribs on the tab or the support member for the catch. The tabs may be designed with a support member similar to that used for catches, either alone or in combination with the reinforcing ribs, to set the amount of force required to open and close the storage container. The rigidity of the material used for the tabs and catches can also be varied. One skilled in the art will readily be able to determine the material needed for the tabs and catches, and the designs of the supporting structures, if any, to meet the specific design requirements of any particular application.
[0037] Returning to FIG. 4, the exemplary storage container can be configured with a pair of removable tabs 72 a and 72 b . During retail distribution of the storage container, the removable tabs are in the closed position as shown by the removable tab 72 a . Once the storage container is removed from the retail environment, it can be opened by first moving removable tabs to the open position as shown by the removable tab 72 b . Once the removable tabs are moved to the open position, the storage container can then be opened by separating the base 16 from the lid 14 . As best shown in FIG. 9, the removable tab can be moved between the open and closed position via a break-away hinge 74 connecting the removable tab to the base 16 . The removable tab 72 is generally square or rectangular shape with an arm 76 extending from an interior portion of the removable tab. The removable tab 72 may also include four prongs 78 with two projecting from each side of the interior portion. When the removable tab 72 is in the closed position, the arm 76 extends through a center slot 80 formed in the peripheral lid wall 48 and the prongs 78 straddle a horizontal bar 81 extending through the peripheral lid wall 48 . This configuration may provide heightened security in the retail environment by making it more difficult to open the storage container without authorization.
[0038] Once the storage container is removed from the retail environment by the consumer, the removable tab 72 can be opened and separated from the base 16 by applying an upward or twisting force to the removable tab 72 to break the hinge connection. The removable tab 72 can then be physically rotated 180° with respect its original position and reinserted into the front portion of the peripheral lid and base walls as shown in FIG. 10. In this position, the arm 76 extends through the aperture 66 in the catch member 64 forcing the detent 64 of the tab 60 out of the aperture 66 to allow the consumer to easily open the storage container by merely applying a force to separate the base 16 from the lid 14 sufficient to overcome the insertion force of any other commonly known latches employed by the storage container. Each prong 78 may be formed with a detent 84 having a tapered surface with an undercut. When the removable tab 72 is being inserted into the front portion of the peripheral lid and base walls, the tapered portion of the detents 84 rides against interior walls 86 of the peripheral base wall 24 hereby flexing the prongs 78 toward one another. Once the detents 84 clear the interior walls 86 , the prongs 78 revert to their non-flexed state with the undercut of the detents 84 engaging the ends of the interior walls 86 . This arrangement holds the removable tabs in place once the hinges have been broken away from the base 16 .
[0039] Returning to FIG. 4, the peripheral base and lid walls 24 and 48 can be formed with slightly concave portions in the front portion. This arrangement provides an area where one can grasp the base and lid to open the storage container. These concave portions may be particularly useful to a consumer opening a storage container that does not have removable tabs that disable the latching mechanism.
[0040] Although exemplary embodiments of the present invention has been described, it should not be construed to limit the scope of the appended claims. Those skilled in the art will understand that various modifications may be made to the described embodiments. By way of example, any feature of the exemplary storage containers can be employed alone or in combination with one or more features. Moreover, to those skilled in the various arts, the inventive features described throughout can be employed with storage containers for other devices such as video cassettes and the like. It is therefore desired that the present embodiments be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than the foregoing description to indicate the scope of the invention.
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A storage container includes a lid having a lid panel and an arm extending from the lid panel, the arm including a detent having a first surface parallel to the lid panel and a second surface having a taper extending at least a portion between the first surface and a distal end of the arm, and a base configured to receive a disc, the base having a base panel and a member extending from the base panel, the member having an opening defined by an interior surface having a portion thereof parallel to the base panel, the first surface of the detent engaging the interior surface portion of the member when the storage container is closed. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or the meaning of the claims.
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This is a division of application Ser. No. 286,613 filed Sept. 5, 1972.
BACKGROUND OF THE INVENTION
Asphalt-aggregate compositions have found great success in road construction and particularly high quality road surfacing. For example, asphaltic concrete is an especially useful and widely used composition consisting of carefully proportioned mix of course and fine aggregate, and mineral filler where required, coated with asphalt. The composition provides a surfacing of exceptional durability and is widely used for heavily trafficked roads, airfield runways and the like for all types of climatic conditions. The composition is laid and compacted while still hot, normally in two or three layers where thick surfacing is required or in a single course for resurfacing.
Although such asphalt-aggregate compositions yield roadways having relatively long life, and which may easily be resurfaced for increased longevity, old roadways become abandoned from time to time due to new highway construction. In other circumstances old asphaltic concrete surfaces may be removed and the road base reworked or improved and a new surface laid, or parking lots removed for buildings. In any of such cases, it is common practice to simply tear up the old asphaltic concrete surface and haul it away to a dump or other remote location. Yet, such used asphalt-aggregate composition are seemingly indestructable and will not deteriorate substantially even after many years. Further, the old compositions still contain substantially all of the asphalt of the original composition as well as the aggregate although some aggregate sizes may have changed somewhat due to fracturing over years of use. Some additional aggregate in the way of sand or rock may also be present.
Costs involved in removing the old discarded road surface materials to dump sites are high due to the bulk and weight. Moreover, large areas may be required for dumping the accumulated and non-deteriorating material. In addition, such disposal sites are most unsightly. In other words, the abandonment of asphalt-aggregate compositions is simply contrary to good ecology practice as well as a waste of valuable natural resources. Accordingly, it is considered most desirable to attempt to recycle and reuse the compositions containing both mineral aggregates and petroleum or natural asphalt. It is to the elimination of waste of such resources as well as in the interest of ecology and as an important advance in the continuing extensive and costly roadway construction that the present invention is directed.
SUMMARY OF THE INVENTION
The concept of the present invention takes advantage of reusing and recycling old asphalt-aggregate compositions which have traditionally been discarded and dumped and which compositions contain the essential and expensive aggregate and asphalt ingredient required to form new road surface material compositions. The invention comprises a method of recycling the asphalt-aggregate compositions, a heat apparatus for treating the compositions during the process as well as an asphalt deficiency detection means.
The process for treating the old asphalt-aggregate compositions comprises heating composition pieces at a temperature and for a time sufficient to form a semi-fluid composition, passing the composition through an asphalt deficiency detecting phase and thereafter adding the proper amount of make-up asphalt.
The heating apparatus comprises an elongated cylindrical heating chamber having a plurality of heating tubes extending the interior chamber length and means for heating the tubes, preferably using hot air heating means. The composition is placed in one end of the cylindrical heating chamber and recovered from the other end in a semi-fluid homogeneous and hot state.
Asphalt deficiency detection comprises exposing the composition to a light source and detecting reflected light by photo-electric means. The amount of reflected light indicates the amount of aggregate surface exposed which has not been covered by asphalt and is thus proportional to the asphalt deficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional elevation of a heating apparatus according to the invention;
FIG. 2 is a sectional elevation of the heating apparatus taken along lines 2--2 of FIG. 1;
FIG. 3 is an exploded partial sectional elevation of the hot air producing means and heating tubes of the apparatus of FIG. 1;
FIG. 4 is a schematic view of screen sizing, asphalt detection and asphalt addition steps and apparatus used in the process of the invention; and
FIG. 5 illustrates an embodiment of asphalt detection apparatus in section.
DETAILED DESCRIPTION OF THE INVENTION
Recycling Process
Initially it will be appreciated that asphalt-aggregate compositions obtained from old road surface contain the two valuable, expensive and substantially non-degradable resources, ashalt and aggregate. Although such composition may have lost small amounts of original asphalt, due to some deterioration or degradation, this valuable component whether it be natural bitumen or petroleum asphalt, as is normally used in this country, is present in substantial amounts. The compositions to be recycled will have between about 1 and about 10% asphalt by weight with the remainder being aggregate. Moreover, because of the exposure and use to which the composition has been subjected on a road surface, the materials have actually aged so that imperfections in aggregates have resulted in some fracturing whereas the asphalt has also become consolidated and more completely wetted the aggregate surfaces. Thus, the composition because of its aging has actually been improved somewhat over a newly formed and mixed composition so that further physical changes when treated and reapplied for a road surface will be minimized as compared to a freshly mixed composition of previously unused asphalt and aggregate.
Recovered asphalt-aggregate compositions to be recycled according to the invention may consist of used road surface materials having those ingredients such as asphalt or bitumen macadam products, cold or hot asphalts or asphaltic concrete, the latter being more extensively used in this country for heavy duty road surfacing. As used hereinafter, the term asphalt-aggregate composition shall mean any of these materials and is not to be so limited as will be understood by those skilled in the art. Again, the compositions will normally have an asphalt: aggregate ratio of between about 0.1:10 and about 1:10 by weight. The compositions may be obtained directly from an old road runway or parking lot surface which has been broken up into slabs or chunks or from a dump site or other accumulation point. Although such materials may be somewhat contaminated, the contamination usually consists only of additional aggregate-type materials such as sand, rock or other mineral materials which will not substantially affect the process of the invention. Indeed, where road base aggregates are also present, such aggregates are valuable and once properly sized during the process are readily used in the recycled composition.
The salvaged pieces or chunks and slabs of used asphalt-aggregate materials are irregular and odd shaped, normally having approximately the same thickness of the original pavement or surface. These slabs or chunks are then treated in a conventional rock crusher of sufficient size to accomodate the pieces so that the material to be processed according to the invention will pass through an approximately one inch screen. The screen size is not particularly critical except that where all of the crushed materials will pass through about a one inch screen size it will be relatively easy to handle and process. Moreover, unduly large aggregate pieces which would affect the homogeneity of the road surface composition are removed. The crushing or grinding phase of the process will also fracture cracked or weak aggregate materials which is desirable at this point whereby further fracturing of the aggregate once it has been applied as a new road surface is less likely to occur. The screen sized composition is then transported or placed into a feeder for measured delivery to a heating apparatus.
HEATING PROCESS AND APPARATUS
Referring now to FIG. 1, there is shown in section a type of heating apparatus that is preferably used in recycling the asphalt-aggregate materials. The material placed on chute 13 passes through input port 22 from a feeder following the crushing phase as previously noted. The chute is located at one end of the heating apparatus. At the opposite end is an outlet port 30 from which the heated composition is drawn and thereafter directed to subsequent processing via conveyor apparatus 35.
Referring also to FIG. 2, the heating apparatus comprises an elongated cylinder 12 which is generally hollow except for heating tubes 20 extending along the length of the interior heating chamber 18. Adjacent material input port 22, which may be in the form of any channel for delivering the composition into the heating apparatus, is an end wall 31. At the opposite end adjacent outlet port 30 is an end wall 33. These opposite walls enclose interior heating chamber 18 except for the port openings 22 and 30 described.
At the end opposite input port 22 of the heating apparatus are located the heat producing means which supply heat to heat tubes 20. The heating means may be any suitable type readily available for such an apparatus and are preferably hot air producing such as gas or low pressure oil burners, nozzles 15 and 17 of which are illustrated in FIG. 1. Other details of such burners are well known to those skilled in the art and will not be further described as part of the present invention except as they are to be installed on a heating apparatus of the type described herein. The heater flame producing nozzle 15 and 17 will produce a hot flame projected into heating cavities 14 and 16 respectively which cavities are in communication with hollow heat tubes 20.
Although the two nozzles 15 and 17 are illustrated, the number of heaters is not particularly critical so long as sufficient energy is provided to adequately heat the asphalt-aggregate composition to the necessary extent and within reasonable time periods. Accordingly, the number and capacity of the heaters installed in a heating apparatus of the type described will depend on the rate at which materials are to be heated and removed from the apparatus, the size of the heating chamber, its efficiency, number of heat tubes, etc. Again, such considerations are not critical so long as the asphalt-aggregate compositions can be sufficiently heated to a viscous or semi-fluid condition above about 225°F and preferably above about 300°F and more preferably about 325°F. For example, another heating means could comprise electric heat strips along the heat tubes or hot water could be passed along the heat tubes. These as well as other equivalent heating means may be used rather than the hot air means described.
Observing also FIG. 3, it will be noted that a heating cavity 16 adjacent nozzle 17 communicates directly with the interior of hollow heat tubes 20. Both ends of the heating tubes are open similar to that shown in FIG. 3. End wall 33 encloses interior heating chamber 18 of cylinder 12 on the one end while a substantially identical wall 31 encloses the other chamber end, again, except for inlet and outlet ports.
Heating tubes 20 extend substantially along the interior length of heating chamber 18 between walls 33 and 31 and may be circular, square, rectangular or other shape in cross section. The shape which offers the greatest amount of exterior surface contact with asphalt-aggregate compositions to be heated are preferred. Square cross-section heating tubes 20 shown in FIG. 2 give approximately 25% more surface area than round heating tubes and are relatively stronger. The heating tubes should also have relatively thin walls to provide for more rapid and efficient heat transfer to a composition 23 shown in FIG. 2 within heating chamber 18.
In a preferred embodiment, the heater apparatus is tilted as shown in FIG. 1 so that input port 22 is elevated above the output port 30. Moreover, in this preferred embodiment, the heating apparatus is rotated so that cylinder 12 rotates about the elongated axis thereby providing a tumbling or cascading effect of the asphalt-aggregate composition being heated therein. At the same time the composition is being advanced downwardly by gravity toward outlet port 30. Thus, in operation, cool aggregate as previously described is placed in the heating apparatus at input port 22 wherein it is directed to interior heating chamber 18. Heaters 15 and 16 provide hot air heating tubes 20 which hot air is forced therealong toward the opposite end of the heating tubes. Since the tubes are open ended and are in contact with the composition they gradually cool somewhat along the heating tube length. An exhaust means for the hot air is provided by exhaust tube or chimney 24 so that the somewhat cooled but still warm air may be vented out of the apparatus at the opposite end. As cylinder 12 is rotated, the asphalt-aggregate material will be tumbled within heating chamber 18 between the hot long hollow heating tubes 20. Again, the temperature of the heating tubes will likely be less at the cool end near inlet port 22 because some heat will have been transferred in heating the composition nearer heating cavities 14 and 16 which may be referred to as the hot end of the apparatus.
As the tumbling action occurs, since the cylinder is tilted with the hot end being lower than the cool end, the composition will advance at its own rate toward the hot end outlet port 30 as it becomes more heated to gradually increasing temperatures. Moreover, the consistency of the composition will change gradually as its temperature rises so that by the time it arrives to outlet port 30, the composition should have achieved its temperature of above about 225°F, preferably above 300°F and more preferably about 325°F. At such temperature, the composition will become viscous or semi-fluid due to the thermoplastic nature of the heated asphalt. Moreover, the composition should be quite homogeneous because of the significant mixing which has been achieved by the tumbling action caused by the rotating cylinder. Thus, such a preferred heating apparatus embodiment offers significant advantages in both heating and mixing the composition.
It is also preferred to heat the asphalt-aggregate composition without substantial oxygen circulation which would cause oxidation of the heated asphalt resulting in reduction of the asphalt penetration value and variation of its flow characteristics. Accordingly, inlet port 22 is preferably provided with a closure member 26 which may be biased so that it will only be opened when composition is being placed into the heating chamber. The closure member is also preferably open only during composition addition so as to not allow a draft to occur between inlet and outlet ports 22 and 30. This feature will prevent undue amounts of fresh oxygen containing gases or air to enter the heating chamber. To further avoid asphalt oxidation, the interior heating chamber could be purged with inert, reducing or non-oxidizing gases or the exhaust gases from the input end could be continually recycled or recirculated into the chamber. A screw-type feeding apparatus may also be used to direct compositions to the heating chamber 26 which would also further reduce the port opening and minimize oxidation. Other components may be installed for that purpose.
Asphalt burning or flashing of its more volatile components are avoided since the compositions are not exposed to direct flame. This can be appreciated in noting particularly FIG. 3 in which a flame extending from heating nozzle 17 and directed into heating cavity 16 does not come in contact with the interior of heating chamber 18 but instead passes along heating tubes 20. In other words, the asphalt-aggregate composition contacts only exterior walls of the heating tubes and even then is heated only gradually from the cool end to the hot end of the heating apparatus. The avoidance of direct contact of the composition with flame or extremely hot air from the heat source to prevent burning or loss of light volatiles is an important aspect of the heating equipment design.
Enough composition should be fed into the heating chamber at one time to provide for a gradual and continuing flow of properly heated composition to outlet port 30. Thus, measured and controlled input amounts will yield a continual flow of properly heated composition at outlet port 30. Line 25 illustrates an approximate level of composition which may be maintained for continually drawing off product at outlet port 30. Noting again FIGS. 1 and 3, undue heat buildup in the heating tubes may be prevented by the embodiment shown wherein cylinder 12 and attached heating tubes rotate independently from the heaters. Thus, heating cavity 16 is continually presented to a flame from heater nozzle 17 although different heating tubes will be continually exposed to the hot gas from the nozzle as the cylinder rotates. The amount of heat directed into the heating tubes can also be controlled by varying the rate of rotation of the apparatus which may be installed along the interior of heating chamber 18. Sensing probes or other heat sensing means may be used and which may control the number of heaters or burners being fired or the amount of heat input. Further composition temperature control may be achieved by changing the angle of tilt or inclination of the heating assembly.
Any means of rotating cylinder 12 may be utilized as desired as will be appreciated by those skilled in the art with rotating rollers 27 illustrated generally in FIGS. 1 and 2 by way of example. FIG. 2 further illustrates a level of composition 23 as the cylinder 12 is rotated clockwise and viewed toward funnel 32 (note also FIGS. 1 and 3) over which the composition is drawn through outlet port 30.
Once the viscous, molten or semi-fluid heated composition is at a sufficient level and temperature at the hot end of the heating apparatus, it is ready to be drawn out for further processing. Noting first FIG. 1, this will be accomplished when the level of sufficiently heated composition is high enough to be drawn into port 30, over funnel 32 and where it may be picked up by conveyer apparatus 35 or other suitable means for transporting it to the next phase of the process. Again, the temperature of the composition will be above about 225°F, preferably above about 300°F and more preferably at about 325°F or so as it leaves the heating chamber. Further, as previously noted and as will be evident, the composition will be quite homogeneous because of its extensive mixing by tumbling or cascading agitation over the heating tubes within the heating chamber as previously described. Conveyer system 35 is preferably closed to retain as much heat as possible in the hot composition. Heat losses should be minimized prior to final mixing of the composition with further make-up asphalt which will make mixing of the hot components at relatively the same or near heated temperatures more efficient.
Referring to FIG. 4, the heated composition is then directed via chute 37 to screening apparatus 39 illustrated schematically in FIG. 4. Any conventional screening process and apparatus may be used, for example, as is commonly found in a pugmill, commonly used in manufacture of hot-mix asphalts. The purpose of the screening process is to separate the composition into different size batches of aggregate material which may be for example 11/2 inch, 1/2 to 1/4 inch and less than 1/4 inch. The three batches sizes are then directed to asphalt quantity detection phase of the process.
ASPHALT DETECTION
The asphalt detection phase is schematically shown in FIG. 4 with example apparatus illustrated in FIG. 5. A stream of asphalt-aggregate composition 23 is passed through funnel 41 having a detection apparatus 38. Referring particularly to FIG. 5, detection apparatus 38 shown in sectional elevation comprises a light producing member or source 42 and photo-electric cell or similar light sensitive detecting means 46. In operation, light source 42, which may be a bulb and produce a light which can be reflected and detected from aggregate surfaces, will direct light toward aperture 47. This light will illuminate the particles of the composition passing before or in front of aperture 47. Since much of the composition will be black because of the substantial amount of asphalt present, little light will be reflected. However, the amount of reflected light will be detected by photo-electric cell 46 and may be transmitted to a meter 49 which will indicate the ratio of aggregate to asphalt. For example, the more asphalt present in the composition, the less the amount of reflected light to be detected by photoelectric cell 46. On the other hand, the less asphalt present, the more aggregate surfaces exposed so that more light will be reflected and be detected by the device. In the embodiment shown, the device is constructed so that light illuminated by light source 42 will pass along the narrower neck portion 48 and thereafter outwardly into expanded portion 44 without directly shining on photo-electric cell 46 which is inset and protected against direct illumination. However, this particular construction is by way of illustration only and not intended to be limiting to the type of detection apparatus which may be used so long as the desired function is achieved.
Referring again also to FIG. 4, asphalt detection means 38 may be connected to a control apparatus associated with asphalt tank 43 and asphalt delivery means 45 so that asphalt deficiency and make-up amounts can be directly added to the asphalt delivered in a storage vessel 27. It will be appreciated by those skilled in the art such a detection device may be callibrated and used with other monitoring and control equipment to achieve automatic addition of proper amounts of asphalt from an asphalt tank 43 and delivery means 45 in response to the detection apparatus and light reflected from a composition as previously described. However, manual make-up asphalt delivery means may be used whereby an operator in response to readings of reflected light of the described device may add indicate amounts of asphalt.
The make-up asphalt will be added while hot, preferably about 225°F depending on the type of specific asphalt material used so that it will be in a fluid state and can be easily mixed with the still hot recycled asphalt-aggregate composition. The materials are then further mixed in vessel 27 or similar device to achieve the final desired homogeneity for direct use as road surfacing composition. However, it should be appreciated that vessel 27 is shown only for purpose of illustration and any other suitable type of device may be used such as a conventional pugmill. It should also be appreciated that the heated composition drawn from the heating apparatus may be stored between the screening asphalt detection and asphalt make-up addition phases of the described process for any length of time. However, it will be preferred that during such storage the composition will be maintained at an elevated temperature so that it will remain semifluid and not become hardened whereby adequate mixture with make-up asphalt would become more difficult to achieve.
A further embodiment or modification of the process is asphalt detection and addition of make-up asphalt in the heating and mixing chamber itself. Accordingly, the asphalt detection phase previously described may be accomplished within the heating chamber and apparatus shown in FIG. 1 and the make-up asphalt added in the same chamber as the composition is heated and mixed. Such an embodiment will further reduce equipment costs and requirements and is particularly advantageous where higher quality and carefully sized aggregate composition are not of primary importance.
It will be evident that the process herein described as well as the apparatus allows for recycle of valuable used asphalt-aggregate composition. The process is relative simple, requiring only adequate apparatus to achieve the desired heating and make-up asphalt detecting phases. Not only does such a method yield an asphalt which is highly practical from an economical standpoint since it utilizes asphalt and aggregate without further depleting those natural resource materials, but also, if extensively used, prevents substantial accumulation of old asphalt-aggregate compositions which are unsightly, expensive to dump or otherwise discard. These as well as other advantages will be evident to those skilled in the art.
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A process for recycling asphalt-aggregate compositions comprises heating pieces of the used composition to form a semifluid or viscous composition, detecting the composition's asphalt deficiency and adding the proper amount of make-up asphalt. The composition is heated in a rotating cylindrical oven to achieve homogeneity, the viscous composition is drawn off, detected for asphalt deficiency, the proper amount of asphalt is added and the composition is then stored until required for use. Asphalt deficiency is detected by exposing the composition to a light source and measuring the amount of light reflected.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention are generally related to safety valves. More particularly, embodiments of the present invention pertain to subsurface safety valves configured to be actuated using wellbore pressure in the event of an unexpected pressure drop.
[0003] 2. Description of the Related Art
[0004] Subsurface safety valves are commonly used to shut-in oil and gas wells and are typically fitted in a string of production tubing installed in a hydrocarbon producing well. The safety valves are configured to selectively seal fluid flow through the production tubing to control the flow of formation fluids upwardly should a failure or hazardous condition occur at the well surface.
[0005] Typically, subsurface safety valves are rigidly connected to the production tubing and may be installed and retrieved by conveyance means, such as tubing or wireline. During normal production, safety valves are maintained in an open position by the application of hydraulic fluid pressure transmitted to an actuating mechanism. The actuating mechanism in such embodiments may be charged by application of hydraulic pressure through hydraulic control systems. The hydraulic control systems may comprise a clean oil supplied from a surface fluid reservoir through a control line. A pump at the surface delivers regulated hydraulic fluid under pressure from the surface to the actuating mechanism through the control line. The control line resides within the annular region between the production tubing and the surrounding well casing.
[0006] In the event of a failure or hazardous condition at the well surface, fluid communication between the surface reservoir and the control line is interrupted. This, in turn, breaks the application of hydraulic pressure against the actuating mechanism. The actuating mechanism recedes within the valve, allowing a flapper to quickly and forcefully close against a corresponding annular seat—resulting in shutoff of the flow of production fluid. In many cases, the flapper can be reopened (and production flow resumed) by restoring the hydraulic fluid pressure to the actuating mechanism of the safety valve via the control lines.
[0007] For safety reasons, most surface controlled subsurface safety valves (such as the ones described above) are “normally closed” valves, i.e., the valves are in the closed position when the hydraulic pressure in the control lines is not present. The hydraulic pressure typically works against a powerful spring and/or gas charge acting through a piston. In many commercially available valve systems, the power spring is overcome by hydraulic pressure acting against the piston, producing axial movement of the piston. The piston, in turn, acts against an elongated “flow tube.” In this manner, the actuating mechanism is a hydraulically actuated and axially movable piston that acts against the flow tube to move it downward within the tubing and across the flapper.
[0008] Safety valves employing control lines, as described above, have been implemented successfully for standard depth wells with reservoir pressures that are less than 15,000 psi. However, wells are being drilled deeper, and the operating pressures are increasing correspondingly. For instance, formation pressures within wells developed in some new reservoirs are approaching 30,000 psi. In such downhole environments, conventional safety valves utilizing control lines are not operable because of the effects of hydrostatic pressure on the hydraulic fluid within the control line. In other words, high-pressure wells have exceeded the capability of many existing control systems, especially hydraulic control systems which rely on control lines, which are susceptible to reliability problems.
[0009] Therefore, a need exists for a subsurface safety valve that is suitable for use in high pressure environments. There is a further need for a subsurface safety valve that does not rely on a control system that requires the use of control lines conveying hydraulic fluid to an actuating mechanism. There is yet a further need for the ability to reopen the safety valve remotely from the surface of the well.
SUMMARY OF THE INVENTION
[0010] In one respect, the present invention provides a downhole valve for selectively sealing a bore. The downhole valve generally includes a closing member for seating in and closing the bore, and a pressure-actuated, retention member having first and second opposed piston surfaces for initially holding the valve in an open position but, in the event of a pressure differential between the piston surfaces, permits the closing member to operate and close the valve.
[0011] In another respect, the present invention provides a method of operating a downhole valve. The method generally includes providing the valve in a down hole tubular, the valve having a closing member and an axially movable retention member having a first piston surface and an opposing piston surface and an interfering member to interfere with the closing member and keep the valve in the open position. A sudden pressure drop in the wellbore, shifts the retention member due to a pressure differential between the first and second piston surfaces, and closing the valve due to the axial movement of the interfering member way from the closing member.
[0012] In yet another respect, the present invention provides a safety valve for use downhole. The safety valve generally includes a pivotly mounted flapper, biased towards a closed position for sealing a bore, an interfering member to hold the flapper in an open position, a first piston surface in fluid contact with the bore, a second opposing piston surface in fluid communication with a pressure chamber having restricted fluid communication with the bore, wherein the valve is constructed and arranged to close in the event of a pressure difference between the bore and the chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0014] FIG. 1 is a cross-sectional view of a wellbore illustrating a string of production tubing having a subsurface safety valve in accordance with one embodiment of the present invention.
[0015] FIG. 2A is a cross-sectional view of the subsurface safety valve in an open position.
[0016] FIG. 2B is a cross-sectional view of the subsurface safety valve of FIG. 2A , shown in the closed position.
[0017] FIGS. 3A and 3B illustrate cross-sectional views of a subsurface safety valve in accordance with an alternative embodiment of the present invention.
[0018] FIGS. 4A-4C illustrate cross-sectional views of a subsurface safety valve in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION
[0019] The apparatus and methods of the present invention allow for a subsurface safety valve for use in high pressure wells. Embodiments of the present invention provide safety valves that utilize normal wellbore pressure for actuation of the valve, which removes the need for hydraulic systems with control lines extending from the surface to the valve.
[0020] FIG. 1 is a cross-sectional view of an illustrative wellbore 10 . The wellbore is completed with a string of production tubing 11 . The production tubing 11 defines an elongated bore through which servicing fluid may be pumped downward and production fluid may be pumped upward. The production tubing 11 includes a safety valve 200 in accordance with one embodiment of the present invention. The safety valve 200 is used for controlling the upward flow of production fluid through the production tubing 11 in the event of a sudden and unexpected pressure loss (also referred to herein as a “pressure drop”) of production fluid may coincide with a corresponding increase in flow rate within the production tubing 11 . Such a condition could be due to the loss of flow control (i.e., a blowout) of the production fluid at the wellbore surface. In the event of such a condition, a subsurface safety valve, implemented according to embodiments of the current invention, automatically actuates and shuts off the upward flow of production fluid. Further, when flow control is regained at the surface, the safety valve can be remotely reopened to reestablish the flow of production fluid. Discussion of the components and operation of embodiments of the safety valve of the present invention are described below with reference to FIGS. 2A-2B , 3 A- 3 B, and 4 A- 4 C.
[0021] It should be understood, that as used herein, the term “production fluid” may represent both gases or liquids or a combination thereof. Those skilled in the art will recognize that production fluid is a generic term used in a number of contexts, but most commonly used to describe any fluid produced from a wellbore that is not a servicing (e.g., treatment) fluid. The characteristics and phase composition of a produced fluid vary and use of the term often implies an inexact or unknown composition.
[0022] FIG. 2A illustrates a cross-sectional view of a subsurface safety valve in a open position, in accordance with one embodiment of the present invention. The safety valve 200 comprises an upper housing 201 A threadedly connected to a lower housing 201 B, which, in turn, is threadedly connected to a bottom sub 202 . The upper housing 201 A makes up the top of the safety valve 200 and extends upward. Accordingly, the bottom sub 202 makes up the bottom of the safety valve 200 and extends downward. Both the upper housing 201 A and the bottom sub 202 are configured with threads to facilitate connection to production tubing 11 (or other suitable downhole tubulars) above and below the safety valve 200 , respectively.
[0023] The safety valve 200 comprises a flapper 203 and a flow tube 204 . The flapper 203 is rotationally attached by a pin 203 B to a flapper mount 203 C. The flapper 203 pivots between an open position and a closed position in response to axial movement of the flow tube 204 . As shown in FIG. 2A , the flapper 203 is in the open position creating a fluid pathway through the bore of the flow tube 204 , thereby allowing the flow of fluid through the valve 200 . Conversely, in the closed position, the flapper 203 blocks the fluid pathway through the bore of the flow tube 204 , thereby preventing the flow of fluid through the valve 200 .
[0024] As stated earlier, FIG. 2A illustrates the safety valve 200 in the open position. It can be seen that the flow tube 204 is positioned such that it physically interferes with and restricts the flapper 203 from closing. As will be described with reference to FIG. 2B , when the safety valve 200 is in the closed position, the flow tube 204 is translated sufficiently upward to enable the flapper 203 to close completely and shut off flow of production fluid.
[0025] While production fluid is being conveyed to the surface under stable and controlled conditions, the safety valve 200 remains in the open position. Under such conditions, the flow tube 204 remains bottomed out against an upward facing internal shoulder 230 of the bottom sub 202 , thereby restricting the flapper 203 from closing. The flow tube 204 is held in this position due to a net downward force resulting from the force exerted by a spring 211 biased towards the extended position. A gap 231 between the inner diameter of the upper mandrel 201 A and the outer diameter of the flow tube 204 allows piston surface 209 to be in fluid communication with the wellbore.
[0026] As shown in FIG. 2A , a pressure chamber 205 is located in the annular space between the outer diameter of the flow tube 204 and the inner diameter of the lower housing 201 B. The pressure chamber 205 is bound by a piston seal 206 on top and the tube seal 207 on bottom. A spring 211 is also located in the annular area between lower housing 201 B and the flow tube 204 . The spring is held in place by a spring retainer 212 and surface 213 of the flow tube 204 .
[0027] During normal operation, while the valve 200 is in the open position, the pressure chamber 205 is filled with production fluid that enters the pressure chamber 205 through an orifice 208 . In this embodiment, the orifice 208 is the only path for fluid to enter and exit the pressure chamber 205 . The orifice is designed to meter flow that passes through it, regardless of whether the fluid is entering or exiting the pressure chamber 205 . While the valve 200 is in the open position, the fluid flow through the orifice ensures that the pressure of the fluid inside the chamber is equalized with the pressure of the fluid flowing through the bore of the flow tube 204 .
[0028] In the event of a catastrophic failure at the surface of the wellbore and loss of flow control, the safety valve 200 is required to assume the closed position, as seen in FIG. 2B . The loss of flow control typically means that production fluid is flowing upward at a flow rate that is much higher than normal. In keeping with Bernoulli's Rule, the pressure of production fluid flowing through the bore of the flow tube 204 is much lower than prior to loss of flow control. However, the pressure in the pressure chamber 205 is not reduced in unison with the production flow pressure. This is because the metering effect of the orifice 208 does not allow the fluid to flow out of the pressure chamber 205 to allow for the equalization process to occur immediately. Accordingly, for a particular time span, the pressure of the fluid flowing through the bore is appreciably lower than the pressure of fluid in the pressure chamber 205 .
[0029] The pressure difference between the fluid within the pressure chamber 205 and the production fluid results in the pressure chamber 205 increasing in volume and the flow tube 204 being urged upward. It should be noted that as the flow tube 204 moves upward, it meets resistance as the spring 211 is compressed. Provided that the pressure difference is large enough and the pressure chamber 205 expands sufficiently, the flow tube 204 travels sufficiently upward so that it no longer restricts the flapper 203 from closing and shutting-in the well as seen in FIG. 2B .
[0030] After the flapper is closed, the pressure of the production fluid acting on the underside of the flapper 203 (pushing upward) is high enough to forceably keep the flapper 203 in the closed position. In terms of the pressure chamber 205 , it should be noted that starting from the instant of the rapid pressure loss (corresponding to the loss of flow control) the metered flow of fluid through the orifice allows for the pressure equalization process to resume. However, even after the pressure equalizes again, the pressure of the downhole fluid against the bottom-side of the flapper will keep it shut.
[0031] Embodiments of the present invention also provide functionality to remotely reopen the subsurface safety valve 200 . Obviously, this would be done after flow control apparatus at the surface of the wellbore are returned to working order. In order to reopen the safety valve 200 from the surface, fluid is pumped down to the safety valve 200 and the pressure is built up so that the pressure above the flapper 203 is the same as the pressure of the production fluid below the flapper 203 (i.e., pressure is equalized across the flapper 203 ).
[0032] It should be noted that by this time, the flow of fluid through the orifice 208 has allowed pressure of fluid within the pressure chamber 205 to again equalize with the pressure of fluid outside the pressure chamber 205 . The spring 211 stays compressed, and the pressure chamber 205 does not return to it's previous volume because the flow tube 204 is not allowed to move downwards due to the closed flapper.
[0033] However, once there is equal pressure on both sides of the flapper 203 , the spring 211 , biased towards the extended position, will urge the flow tube 204 downwards, which in turn will push the flapper to the open position. Thereafter, the flow tube will bottom out against a corresponding interior shoulder of the bottom sub 202 .
[0034] With reference to the discussion above, it can be understood that the amount of upward movement of the flow tube 204 is dependent on the difference in pressure (i.e., “pressure drop”) between the fluid in the pressure chamber 205 and the pressure of the fluid flowing through the bore of the flow tube 204 at the moment of loss of flow control. In other words, the higher the difference in pressure between the fluid in the pressure chamber and the fluid flowing through the bore of the flow tube 204 , the greater the amount of upward movement of the flow tube 204 . Maximizing upward movement of the flow tube 204 is important because it ensures that the flow tube does not restrict the flapper 203 from fully closing in the event of a loss of flow control.
[0035] Other embodiments of the present invention are envisioned for providing more upward movement of the flow tube for a given pressure drop. FIG. 3A , for instance, illustrates a cross-sectional view of a subsurface safety valve configured with bellows according to an alternative embodiment of the present invention. As will be described below, use of bellows for creating a pressure chamber is beneficial because bellows provide a large change in volume between the compressed and uncompressed position. Greater variance in the volume of the pressure chamber while the safety valve is in the open position versus closed position translates into more axial movement of the flow tube, which ensures complete closure of the flapper.
[0036] Referring now to FIG. 3A , a safety valve 300 is provided with a housing 301 that is threadedly connected to a bottom sub 302 . Both the housing 301 and the bottom sub 302 are configured with threaded connections to allow for installing the safety valve 300 in a string of production tubing 11 .
[0037] As with the embodiment described earlier, safety valve 300 comprises a flapper 303 and a flow tube 304 . The flapper 303 is rotationally attached by a pin 303 B to a flapper mount 303 C. The flapper 303 pivots between an open position and a closed position in response to axial movement of the flow tube 304 . As shown in FIG. 3A , the safety valve 300 is in the open position; the flow tube 304 restricts the flapper 303 from pivoting. However, with sufficient upward movement of the flow tube 304 , the flapper 303 can pivot to block the upward flow of production fluid.
[0038] An important component of this embodiment is the use of bellows 306 for creating an expandable pressure chamber 305 . The bellows 306 may be made of a variety of materials, including, but not limited to metals. For one embodiment, the bellows 306 are configured with pleated metal to facilitate a volumetric variance between its compressed and uncompressed positions.
[0039] The pressure chamber 305 is defined by the annular space between the bellows 306 and the flow tube 304 . The pressure chamber 305 is bound on the top by the connection between the bellows 305 and the bellows retainer 307 . The lower end of the pressure chamber 305 is bound by a cap 320 . There are two channels by which production fluid can enter the pressure chamber 305 : fluid can go past a packing 309 , or fluid can flow into the pressure chamber 305 via an orifice 308 . While the valve 300 is in the open position, the fluid flow through the orifice 308 and the packing 309 ensures that the pressure of the fluid inside the pressure chamber 305 is equalized with the pressure of the fluid flowing through the bore of the flow tube 304 . FIG. 3B provides a detailed view of the orifice 308 and the packing 309 .
[0040] In the context of the current application, the packing 309 can be thought of as a one-way valve. As seen in FIG. 3A , the packing 309 is configured to allow fluid to flow into the pressure chamber 305 , but not out of it. An orifice 308 is also provided to allow for fluid to flow into the pressure chamber 305 . It should be noted that the orifice 308 provides the only path by which fluid is allowed to flow out of the chamber. The orifice 308 is configured to meter the fluid that flows through at a relatively low flow rate.
[0041] A pressure equalization port 321 extending through the cap 320 is provided to ensure that the pressure on either side of the cap 320 is equalized. Further, the port 321 provides a secondary path for production fluid to reach the packing 309 in the event that the path formed around the bottom end of the flow tube 304 and through the area adjacent to the flapper 303 is plugged.
[0042] The safety valve 300 comprises a spring 311 that resists the upward movement of the bellows retainer 307 and the flow tube 304 . The bottom of the spring 311 rests against the bellows retainer 307 . The top portion of the spring 311 interfaces with a downward-facing internal shoulder of the housing 301 . In the open position of the safety valve 300 , with the flow tube 304 bottomed out, the spring 311 is fully extended. In the closed position of the safety valve 300 , with the flow tube 304 all the way up, the spring 311 is compressed and it exerts a downward force against the bellows retainer 307 .
[0043] In the event of a loss of flow control at the surface of the wellbore, there would be a pressure drop between the fluid flowing through the bore of the flow tube 304 and the fluid in the pressure chamber 305 . As with the previous embodiment, the pressure in the pressure chamber 305 is not reduced in concert with the pressure of the production flow because the metering effect of the orifice 308 does not allow the fluid to flow out of the pressure chamber 305 to allow for pressure equalization to occur immediately. As a result, the pressure chamber 305 expands by extending the bellows 306 axially, which, in turn, urges the bellows retainer 307 and flow tube 304 to move upward, compressing the spring 311 . Upon sufficient upward movement of the flow tube 304 , the flapper 303 will close to shut-in the wellbore.
[0044] As with the embodiment described earlier with reference to FIGS. 2A and 2B , the valve can be reopened by equalizing pressure on both sides of the flapper 303 and allowing the spring 311 to urge the flow tube 304 downwards. This, in turn, would return the flapper 303 to the open position.
[0045] FIG. 4A illustrates yet another embodiment of the present invention that is designed to provide additional axial movement of the flow tube for a given pressure drop. A cross-sectional view of a subsurface safety valve configured with extension rods sliding in their corresponding cylinders is provided. As will be described below, the axial movement of rods for expanding a pressure chamber is beneficial because the process of displacing rods in cylinders with fluid can yield a tremendous amount of axial movement of a flow tube for a given pressure drop. As stated earlier, complete upward movement of the flow tube ensures complete closure of the flapper.
[0046] Referring now to FIG. 4A , a safety valve 400 is provided with a housing 401 that is threadedly connected to a crossover sub 402 , which is threadedly connected to a lower housing 403 . The lower housing 403 is connected to a bottom sub 404 . Both the housing 401 and the bottom sub 404 are configured with threaded connections to allow for installing the safety valve 400 in a string of production tubing 11 . As with previously described embodiments, the safety valve 400 includes a flow tube 404 , spring 411 and flapper 406 , each of which provides generally the same functionality as with other embodiments described above.
[0047] The lower end 422 of the crossover sub 402 seals into the lower housing 403 at position 422 . It should be understood that because the lower end 422 of the crossover sub 402 is sealingly connected (e.g., press fit, static seal, etc.) to the lower housing 404 , production fluid is not able to flow past the seal between the lower end 422 of the crossover Sub 402 and the lower housing 404 . However, the lower end 422 of the crossover sub 402 does contain an orifice 408 that allows fluid to flow into and out of a pressure chamber 405 . Fluid arrives at the orifice 408 by flowing around the top or bottom of the flow tube 404 and within the annular space between the lower end 422 of the crossover sub 402 and flow tube 404 .
[0048] The pressure chamber 405 is defined by the annular space between the lower housing 403 and the lower end of the crossover sub 402 . The pressure chamber 405 also includes the bores within the crossover sub 402 in which rods 420 are located. Fluid can flow into the pressure chamber via the orifice 408 and by flowing past rod packings 421 . As with the packing 309 described with reference to the previous embodiment, rod packings 421 function as one-way valves, wherein fluid is allowed to flow into the pressure chamber 405 (downwards) past the rods 420 , but the fluid is not allowed to flow out from the pressure chamber 405 (upward) past the interface between the rods 420 and the rod packings 421 . FIG. 4B provides a detailed view of the interface between a rod 420 and a rod packing 421 .
[0049] During normal operation, while the valve 400 is in the open position, the pressure chamber 405 is filled with the production fluid. While the valve 400 is in the open position, the fluid flow into the pressure chamber 405 ensures that the pressure of the fluid inside the chamber is equalized with the pressure of the fluid flowing through the bore of the flow tube 404 .
[0050] In the event of a sudden pressure drop, the fluid is not capable of immediately exiting the pressure chamber via the orifice 408 (for purposes of pressure equalization), so the pressure in pressure chamber 405 is higher than the pressure of the flowing production fluid. Consequently, the pressure chamber 405 expands and displaces the rods 421 upward from the cylinders. The rods 420 move the flow tube 404 upward against the spring 411 . After the flow tube 404 has moved sufficiently upward, the flapper 403 closes and shuts-in the well.
[0051] It can be seen from FIG. 4C that the collective cross-sectional area of rods 420 is considerably less than the annular area between the inner diameter of the lower housing 403 and the lower end of the crossover sub 402 . Accordingly, the use of rods 420 in this manner requires less expansion of pressure chamber 405 to achieve the required amount of axial movement of the flow tube 404 to allow the flapper 403 to close. This is because the volumetric change of the pressure chamber 405 need only be enough to displace the volume of the rods 420 , rather than the entire annular area between the lower mandrel and the sleeve 409 . While three rods 420 are shown for the current embodiment, it should be understood that the number of rods can vary based on the requirements of a particular implementation.
[0052] Those skilled in the art will recognize that safety valves according to embodiments of the present invention may be utilized in any wellbore implementation where a pressure differential (i.e. pressure drop) may arise. For instance, the safety valves described herein are fully functional if there is a pressure differential between fluid in the pressure chamber and fluid flowing through the bore of the safety valve, regardless of the absolute pressures of the respective fluids. Therefore, safety valves according to embodiments of the present invention may be utilized in low pressure wellbores as well as high pressure wellbores.
[0053] While the exemplary safety valves described herein are configured for use with production tubing, those skilled in the art will acknowledge that embodiments of the present invention may be configured for use in a variety of wellbore implementations. For example, some embodiments of the present invention may be implemented as safety valves configured for use with wireline. Yet other embodiments may be configured for use with drill pipe or coiled tubing.
[0054] 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 provides a downhole valve for selectively sealing a bore. The downhole valve generally includes a closing member for seating in and closing the bore, and a pressure-actuated, retention member having first and second opposed piston surfaces for initially holding the valve in an open position but, in the event of a pressure differential between the piston surfaces, permits the closing member to operate and close the valve.
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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 the automatic tallying of uniquely serialized oil field tubulars as they enter or are withdrawn from well bore service and the application of these tallies to service records and down hole depth monitoring.
BACKGROUND OF THE INVENTION
In the oil industry drilling, completion or working-over of wells, drill or tubing strings are used to physically enter and enable performance of desired work functions down hole. In drilling operations drill strings are generally categorized as drill stem or drill pipe and bottom hole assemblies. Drill pipe joint lengths vary in the range of 30 feet and are connected together by "tool joints" having a "box", or female thread on the upper end, and a "pin" or male thread on the down-hole end. Tool joints are commonly an "integral" type attached to the drill pipe by a friction or flash weld. A large drilling rig for deep drilling may have drill pipe sections in excess of 500 or 600 joints. Drill pipe makes up the principal length and investment of a given drill string.
Bottom hole assemblies represent a lesser overall footage of the drill string and are thick walled approximate 30 foot long tubular sections called "drill collars." Drill collars provide weight to be run on drill bits. Drill collars have larger and more rugged box and pin connections than drill pipe and the threads of these connections are machined from the body of the drill collar itself. Bottom hole assemblies may include various "subs" of relatively short length for crossover between dissimilar thread sizes or forms as between drill pipe and drill collars. Other subs might include bit subs for adapting a bit thread to a drill collar, stabilizer subs serve to center drill collars in the well bore and safety valves
A square or hexagonal cross section "kelly" passing through a roller kelly drive bushing seated in the rotary table serves to impart rotation to the drill string in the hole. A kelly saver sub is customarily screwed onto the lower end of the kelly and provides a wear thread for the repeated make and break of the kelly when adding drill pipe when drilling. Many offshore rigs now use a "top drive" in lieu of the rotary table and kelly while drilling and drill down an entire "stand" of three joints of drill pipe before a new connection is required.
The hole depths at which the bit is drilling or other types of down hole work is being conducted is presently determined by measurements taken by rig crewmen with a steel tape and are hand written and totaled by the driller in his tally book. In the case of drilling, these tallies are usually broken down by bottom hole assemblies, drill pipe and the amount of footage the kelly is in the hole using as a reference point, or datum, the top of the kelly drive bushing or top of the rotary table as zero elevation. The total of these three general categorizations therefore provides hole depth.
During normal drilling procedures, individual drill pipe joints, subs or drill collars are measured immediately prior to picking up for insertion in the well bore string. Similarly, joints are measured when laid down as to be later picked up or to be replaced by other drill string components. Over only short periods of time, errors invariably occur which are usually the cause of inadvertently omitting entries into the tally, arithmetic errors or incorrect measurements made or reported by crewmen. To check measured depth tallies, the common practice is to measure and tally each three joint stand stood back in the derrick when tripping out of the hole to replace a bit or other down hole tool. This tally of approximate 90 foot stands, including bottom hole assembly stands, is used as a check of depths and serves to check and correct faulted tallies.
Due to tally errors being common, it is normal good practice to maintain a count of total joints of drill pipe on a rig when drilling starts and when drilling has progressed, occasionally reconciling a count of tallied joints in the hole and joints on the pipe rack with the original inventory. Hole depth is critical for geological reference and for operations such as when casing a hole in order to establish the amount of casing required to be landed at the correct depth. For these reasons, accurate pipe tallies of both joint quantities and total lengths are important and much expensive rig time is spent checking and rechecking such tallies.
Drill stem retirement from service is frequently necessitated by wear on the outside diameters of pipe, tool joints and drill collars which reduces wall area and both tensile and torsional load capacity; excessive corrosion or erosion; and physical damage from poor handling practice. Also of concern is the potential development of cracks or complete failure due to stress and fatigue especially in corroded, worn and thinner walled pipe.
Drill pipe life has traditionally been evaluated in terms of total feet of hole drilled by the composite several hundred joints that make up a given string of pipe. Service life of bottom hole assembly components is usually limited by outside diameter wear or from the repeated re-machining connection threads to eventually cause too short an overall length for handling by the derrick man in the derrick. Therefore drill collar or bottom hole assembly service factor measurements, such as cumulative footage drilled or fatigue damage, may not be generally as important as for drill pipe.
Although an identification serial number may be stenciled on each joint in a non-wear area, it is virtually impossible for field crews to keep track of individual joint usage whereby the total footage each joint drills may be manually recorded and accumulated. For this reason down hole service and wear is not evenly distributed to each individual joint of an entire drill string and some joints invariably receive much greater service than others. Equalizing service presents even more difficult problems if a portion of a drill string is lost in the hole and new pipe is added and indistinguishably mixed into an existing string.
Disproportionate down hole service may often be recognized by outside diameter wear but all too frequently, particularly in deviated holes, fatigue damage may become a deciding factor in the decision to retire drill pipe. Present day drill pipe inspection methods are capable of measuring wall wear or the extent of internal pitting but can only detect fatigue in the form of cracks already initiated in service. When a few cracks begin to appear in successive routine inspections, it is currently necessary to assume every joint in the string has been subjected to identical fatigue damage and the entire string requires retirement from service.
SUMMARY OF THE INVENTION
This invention provides a means of automatically tallying and maintaining a inventory of oil rig drill stem components within the well bore. Uniquely serialized electronic identification, or transponder, tags contained by individual drill string components are recognized by an antenna and reader system as they pass through the rig floor. The uniquely serialized identification code accesses a computer data base to recall individual component information. Footage lengths of recalled in-hole components are maintained in a tally to provide a location of the components within the hole and a summation of total lengths is applied for hole depth and drill tool or bit depth determinations.
Down hole service factors indicative of component wear and useful life are also measured and computed for cumulative recording to the individually serialized components tallied in the well bore. These individual drill string component service factors include footage of hole drilled by each identified drill string component rather than the total hole drilled by the entire composite string during its useful life. Another service factor hitherto not practical to record during the useful life of each individual drill string component is the cumulative total rotations experienced during drilling or reaming. An estimate of fatigue wear, or damage, experienced by drill pipe joints rotating through abrupt hole curvatures, or "dog legs", may also be automatically computed. Fractions or percentages of fatigue life expended due to fatigue damage may be accumulated for each identified component. An additional feature of the invention is the tracking of individual components through floating drill rig sub-sea blowout preventer stacks so as to avoid attempting to seal off abnormal pressures by closing the preventers around odd size component diameters.
This invention enables grading components according to various service factors including footage of hole drilled, rotations and fatigue damage. Selection of components for down hole service may then be made to remove excessively worn joints or to better distribute equivalent service to each joint in a drill string. Equalization of service factors amongst each joint of a drill string will result in lengthened composite string life. Intervals for routine and expensive component inspections may also be extended with improved service factor equalization.
Identification is accomplished by means of uniquely coded radio frequency (RF) frequency electronic identification tags individually and protectively affixed to each component. Drill mud and earth formation material accumulations are very poor conductors of RF electromagnetic signals and severely restrict read distances between tag and the reader antenna. Electronic tags have been used to a limited extent in oil rig equipment identification including drill stem. However, their use has been hampered by short read distances further limited by contaminants encountered on the rig or in the well bore.
A preferred embodiment of my invention provides a means of tag mounting in drill string components in which tags are encapsulated in an electromagnetically conductive plastic type material. The plastic type material essentially fills the tag mounting recess in the component and provides an external surface flush with the outer surface of the mounting recess therby eliminating depressions or cavities which collect deposits of mud or formation materials. As the outside diameter of the component contacts the well bore walls while moving in the hole, the component is continually wiped of deposits which cause tag communication signal attenuation. As the component outside diameter wears in the hole, sacrificial material of the tag encapsulation will wear at a similar rate and maintain the smooth outside diameter. This feature of the invention significantly improves read distance between tag and reader as compared to a tag mounting in a recess which allows mud and formation deposition.
Electronic identification tag manufacturers have developed tag, antenna and reader systems operating on RF frequencies approved by the FCC for industrial, scientific and medical (ISM) applications. Destron-IDI of 2542 Central Avenue, Boulder, CO 80301 offer tags in a kilohertz frequency ranges. These tags have a maximum read distance limited to approximately one foot in clean conditions and are used for fish, animal and manufacturing process identification. A 915 Mhz ISM frequency system is extensively used in vehicle toll road collection and railroad car identification. Amtech Corporation, 17403 Preston Road, Dallas, TX 75252, is a major developer and supplier of tags, antennae and reader systems for this type application. Although the 915 Mhz has a more than adequate clean environment read range, minute films of drill mud or other drill rig contaminants restrict transmission of electromagnetic signals between reader and tags to the extent this frequency is not possible for this invention.
My invention anticipates the use of an ISM allocated RF frequency within the 125 Khz to 100 Mhz range, and more specifically, a preferred frequency of 27.1 Mhz. The tags of this frequency provide an adequate read distance for the requirements of this invention. A tag, reader and antenna in the 27,1 Mhz frequency range has been developed for another type application by Integrated Silicon Devices Pty. Ltd., 99 Frome Street, Adelaide, S.A. 5000, Australia. However, it is intended this invention not be limited only to the specific and preferred 27.1 Mhz frequency. dr
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically a drill rig derrick with the traveling block suspending the swivel, kelly and drill string.
FIG. 2 shows a drill collar with subs and bit which constitute the components of a typical bottom hole assembly. Drill pipe then completes the drill string up the hole to the rig.
FIG. 3 is a partial section of the pin end of a drill pipe tool joint showing an identification tag in a recess and retained by a plug.
FIG. 4 shows a block flow diagram typical of the reader and computer system.
FIG. 5 shows a basic data acquisition and flow diagram for the computer system.
FIG. 6 schematically illustrates a sub-sea blowout preventer stack on the sea floor below a floating drill vessel which has drifted off the hole center.
FIG. 7 shows a drill rig in which measurements are made to correct locations of tallied and tracked components.
FIG. 8 shows a drill string fatigue curve, without axial tension.
FIG. 9 shows a drill string fatigue curve, with axial tension.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, traveling block 8, reeved with crown block 36 in the drill rig derrick, is shown suspending swivel 10. The swivel is screwed into hexagonal or square drive kelly joint 12 with kelly drive bushing 14 riding on the drive flat shoulder on the lower end of the kelly. The kelly saver sub 16 is screwed into the kelly joint pin 18 and, in turn, the saver sub pin is screwed into the tool joint box 20 of drill pipe joint 22. Uniquely coded electronic identification tags 24 are shown recessed in the pin end of drill string components 12, 16 and 22. The drill pipe extends through the rotary table 26, through the identification tag reader antenna 28 and into the well bore through bell nipple 30 mounted on top of the blowout preventer stack 32. Antenna 28 is preferably positioned just below the rotary table and its elevation is known. The illustrated position of the traveling block in the derrick with a single joint of drill pipe made up in the kelly saver sub is characteristic of having just made a connection of an additional pipe joint and prior to lowering the drill string to engage the kelly drive bushing in the rotary table to turn the drill string and recommence drilling.
Still referring to FIG. 1, interface sensor 101 may be supported from the frame beams of crown block 36 and measures rotation of fast line sheave 101B. Sensor signals are computer translated into traveling block vertical travel with consideration of the number of lines strung between the blocks having been manually keyed in the computer. Through knowledge of the sheave pitch diameter for the wire line passing over the fast line sheave, the footage of wire line used to either hoist or lower the traveling block 8 is computed with input from sensor 101 of sheave revolutions or fractions thereof. Fast line footage divided by the number of lines reeved between the blocks will equal the footage of travelling block travel. This sensor may include small magnets 101A positioned around fast line sheave 101B and magnetic switches actuated by the proximate passing of the magnets. Interface sensor 102 may also employ proximity switches for counting revolutions of the rotary table 26 and drill stem when drilling or reaming. Deadline anchor 34 commonly supported on the derrick floor employs a hydraulic load cell for measuring weight suspended by the traveling block and interface 103 uses a pressure transducer for transmitting this measurement to the computer. These interface units are commercially available from Oilfield Instruments, Inc., 17923 Fireside Drive, Spring, Texas, 77379.
Referring now to FIG. 2, additional drill string components are shown as might typically be located at the bottom of the hole. Drill pipe 22 is connected to other pipe joints up the hole by tool joint 38 consisting of box 20 and pin 40. The drill pipe tool joint pin is made up in the box of crossover sub 42. The crossover sub pin in turn is screwed into the drill collar 44. Although but one drill collar is shown, there are ordinarily multiple collars in the hole. The drill collar is shown screwed into a bit sub 46 and the drill bit 48 is made up in the bit sub. The components 42, 44 and 46 are conventional and are referred to as the bottom hole assembly. Note that drill stem boxes are up and pin threads are on the lower end of a component. Few exceptions to this general rule occur and are primarily in bottom hole assemblies.
My novel well component identification tag assembly is shown in FIG. 3. A segment of a drill pipe tool joint has been cut away to illustrate the identification tag 24 in a protective recess 50 in the tool joint pin. These identification tags receive an electromagnetic signal from the reader antenna 28 by means of the tag's own internal antenna. The energy derived from the reader transmission is sufficient to enable the tag to re-transmit a uniquely coded binary signal back to the reader. The identification tag 24 is held and retained in place by a plastic type plug 52 which is conductive to electromagnetic signals. The plugs may be bound, pressed, threaded, cast and hardened in place or otherwise secured in the recess. The plugs serve the primary and key function of keeping formation clays, cuttings or drill fluids from accumulating over the tag antenna and attenuating the electromagnetic communication signals between the tag and reader. These plugs are installed flush with the outside diameter of the component in which a tag is mounted and provides a sacrificial wear surface remaining smooth with the outside diameter of the tool joint or component as it wears in the hole. An additional advantage of the plug is in buffering and protecting the tag from handling on the rig or from in-hole damage.
Referring now to FIG. 4, a block diagram of a typical information or data flow method of the system illustrates the reader 109 with antenna 28 transmitting an electromagnetic energizing signal to identification tag 24 and a coded identification response being returned to the reader by the tag. The antenna is connected to the reader by means of suitable wiring or cable and the reader may be remotely located or housed with the computer 106. Various developers and manufacturers of electronic identification tags and readers are available offering several different technological approaches to reader and tag transponder electronics. For instance, the identification tag may respond with a modulated excitation signal to provide the binary identification code or the tag might contain an oscillator energized by the reader excitation transmission enabling a coded response on a different electromagnetic frequency.
Still referring to FIG. 4, the interfaces from rig equipment are shown; sensor 101 providing the computer information regarding the direction and travel distance of the traveling block; a rotary table rotation sensor 102 for counting revolutions, or in the case of a top drive, a revolution counter sensor at the top drive mechanism; and weight indicator sensor 103 to provide information regarding the weight suspended from the traveling block. Interface sensors 104 and 105 are described later. The keyboard 107 permits manual entry into the computer 106 of drill string serial numbers and physical information to the data base related to identification tag coding; untagged component lengths and physical data which are to be included in a tally; datum elevation measurements from the reader antenna elevation; well bore inclination and direction survey readings with depth interval; selection of desired display or print-out; the number of lines reeved to the traveling block; the traveling block suspended weight, or load, setting which activates travel distance and direction into depth computations; and sub-sea blowout preventer seal elevations. The visual display 110 may be by means of a CRT or LCD screens.
As the drill string passes through the drill floor, reader 109 by means of antenna 28 transmits and receives electromagnetic signals to identify tagged components. Tag coding accesses the unique data base record to recall component length and features. This tally is maintained in a computer data element as an inventory by component type and tallied length and tally summations. Appropriate adjustments by the computer are made for block travel and correction from antenna to datum elevations. By means of visual display 110 to the driller, tallied and computed depth determination may be categorized similar to a common form as in the drillers hand kept records. Driller records are normally separated into feet of kelly in the hole, drill pipe joint quantity and total length and bottom hole assembly component quantity and total length. The total footage of these categories when drilling represent total well depth to the driller which will be retained by the computer for display when the string is hoisted off bottom. A like procedure is followed in the case of top drive substitution for the swivel and kelly except that feet of pipe of the last identified joint will be recorded into the hole rather than kelly footage.
An additional feature of the invention as shown in FIG. 4 is a battery powered hand held reader 108 with memory means capable of identifying components on the pipe rack or in remote locations. This inventory data may be communicated with the main computer Identification remote from the drill floor is desirable for the grading, selection and sorting for improved service factor equalization among all components of a composite drill string. An umbilically attached reader is also a feature of the invention and may be substituted for a battery powered unit when the computer system is sufficiently nearby.
Referring now to FIG. 5, a basic data acquisition and flow diagram within the computer system shows data acquisition from reader and sensors contained in the Read block 112. The Accept Keyboard Overrides 114 is intended for keyboard input of various data as so described elsewhere in this description of the preferred embodiments. The Compute Update Values 116 provides tally totalization, service factor computation and other like calculations for the Update Data Base 118 segment of the flow diagram. Visual or printed results of such computations or keyboard override instructions is represented by the Update Display 120 block. Other off-line features include data reporting and portable hand reader inventory monitoring.
Referring again to FIG. 1, to illustrate an example in which bit depth and total depth may be determined by the system computer, consider the traveling block 8 supporting swivel 10 and kelly 12 has drilled down maximum kelly travel to the top of the kelly drive bushing 14 in the rotary table 26. Pipe and bottom hole assembly tally totalization is combined with kelly travel which is measured by means of block travel sensor 101 activated into depth computations by a sufficient suspended weight detected by means of sensor 103. When drilling new hole, these summations establish the current total depth for driller display. When the drill string is hoisted off bottom, as for the purpose of adding an additional pipe joint for drilling deeper, a negative block travel distance is activated into bit depth calculation. The block with swivel and kelly lifts the string to where the upper-most tool joint box 20 may be suspended in the rotary table by means of drill pipe slips. The connection between the kelly saver sub 16 and the pipe tool joint box is broken, the kelly lifted out of the box and lowered for make up into the box of the drill pipe joint located in the "mouse hole" 54. As block suspended weight with only the swivel, kelly and a single joint is not sufficient to trigger incorporation of block travel distance into tally calculations, the new connection is hoisted out of the mouse hole by the kelly with no change in bit depth and made up into the joint supported by slips in the rotary table. On picking up the entire string from the slips, drill string weight is adequate to cause block travel to be included in bit depth computation and the entire assembly appears as shown in FIG. 1.
As the string is then lowered, the newly added section with tool joint pin 40 containing identification tag 24 is recognized passing reader antenna 28. The reader provides a unique coding to the computer which recalls from the data bank the newly identified joint's length and incorporates it with the tally of in-hole components but does not yet include the new joint footage in the totals. Were the newly picked up joint to be added forthrightly, summation of the new joint length into total tallied footage will provide an erroneous and excessive bit depth as most of the new joint footage is in the derrick and not yet in the well bore below datum elevation. A datum elevation representing top of kelly drive bushing (KDB) or top of the rotary table is ordinarily used when drilling with a kelly. Assuming a KDB reference datum, the bit depth computation will provide a footage equaling the antenna to KDB measurement plus the previously tallied component totals of footage in the hole and plus lowering traveling block distance.
As lowering block travel adds to bit depth, the kelly saver sub is next identified. With new tag recognition, the newly picked up joint actual data base measured length is added in the tallied length totals as a replacement for the block travel measurement. Any error in block travel measurement may thereby be corrected. When the kelly pin 18 is identified with continued lowering of the traveling block the same process replaces measured travel with data base actual measurement of the saver sub. The footage of kelly in the hole is thereafter measured by means of block travel and totaled into bit depth until such time as the bit reaches the well bore bottom and the bit depth display thereafter equals the total depth display as drilling new hole recommences.
In the case of a top drive, the same general procedure is followed except that neither the kelly, the kelly drive bushing or mouse hole is used and an entire three joint stand 56 as shown in FIG. 1 is connected in the derrick by the top drive from the stand stood back position. With the kelly and kelly drive bushing not used, the conventional swivel is replaced by a motor driven swivel suspended by the traveling block. This powered swivel is known as a top drive. With no kelly drive bushing, reference datum elevation of top of rotary is desired. When the lower-most joint tag of a stand 56 is identified by the reader and processed in the computer in a like manner to that used with the kelly lowering a newly picked up single joint into the hole. However, the distance between the reader antenna and top of rotary is substituted for the KDB datum. This process is then repeated for the next two joints of the stand as deeper drilling progresses.
As the drill string is hoisted, or as a trip out of the hole is made and pipe withdrawn from the well, the tally is adjusted through block travel and reader identification of withdrawn components and bit depth is displayed. When tripping in the hole, the tally of pipe and bottom hole assembly provides the bit depth in a computation also utilizing the block travel and weight interface inputs. As in making connections either with a kelly or with a top drive, block travel is recorded into depth computation only when the weight indicator interface setting in the computer is exceeded.
A computer comparison of block travel distance to successive reader identified tag tallies will serve as a check against insertion in the string of untagged components not properly keyed in the tally record. This check may also reveal a possible tag malfunction so the faulty tag can be replaced and the identification code of the new tag re-identified with a stenciled serial on the component. When block travel does not match identified contiguous component tally combinations, an error will be noted in the tally record and an audible signal notifies the driller of the tally discrepancy.
When a tally display or print out by each individual section of drill stem either in the hole or as to be stood back in the derrick during a trip is desired, such display for the driller may be as subassemblies of three joints, or stands. On trips out of the hole, this is for such purposes as easy driller identification of the stage he is at on a trip; locating components to be changed out or relocated; changing thread breaks from the last trip to check for possible dry or leaking connections; and anticipating the method drill collar stands will be stood back in the derrick for handling convenience.
An additional feature of the invention is the capability to compute and record various service factors which serve as a measure of wear and useful service life of a drill string and its components. One such embodiment is the service parameter represented by the total footage drilled by each drill string component. Total cumulative footage drilled by individual component may be determined by the computer utilizing the tally of pipe in the hole and the recording of footage drilled during the interval each identified component is in well bore service.
Another embodiment of the invention is the measurement of a drill string service factor represented by the cumulative total count of revolutions imposed on each tagged component while drilling or reaming. This count is provided through an interface with a rotation sensor 102 of FIG. 1 mounted on the rotary table or top drive. The count will be activated from drill string rotation and recorded to each individual component present in the well bore.
An additional embodiment of the invention is a system for automatically determining and recording to a cumulative service data element an estimation of fatigue damage experienced by tagged and tracked drill pipe joints rotating through relatively sharp well bore curvatures. The curvatures, or dog legs, that may cause fatigue damage occur in "straight" or non-directional holes but are commonly present in directionally drilled holes. Dog leg curvatures are measured in terms of the change in degrees of angle per 100 feet of hole. This change is actually the change in overall angle produced by a change in inclination as well as a change in direction as from a compass heading. For the location of these curvatures, surveys are commonly taken at various depth intervals and in problem straight hole areas, as in directional drilling, may be run every thirty feet or less of hole drilled.
The system computer calculates overall changes in hole angle from keyboard entry of depth, hole inclination and direction in directional holes. Only the change of inclination is entered if straight hole is being drilled and directional information is not provided by the survey instrument. Dog leg severity is computed to provide degrees per 100 foot of overall angle change. This calculation is by means of solid geometry and trigonometry. Equations for calculation of dog leg severity have been derived by several sources, one of which was by Arthur Lubinski, then of Stanolind Oil and Gas Company, and presented in his paper entitled "Chart for Determination of Hole Curvature (Dog Leg Severity)". This paper was presented to the American Petroleum Institute Mid-Continent District Study Committee on Straight Hole Drilling on Oct. 31, 1956.
To ascertain dog leg reverse bending stresses which occur to cause component fatigue damage, the computer calculates the bending stress imposed by hole curvature. As shown in the following equations, bending stress calculations consider the "effective tension" occasioned by the weight of the drill string suspended below the curvature interval by the drill pipe in the dog leg and a buoyancy factor. The general equation for determination of bending stress may be stated as: ##EQU1## In field units, this equation becomes: ##EQU2## in which: O b =unit bending stress, psi
c=hole curvature, degrees per 100 feet
E=modulus of elasticity
D=drill pipe OD, inches
K= ##EQU3## T s ="effective tension" in the drill string in 4 L=half the distance between tool joints, inches
The "effective tension", T s , or more precisely the bending-coupled tension, is calculated from the computer tally of drill string components by means of an equation taking the form of:
T.sub.s =T.sub.tb -ΣM.sub.a W.sub.a K.sub.b
in which
T tb =weight suspended by the traveling block, pounds
M a =tallied component lengths above the dog leg, feet
W a =weights in air of tallied components above the dog leg, pounds/foot ##EQU4##
The drill mud density may be manually keyed in the computer or an interface to the computer system may be employed with an automatic drill mud density sensor common to many drill rigs.
Fatigue data is usually developed in the laboratory by testing polished specimens subjected to fully reversed bending stresses with no axial tension. Such a fatigue curve typical of a Grade E drill pipe suggests the bending stress vs cycles to failure. (σ-N) curve in a non-corrosive environment shown in FIG. 8.
In the presence of an corrosive environment, this curve may be replaced by a curve located below the non-corrosive environment curve. For an extremely corrosive environment such as many drill muds, it is suggested a factor of 0.6 be applied to the ordinate of the σ-N curve. The o-N curve to be next illustrated demonstrates the application of a 0.6 corrosion factor to the non-corrosive environment curve. This corrosion factor may be varied according to field experience with various drill muds.
Drill string weight below the dog leg is suspended by the joints in the dog leg to result in axial tension in the components undergoing bending stress in the dog leg. In the presence of this axial tension, the fatigue effect of bending becomes much more severe. The effect of axial tension may be represented by the same σ-N curve previously illustrated but with bending stress 0 being replaced by an effective bending stress. τσ b , which accounts for axial tension. With this correction for tensile stress, the τσ b -N curve becomes that shown in FIG. 9.
The axial stress correction factor is obtained from the equation: ##EQU5## in which: t=ultimate tensile strength of the drill pipe, psi
O t =tensile stress, in psi, imposed on the drill pipe in the dog leg as calculated by: ##EQU6## in which: T tb =weight suspended by the traveling block, pounds
M a =tallied component lengths above the dog leg, feet
W a =weight in air of tallied components above the dog leg, pounds/foot
A=cross sectional area of a component in the dog leg, in 2
For steel pipe having a density of 489.5 pounds/cu. ft., the equation for σ t may be expressed as: ##EQU7## in which: W ac =weight in air of component in the dog leg, pounds/foot
The block suspended weight, T tb , is the total buoyed string weight with the bit off bottom minus the amount of weight run on the drill bit. The tension on the dog leg components regardless of weight run on the bit then is the traveling block suspended weight minus the summation of footage weights in air times their lengths of the components above the dog leg. There is no essentially no projected component area upon which incremental hydrostatic head differentials buoy the drill string components extending to the surface and the buoyancy factor need not enter this equation.
The estimate of the fraction of fatigue life expended by a drill pipe joint rotated at a certain number of cycles and stress as to incur fatigue damage is computed according to Miner's Rule by means of appropriate τσ b -N curves stored in the computer. This rule is illustrated in the above illustrated τσ b -N curve by an example whereby point "b" represents fatigue damage for the number of rotations counted by the rotary interface at computed stress level "b" while traversing a particular hole curvature. The fraction of fatigue life, f, expended by a component reaching this point of fatigue damage is: ##EQU8## in which: N b =number of cycles to point "b" at stress level "b"
N f =total number of cycles to failure at stress level "b"
According to Miner's Rule, these fractions of fatigue life expended are additive and the summations will provide a record of individual component cumulative fatigue damage recorded in a data element. Fatigue damage summations may be recalled from the data element as a percentage of fatigue life or as a fraction in which unity indicates imminent failure.
Bottom hole assembly drill collar fatigue estimates can also be mathematically computed through a procedure which requires additional input of information such as drilled hole sizes, whether and how drill collars are made concentric within the hole curvature with stabilizers, the amount of weight run on the bit with respect to buoyed bottom hole assembly weight and whether the dog leg angle is increasing or decreasing.
Referring now to FIG. 6, an additional embodiment of the invention is the ability to continuously monitor the exact location of tool joints, subs, valves or other shapes and diameters with respect to seal locations and elevations within sub-sea blowout preventer (BOP) stack 74. Sub-sea ram type BOP's are for the common purpose of closing around drill pipe in order to contain abnormal formation pressures. Ram type preventers 64 are outfitted with a pair of heavy steel rams containing a half circle with an elastomer type ram pack-off seal 58. When the ram pairs come together they completely encircle and seal around the drill pipe body. Due to the close tolerances necessary to encircle the pipe body and support the ram seal element under pressure, rams are unable to close properly around diameters different than what they were intended. Therefore is is essential that pipe ram closure around tool joints or off-size diameters be avoided and that the driller knows the position of tool joints or other unsealable objects within the BOP stack. Complete shut-off or blind rams 66 do not contain a pipe configuration and are designed to act as a valve if no pipe is in the hole. An annular type preventer 60 employs a large donut shaped elastomer seal element 62 forced into the well bore by an hydraulically activated cone arrangement. This type preventer is usually of a lesser pressure capability but is able to close around almost any shaped object. Annular preventer seal elements wear rapidly should a tool joint or off-size diameter repeatedly pass up and down through the element as caused by drill vessel heave in rough seas and therefor closure should also be maintained around the drill pipe body.
A distance measurement from the rig floor datum elevation is used to compare the location of tallied and tracked component and physical characteristics relative to pack-off or seal area elevations within the blowout preventer stack. Corrections to measurements from rig floor datum elevations to BOP seal areas are made for tides, vessel draft, vessel drift off hole center and vessel heave. These corrections are made by means of measuring distance variations from the drill floor elevation to the top marine riser section 68 just below the riser slip joint 70. As the top section of the marine riser represents a fixed length measurement to the sub-sea BOP stack, interface sensor 105 provides the measurement correction for tides, vessel draft, vessel movement off the well bore and sub-sea blowout preventer stack 74. This correction is made by means of a small diameter wire line connected to the top marine riser section which is spooled on an constant tension air hoist drum. As the vessel distance from the sub-sea stack varies, the constant tension air hoist drum either pays out or takes up the wire line. Line travel distance may be measured by sensor 105 using proximity switches in an similar manner to crown block fast line sensor 101. This correction is summed with block travel as compensated for vessel heave by piston travel of hydraulic cylinder type heave compensator 72 containing interface sensor 104. Interface sensors 104 and 105 are available from Oilfield Instruments, Inc., 17923 Fireside Drive, Spring, Texas, 77379.
A mathematical correction is also made by the computer for drill string stretch due to the drill string weight. In deep water this stretch is significant in the pipe section between the drill floor datum and the BOP stack elevation. This stretch or elongation computation is based upon pipe tension as determined by the weight suspended from the blocks, the distance to the sub-sea stack which has been established and entered in the computer and the automatic component tally with physical data, cross sectional areas, modulus of elasticity, Poissons Ratio and manually keyed drill fluid weight. Should the mud system have an automatic mud weight measurement device installed, sensor means can be substituted for manual drill fluid weight input. An equation for this elongation in general form is: ##EQU9## in which: Δz=total elongation
T tb =weight suspended by the traveling block
A=cross sectional area
L=distance between rig floor datum and sub-sea BOP stack
E=modulus of elasticity
δ s =density of steel
δ m =density of drill mud
ν=Poissons Ratio
In field units and with δ s =489.5 lbs/cu. ft., E=30,000,000 and ν=0.28, this equation may be expressed as: ##EQU10## in which: e=total elongation, inches
L=feet
T tb =pounds
W dp =drill pipe weight, lbs/ft
W g =drill mud weight, lbs/gal
Audible or visual alarms at preventer operating stations will provide warning against improper closure and a means of graphic display of the stack depicting component passage will be displayed to the driller.
While the above descriptions contain many specifics, they should not be construed as limitations on the scope of the invention, but rather as an exemplification of the preferred embodiments and applications thereof.
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A system for the automatic tallying of uniquely serialized drill string components from which well depth is determined, in hole component inventories are maintained, individual components are tracked through the well bore, component diameters are identified with respect to blowout preventer seal elevations and the determination and measurement of individual component down hole service factors with cumulative totalization in a computerized data base management system for these service factors for the purpose of better equalizing wear in order to obtain optimum life from drill strings.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of U.S. Ser. No. 10/024,410, filed Dec. 18, 2001.
BACKGROUND OF INVENTION
[0002] The subject matter of the present invention relates to providing redundant metal-metal seals to protect downhole communication lines from the surrounding environment.
[0003] Communication lines are used in a wide range of applications in the oilfield industry. The communication lines transmit monitored data regarding downhole conditions such as temperature and pressure to surface instrumentation. The communication lines can also be used to send information down the well from the surface. Additionally, communication lines may also be used to electrically power downhole equipment. Communication lines may include electrical conduits, optical fibers, hydraulic lines and other methods for data or power transmission.
[0004] In environments such as those encountered in downhole wells, the communication lines are exposed to hostile conditions such as elevated temperatures and pressures. To protect the fragile communication lines from the hostile conditions, the communication lines are generally carried within protective tubing that provides an environmental seal. Problems arise when the seal must be broken during assembly, installation and/or repair of the communication line. For example, in downhole applications, in order for the communication line to be fed through production equipment such as packers, the line must be cut and then spliced with the downstream line. Thus, after splicing, the communication line must once again be sealed from the harsh environment.
[0005] There exists, therefore, a need for an apparatus and method of sealing communication lines from the surrounding environment.
BRIEF DESCRIPTION OF DRAWINGS
[0006] [0006]FIG. 1 provides a sketch of a downhole electric splice assembly that incorporates the redundant metal-metal seal assembly.
[0007] [0007]FIG. 2 provides an illustration of the configuration of the seal assembly 1 used to pressure test the primary seal.
DETAILED DESCRIPTION
[0008] In the following detailed description of the subject matter of the present invention, the apparatus and method of providing redundant metal-metal seals for communication lines is principally described with reference to downhole well applications. Such description is intended for illustration purposes only and is not intended to limit the scope of the present invention. In addition to downhole well applications, the present invention can be used with any number of applications such as pipeline monitoring, subsea well monitoring, and data transmission, for example. Furthermore, the communication lines may comprise electrical wiring, fiber optic wiring, hydraulic lines, or any other type of line which may facilitate transfer of information, power, or both. All such types of communication lines are intended to fall within the purview of the present invention. However, for purposes of illustration, the present invention will be principally described as being used in downhole well applications.
[0009] [0009]FIG. 1 provides a sketch of a downhole electric splice assembly that incorporates the redundant metal-metal seal assembly, indicated generally as numeral 1 , of the present invention. In FIG. 1, the cables 5 are spliced together within a housing 10 . Each of the cables 5 are carrying two communication lines 22 , 23 from which spliced connections 20 a , 20 b are formed. The spliced connections 20 a , 20 b are located within an internal cavity 15 within the housing 10 and are each housed within protective casings 25 a , 25 b.
[0010] It should be noted that the spliced connections 25 a , 25 b shown in FIG. 1 are intended to illustrate one possible application of the present invention, and are not intended to limit the inventions scope. The present invention can be used with all types of communication line connections and is not limited to spliced connections.
[0011] The primary metal-metal seal is formed by a pair of ferrules 30 , 32 . The primary seal is energized and held in place by action of the primary retainer 35 . In the embodiment shown, the primary retainer 35 comprises securing dogs 36 and a threaded outer diameter 37 . The securing dogs 36 correspond to mating dogs on an installation tool (not shown). In one embodiment, the installation tool has a circumferential gap that enables it to be installed and removed over the cable 5 . The installation tool is used to apply torque to the primary retainer 35 , which in turn imparts a swaging load on the ferrules 30 , 32 and imparts contact stress between the ferrules 30 , 32 and the cable 5 and between the ferrules 30 , 32 and the housing 10 . As such, a seal is formed by the ferrules 30 , 32 between the housing 10 and the cable 5 . The swaging load and contact stress, and thus the seal, is maintained by the threaded outer diameter 37 of the primary retainer 35 .
[0012] It should be noted that the above description of the primary retainer 35 is exemplary of one particular embodiment of the retainer 35 , and is not intended to limit the scope of the invention. There are any number of embodiments of the primary retainer 35 that can be used to advantage in the sealing assembly 1 . The primary retainer 35 is any means capable of energizing the ferrules 30 , 32 and maintaining the primary seal.
[0013] In some instances, to ensure a proper seal, it may be necessary to coat the ferrules 30 , 32 with a soft metal such as gold. Typical cable 5 are characterized by non-circularity or non-uniformity of surface. Although the process of swaging the ferrules 30 , 32 on the cable 5 deforms the surface considerably, often it is not enough to provide sufficient local contact stresses between the ferrules 30 , 32 and the troughs existing in the surface of the cable 5 . Thus, the metal-metal seal cannot withstand a substantial pressure differential for a long duration of time. Coating the ferrules 30 , 32 with a soft metal causes the troughs to be filled with the soft metal, substantially increasing the local contact stresses.
[0014] The secondary metal-metal seal is formed by a seal element 40 having a conical section 41 that corresponds with a mating section 14 of the housing 10 . The secondary metal-metal seal provides redundancy to prevent leakage between the housing 10 and the seal assembly 1 . The conical section 41 is forced into sealing contact with the mating section 14 by action of a secondary retainer 45 . Similar to the primary retainer 35 , the secondary retainer 45 comprises securing dogs 46 and a threaded outer diameter 47 . As with the primary retainer 35 , an installation tool (not shown) is used to apply torque to the secondary retainer 45 , which in turn imparts contact stress between the conical section 41 and the mating section 14 to form a seal therebetween. The contact stress of the shouldered contact is maintained by the threaded outer diameter 47 of the secondary retainer 45 . It should be noted that the primary gap 85 that exists between the primary retainer 35 and the seal element 40 ensures that the process of energizing the secondary metal-metal seal does not affect the contact stresses on the primary seal between the housing 10 and the cable 5 . It should further be noted that in one embodiment, the seal element 40 comprises one or more ferrules forced into sealing contact with the mating section 14 of the housing 10 .
[0015] As discussed above with reference to the primary retainer 35 , it should be noted that the description of the secondary retainer 45 is exemplary of one particular embodiment of the retainer 45 , and is not intended to limit the scope of the invention. There are any number of embodiments of the secondary retainer 45 that can be used to advantage in the sealing assembly 1 . The secondary retainer 45 is any means capable of energizing and maintaining the secondary seal.
[0016] The tertiary metal-metal seal is formed by a pair of ferrules 50 , 52 that engage the end 42 of the seal element 40 . The tertiary metal-metal seal, energized by the end plug 55 , provides redundancy to prevent leakage between the cable 5 and the seal assembly 1 . As with the ferrules 30 , 32 of the primary seal, in certain instances, the ferrules 50 , 52 of the secondary seal are coated with a soft metal to increase the local contact stresses with the cable 5 . A secondary gap 90 exists between the secondary retainer 45 and the end plug 55 that prevents the energizing load from affecting the mating components on the secondary seal. Load transmitted to the end of the secondary retainer 45 is dissipated through the end plug 55 to the housing 10 . The end plug 55 further comprises a pressure port 62 and one or more elastomeric seals 60 a , 60 b that enable pressure testing (as will be discussed below) of the seal assembly 1 .
[0017] To isolate all the seals from axial loading, vibration and shock conveyed from the cables 5 a , 5 b , an anchor 65 is energized against the cable 5 by action of the end nut 70 . In one embodiment, the anchor 65 is a collet style anchor.
[0018] [0018]FIG. 2 provides an illustration of the configuration of the seal assembly 1 used to pressure test the primary seal. Testing of the primary seal requires insertion of spacers 75 , 80 to prevent accidentally engaging the secondary and tertiary seals. In one embodiment, the spacers 75 , 80 are constructed with a circumferential gap to enable installation and removal from the seal assembly 1 . The first spacer 75 prevents the conical section 41 of the seal element 40 from contacting the mating section 14 of the housing 10 to form the secondary metal-metal seal. Likewise, the second spacer 80 prevents the ferrules 50 , 52 from engaging the end 42 of the seal element 40 to form a seal. To test, fluid is pumped through the pressure port 62 . The fluid is prevented from escaping the housing 10 opposite the primary seal by the one or more elastomeric seals 60 a , 60 b . After testing, the spacers 75 , 80 are removed and the seal cavity is cleared of the test fluid. Subsequently, the secondary and tertiary seals are energized as described above, and the anchor 65 is installed and energized.
[0019] In one embodiment, pressure testing of the secondary and tertiary seals is done by pumping a fluid that cures into a gel under downhole conditions through the pressure port 62 . After testing, the pressure port 62 is plugged to maintain the gel within the seal assembly 1 . The gel protects the secondary and tertiary seals from corrosion due to exposure to completion or produced fluids. Further, the gel acts to protect the seals from the effects of shock and vibration.
[0020] Referring back to FIG. 1, one method of verifying successful secondary and tertiary sealing is achieved by use of a chemical that produces an exothermic reaction when exposed to the test fluid. In this method, the chemical is deposited via porous bags into the interior of the housing 10 . Failure of either seal causes the test fluid to invade the interior of the housing 10 and the resultant differential temperature increase can be read by thermal strips (not shown) placed on the outer diameter of the housing 10 .
[0021] Another method of verifying successful secondary and tertiary sealing is to load the interior of the housing 10 with a porous bag containing small hollow beads made of a material that emits noise upon failure. The increase of pressure in the interior of the housing 10 due to a failed seal causes the hollow beads to fail, emitting a sound that can be picked up by a sonic sensor.
[0022] Yet another method of verifying successful secondary and tertiary sealing include using an ultrasonic sensor to detect the presence of test fluid in the interior of the housing 10 . Similarly, a sonic sensor can be used to detect the change in acoustic response due to test fluid in the interior of the housing 10 . A portable x-ray machine can also be used to detect the presence of test fluid in the interior of the housing 10 .
[0023] The invention being thus described, it will be obvious that the same may be varied in many ways. For example, it is not necessary that one or both gaps 85 , 90 exist within the seal assembly 1 . The gaps 85 , 90 are useful to allow independent loading, prevent undue loading and to enable various pressure testing methods, but are not necessary for the function of the seal assembly 1 . Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such are intended to be included within the scope of the following non-limiting claims:
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The present invention provides a sealing assembly for protecting a downhole connection. The sealing assembly comprises independently energized metal-metal seals and a housing that prevents the energization of individual seals from affecting other seals.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
Heretofore, oil and/or gas fields have been developed onshore by drilling a plurality of essentially vertical, spaced apart wellbores in checkerboard fashion. In the offshore environment, a plurality of curved wellbores have been drilled from a single platform, each curved wellbore extending outwardly in a different direction away from the platform.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention, there is employed a method for drilling a plurality of wellbores to develop an oil and/or gas field which uses curved wellbores but which uses such wellbores in a manner significantly different from that of the prior art. In this invention, at least one pair of elongate drilling zones which are essentially parallel to and spaced from one another are employed across a substantial portion of the oil and/or gas field to be developed. Alternate curved wellbores are drilled along the length of both drilling zones, adjacent wellbores being longitudinally spaced from one another. Each wellbore is deliberately directed toward a predetermined oil and/or gas producing formation and the opposing drilling zone. When the wellbore reaches the predetermined oil and/or gas producing formation, the wellbore is straightened to thereafter follow the formation until the wellbore reaches the vicinity of the opposing drilling zone. A plurality of such alternate longitudinally spaced curved wellbores are drilled along any given pair of drilling zones and a plurality of pairs of drilling zones can be employed to develop fields of larger areas.
Accordingly, it is an object of this invention to provide a new and improved method for developmental drilling of an oil and/or gas field. It is another object to provide a new and improved method for maximum developmental drilling of a producing field with the least number of wellbores. It is another object to provide a new and improved method for developmental drilling for carrying out enhanced oil recovery processes.
Other aspects, objects and advantages of this invention will be apparent to those skilled in the art from this disclosure and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross section of the earth with a wellbore extending downwardly from the surface and then curving towards and into a producing formation after which the wellbore is straightened to follow the formation.
FIG. 2 shows a plan view of the development of a field in accordance with this invention using a plurality of spaced apart drilling zones and a plurality of curved wellbores drilled along and away from each drilling zone.
FIG. 3 shows a plan view of the various straightened portions of the curved wellbores of FIG. 2 and how these wells can be employed in an enhanced oil producing process.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the earth's surface 1 with a drilling rig 2 mounted thereon. A wellbore 3 is drilled from rig 2. Wellbore 3 starts initially as a conventional essentially vertical wellbore which is denotated in FIG. 1 by the portion V. At kick-off point 4, wellbore 3 is curved from vertical in a conventional manner. A radius of curvature R is employed which is designed, based upon the depth of producing formation 5, to reach a point 6 in the interior of formation 5 at which point 6 the curving wellbore 3 is straightened so that an essentially straight portion H of wellbore 3 can be drilled following along formation 5.
FIG. 2 shows the irregular outline 10 of an oil and/or gas field. Across a substantial portion of field 10 are laid out elongate drilling zones 11, 12 and 13 on the surface of the earth 1. Drilling zones 11 through 13 can be a continuous roadway or merely an imaginery zone along which wells are to be drilled at various drill sites.
Drilling zones 11 and 12 form a pair of spaced apart longitudinally extending drilling zones which are essentially parallel to one another, although true parallelism is not required. If the first drilling site on first drilling zone 11 is denotated by drilling rig 2, then it can be seen that wellbore 3 curves from kick-off point 4 towards producing formation 5 and, at the same time, towards opposing, second drilling zone 12. Note that the curved portion R of wellbore 3 extends across a substantial part of the space between opposing adjacent drilling zones 11 and 12 and that the remainder of such space is covered by essentially straight wellbore portion H.
Wellbore portion H is shown in FIG. 1 to be essentially horizontal, although this may not necessarily be the case in actual practice if formation 5 is tilted upwardly or downwardly from point 6. However, for sake of simplicity, portion H will be described as the horizontal portion of the wellbore although it is to be understood that this portion does not need to be truly horizontal anymore than vertical portion V need be truly vertical.
Horizontal portion H extends toward opposing drilling zone 12 and is terminated somewhere in the vicinity of drilling zone 12. That is to say, end 7 of wellbore 3 is somewhere near or under drilling zone 12 although it should not extend until it interferes with curved wellbore 14 which extends from drilling rig 15 towards opposing drilling zone 13. Although wellbore 3 is shown to be drawn essentially perpendicular to drilling zones 11 and 12, this is not a requirement for this invention. Wellbore 3 could be drilled at an angle to drilling zones 11 and 12 if desired or necessary and the benefits of this invention still achieved. For example, this might be done in some fields to more precisely fit the direction of the minimum horizontal stress and hydraulic fracture planes of the producing formation in question. This modification would increase the length of the drilling zones and the surface distance between wellheads and decrease the perpendicular distance between drilling zones but would not change the number of wells required for a given subsurface spacing of horizontal well paths.
In accordance with this invention, after drilling first curved wellbore 3 from first drilling zone 11, a first curved wellbore 16 is drilled from second drilling zone 12 by use of drilling rig 17. Curved wellbore 16 curves toward formation 5 and, at the same time, toward opposing drilling zone 11 so that the resulting curved wellbore 16 looks like wellbore 3 of FIG. 1 but curves in the opposite direction. End 18 of the horizontal portion H of curved wellbore 16 terminates in the vicinity of drilling zone 11.
Wellbore 16 is deliberately drilled so that it is longitudinally spaced a distance L from wellbore 3 along the length of drilling zones 11 and 12.
Thereafter, drilling rig 19 which can be the same or different rig as those used for 2 or 17, is employed to drill from drilling zone 11 a third longitudinally displaced curved wellbore 20 which extends over to the vicinity of opposing drilling zone 12. This drilling of alternating curved wellbores is repeated along the length of drilling zones 11 and 12 for a distance deemed necessary for adequate developmental drilling of that portion of field 10.
If field 10 is sufficiently large in area that a single pair of drilling zones 11 and 12 does not adequately develop the field, then additional pairs of drilling zones can be employed such as drilling zones 12 and 13 of FIG. 2 using alternating longitudinally spaced apart curved wellbores 14, 21, and 22 which are drilled in the same manner as wellbores 3, 16 and 20.
The distances R, H, and L can vary widely depending upon the depth of formation 5, the capacity of the drilling rigs being used, the spacing between adjacent opposing drilling zones and a number of other factors. For example, this invention can be employed when a plurality of producing zones are available in which case, a single predetermined producing zone will be used as a target zone, as shown in FIG. 1 for formation 5.
After field 10 has been developed by drilling curved wells in the manner described for FIG. 2, when considering only the horizontal portions of each wellbore, a staggered sequence of horizontal wellbores is achieved as shown in FIG. 3, each horizontal portion being spaced from the other by a longitudinal length L. If a plurality of wellbores near the top side of field 10 in FIG. 3 are employed to inject an oil production enhancing fluid, e.g. a micellar displacement or miscible displacement fluid, into formation 5, a bank of such fluid can be formed in formation 5 to form a line drive 30 in that formation. Then, with additional injection of the oil production enhancing fluid and/or a drive fluid to push the oil production enhancing fluid, a line drive 30 is formed from such fluid(s) and pushed in the direction of arrows 31 so that a greater amount of oil than normal can be produced from production wells which lie ahead of line drive 30, e.g., wells 32 through 35 in FIG. 3. It can be seen from the pattern of overlapping horizontal portions H, that essentially complete coverage of field 10 can be achieved and enhanced oil recovery realized by using the drilling pattern of this invention as disclosed hereinabove with respect to FIG. 2. If an enhanced oil recovery process is anticipated, the original curved wells could be drilled in a direction that essentially parallels the expected plane of the vertical fractures for formation 5. With this arrangement, injection in a well could cause a fracture that would extend vertically upward to the top of formation 5 and laterally along the length of the horizontal hole H. This could tend to more uniformly distribute the injected enhanced oil recovery fluids across the full face of producing formation 5 and could also prevent streaks from causing vertical flow barriers.
Although the radius of curvature R and horizontal distance H can vary widely depending upon the drilling apparatus available, the nature of formation 5 and many other parameters, for sake of example, if the curved portion of the wellbore has a build rate of 21/2° per 100 foot of wellbore drilled, this is equivalent to a radius of curvature R for the wellbore of 2300 feet. If formation 5 is about 3500 feet below the earth's surface 1, wellbore 3 could be drilled vertically to a depth of 1200 feet at point 4 at which time, the wellbore would be kicked off of vertical and start to build at 21/2° per 100 foot towards horizontal.
Thus, wellbore 3 would curve from point 4 to point 6 a lateral distance of 2300 feet away from the vertical projection of wellbore 3. If drilling zones 11 and 12 are spaced 4600 feet apart as indicated by arrow 23 in FIG. 2, center-to-center, and horizontal distance H of wellbore 3 is also 2300 feet, then wellbore 3 will reach essentially to the center of drilling zone 12. The foregoing would also be true for each of wells 16, 20, 14, 21, 22, using the 2300 foot radius of curvature, 2300 foot horizontal segment H for a total of 4600 feet between adjacent opposing drilling zones.
In this situation, it would take 10 wells per 1000 foot of longitudinal length L of drilling zone in order to place the horizontal drainhole segment on 200 foot spacing in formation 5. In an area of 528 acres, 50 wells would be employed if drilled in the manner described in relation to FIG. 2 and this would yield a total wellbore contact length with formation 5 of 115,000 feet. It would require about 2300 vertical wells in a 50 foot thick producing formation 5 to have the same 115,000 foot contact length produced by following the pattern of this invention. Accordingly, by this invention, there is produced an equivalent well spacing from a surface contact point of view of 0.238 acres per well by drilling 50 wells in 528 acres or roughly 1 well for every 101/2 acres of surface area.
The 2300 foot radius of curvature and length of horizontal segment H is not required for this invention. Other curvatures and horizontal lengths can be employed to provide even greater incentives. For example, with a 2640 foot radius of curvature, the horizontal tail and build portion would be lengthened by a little over 500 feet to a measured depth of 7647 feet but would permit placing adjacent opposing drilling zones essentially one mile apart.
It can be seen from the above description of this invention even if the effective cost of the curved wellbores employed by this invention were twice the cost per foot of conventional vertical wellbores, the horizontal wellbores would be less than one-tenth the cost of wells required for the pattern than vertical wellbores so that substantial net savings could be realized from the proper application of this invention even though more expensive wellbores are employed in carrying out the pattern of this invention.
Reasonable variations and modifications are possible within the scope of this disclosure without departing from the spirit and scope of this invention.
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A method for drilling a plurality of wellbores for producing an oil and/or gas field to the maximum extent with the least number of wellbores wherein at least two longitudinally extending drilling zones are established spaced apart and essentially parallel to one another and drilling alternate longitudinally spaced apart curved wellbores from said drilling zones, each curved wellbore extending toward the producing formation and the opposing drilling zone, each curved wellbore being straightened out and thereafter following a predetermined producing formation until the wellbore reaches the vicinity of the opposing drilling zone. A plurality of the alternating longitudinally spaced wellbores are employed along a pair of drilling zones and a plurality of pairs of drilling zones can be employed. The resulting series of wellbores can be employed to carry out an enhanced oil recovery process by using part of said wellbores as injection wells and part of said wellbores as producing wells.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 10/704,105, filed Nov. 7, 2003 now U.S. Pat. No. 6,974,277 and entitled DYNAMICALLY BALANCED WALK BEHIND TROWEL, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to concrete finishing trowels and, more particularly, relates to a method of making and using a walk-behind rotary concrete finishing trowel which is dynamically balanced to reduce operator effort.
2. Discussion of the Related Art
Walk behind trowels are generally known for the finishing of concrete surfaces. A walk behind trowel generally includes a rotor formed from a plurality of trowel blades that rest on the ground. The rotor is driven by a motor mounted on a frame or “cage” that overlies the rotor. The trowel is controlled by an operator via a handle extending several feet from the cage. The rotating trowel blades provide a very effective machine for finishing mid-size and large concrete slabs. However, walk behind trowels have some drawbacks.
For instance, the rotating blades impose substantial forces/torque on the cage that must be counteracted by the operator through the handle. Specifically, blade rotation imposes a torque on the cage and handle that tends to drive the handle to rotate counterclockwise or to the operator's right. In addition, blade rotation tends to push the entire machine linearly, principally backwards, requiring the operator to push forward on the handle to counteract those forces. The combined torque/forces endured by the operator are substantial and tend to increase with the dynamic coefficient of friction encountered by the rotating blades which, in turn, varies with the “wetness” of curing concrete. Counteracting these forces can be extremely fatiguing, particularly considering the fact that the machine is typically operated for several hours at a time.
The inventors investigated techniques for reducing the reaction forces/torque that must be endured by the operator. They theorized that these forces would be reduced if the trowel were better statically balanced than is now typically the case with walk behind trowels, in which the center of gravity is located slightly behind and to the left of the rotor's axis of rotation. The inventors therefore theorized that shifting the trowel's center of gravity forwardly would reduce reaction forces. However, they found that this shifting actually led to an increase in reaction forces generated during trowel operation.
The need therefore has arisen to provide a walk behind rotary trowel that requires substantially less operator effort to steer and control than conventional walk behind trowels.
The need additionally has arisen to reduce the operator effort required to steer and control a walk behind rotary trowel.
SUMMARY OF THE INVENTION
Pursuant to the invention, a method is provided of making and using a walk behind rotary trowel is better “dynamically balanced” so as to minimize the forces/torque that the operator must endure to control and guide the trowel. The design takes into account both static and dynamic operation and attributes of the trowel, and “balances” these attributes with the operational characteristics of concrete finishing. Characteristics that are accounted for by this design include, but are not limited to, friction, engine torque, machine center of gravity, and guide handle position. As a result, dynamic balancing and consequent force/torque reduction were found to result when the machine's center of gravity was shifted substantially relative to a typical machine's center of gravity. This effect can be achieved most practically by reversing the orientation of the engine relative to the guide handle assembly when compared to traditional walk behind rotary trowels and shifting the engine as far as practical to the right. This shifting has been found to reduce the operational forces and torque the operator must endure by at least 50% when compared to traditional machines. Operator fatigue therefore is substantially reduced.
These and other advantages and features of the invention will become apparent to those skilled in the art from the detailed description and the accompanying drawings. It should be understood, however, that the detailed description and accompanying drawings, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred exemplary embodiment of the invention is illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:
FIG. 1 is a perspective view of a walk-behind rotary trowel constructed using a method performed in accordance with a preferred embodiment of the present invention;
FIG. 2 is a side elevation view the trowel of FIG. 1 ;
FIG. 3 is a front elevation view of the trowel of FIGS. 1 and 2 ;
FIG. 4 is a series of graphs charting force v. RPM for a variety of operating conditions; and
FIGS. 5A–5C are a series of force diagrams that schematically illustrate the forces generated upon operation of a walk behind trowel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. Construction of Trowel
A walk behind trowel 10 constructed in accordance with a preferred embodiment of the invention is illustrated in FIGS. 1–3 . In general, the walk behind trowel 10 includes a rotor 12 , a frame or “cage” 14 that overlies and is supported on the rotor 12 , an engine 16 that is supported on the cage 14 , a drive train 18 operatively coupling the engine 16 to the rotor 12 , and a handle 20 for controlling and steering the trowel 10 . Referring to FIG. 2 , the rotor 12 includes a plurality of trowel blades 22 extending radially from a hub 24 which, in turn, is driven by a vertical shaft 26 .
The motor 16 comprises an internal combustion engine mounted on the cage 14 above the rotor 12 . Referring again to FIGS. 1–13 , the engine 16 is of the type commonly used on walk behind trowels. It therefore includes a crankcase 30 , a fuel tank 32 , an air supply system 34 , a muffler 36 , a pull-chord type starter 38 , an output shaft (not shown), etc. The drive train 18 may be any structure configured to transfer drive torque from the engine output shaft to the rotor input shaft 26 . In the illustrated embodiment, it comprises a centrifugal clutch (not shown) coupled to the motor output shaft and a gearbox 40 that transfers torque from the clutch to the rotor input shaft 26 . The gearbox is coupled to the clutch by a belt drive assembly 42 , shown schematically in FIG. 1 . The preferred gearbox 40 is a worm gearbox of the type commonly used on walk behind trowels.
The handle assembly 12 includes a post 44 and a guide handle 46 . The post 44 has a lower end 48 attached to the gearbox 40 and an upper end 50 disposed several feet above and behind the lower end 48 . The guide handle 46 is mounted on the upper end 50 of the post 44 . A blade pitch adjustment knob 52 is mounted on the upper end 50 of the post 44 . Other controls, such as throttle control, a kill switch, etc., may be mounted on the post 44 and/or the guide handle 46 .
The cage 14 is formed from a plurality of vertically spaced concentric rings 54 located beneath a deck 56 and interconnected by a number of angled arms 58 , each of which extends downwardly from the bottom of the deck 56 to the bottommost rings 54 . The rings 54 may be made from tubes, barstock, or any other structure that is suitably rigid and strong to support the trowel 10 and protect the rotor 12 . In order to distribute weight in a desired manner, one or more of the rings 54 may be segmented, with one or more arcuate segment(s) being made of relatively light tubestock, other segment(s) being made of heavier barstock, and/or other segment(s) being eliminated entirely. One or more of the arm(s) 58 could be similarly segmented. Weights could also be mounted on the cage 14 at strategic locations to achieve additional strategic weight distribution.
2. Center of Gravity Offset
Still referring to FIGS. 1–3 , and in accordance with the invention, the trowel's center of gravity “C/G” is offset laterally and longitudinally relative to the rotor's rotation axis “A.” Specifically, the center of gravity is spaced rearwardly and to the right of the rotational axis A. The considerations behind this positioning and the optimal positions are discussed in more detail in Section 3 below. In the illustrated embodiment, practical dynamical balancing is best achieved through two effects. First, the engine 16 is rotated 180° relative to the guide handle 20 when compared to a conventional machine. Hence, the fuel tank 32 faces rearwardly, or towards the operator, and the air supply system 34 and muffler 36 face forwardly, away from the operator. In addition, the torque transfer system 18 is positioned to the operator's right as opposed to his or her left, and the pull chord 38 is positioned on the operator's left as opposed to his or her right. The engine 16 therefore can be considered “forward facing” as opposed to “rearward facing.” As a result, the engine's center of gravity C/G is disposed to the right of trowel's geometric center. The gearbox 40 is also rotated 180° to accommodate the engine's reorientation. The combined effect of these reorientations is a significant shift of the machine's center of gravity C/G to the right when compared to prior machines. It also moves the center of gravity C/G to a location further behind the rotor's rotational axis A.
In the illustrated embodiment of a 48″ trowel, i.e., one whose blade circumference is a 48″ diameter circle, optimal results given the practical limitations of the machine design, such as guide handle length, engine mass, limitations on engine to gearbox spacing, etc., resulted when the engine 16 was shifted so as to shift or relocate the center of gravity C/G to a location 3.75 inches behind and 0.375 inches to the right of the trowel axis A. The resultant longitudinal and lateral offsets, “d” and “c”, are illustrated in FIGS. 2 and 3 , respectively. Of course, some of the beneficial balancing effects would result with smaller offsets, particularly smaller lateral (X) offsets, such as 0.125. Optimum offset calculations and offset interdependence are discussed in section 3 below.
This relocation has been found to nearly eliminate the linear forces acting on the guide handle 46 , requiring that the operator only need to counteract the rotational torque imposed on the handle and the linear forces resulting from that torque. This effect is illustrated in the series of graphs of FIG. 5 , which compare the forces and endured by an operator of a prior art 48″ trowel to those imposed by a trowel constructed as described above. The forces were measured with standard blades operating on a steel sheet. A comparison of curves 60 to 64 confirm that, depending on engine RPM, total forces endured are reduced from about 65–75 lbs, to 20–30 lbs. A comparison of curves 62 and 66 reveals that linear forces, i.e., those resulting from factors other than blade torque and compensated for by offsetting the machine's center of gravity as described above, are reduced from about 40–45 lbs to less than 10 lbs.
An ancillary benefit of this engine reorientation is that it increases operator comfort because the heat and fumes from the exhaust are now directed away from the operator rather than towards the operator.
3. Center of Gravity Offset Determination
The optimal lateral and longitudinal center of gravity offsets “c” and “d” relative to the rotor's rotational axis A, i.e., the optimal center of gravity position for a given trowel design, could be determined purely empirically by trial and error. They could also be determined mathematically by taking practical considerations into account, such as machine geometry and changes in coefficient of dynamic friction experienced by the trowel during the curing concrete process, etc. These calculations will now be explained with reference to FIGS. 5A–5C , which schematically illustrate the forces generated during operation of the walk behind trowel.
Dynamically balancing the trowel requires that as many forces acting on the handle as possible be eliminated. Referring first to FIG. 5A , which is a force diagram in the horizontal (XY) plane, the lines 70 designate the blades, it being assumed that each blade has the same effective length “a,” as measured from the rotor rotational axis A to the centroid of the forces acting on the trowel blade. The line 72 designates the handle in the lateral (X) plane and has effective lengths “e” on either side of the center post 44 ( FIGS. 1–3 ), i.e., the guide handle and has a lateral length of 2e. The handle 12 has an effective longitudinal length “b,” as measured from the rotational axis A of the rotor to the grips on the guide handle as schematically represented by the line 74 . In operation, the four blades are subjected to friction-generated horizontal forces F Af , F Bf , F Cf , and F Df , respectively, which result in corresponding moment arms aF Af , aF Bf , aF Cf , and aF Df about the rotor axis A. The handle 12 is subjected to longitudinal (Y) horizontal forces F H2 and F H3 and a lateral (X) force F H1 . The forces acting on the handle in the X direction can balanced or set to zero using the equation:
F H1 +F Af =F Bf Equation 1
The forces acting on the handle in the Y direction can balanced or set to zero using the equation:
F Cf =F Df +F H2 +F H3 Equation 2
The moment in the XY plane can be balanced or set to zero using the equation:
a ( F Af +F Bf +F Cf +F Df )= bF H1 +eF H2 −eF H3 Equation 3
The same procedure can be used to represent the balancing of forces in the remaining planes. Hence, referring to FIG. 5B , which represents the trowel in the XZ plane, the vertical (Z) forces acting on the handle can balanced or set to zero using the equation:
F w =F AZ +F BZ +F CZ +F DZ +F H4 +F H5 Equation 4
Where, in addition to the forces defined above:
F AZ , F BZ , F CZ , and F DZ =the vertical forces acting on the blades; F H4 and F H5 =the vertical forces acting on the ends of the guide handle; F w =the gravitational force acting through the machine's center of gravity; and c=the lateral (X) offset between the machine's center of gravity C/G and the center of the machine, which coincides with the rotor axis of rotation A.
The moment in the XZ plane can be balanced or set to zero using the equation:
aF Dz +hF H1 +eF H5 −eF H4 −aF Cz −cF w =0 Equation 5
Where: h=height of the guide handle (see line 76 in FIG. 5B ).
Referring to FIG. 5C , which represents the trowel in the YZ plane, the moment in the YZ plane can be balanced or set to zero using the equation:
aF AZ +dF w =aF BZ +bF A4 +bF A5 +hF H2 +hF H3 Equation 6
Where: d=the longitudinal (Y) offset between the machine's center of gravity C/G and the center of the machine, which coincides with the rotor axis of rotation A.
Using the above parameters, the side-to-side center of gravity, c, as a function of forces on the handle, the trowel dimensions, and the coefficient of friction, μ, of the surface to be finished, can be expressed as:
hF
H1
+
e
(
F
H5
-
F
H4
)
-
[
bF
H1
+
e
(
F
H2
-
F
H3
)
μ
2
(
F
w
-
F
H4
-
F
H5
)
]
(
F
H2
+
F
H3
)
F
w
=
c
Equation
7
The force F H1 results for torque imposed by blade rotation and cannot be eliminated by adjusting the trowel's center of gravity. However, by simplifying equation 7 to set the remaining forces F H2 , F H3 , F H4 , and F H5 to zero, the lateral offset, c, required to eliminate those forces can be determined by the equation:
c
=
ha
μ
b
Equation
8
Similarly, the front-to-rear center of gravity, d, as a function of forces imposed on the handle, the trowel dimensions, and the finished surface coefficient of friction, μ, can be expressed as:
d
=
bF
H1
2
+
eF
H1
(
F
H2
-
F
H3
)
μ
2
(
F
w
-
F
H4
-
F
H5
)
+
b
(
F
H4
+
F
H5
)
+
h
(
F
H2
+
F
H3
)
F
w
Equation
9
By simplifying equation 9 to set the forces F H2 , F H3 , F H4 , and F H5 to zero, Equation 9 can be solved for d using the equation:
d
=
a
2
b
Equation
10
Hence, a machine configured to have a center of gravity C/G that is laterally and longitudinally offset from the center of the machine (as determined by the rotor's axis of rotation A) by values c and d as determined using equations 8 and 10 would theoretically impose no non-torque induced forces on the handle during trowel operation.
The theoretical values of c and d are not practical for most existing walk-behind trowel configurations and might not even be possible for some trowels. For instance, the theoretical best lateral offset c might be spaced so far from the rotor rotational axis A that the engine would have to be cantilevered off the side of the machine.
As such, it is necessary as a practical matter to determine the effects that c and d have on each other over a range of offsets and to select practical values of c and d that best achieve the desired goal of dynamic balancing. This can be done using the followings steps:
First, to simplify the calculations by discounting the least problematic forces to the extent that they are minimal and/or relatively unlikely to occur, it can be assumed that no twisting forces are imposed on the guide handle 46 (i.e., F H4 =F H5 ) and that F H3 =0 due to the fact that the operator typically pushes on the handle with only the left hand to be counteract the torque imposed by the clockwise rotating blades. The combined force F 23 (resulting from the combination of the longitudinal forces F H2 and F H3 ) can be determined for each of a number of practical longitudinal offsets d using the following equation:
F
23
=
dF
w
-
a
2
b
(
F
w
-
F
45
)
-
bF
45
(
h
-
ea
b
μ
)
Equation
11
Second, the combined force F 45 (resulting from the combination of the vertical forces F H4 and F H5 ) can be determined for each of a number of practical longitudinal offsets d and practical lateral offsets c using the following equation:
F
45
=
F
w
(
μ
b
2
hc
-
ceab
-
h
2
a
μ
2
b
+
hea
2
μ
+
ehb
μ
d
-
eh
μ
a
2
+
ab
2
d
-
a
3
b
)
(
-
h
2
a
μ
2
+
hea
2
μ
-
eh
μ
a
2
+
ehb
2
μ
-
a
3
b
+
ab
3
)
Equation
12
A table can then be generated that permits the designer to select the offsets c and d that strike the best balance between F 23 and F 45 . Of course, the designer may choose to place priority on one of these values, for instance by selecting an offset that reduces F 45 as much as practical while sacrificing some reduction in F 23 .
The effects of this analysis and its practical implementation can be appreciated from Table 1, which relays traditional typical (prior art) offsets, theoretical offsets, and practical offsets as selected using the procedure described immediately above for both a 36″ trowel and a 48″ trowel, where positive values indicate locations behind or to the right of the rotor axis A and negative values indicate locations ahead or to left of the rotor axis A. Note that the terms “36 inch trowel” and “48 inch trowel” are accepted terms of art designating standard trowel sizes rather than designating any particular precise trowel dimension. Note also that a few manufacturers refer to what is more commonly known as a “48 inch trowel” as a “46 inch trowel.”
TABLE 1
Typical Offsets
36″ Trowel
48″ Trowel
Standard x offset
−0.375″
−0.125
Standard y offset
3.25″
2.50″
Theoretical x offset
3.46″
3.88″
Theoretical y offset
1.59″
2.38″
Typical practical x offset
0.75″
0.375″
Typical practical y offset
3.875″
3.75″
4. Operation of Trowel
During normal operation of the trowel 10 , torque is transferred from the engine's output shaft, to the clutch, the drive train, the gearbox 40 , and the rotor.
The blades 22 are thereupon driven to rotate and contact with the surface to be finished, smoothing the concrete. The frictional resistance imposed by the concrete varies, e.g., with the rotor rotation or velocity, the types of blades or pans used to finish the surface and the orientation of the blades or pan relative to the surface, and the coefficient of friction of the surface. The operator guides the machine 10 along the surface during this operation using the guide handle. In prior walk behind trowels, this operation would be resisted by substantial forces totaling 60–75 lbs. However, because the trowel 10 is dynamically balanced as described above, the total forces endured by the operator to 20–30 lbs., a reduction of well over 50%. As indicated above, many changes and modifications may be made to the present invention without departing from the spirit thereof. The scope of some of these changes is discussed above. The scope of others will become apparent from the appended claims.
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A method is provided of making and using a walk behind rotary trowel that is “dynamically balanced” so as to minimize the forces/torque that the operator must endure to control and guide the trowel. Characteristics that are accounted for by this method include, but are not limited to, friction, engine torque, machine center of gravity, and guide handle position. As a result, dynamic balancing and consequent force/torque reduction were found to result when the machine's center of gravity was shifted substantially relative to a typical machine's center of gravity. Dynamic balancing can be achieved most practically by reversing the orientation of the engine relative to the guide handle assembly when compared to traditional walk behind rotary trowels and shifting the engine as far as practical to the right. This shifting has been found to reduce the operational forces and torque the operator must endure by at least 50% when compared to traditional machines.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority, under 35 U.S.C. §119, to European Patent Application No. 12169829.4, filed May 29, 2012, entitled “Drill Bits,” which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to drill bits and cutting heads for drill bits, in particular for drilling concrete and rock.
BACKGROUND
[0003] Drill bits may comprise a steel fluted section with a hard material cutting head, for example a tungsten carbide head, attached at one end. Located at the other end of the shaft is a shank to releasably connect to a tool holder or a drill or the like, for example, a rotary drill, a rotary percussion drill or a rotary hammer. In order to minimise the amount of power required to drive the drill, the cutting head conventionally comprises two opposing main cutting arms extending from a central point. Conventionally, the drilling of holes with a cross-section closely approaching a geometric circle is assisted by provision of two auxiliary hard material head parts axially set back from the main cutter and radially set back from the outer diameter swept by the end of the main cutting arms, which are either connected to the main cutting head as in U.S. Pat. No. 7,861,807, or are spaced apart from the main cutting plate on the head of the steel fluted section as in European Patent No. EP 1 506 830.
SUMMARY
[0004] The present disclosure seeks to provide improved drill bits and improved cutting heads for drill bits.
[0005] A first aspect of the disclosure provides a cutting head for a drill bit, the cutting head comprising four substantially identically shaped cutting arms extending radially from a common central axial point, each cutting arm comprising a cutting edge extending outwardly and axially backwards from the common central axial point. The cutting edges are equiangularly spaced apart from each other at all points about the central axis of the cutting head. Each cutting arm further comprises a side chamfer extending between its radially outer face and its rotationally trailing side face.
[0006] Each cutting edge may extend in a straight unbroken line from the central axial point to the outer radius of the cutting head. Each cutting edge may comprise three or more sections, for example four sections, wherein the point angle between corresponding sections of opposing cutting edges is different to the point angle of any neighbouring sections. Each section may transition to its neighbouring sections at a transition having a large curve radius.
[0007] Each cutting arm may comprise two side faces falling axially away from each cutting edge, wherein each side face comprises a number of side face sections and transitions, corresponding to the sections and transitions of the cutting edge. The two side faces of each cutting arm may be angled symmetrically about the longitudinal central plane of the cutting arm.
[0008] A further aspect of the disclosure provides a drill bit including a cutting head according to the first aspect of the disclosure.
[0009] Advantages of the disclosed inventions may include one or more of the following. An advantage of the four identically shaped cutting arms of the cutting head of the present invention is that the beat force or hammering force is evenly distributed to all four cutting edges, rather than being distributed unequally between a main cutting edge and auxiliary cutting edges. This even distribution of the beat force over a larger number of cutting edges than conventional heads leads to reduced breakage of the cutting edges.
[0010] In addition, it has been found that the cutting head according to the invention does not require significantly more power to drive than conventional heads, even though it has four cutting arms extending to the same outer radius. The cutting head according to the invention improves the durability, speed and overall life of a drill bit.
[0011] Further areas of applicability will become apparent from the description provided herein. The description and specific examples herein disclosed are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
[0013] FIG. 1 is a side elevation view of a drill bit in accordance with the present disclosure.
[0014] FIG. 2 is a perspective view of a cutting head for a drill bit in accordance with the present disclosure.
[0015] FIG. 3 is a side elevation view of the cutting head of FIG. 2 .
[0016] FIG. 4 is a top plan view of the cutting head of FIG. 2
[0017] FIG. 5 is a perspective view of an alternative cutting head for a drill bit in accordance with the present disclosure.
[0018] FIG. 6 is a side elevation view of the cutting head of FIG. 5 .
[0019] FIG. 7 is a top plan view of the cutting head of FIG. 5 .
[0020] FIG. 8 is a perspective view of the cutting head of FIG. 2 , set into the top part of the fluted section of a drill bit.
[0021] FIG. 9 is a side elevation view of the cutting head of FIG. 8 .
[0022] FIG. 10 is a top plan view of the cutting head of FIG. 8 .
[0023] FIG. 11 is a cross sectional view of a fluted section of a drill bit in accordance with the present disclosure.
DETAILED DESCRIPTION
[0024] Referring to FIG. 1 , a drill bit 10 comprises a fluted section 20 and a cutting head 30 . The fluted section 20 comprises four helical discharge grooves or flutes. The cutting head 30 may be joined to the fluted section 20 by any known method. For example, appropriately sized head accepting areas, which may be in the form of a roughened surface, slots, holes, or any other suitable platform area is formed at the top end 21 of the fluted section, for example by milling. The cutting head, in one piece or in component parts which together comprise the cutting head once fitted, may then be fitted and brazed into place.
[0025] The fluted section may be formed using any known method. Preferably, the fluted section for use with the cutting head of the present invention has four flutes. As shown in FIG. 11 , the fluted section may have four lands 22 joined by a web in the conventional way. The cut-away curve joining two neighbouring lands may be a smooth curve. Alternatively, the fluted section may have cut-away curves which are not smooth, to result in a cog-like cross section with protrusions 23 . Such protrusions can reduce bending of the fluted section during drilling, and therefore help to prevent drill bit failure due to fatigue fracture.
[0026] Turning to FIG. 2 , a cutting head 30 of the present invention comprises four cutting arms 300 , each of the same shape, and at right angles to both neighbouring cutting arms. Furthermore, the cutting edge 301 of each cutting arm 300 extends from a common central axial point 40 to the outermost radius of the cutting edge, along a straight line. Each cutting arm 300 has an axis of reflectional symmetry along the cutting edge 301 , until the arm approaches the outermost radius.
[0027] Each cutting arm may be symmetric about the longitudinal central plane of the cutting arm (defined by the central axis and the cutting edge of the cutting arm), except for the formation of a side chamfer 350 extending between a radially outer face 302 of the cutting arm and a rotationally trailing side face 351 of the cutting arm. As shown in FIG. 4 , the side chamfer 350 may for example have an angle (Y) of approximately 45° to a longitudinal plane (L) of the cutting arm, although it may be at a greater or smaller angle. The side chamfer 350 may be in a plane which extends parallel to the axial direction (Z) of the cutting head. The rotationally forward edge 351 of the side chamfer preferably approaches but does not intersect with the longitudinal central plane (L) of the respective cutting arm. Such a side chamfer reduces the area of the radially outer face 302 of the cutting arm which decreases the force required for drilling using the cutting head. The radially outer face 302 of each cutting arm may also include a check groove 303 .
[0028] The cutting head 30 may be formed with base chamfers 360 at the base of the sides of the arms, as shown in FIG. 3 . Such base chamfers 360 assist in fixing the cutting head securely into head accepting areas in the form of rectangular slots 368 in the top end 21 of the fluted section of a drill bit, as shown in FIGS. 8-10 (continuation of fluted section not shown). Such slots may have a slightly curved joining line between the walls and the bottom of the slot due to the manufacturing process, which slightly protrudes into the slot. The base chamfers 360 ensure that any such protrusions do not interfere with the proper insertion of the cutting head. Base face 365 of the cutting head 30 can closely approach a bottom surface 366 of the slot 368 regardless of any protrusions at the line joining the walls and bottom of the slot, which improves the assembly tolerances and strength.
[0029] The cutting head 30 may also be formed with end chamfers 370 at the base of the outer end of each arm 300 . If the cutting head 30 is attached to the top end 21 of the drill by insertion of the arms 300 into the slots 368 , end chamfers 370 may protrude from the ends of the slots 368 after assembly, as shown in FIG. 8 . End chamfers 370 may be at any suitable angle, such as for example 45° to the base 365 and radially outer faces 302 of the cutting head 30 . End chamfers 370 assist in drilling, for example, when drilling in rebar or similar material, such chamfers allow easy retraction of the drill bit after a drilling operation.
[0030] As shown in FIGS. 2 and 3 , the four cutting arms 300 meet at a central axial point 40 which is the axially highest point of the cutting head 30 . The cutting head may comprise a small rounded protruding tip of which the central axial point is the apex. Such an arrangement permits excellent performance in both centering and in speed while drilling. The central axial point 40 is joined to the most central first section 310 of the cutting edge of each cutting arm via a transition 304 having a large curve radius.
[0031] The cutting edge 301 of each identical arm is divided into four sections, 310 , 320 , 330 , 340 , of different radial lengths and angles. Each cutting edge section transitions into the next cutting edge section via a transition 314 , 324 , 334 , having a large curve radius.
[0032] As shown in FIG. 4 , a similar large curve radius transition 344 may separate each of the four cutting arms axially. Each curved transition avoids sharp transitions between adjacent non-contiguous planes, and therefore avoid points of high stress which can cause failure of the head.
[0033] A point angle (A) between opposing first sections 310 may be between 140° and 150°, for example 145°. A point angle (B) between opposing second sections 320 may be between 105° and 115°, for example 112°. A point angle (C) between opposing third sections 330 may be between 135° and 145°, for example between 140° and 142°, for example 142°. A point angle (D) between opposing fourth sections 340 may be between 100° and 110°, for example 105°.
[0034] FIGS. 5-7 show an alternative embodiment of a cutting head according to the present disclosure. Cutting head 50 has parts corresponding to the parts of cutting head 30 , numbered correspondingly. Hence, cutting head 50 has cutting arms 500 , each with a cutting edge 501 , a radially outer face 502 with a check groove 503 , and a side chamfer 550 with a leading edge 551 . As shown on FIG. 6 , cutting head 50 has a base 565 with base chamfers 560 , and end chamfers 570 .
[0035] In the alternative cutting head 50 , as shown in FIGS. 5 to 7 , the point angle (A′) between opposing first sections 510 may be between 95° and 120°, for example between 95° and 105°,for example 100°. The point angle (B′) between opposing second sections 520 may be between 110° and 120°, for example 115°. The point angle (C′) between opposing third sections 530 may be between 135° and 145°, for example between 140° and 142°, for example 142°. The point angle (D′) between opposing fourth sections 540 may be between 100° and 110°, for example 105 °
[0036] The point angles (D, D′) between opposing fourth sections 340 , 540 , in the embodiments of FIGS. 2-4 and FIGS. 5-7 , respectively, is relatively small. This improves durability of the cutting head by reducing the likelihood of breakage of the ends of the cutting arms due to drilling, and also allows the speed while drilling to be high. The point angles (C, C′) between opposing third sections 330 , 530 , in the embodiments of FIGS. 2-4 and FIGS. 5-7 , respectively, allows the speed while drilling to be high in comparison to axially flatter cutting heads.
[0037] For cutting head 30 , the first section 310 of the cutting edge may comprise approximately 17% to 23%, for example 20% of the length of the entire cutting edge 301 of the cutting arm. The second section 320 may comprise approximately 8% to 13%, for example 10% of the length of the entire cutting edge. The third section 330 may comprise approximately 22% to 50%, for example 35% to 45%, for example 40% of the length of the entire cutting edge. The fourth section 340 may comprise approximately 8% to 13%, for example 10% of the length of the entire cutting edge. The transitions 304 , 314 , 324 , 334 between the central axial point and the four sections each comprise approximately 2% to 6%, for example 5% of the length of the entire cutting edge. Such an arrangement provides a compromise between an axially protruding central area for higher drilling speed and good centering performance, with low overall power requirements to drive the cutting head while drilling. The corresponding sections 510 , 520 , 530 , 540 and transitions 504 , 514 , 524 , 534 of cutting head 50 may have corresponding proportions.
[0038] Two side faces 308 a, 308 b fall axially away from each cutting edge 301 , symmetrically. The side faces 308 a facing in the drilling direction (ω) will act as rake faces and relief faces 308 b facing the other direction will act as relief faces. As shown in FIG. 3 , each pair of side faces 308 a, 308 b has an internal angle (X), of approximately 80° to 90°, for example 85°, forming a relatively steep roof shape arm. The symmetry of the cutting edge causes the forces produced when drilling, in particular the beat forces, to be transmitted evenly through the cutting head and into the bottom of the slot, which reduces stresses on the connection between the cutting head and the end of the fluted section, and on the end of the fluted section itself. Cutting head 50 has corresponding side faces 508 a, 508 b.
[0039] The cutting head may be of a material conventionally used for cutting heads, for example, tungsten carbide. The cutting head may be made using any known method for forming parts from such material, for example by pressing or grinding.
[0040] The cutting head may be made in one piece. It is also possible to make the cutting head in more than one piece and bring the pieces together when the cutting head is attached to the end of the fluted section. For example, the cutting head could comprise three separate plates, one central plate forming two opposite arms, and two identical side plates one of which could be positioned extending from either side of the central plate, to form the other two opposing arms.
[0041] It should be understood that although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the scope of the claims.
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The invention provides a cutting head for a drill bit, the cutting head comprising four substantially identically shaped cutting arms extending radially from a common central axial point, each cutting arm comprising a cutting edge extending outwardly and axially backwards from the common central axial point. The cutting edges are equiangularly spaced apart from each other about the central axis of the cutting head. Each cutting arm further comprises a side chamfer extending between its radially outer face and its rotationally trailing side face.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from Provisional Application No. 60/447,980 entitled “Drinking Water Pumping System” filed on Feb. 18, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a drinking water pumping system for receiving drinking water from an outside source for storage in a storage tank and for pumping the drinking water from the storage tank by a pump through a pressure tank for delivery to a drinking water faucet or the like.
[0004] 2. Description of the Related Art
[0005] Because of the high level of impurities found in many domestic water supplies, whether from a municipal or private or rural source, which might include river or well water, a substantial number of households prefer not to use their domestic water supplies for drinking water or for use when making ice, coffee or the like. As a consequence, such households frequently purchase bottled water for such use. While there have been numerous devices for dispensing bottled water for drinking, they have not been configured to automatically supply such water under pressure which is comparable to normal domestic water supply systems for convenient use at conventional water faucets or at refrigerators including automatic icemakers.
[0006] Accordingly, a number of other prior art devices are intended to provide pressurized water for such purposes but have been configured to use the large 5-gallon bottles of water that are very heavy and difficult to replace. In some cases, these water bottles must even be opened and inverted in the same manner as typically found in gravity fed water fountains for many years. While such devices might work satisfactorily, the limited amount of water used in such systems without having to change the bottle and the difficulty of manually handing such large bottles when changing have clearly limited their acceptability. There is a continuing concern that the water in the bottles will be expended during use in the household at inconvenient times when more water is desired but no one in the household is able or available to quickly change such large bottles. Typical such devices are disclosed in U.S. Pat. Nos. 4,456,149; 4,848,097; 4,941,806; 5,638,991; 6,155,460; and 6,352,183.
[0007] While a number of these devices include means for easing the difficulty of changing the water bottle, most include one or more features that limit their ability to properly and reliably provide uncontaminated drinking water better than the water provided by the normal domestic water supply system. Some include no means for preventing the introduction into the system of various contaminants when changing the bottle or when venting the system during normal operation. Others have little or no warning systems for properly allowing the bottles to be changed without resulting in a loss of service that might last for an extended period of time. Still others do not even include means for protecting the pump should the bottle be emptied during service which is very significant since most of these devices require the pump to be operated each time that water is being use at the water faucet, icemaker or the like.
[0008] U.S. Pat. Nos. 4,027,499 and 4,597,270 disclose devices that are primarily intended to provide water for icemakers, were probably intended to protect the icemakers from the contaminants found in many water systems and do not directly require the larger 5-gallon water bottles. However, the primary storage containers for the water in such systems appear to be open to possible contamination and to be too small to be able to also satisfy other household needs for the drinking water.
[0009] On the other hand, U.S. Pat. No. 6,349,733 does disclosed a pressurized water supply system that does not directly use the large 5-gallon water bottles but does include a storage tank that is sufficiently large to be able to satisfy the many needs for drinking water that may occur throughout an active household. However, again the acceptability of such a system is in doubt because it includes no means to prevent airborne contamination thought an overflow port and requires that the pump be operated for each use. This is significant because the system appears to include no remote low level warning means and no means for protecting the pump when the storage tank is emptied.
BRIEF SUMMARY OF THE INVENTION
[0010] The preferred drinking water pumping system of the present invention is for receiving and storing drinking water from an outside source and for delivering the drinking water under pressure to a drinking water faucet or the like. The drinking water pumping system includes a water storage tank having an upper portion including a sealable filler opening for receipt of the drinking water from the outside source and filtered venting. The water storage tank has a lower portion including a suction line extending therefrom that is connected to an input side of a water pump having an output side connected to a pressure tank for receiving the drinking water being pumped from the water pump. A discharge line from the pressure tank is for being connected to the drinking water faucet or the like to supply pressurized drinking water thereto. The water pump includes a pressure sensing switching device for sensing a pressure of the drinking water at the output side. The pressure sensing switching device is for operating the water pump to stop the water pump when the drinking water at the output side being delivered to the pressure tank is at a predetermined maximum pressure and to start the water pump when the drinking water at the output side is at a predetermined minimum pressure below the predetermined maximum pressure.
[0011] The pressure tank is capable of storing a variable amount of the drinking water therein. The variable amount of the drinking water in the pressure tank ranges between a first amount and a second amount that is greater than the first amount. The second amount of the drinking water is stored in the pressure tank when the drinking water therein is at the predetermined maximum pressure. The first amount of the drinking water is stored in the pressure tank when the drinking water therein is at the predetermined minimum pressure.
[0012] The preferred water storage tank also includes a first water level sensor that is vertically located in a middle portion thereof to be above and separated from the lower portion of the water storage tank. A second water level sensor in the water storage tank is vertically located in the lower portion above the suction line and below the first water level sensor in the middle portion. The second water level sensor is electrically connected to the water pump for electrically disconnecting the water pump when a level of the drinking water in the water storage tank is below the second water level sensor. The first water level sensor is electrically connected to activate a warning device remote from the water storage tank for indicating when a level of the drinking water in the water storage tank is below the first water level sensor.
[0013] Accordingly, the preferred drinking water pumping system will continue to operate after activation of the remote warning device until a level of the drinking water in the water storage tank has been lowered from the middle portion to the second water level sensor in the lower portion of the water storage tank and the variable amount of drinking water in the pressure tank has been reduced to the first amount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective view illustrating the base system of the present invention.
[0015] [0015]FIG. 2 is a perspective view illustrating the combination faucet, warning light of the present invention.
[0016] [0016]FIG. 3 is a diagram of the electrical circuitry.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring to the drawings, FIG. 1 shows a perspective view of a basic version of the drinking water delivery system. The drawing is laid out in a sequential form to better explain the system and those components thereof that could be installed in a basement, closet, or an out of the way location while still being accessible to service and to add water to the system. The system of FIG. 1 would require an electrical power supply, as shown in FIG. 3, for overall operation and include a discharge hose 38 that would extend from the remote location for being connected to an existing refrigerator, water cooler, icemaker, or the like. For example, as shown in FIG. 2, the discharge hose 38 is connected to a drinking water faucet 42 , but could further include any number of additional such various components, as will be discussed in further detail herein below.
[0018] As seen in FIG. 2, the drinking water faucet 42 , at a location remote from the system of FIG. 1, includes a warning light 44 that will light to indicate the existence of a low water level in the system of the present invention. The faucet 42 could be added to an existing kitchen sink or bathroom sink of a home or office so that a person could operate a flow control lever of the faucet 42 to fill a glass with water or to acquire water for cooking, etc. One or more of these drinking water faucets or the like could be added to the system as needed and would be connected through additional supply hoses to the discharge hose 38 of the base system shown in FIG. 1.
[0019] [0019]FIG. 3 is a diagram of the electrical circuitry of the present invention and, for the following discussion of the overall operation of the preferred embodiment, reference will be made to all three figures.
[0020] The water delivery system includes a water tank 10 that includes, as can be clearly seen in FIG. 1, a filter vent 12 and a removable filler lid 14 at the upper portion thereof, a low level switch 16 in the middle portion thereof, a shut off switch 18 below the low level switch 16 , and a bulkhead fitting 20 in the lower portion of the tank 10 just below the shut off switch 18 . The bulkhead fitting 20 is connected to a valve 24 by a suction hose 22 A. A suction hose 22 B then connects valve 24 to a strainer 26 while a suction hose 22 C then connects strainer 26 to the inlet side of a diaphragm pump 28 . The valve 24 is used to isolate the water tank 10 by shutting off the water therein for service and repairs to the system. The strainer 26 is installed to protect the diaphragm pump 28 by preventing any foreign materials from entering and damaging diaphragm pump 28 .
[0021] The diaphragm pump 28 has an internal pressure switch 48 at the outlet side thereof, shown in the electrical diagram of FIG. 3, that controls the starting and stopping of the drive motor of the diaphragm pump 28 to controls the “cut in” and “cut out” water pressure of the system. The preferred diaphragm pump 28 does not require priming and can run dry for short periods of time without damage to the diaphragm pump 28 . When pressure switch 48 opens at the set “cut out” pressure, the diaphragm pump 28 includes an internal checking feature to keep the water pressure from feeding back into the tank 10 . The diaphragm pump 28 used in present invention is also thermally protected to prevent damage to the diaphragm pump 28 .
[0022] When a person opens up the flow control lever of the drinking water faucet 42 , or if an icemaker, refrigerator, etc. that is connected to the system requires sufficient water, so that the water pressure in the system at the pressure switch 48 drops to the “cut in” pressure, electrical contacts in the pressure switch 48 will close to start the diaphragm pump 28 and bring the system water pressure up. When the system water pressure at the pressure switch 48 reaches the “cut out” pressure setting, the electrical contacts in the pressure switch 48 will open and the diaphragm pump 28 will shut off.
[0023] The system is designed so that drinking water can be added to the water tank 10 at the upper portion thereof by removing the filler lid 14 . The water in the tank 10 will be gravity feed through the bulkhead fitting 20 in the lower portion of the tank 10 . The filter vent 12 in the upper portion allows atmospheric air to be filtered and enter water tank 10 , so that the drinking water will flow freely out of water tank 10 through the bulkhead fitting 20 , suction hose 22 A, valve 24 , suction hose 22 B, strainer 26 , and suction hose 22 C, and into the diaphragm pump 28 .
[0024] As best seen in FIG. 3, the low level switch 16 in a middle portion of the tank 10 is a “normally closed” switch. As long as the water level in the water tank 10 is above the low level switch 16 , the low level switch 16 , will be held “open” and the warning light 44 , shown in FIG. 2, will not be lit. If the water level in water tank 10 goes below the low level switch 16 , the low level switch 16 will “close” and the warning light 44 will light to indicate the need to add water to the water tank 10 . Water would then be added through the upper portion of the water tank 10 by temporarily removing the filler lid 14 in order to raise the level therein to the upper portion of the tank 10 well above the low level switch 16 .
[0025] As seen in FIG. 3, the shut off switch 18 is a protective device and is a “normally open” switch. The water level in water tank 10 will need to be above the shut off switch 18 to hold the switch “closed” for the diaphragm pump 28 to be operable. If the water level in water tank 10 drops below the low level switch 16 , the warning light 44 will come on. If no water is added to the water tank 10 , the water level will continue to drop, as the diaphragm pump 28 pumps water out of the water tank 10 . The diaphragm pump 28 can continue to pump until the water level drops below the shut off switch 18 , at which point, the shut off switch 18 , will “open” and stop the diaphragm pump 28 .
[0026] The shut off switch 18 shuts down the diaphragm pump 28 before the water level in the tank 10 reaches the bulkhead fitting 20 . This prevents air from being sucked into the diaphragm pump 28 and running dry. The system is designed so that when the warning light 44 lights up, a person would then add water to the water tank 10 and the shut off switch 18 would not be used. Shut off switch 18 is only a protective device for the diaphragm pump 28 and is not used during normal operation to control the diaphragm pump 28 . The diaphragm pump 28 during normal operation is controlled to start and stop by its internal pressure switch 48 as indicated earlier.
[0027] The discharge or outlet side of the diaphragm pump 28 is connected to a tee fitting 32 by a pressure hose 30 . The tee fitting 32 is connected to a pressure tank 34 and also accepts a pressure gauge 36 to indicate the system pressure of the discharge water supply. The discharge hose 38 is connected to the tee fitting 32 for distributing pressurized water to the drinking water faucet 42 of FIG. 2 or the like. The pressure tank 34 is used in the system to store energy and for the protection of the diaphragm pump 28 in the same way it is be used in typical water systems.
[0028] The pressurized drinking water can also tee off discharge hose 38 , as discussed above, to a refrigerator water supply, icemaker, water cooler, another bathroom drinking water faucet, such as seen in FIG. 2, or any other place where quality water is desired.
[0029] A plurality of hose clamps 40 are respectively used at all ends of suction hoses 22 A, 22 B, 22 C, pressure hose 30 , and discharge hose 38 , to insure a leak free system. The hose lengths shown in FIG. 1 are for illustration purposes only and will vary depending on location of components within the system. All of the components of the system in FIG. 1 can be mounted together as one unit including the electrical controls of FIG. 3. Items or components outside of the base system as shown in FIG. 1 and would include any item or component beyond the discharge hose 38 , including but not limited to the faucet 42 of FIG. 2, auxiliary lights, alarms, etc.
[0030] The base system of FIG. 1 would typically be installed in a basement, closet, or anywhere out of the way as a complete package. It would require a wall outlet for electrical power and then plumbed and wired into the faucet 42 of FIG. 2 at a kitchen or bathroom or plumbed to a refrigerator, ice maker, etc.
[0031] Additional warning lights or audible alarms can be added as needed to indicate a low water level in the tank 10 so that water can be supplied uninterrupted to the faucets and appliances mentioned above. These additional warning lights and alarms would be connected to a conductor 76 A and a conductor 70 A, as shown in the wiring diagram of FIG. 3.
[0032] Referring to the wiring diagram in FIG. 3 for a better understanding of the various features of the invention, 115V/AC power from a wall outlet would provide power for the base system through a live conductor 60 and a grounded or neutral conductor 62 . The grounded conductor 62 is connected to the neutral side of the motor of the diaphragm pump 28 and to the neutral side of a power supply 50 .
[0033] The power supply 50 includes a transformer and rectifying circuit to convert the 115V AC incoming power to a control voltage, in this case 12V DC. It is obvious that, if desired, different voltages and power supplies, a different voltage diaphragm pump, etc. could be used to operate the various components of the invention.
[0034] The active conductor 60 is also connected to the power supply 50 so that the output or control voltage from the power supply 50 would be 12V DC between a positive conductor 68 and a grounded or negative conductor 70 . The positive side conductor 68 includes a control fuse 52 that is used to protect the control voltage or low voltage side of the circuit of FIG. 3.
[0035] The conductor 60 is also connected to a “normally open” control contact 46 which is operated by a control relay 56 located in the low voltage side of the circuit. The control contact 46 will remain “closed” and provide 115V AC power through a conductor 64 to pressure switch 48 when the control relay 56 is energized. A conductor 66 leads from pressure switch 48 to the active side of the motor of the diaphragm pump 28 .
[0036] A conductor 68 A leads from the fuse 52 to the “normally open” contact of shut off switch 18 and to one side of the “normally closed” low level switch 16 . A conductor 72 leads from other side of the shut off switch 18 to one side of a main “on-off” switch 54 . A conductor 74 leaves the other side of the main “on-off” switch 54 and goes to the control relay coil 56 and to a power on light 58 . The power on light 58 would be mounted at the base system to show the system is energized and in use. The neutral conductor 70 leads from the control relay coil 56 and from the light 58 back to the neutral side of the power supply 50 to complete the circuit. A conductor 76 leads from the other side of the low level switch 16 to the warning light 44 . The conductor 76 A is also the conductor for the positive terminal for auxiliary warning lights or audible alarms. The conductor 70 connects out of warning light 44 to return it to neutral back to the power supply 50 . The conductor 70 A is the neutral connection for auxiliary warning lights or audible alarms.
[0037] The present invention for a drinking water pumping system provides an internal drinking water supply for home or business. It is separated from the city water or well water supply, etc. The system provides high water pressure, non-stop uninterrupted quality drinking water to drinking water faucets, water coolers, icemakers, refrigerators, bathrooms, etc. The drinking water pumping system can be easily installed and operated with very low maintenance. This system would be installed in a basement, closet, or an out of the way space that has access to electrical power and can be accessed to add water to the unit.
[0038] For explaining the operation of the system, the base unit of the system is shown to be connected to one outlet faucet assembly 42 of FIG. 2. However, the present invention is designed to operate multiple fixtures and appliances that would be plumbed and wired into and along with the one being described.
[0039] After the base unit of FIG. 1 is set in place, typically in the basement, the discharge hose 38 will need to be plumbed into a designated drinking water faucet assembly such as that shown in FIG. 2 at a kitchen sink or bathroom and the low voltage wiring, positive conductor 76 A and negative conductor 70 A will be run from base unit of FIG. 1 to the warning light 44 of the water faucet shown in FIG. 2. With the main “on-off” switch 54 in the open or “off” position, one must simply plug in the power feeding 115V AC to conductor 60 and conductor 62 . To fill water tank 10 up with selected drinking water, one pours the water into the tank 10 and replaces the filler lid 14 .
[0040] The drinking water pumping system is ready to be operated and put into service. The valve 24 should be in the open position and is only used for service to the unit and should not be run in the closed position.
[0041] With the water tank 10 , full of drinking water, the “normally closed” low level switch 16 will be open, and warning light 44 will not be lit, indicating that the system water level is at least over the low level switch 16 . The “normally open” shut off switch 18 will be closed leaving the diaphragm pump 28 ready to be operated by the internal pressure switch 48 of the diaphragm pump 28 .
[0042] With the “on-off” switch 54 turned “on” or closed, the control relay 56 will be energized, closing its normally open control contact 46 . The 115 V AC power will then be provided through conductor 60 and the closed contact 46 to pressure switch 48 . If there is no water pressure in the system, the pressure switch 48 contacts will be closed providing power to the diaphragm pump 28 to cause it to run. The diaphragm pump 28 will continue to run until the pressure in the pressure tank 34 and discharge hoses 38 build up to the “cut out” pressure to cause contacts of the pressure switch 48 to open. System pressure can be observed at pressure gauge 36 . Water flows from water tank 10 through bulkhead fitting 20 , suction hose 22 A, valve 24 , suction hose 22 B, water strainer 26 , suction hose 22 C, to the suction side of the diaphragm pump 28 and through the pressure hose 30 to pressure tank 34 to pressurize the discharge side of the system and the discharge hose 38 .
[0043] When the drinking water pumping system is initially first started up, air will be trapped in the discharge line 38 . The air can be bled out of discharge line 38 by opening the lever of the faucet assembly 42 until water flows out freely from faucet 42 of FIG. 2.
[0044] The system now in operation allows a person to get a glass of drinking water from the faucet 42 of FIG. 2 to use water for cooking, ice cubes, coffee, etc. The diaphragm pump 28 will start up and shut off maintaining discharge pressure through the pressure switch 48 . The diaphragm pump 28 , through water usage, will lower the water level in water tank 10 . Once the water level drops below the low level switch 16 , the warning light 44 will light indicating to add more water to water tank 10 . Water can still be used without adding water immediately to water tank 10 , but continued use, before adding water, can drop water level below shut off switch 18 , opening up the shut off switch 18 to turn off the diaphragm pump 28 .
[0045] As long as water is added as indicated by warning light 44 , or before water level drops to shut off switch 18 , a non-stop, continuous flow of water will be provided to insure good quality drinking water or other supply water.
[0046] The power on light 58 will be lit to show unit is operable when the water level in the water tank 10 is above shut off switch 18 , closing its contacts, and the main “on-off” switch 54 is closed and on.
[0047] Extra auxiliary warning lights or audible alarms can be connected to the positive conductor 76 A and the negative conductor 70 A. These extra auxiliary warning lights or audible alarms can be placed remotely and are used to alarm users that the water level is low and the water tank 10 needs to be refilled through the filler lid 14 .
[0048] While the description provided herein above will enable one skilled in the art to understand and practice the invention, it is appropriate to discuss more details of the preferred embodiment that represent the best mode of operating the invention. For example, the water tank 10 is sized to hold about fifteen gallons of drinking water and would be filled or re-supplied with drinking water from 5-gallon bottles, if a member of the household can handle bottles of such size, or smaller bottles such as 1-gallon jugs or 1-pint bottles so that anyone could add drinking water if necessary. The low level switch 16 or first water level sensor would activate the warning light 44 when about five gallons remains in the water tank 10 . The shut off switch 18 or second water level sensor would be activated to protect the diaphragm pump 28 when less than one gallon of water is left in the tank. Accordingly, after the warning light 44 is activated to indicate a low level in the tank 10 , which might be soon need to be re-supplied, the four gallons in the tank 10 between the low level switch 16 and shut off switch 18 would continue to be available for continued use of the system.
[0049] The diaphragm pump 28 is of a type that is well known in the art to produce a pressure differential between the input side and the output side with the diaphragm thereof preventing the water from flowing or returning to the input side from the output side. The preferred internal pressure switch 48 of the pump 28 has a “cut out” pressure or predetermined maximum pressure of about 40 pounds per square inch and a “cut in” pressure or predetermined minimum pressure of about 20 pounds per square inch.
[0050] The pressure tank 34 is of a type that is well known in the art to store energy as it produces “pressure” on the water stored therein. The volume of water stored in the pressure tank 34 changes, depending on whether the pressure at the output side of the pump 28 is at the “cut out” pressure (predetermined maximum pressure) or at the “cut in” pressure (predetermined minimum pressure). The preferred pressure tank 34 includes a fixed quantity of gas, such as nitrogen, acting on an internal rubber wall in opposition to the water stored therein. The water in the pressure tank 34 is at its normal maximum volume at the “cut-out” or predetermined maximum pressure and is at its normal minimum volume at the “cut-in” or predetermined minimum pressure. It has been found that the best mode of operating the invention occurs when the maximum volume of the pressure tank 34 is about six gallons and the minimum volume is about four gallons. Accordingly, during normal operation of the system, use of the drinking water faucet 42 or the like would initially reduce the volume of the water therein until the volume is at the normal minimum volume, at which time the pump 28 would be activated to return the volume to the normal maximum volume. If the diaphragm pump 28 were deactivated by the shut off switch 18 , the system would continue to operate normally to provide drinking water at the drinking water faucet 42 or the like until the water in the pressure tank 34 is at the normal minimum volume.
[0051] It should be clear to those skilled in the art that various features of the preferred embodiment might be altered without departing from the scope if the invention as claimed.
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The preferred drinking water pumping system is for receiving and storing drinking water from an outside source and for delivering the drinking water under pressure to a drinking water faucet or the like. A refillable drinking water storage tank provides the drinking water for a water pump that delivers the drinking water to a pressure tank for storing a variable amount of drinking water therein. Use of the drinking water faucet or the like reduces the volume of drinking water in the pressure tank that will be restored by the water pump as needed. The drinking water storage tank includes water level sensors to provide remote indication when the level of drinking water is low and to protect the water pump prior to the drinking water in the drinking water storage tank being expended.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a bendable door shutter that is slid following a guide groove on a device side.
Among door shutters, there is one, as shown in Patent Document 1, having a main body on a design surface side which is bent via thin parts in the width direction, and plural block pieces (same as frame or core wood) disposed on the underside of that main body, for opening and closing a device opening by being slid following a guide groove having a curved part on the device side. Here, as the main body, a soft resin, or the like, is used in order to maintain bendability, the thin parts are formed at equal intervals, and each thin part and the parts between the thin parts are formed as a plane surface. As the block pieces, a hard resin, or the like, is used in order to give rigidity, and from the viewpoint of bendability, they are disposed integrally between the thin parts on the underside of the main body.
Patent Document 1: Japanese Unexamined Patent Publication No. 2003-90186
In the structure of the door shutter as above, in maintaining bendability, the design surface of the main body, that is, the part between the thin parts was limited to a plane surface. In other words, as the shutter, although it is preferable to make the design surface of the main body an upwardly convex curved shape, it was considered impossible in connection with that the bendability is impaired.
Therefore, the purpose of the present invention is to solve the problems such as above, and to make it such that a cosmetic shape hitherto considered impossible can be given while maintaining bendability.
SUMMARY OF THE INVENTION
In order to achieve the above purpose, the present invention is a door shutter, having a main body on a design surface side which is bent via thin parts in the width direction, and plural block pieces disposed between the thin parts on the underside of that main body, for opening and closing an opening on a device side by sliding along a guide groove on the device side, wherein on the main body, the thin parts are formed as a plane surface, and the parts overlapping with the block pieces are formed in an upwardly convex curved shape.
It is preferable that the structure of the above door shutter of the present invention be made concrete as follows:
(a) the block pieces are roughly inverted U shaped or T shaped in vertical section, and they project from the underside of the main body in a condition having the lower side not joined to that main body (second feature);
(b) the block pieces are integrally formed on the main body (third feature);
(c) the block pieces are formed with hard resin material, and the main body is formed with soft resin material (fourth feature).
In the invention of the first feature, as a shutter having a main body which is bent via thin parts in the width direction and plural block pieces disposed between the thin parts on the underside of that main body, by the fact that the main body is formed with the thin parts as a plane surface and the parts overlapping the block pieces in an upwardly convex curved shape, a novel cosmetic appearance can be given while maintaining bendability.
In the invention of the second feature, by the fact that the block pieces are made to project from the underside of the main body in a condition having the lower side not joined to the main body, the overall rigidity can be improved by making the block pieces larger without impairing the bendability. As opposed to this, in the inventions of third and four features, for example, the manufacturing expense can be reduced by the fact that the block pieces and the main body are integrally formed by two-material molding method, or the like. Also, the overall rigidity can be fulfilled by the block pieces made of hard resin, and the bending characteristic of the thin parts can be fulfilled by the main body made of soft resin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is top view showing the state having closed the device opening with the shutter of a mode of the present invention.
FIG. 2 is a generalized perspective view showing only the device of FIG. 1 .
FIG. 3 is a generalized perspective view showing only the shutter of FIG. 1 .
FIGS. 4( a ) and 4 ( b ) are parts of the above shutter, wherein FIG. 4( a ) is a partial top view, and FIG. 4( b ) is a partial bottom view.
FIG. 5( a ) is a sectional view taken along line 5 ( a )- 5 ( a ) in FIG. 4( a ), FIG. 5( b ) is a sectional view taken along line 5 ( b )- 5 ( b ) in FIG. 5( a ), and FIG. 5( c ) is a sectional view taken along line 5 ( c )- 5 ( c ) in FIG. 5( a ).
FIG. 6 is a drawing showing a modified example of the above shutter in correspondence with FIG. 5( a ).
DETAILED DESCRIPTION OF THE EMBODIMENTS
Below; examples of the present invention are explained while referring to the attached drawings. FIG. 1 to FIG. 5 show an example of a shutter having applied to the present invention and a device using that shutter, and FIG. 6 shows a modified example.
(Structure)
This shutter 3 has a main body 1 which is bent via plural thin parts 11 and has plural projections 15 formed on both side parts, and plural block pieces 2 disposed between the thin parts 11 on the underside of that main body 1 , and it is disposed so as to slide freely on guide grooves 6 provided on both sides of a receiving part 5 of a device 4 to open and close the opening of the receiving part 5 . This device 4 or receiving part 5 is provided in the center console of an automobile as disclosed in the Publication of Japanese Patent No. 3319202, and the guide groove 6 has a linear part 6 a which extends front to back and a curved part 6 b . Also, the shutter 3 becomes the closed state when it is slid in the direction of the linear part 6 a , and it becomes the open state when it is slid in the direction of the curved part 6 b . However, there is no trouble even if the use of the shutter 3 is other than this.
Here, the main body 1 is set in a length dimension corresponding to the opening of the receiving part 5 , and it has plural thin parts 11 and parts 12 between the thin parts, as well as a handle part 13 provided as a recess in front on the leading end side, a coupling part 14 placed to project on the edge part of the leading end, and a large number of projections 15 provided on both sides.
Of these, each thin part 11 , as shown in FIGS. 4( a ), 4 ( b ) and FIGS. 5( a ) and 5 ( b ), extends in the width direction and is provided at equal intervals in the front-back direction, and its shape in the plate width or left-right direction is formed as a plane surface. The part 12 is a part overlapping the block piece 2 , and the shape in the plate width or left-right direction is formed as an upwardly convex curved shape made to fit the block piece 2 . The handle part 13 is used as a part for hooking the finger or hand when opening and closing the shutter 3 . The coupling part 14 is a place for maintaining the closed state by entering into a catch recess 7 provided on the front side of the receiving part 5 when the shutter 3 is disposed in the closed state in FIG. 1 on the opening of the device side receiving part 5 . However, this coupling part 14 also may be omitted.
The projections 15 are provided between each thin part 11 , that is, on each part 12 , on both sides of the main body 1 . Each projection 15 , as shown in FIG. 3 and FIG. 5( a )- 5 ( c ), is roughly L shaped, and it is positioned beneath the main body 1 by an amount equivalent to the vertical part 15 a of the L shape. On the horizontal part 15 b of the L shape, there is provided a slot 16 running in the front-back direction, and the side forward from that slot 16 serves as a part for coupling with the guide groove 6 . On this part, a dome-shaped small convex part 17 is provided on the terminal side of the horizontal part 15 b . The small convex part 17 makes reduction of sliding resistance possible by elastic action via a hollow 18 inside it when the projection 15 slides following the guide groove 6 .
As opposed to this, each block piece 2 , as shown in FIGS. 4( a ), 4 ( b ) and FIG. 5( a )- 5 ( c ), is roughly inverted U shaped in vertical section, and it is integrated on the main body 1 in a condition having the upper side from the middle part joined and the lower side not joined. Therefore, each block piece 2 , when viewed from the underside of the shutter 3 , has the lower end part 2 b made to project from the underside of the main body 1 in a condition having the area up to the near-middle part 2 a of the inverted U shape buried in the part 12 between thin part 11 and thin part 11 . Also, on both sides of the block piece 2 , there is a small projection 20 which is smaller than the projection 15 as in FIG. 5( b ), and that small projection 20 is made integrally on a part corresponding to the projection 15 on the main body 1 .
The above shutter 3 is fabricated by two-material molding method. In this molding, in the first molding, the plural block pieces 2 are formed inside a mold using a hard resin material such as ABS (acrylonitrile-butadiene-styrene polymer) or polypropylene, and then it is second molded. In the second molding, the main body 1 comes to be formed using a soft resin material such as polyester elastomer or polypropylene elastomer. Therefore, in this shutter 3 , the parts other than each block piece 2 which is the hard-resin part, the thin part 11 , the part 12 , the parts where the handle part 13 and the coupling part 14 are formed, the projections 15 on both sides, and the small convex parts 17 become the soft-resin parts formed with soft resin.
(Operation)
The above shutter 3 is incorporated into the device 4 in a state with each projection 15 coupled in the guide grooves 6 on both sides. In this state, as a shutter 3 , because the part 12 of the main body 1 overlapping with the block piece 2 is formed as an upwardly convex shape, the design surface comes to have a novel cosmetic appearance exhibiting roundness. Also, as for the shutter 3 , in the opening and closing operations, because the thin part 11 of the main body 1 is formed as a plane surface just as in the past, and moreover because the repelling force during bending deformation is absorbed by the dome shape being the hollow 18 of the small convex part 17 , the bendability is kept good and it becomes capable of sliding without the curved part 6 b of the guide groove 6 receiving unnecessary resistance.
MODIFIED EXAMPLE
FIG. 6 shows an example having changed the shape of the above block piece. This block piece 2 A is roughly T shaped in vertical section, and it is integrated on the main body 1 in a condition having the horizontal part 2 a joined and the vertical part 2 b not joined. In this case as well, each block piece 2 A, when viewed from the underside of the shutter 3 , is made to project in a condition having the horizontal part 2 a of the T shape buried in the part 12 between thin part 11 and thin part 11 of the main body 1 and in a condition having the vertical part 2 b not joined with the main body 1 . Thus the present invention can be modified variously except for the essential conditions specified in the claims. Also, it is optional concerning the use of the shutter 1 , the shape of the device-side guide groove, and the like.
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While a bending ability is maintained, it is possible to provide an outer appearance which is not made possible in the past. A door shutter includes a main body on a design surface side which is bent in a width direction through thin parts, and plural block pieces disposed between the thin parts on an underside of the main body, wherein an opening on a device side is opened or closed by sliding along a guide groove on the device side. On the main body, the thin parts are formed as a plane surface, and parts overlapping with the block pieces are formed in an upwardly convex curved shape.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The instant invention concerns a method and an apparatus for making shafts, whereby a device working from the top towards the bottom is used for sinking the shaft, and the shaft space thus obtained is provided with wallings comprising sections which are connectable with each other and each forming a circle.
In the production of vertical shafts it is known in the art to first drill an initial borehole with a comparatively small diameter and subsequently to widen said initial borehole to a larger diameter, whereby the resultant rocks are removed through the borehole. Such a method, however, is not applicable when it is not desired, or not possible, to drill an initial borehole.
This holds true for all such cases in which a dead-end shaft should be produced. Such type of shafts have in the prior art been sunk using the plate-propulsion method, whereby the rocks had to be loosened by hand and moved upwards by means of a special device. Such a working method is not only costly but it is connected with great danger for the personnel working at the bottom of the shaft.
The installation of wallings in a shaft in the prior art has mostly been accomplished in a manner whereby a special stage or platform is provided at a distance above the working area in which the propulsion work is being performed, with those people located on said platform being charged with the task of assembling the individual sections of the wallings at that area, whereby the additional sections are adjoined to the already installed sections of the walling in a downward direction. Such a method necessitates tremendous costs, it is time-consuming and produces dangers for the workers. Additionally, normally the final walling of the shaft is not yet completed, before there are further measures required, for example the rear-pouring with concrete of a walling consisting of sheet metals in order to obtain the type of a shaft which will be able to withstand the expected stresses and which only then renders the shaft suitable for the respective purposes for which it is designed.
It is an object of the instant invention to overcome the above disadvantages and to provide a method for the favorable production of dead-end shafts with a final walling, whereby the utilization of personnel working in the shaft can be made extensively or even entirely unnecessary.
SUMMARY OF THE INVENTION
The instant invention proposes to sink the shaft by means of a rotating driveable drill head as a full-drilling process, and that the walling is installed as the final walling of the shaft simultaneously with the drilling process, whereby the lower end portion of the lowermost section of the walling, in a position immediately adjacent the drill head and corresponding to the drilling advancement, is moved downwards while most possible thereby preventing a rotation. This method has the advantage that the sinking of the shaft can be accomplished without the need for utilizing manual labor inside the shaft or at its bottom, and that a walling is installed representing a walling of the shaft which can withstand the respective stresses to a full measure, so that the shaft can be completed at least to a great extent practically in one continuous working operation.
A preferred embodiment of the instant invention consists in that the walling is supported on an element associated with the drill head or forming a part of said drill head, and the drill head is thereby stressed with at least a portion of the weight of the walling. This provides the drill head during its operation with the necessary auxiliary force, without the requirement for a special device. Additionally, the walling which finds support on the drill head functions as a long stabilizer means so that the drilling process can be performed with great precision.
Suitably, the drilling process is performed with a drilling rod system carrying at its lower end portion the drill head and obtaining rotational movements by means of a motor, or a power swivel above the shaft. It is however also possible to provide the drill head directly with a rotary drive.
A preferred embodiment calls for the utilization of an initial drilling method during the drilling process, having a fluid circulation, whereby the fluid medium may either be a liquid or air. Advantageous, for example, is the socalled air-lift drilling procedure.
The walling which has been installed during the drilling process and forming the final shoring of the shaft may, for example, consist of concrete rings or concrete segments which can be assembled into rings, or may comprise steel-pipe elements or steel-pipe segments, or of tubing sections or other suitable elements, whereby these, in case where necessary, may have large wall-thicknesses. The individual sections of the walling are connected in longitudinal direction, i.e., in the direction of the height of the shaft, in such a manner so that they form a continuous unit.
An advantageous form of equipment for sinking a shaft according the the above-disclosed method is provided with a drill head and an associated bearing for the lowermost sections of the walling or for a support element which is mounted on such lowermost section, or the like. Suitably, the drill head with the associated bearing for supporting the walling is constructed in such a manner so that can be removed from the shaft at the completion of the drilling process, or at any desired point in time, i.e., it may be moved upwards. This may be obtained, among others, in that the bearing for the walling contains movable sections each of which is movable from an operational position supporting the walling into an inner rest position without coming in contact with the walling and that the remaining section of the drill head has no larger outer dimensions than the free inner cross-section of the walling. If necessary, the walling can be held and retained by a device located above the shaft during the removal of the drill head from the shaft.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows an apparatus for sinking a shaft, in operational position;
FIG. 2 shows a different embodiment of a drill head;
FIG. 3 shows a portion of the drill head according to FIG. 1 in enlarged form in operational position of the bearing for the support of the walling;
FIG. 4 shows a portion of the drill head according to FIGS. 1 and 3, wherein the bearing for the walling is in a rest-position;
FIG. 5 shows an operational position according to FIG. 3 with a drill head according to FIG. 2;
FIG. 6 shows a rest-position with a drill head according to FIGS. 2 and 5;
FIG. 7 shows a section of the walling in cross-section; and
FIGS. 8 and 9 show two different embodiments of the bearing for the support of the walling.
DESCRIPTION OF PREFERRED EMBODIMENT
The apparatus shown in FIG. 1 is provided with a drill device 1 which is constructed to be moveable, and being equipped with a caterpillar-type drive gear. On a pole 3 is slidably guided a traverse element 4, having its end portions connected with hydraulic cylinders 5. The piston rods 6 of the latter are fastened on a bridge of the drill instrument 1 by means of a pin connection 8 or the like. This bridge 7 carries also the pole 3 and additionally is provided with lifting means 9, for example movable winches, cranes, single-rail suspension-trains or the like, by means of which the individual sections of the wallings to be installed in the shaft S can be moved to the working site and moved down into the shaft.
On the traverse element 4 is located a power swivel 10 for the rotational drive of a drill rod system 11 which is formed as an air lift rod system. Above the power swivel 10 there is placed a flush joint 12, which can be supplied with a flow medium through the inlet pipe 13, in a manner so that this can be guided downwardly in the sense of the arrows shown in the drawing through an annular space 11a of the drill rod system. Numeral 14 indicates an outlet pipe guided away from the flush joint 12, by means of which flushing medium which is loaded with the mass from the drilling and which rises through an inner conduit 11b of the rod system, can be discharged. The details of such a flush joint 12 as well as of a power swivel 10 may be of the prior art structure, as is known to a person familiar with the art.
At the lower end of the drilling rod system 11 there is mounted a drill head 15, which is provided with roller chissels 16 of which only some are illustrated, or with other suitable tools. The drill head 15 may especially be a socalled large diameter bit. The drill head is provided with outlets, or lead-passages 17 for the inflow of the flushing medium from the drill rod system 11 and with a medium sized opening 18 for removing the flushing medium loaded with the resultant mass from the drilling, as only shown in FIG. 1.
A shaft having the desired dimensions, for example with a diameter of 5 meters and a depth of 40 meters, will be advantageously produced in that the drill head 15 works out a drill-hole of the corresponding size in full rock formations or in mountains by means of rotational movement and downwardly-directed advancing movement, and in that simultaneously with the downwards movement of the drill head 15 there is moved down simultaneously a walling 20 which forms the final shoring for the shaft S. Depending on the drilling progress, further portions are emplaced from the top downwardly onto the sections 20a of the walling which has already been installed in the drilled hole, and which can be accomplished by means of the lifting tools 9. The portions 20a of the walling may for example be rings or annular segments consisting of concrete. Advantageously, the sections are connected with each other in axial direction in a manner so that there results an interconnected entity.
One embodiment for such a type of walling section 20a is shown in FIG. 7. Passage-openings 22 are located at points which are evenly distributed over the circumference of the concrete ring 20a and are delimited by a casing 21 which is embedded in concrete; with connection pins 23 being pushed through said passage openings. Each of the pins 23 is provided with an outer-threaded portion 24, which can be screwed into an inner threading 25 at the head 26 of the adjoined bolt in the concrete section 20a positioned therebelow. The heads 26 rest on plates 27. Numeral 28 denotes sealing elements.
On the bolt of the respective uppermost section 20a may temporarily be fastened sleeves 29 at opposite points, which slidingly engage on vertical rails 30 of the drilling apparatus 1 and thereby serve for securing the entire walling 20 against turning so that the same moves only translatorily downwards.
According to a preferred characteristic, the walling 20 finds its support on the drill bit 15 or on the sections associated with the same. For this purpose, there exist varying possibilities. As may be seen from FIGS. 1, 3 and 4, bearing sections 31 are proposed on the drill bit 15 at points which are distributed over the circumference of the drill bit, and are equipped with horizontal rollers 32 and vertical rollers 33. The latter form a bearing for the horizontal bottom side or for the vertical inside of a footing piece 34, which is fastened to the lowermost end portion of the lowermost walling sections 20a, or is formed by the same. The footing piece 34 may consist of steel, for example. The bearing piece 31 can be moved from the operational position shown in FIG. 3, in which it supports the walling 20, into a rest-position according to FIG. 4 radially to the inside, in which lies also its outermost point within the inside area of the shaft enclosed by the walling 20, by means of a pressure-element cylinder 35 which, via pipes (not shown) is supplied and controlled by the drilling instrument.
The bearing piece 31 is displaceable on suitable guides on the drill bit 15. When in an operative position, according to FIG. 3, the bearing piece 31 rests on fixed support areas on the drill bit in such a manner so that the weight of the walling 20 acts on the drill bit 15 through the bearing pieces and stresses the same. The bearing pieces themselves may also be provided with cutting rollers 36 or with other suitable tools so that there results the effect of under-cutters which drill the outer border area below the walling of the shaft to be produced. Also these tools 36 are arranged on the bearing pieces 31 in such a manner so that they are located in the inoperative position according to FIG. 4 within the contour of the walling 20. Corresponding lateral guide means on the drill bit 15 will guarantee that the forces originating from the cutting rollers 36 can be securely accepted.
The outer dimensions of the drill bit 15 are also smaller than the space enclosed inside by the walling 20. This means that the drill bit 15, when the bearing member 31 is in a rest-position, can be moved upwards or downwards, without interference, together with the drill rods carrying the same, through the walling of the shaft. In this manner, it is possible to remove the drill bit 15 in any case after completion of the drilling operation, i.e., after the desired depth of the shaft has been obtained.
As shown in FIG. 4, the walling 20, when necessary, such as during the pulling-in of the bearing piece 31, can be stopped and retained in the established position. For this purpose hydraulic support cylinders 37 are distributed around the upper shaft-opening engaging the outwardly protruding side of a traverse piece 38, which is screwed together with the anchor bolt 23. By means of this support cylinder 37, it will be possible to sink the walling 20 still deeper until it comes to rest on the sole of the shaft. Any differences of height in the circumference of the shaft opening can be corrected by means of the cylinders 37, when, as shown in FIG. 1, there exists no concrete-foundation 39. The drill bit 15, when needed, may obtain its pressing force also by means of the hydraulic cylinders 5 of the drilling apparatus 1 via the drill rod system 11, for example, in case where such a pressing becomes necessary or desired for operations which are performed separate from the walling 20 operation. In general, it is possible to lift or lower the power swivel 10 in a manner required for the adjusting or pulling of the drill rods 11. The drilling apparatus 1 may be provided with a prior art catch-device (not shown) for the rod system.
The above-mentioned holds true correspondingly also for the embodiments shown in FIGS. 2, 5 and 6. The bearing pieces 41 proposed here are guided on the drill bit 15 by means of pins 42 and may be tilted upwards with the aid of pressure-cylinders 35 from the operational position according to FIG. 5, in which they support themselves on an area 40 on the drill bit 15, being tilted upwards in the rest position according to FIG. 6 in which again are positioned the outermost points of these bearing pieces and the drill bit within a space enclosed by the walling 20. Numeral 36 denotes here again the cutting rollers.
In place of a roller bearing for the lower end portion of the walling 20, as shown in FIGS. 1 to 6 at rollers 32 and 33, there may also be proposed a different type of bearings. Thus, FIG. 8 shows a slide bearing in which at the lower end of the lowermost section 20a of the walling there is attached a glide plate 43 which lies opposite a slide member 44 on a bearing piece 45. The slide plate 43 and slide member 44 consist of wear-resistant materials having good sliding characteristics, thus, for example, a synthetic material such as PTFE. FIG. 9 shows an embodiment using a hydrostatic bearing, wherein numerals 46 and 47 denote chambers for receiving a suitable medium, especially grease, whereby such a medium can be supplied to said chambers by means of channels 48 and 49. These channels are located in the respective bearing piece 51, while the associated walling section 20a is provided with a bearing plate.
Disregarding the bearing structure in general, the embodiment may also be such that in place of moveable bearing pieces on the drill bit there may be provided an annular cutting shoe or the like, which drills the area below the walling 20, as is accomplished in the bearing pieces 31 and 41 by means of the cutting rollers 36. This cutting shoe or cutting circle may be connected with the drill bit in a manner so that at the completion of the drilling operation, when the desired depth of the shaft is obtained, it can be disconnected from the drill bit. The cutting shoe remains then in the shaft, while the drill bit, having dimensions which are smaller than the inner diameter of the walling, may be lifted out of the shaft together with the rod system. The coupling between the drill bit and the cutting shoe may, for example, also be shaped as a bayonet-type closing which, during rotation of the drill rods with the drill bit, turns in a rotational direction counter to the normal rotational direction during the drilling, so that then the connection between both members is released and the drill bit may be pulled.
All characteristics mentioned in the above disclosure and illustrated in the drawings should be considered in themselves or also in combination as part of this invention, in so far as the state of the art permits.
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Disclosed is a method and apparatus for sinking shafts in which ring-like walling elements used as a shaft shoring are inserted into the shaft concurrently with the drilling thereof. The walling elements are held against rotation by a mechanism at the top of the shaft which sequentially inserts the walling elements into the shaft as dictated by the depth thereof as drilling progresses. The lowermost end of the lowermost walling element is supported on a bearing associated with the shaft drill bit.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a sheet, especially for use in the building sector, with a planar sheet body.
[0003] 2. Description of Related Art
[0004] Sheeting and film products in the most varied applications must be fastened to undersurfaces. In the building sector, this relates, for example, to sheets which are used for sealing (airtightness and watertightness) of a building shell (for example, sealing sheets, facade sheets, air and vapor barriers, underlay sheets). If there is wood or wood material in the undersurface, fastening is generally performed mechanically, for example, by tacking, nailing, screwing and/or shooting. The latter three methods are also used in undersurfaces of plasterboard, concrete, plaster and rock. Here, the sheets are perforated such that the sealing function at the perforation site is no longer maintained.
[0005] At present, the sealing function is manually restored in a complex manner by subsequent sealing by means of sealing masses, sealing strips or adhesive tapes. One special case is the sealing of nails through counter laths. This is achieved by interposed foam strips (nail sealing strips).
[0006] The aforementioned known methods constitute a major additional effort and moreover entail the risk that undetected perforations and damage will continue to cause leaks.
SUMMARY OF THE INVENTION
[0007] Therefore, the object of this invention is to avoid the disadvantages of the prior art.
[0008] In one embodiment of this invention, it is provided that the sheet body has at least one elastic layer as a sealing layer. Here, the material of the layer has an elasticity and a restoring force such that, when the elastic layer is penetrated by a fastener, the material of the elastic layer surrounding the fastener encompasses the fastener and seals in the region of the fastener.
[0009] To achieve the aforementioned object, in one alternative embodiment, it is provided in accordance with the invention that the sheet body contains a material which, in the case of a perforation of the sheet body, emerges or swells automatically out of the sheet body to close and/or seal the perforation opening.
[0010] Ultimately, this invention is a self-sealing or self-healing sheet which automatically recloses perforations or perforation openings. Here, the term “perforation” means openings of any type which arise when the sheet is fastened to the undersurface or which are due to damage. This includes perforation openings which arise during fastening, such as unintentional tears or other damage to the sheet.
[0011] Otherwise, this invention relates fundamentally to sheeting of any type as well as film products, where the sheet body is made of plastic.
[0012] The basic idea of an embodiment of the invention lies in that the elasticity and restoring properties of the material of at least one elastic layer of the sheet body is used in order either to eliminate or close minor damage of the sheet body itself or to seal on the fastener which is penetrating the sheet by corresponding elastic contact itself. In another embodiment, the approach involves the body of the sheet contains a closing or sealing material which in the unperforated state of the sheet remains in the sheet body and is inactive. When the sheet body is perforated/damaged and especially when water and/or air enters, automatic activity of the material arises causing the material to emerge from the sheet body at the perforation site, i.e., runs out and/or swells out, and then, contributes to closing the perforation opening, and in the best case, closes it completely.
[0013] In all alternatives, a perforation opening can mean a complete opening or also an annular opening when there is, for example, a nail or fastener in the perforation.
[0014] The effect in accordance with the invention can be achieved by the following different principles:
1. Use of Adhesive-Containing Microcapsules in the Sheet.
[0015] When a fastener penetrates into the sheet, the capsules are destroyed, the adhesive emerges and seals the site. In this case, different alternatives are possible:
[0016] a) The microcapsules contain a single-component adhesive. It sets physically or chemically. Preferably, reaction partners in chemical setting are (penetrating) water, oxygen and/or reactive groups of the surrounding matrix material.
[0017] b) The microcapsules contain a binary adhesive. The reaction partners react with one another only after release.
[0018] c) The contents of the microcapsules react with the material (for example, steel) of the fastener (for example, nails) and form a sealing mass.
[0019] d) Two different types of microcapsules are used which contain different reaction partners (for example, resin and curing agent). When the fastener is inserted both types of capsules are destroyed, the reaction partners emerge, react with one another and seal.
[0020] e) Use of split microcapsules, for example, a core with a first material (resin) and a shell with a second material (curing agent).
2. Use of Flowing Sealants in Microcapsules.
[0021] When the fasteners are inserted, the capsules are destroyed, the sealant flows out and seals the site. Depending on the sealant the following processes can arise:
[0022] a) The solvent evaporates, the sealing mass becomes hard.
[0023] b) A dispersion is present, the liquid evaporating. Then, the viscosity of the sealing mass rises.
[0024] c) There is a swollen and thus easily flowable rubber. The swelling agent evaporates or is taken up and drawn off by the underlay sheet material.
3. Swelling Material in the Microcapsules.
[0025] When water enters, the material emerging from the capsules swells up and seals. In doing so, the diameter of the original perforation opening is narrowed, and in the best case, completely closed.
4. Incorporation of at Least One Flowing (Intermediate) Layer.
[0026] When the sheet is perforated/damaged the flowing resin emerges from the inner intermediate layer and flows together at the corresponding site and seals.
5. Incorporation of at Least One Swelling (Intermediate) Layer.
[0027] When the sheet is perforated/damaged, water enters and leads to swelling of the inner intermediate layer, and thus, to sealing. In doing so, the effect is the same as in alternative number 3.
6. Use of an Elastic Layer as Sealing Layer.
[0028] When a fastener (for example, a nail) is inserted, a layer of an elastic layer material surrounds the fastener, presses radially against it and seals in the region of the fastener. In conjunction with the elastic layer as the sealing layer, there are, among others, the following possibilities:
[0029] a) The sheet is formed of a multilayer composite of individual function layers. The sealing layer is made preferably of an elastomer. In this connection, both conventional and also thermoplastic elastomers are possible for use as the layer material. During elongation or under pressure, elastomers briefly change their shape, and after stress, return to their original shape. This effect is used for permanent sealing between the sealing layer and the perforation medium.
[0030] b) The sheet as the sealing layer has at least one layer of a closed-cell elastic foam. Here, the restoring force of the elastic material is also used. It is even possible to combine several function layers in only one single layer.
[0031] c) A layer of a viscoelastic gel is used as the sealing layer.
[0032] It is pointed out, first of all, that the aforementioned alternatives can each be used by itself or also in any combination with one another. Thus, for example, microcapsules according to alternative 1 can be provided in conjunction with a flowing intermediate layer according to alternative 4 and/or a supplementary elastic layer according to alternative 6. However, this is only one example of the possible layer structures.
[0033] In conjunction with the alternatives of an elastic layer as a sealing layer in accordance with the invention as mentioned under 6a) the following features by themselves or in any combination acquire importance:
There is a multilayer composite of the sealing layer and at least one other layer, especially of at least one membrane and/or at least one mechanical protective layer. The membrane has the function of a water vapor-permeable film or foam film, made preferably of thermoplastic elastomers such as thermoplastic polyurethanes (TPE-U) or thermoplastic polyester elastomer (TPE-E), thermoplastic polymers, such as, for example, polypropylene (PP), cellophane (cellulose film) or a water vapor-permeable coating, for example, based on polyurethane or acrylate or another water vapor-permeable layer of another type. The layer thickness of the membrane is between 10 μm and 1000 μm, any individual value and any intermediate interval being fundamentally possible even if this is not specifically mentioned. The layer composite, i.e., the sheet, as such, ensures watertightness and is made such that it withstands a hydrostatic water pressure of greater than 100 mm, preferably greater than 200 mm, furthermore preferably, greater than 1000 mm and even more preferably greater than 1500 mm. Here, any individual value within the indicated ranges is also possible. The sealing layer is designed for sealing to the perforation medium which is, for example, a nail. The sealing layer made preferably of elastic materials, such a films, foams, nonwovens, knits or woven fabrics. The material of the sealing layer is especially conventional and thermoplastic elastomers.
[0041] Among conventional elastomers are all types of synthetic and natural rubbers which can be irreversibly chemically crosslinked. The crosslinking takes place, for example, by vulcanization with sulfur, by means of peroxides or metal oxides. Examples for conventional elastomers are natural rubber (NR), acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), butadiene rubber (BR) and ethylene-propylene-diene rubber (EPDM).
[0042] Thermoplastic elastomers (TPE) are elastomers which are reversibly chemically crosslinked. At room temperature they show behavior similar to conventional elastomers. At elevated temperatures the physical crosslinking is cancelled so that these elastomers show a typical processing behavior of thermoplastics. Thermoplastic elastomers include elastomer alloys/polymer blends having polyolefins and uncrosslinked or partially crosslinked types of rubber (TPE-V, TPE-O) and also multiblock polymers (TPE-E, TPE-A, TPE-U, TPE-S).
Materials of the sealing layer are especially thermoplastic polymers such as PE, PP, PET, EVA, PA in crosslinked or uncrosslinked form, thermoplastic elastomers (TPE) such as for example, TPE-U, TPE-S, TPE-A, TPE-O or TPE-E, elastomers such as EPDM or natural rubber. The weight per unit of area of the sealing layer is between 10 and 3000 g/m 2 , preferably between 50 and 500 g/m 2 , any individual value and any intermediate interval within the indicated range boundaries being possible. The layer thickness of the sealing layer is between 10 μm and 3000 μm, any individual value and any intermediate interval within the range boundaries being possible. The layer thickness is conventionally greater than 50 μm, preferably greater than 150 μm, and more preferably is between 250 to 800 μm. The modulus of elasticity of the material of the sealing layer is between 0.001 and 20 kN/mm 2 , preferably between 0.005 and 1 kN/mm 2 , in this case, any individual value and any intermediate interval within the range boundaries also being possible. The restoring force of the material of the sealing layer is in the range between 1 and 2000 N/5 cm, preferably, between 20 and 500 N/5 cm, here, any individual value within the range boundaries being possible. Depending on the material and layer thickness, the elastomer layer can, fundamentally be open to diffusion or closed to diffusion. Thermoplastic elastomers such as representatives of the elastomer types TPE-E, TPE-A and TPE-U are already open to diffusion in films of a certain thickness, i.e., they have a watertight but water-vapor permeable nature. In other elastomer types such as conventional elastomers and some representatives of thermoplastic elastomers (TPE-O, TPE-V and TPE-S) or in the case of insufficient vapor diffusion, for example, due to the layer thickness, the diffusion-open property can be ensured by an additional planar perforation. This can take place in particular by mechanical or electrostatic perforation, by heat perforation, laser perforation and/or water jet perforation and/or punching of the film. The mechanical perforation or punching takes place for example, by needle materials, roll materials, plate or sheet materials and can thus have different hole shapes. The sealing layer or the material of the sealing layer has a water vapor permeability (WDD) between 10 and 10,000 g/m 2 d. Here, any individual value and any intermediate interval within the range boundaries are also possible. The material of the sealing layer can by nature have an open-pore character (intrinsic) and can be made, for example, as a nonwoven, woven fabric or knit. Alternatively, an open surface portion can be generated by punching or needle perforation. The portion of the open surface in the total area can be between 2% and 85%, preferably, between 10% and 60%. In this case, any individual value and any intermediate interval within the range boundaries are also possible. It is decisive that the diameter of the hole of the perforation or the mesh width of the woven fabric/knit/nonwoven be below the diameter of the perforation medium. The diameter of the hole of the perforation or the mesh width should be between 10 mm and 4 mm, preferably, less than 2 mm, and especially, in the range from 0.1 to 2.0 mm, here also, any individual value and any intermediate interval within the range boundaries being possible. In order to achieve an optimum sealing effect, the diameter of the holes of the perforations should, preferably, be less than 90% of the diameter of the fastener, preferably less than 75%, and more preferably, in the range less than 50%. In order to guarantee watertightness in an elastic layer with a large-pore perforation, additional backing/coating with a diffusion-open layer can be done. Other backings or coatings, for example, with layers of nonwovens, can contribute to planar stability of shape of the film. Furthermore, there is at least one mechanical protective layer which is designed mainly to protect the membrane against mechanical damage, such as for example, by wood splinters during perforation by nailing or screwing. Preferably, there are two protective layers which are located on the outer side, and thus, also the elastic sealing layer is protected against unnecessary mechanical damage. The mechanical protective layer can be made of nonwoven fabrics, woven fabrics, knits, films and/or open-cell or closed-cell foamed films. Materials for the mechanical protective layer can be thermoplastic polymers such as, for example, PE, PP, PET, EVA, PA in crosslinked or uncrosslinked form, thermoplastic elastomers such as for example, TPE-U, TPE-S, TPE-A, TPE-O or TPE-E, elastomers such as ethylene propylene diene monomer (EPDM) or natural rubber, but also natural or semi-synthetic materials, such as, for example, cotton, hemp, jute or viscose. Materials as blends of the aforementioned materials are also possible. The density of the material of the protective layer is between 1 and 2200 kg/m 3 , preferably between 5 and 500 kg/m 3 , any individual value and any intermediate interval within the range boundaries also being possible here. The layer thickness of the mechanical protective layer is between 30 μm and 3000 μm, any individual value and any intermediate interval within the range boundaries also being possible here. The weight per unit of area of the mechanical protective layer is between 10 and 1000 g/m 2 , preferably between 50 and 500 g/m 2 , with any individual value and any intermediate interval within the range boundaries also being possible here. It goes without saying that the protective layer must be water vapor-permeable when the sheet, therefore the composite, is used as a water vapor-permeable underlay sheet. In this case, the water vapor permeability (WDD) should be between 10 and 3000 g/m 2 d, preferably, between 100 to 1500 g/m 2 d, with any individual value and any intermediate interval within the range boundaries being possible. The individual layers of the multilayer composite, which is preferably provided in the sequence protective layer-membrane-sealing layer-protective layer, are joined by bonding, cement backing, extrusion coating or dispersion coating. Combinations of the methods are also easily possible. Thus, for example, adjacent layers can first be connected to one another by a certain method, and then, other layers can be connected to the pertinent prelaminate via another method. The technique of joining the layers must be matched to the application. If the sheet is being used as a water vapor-permeable composite, the joining of the layers should not, at least largely should not, adversely affect the water vapor permeability. The water vapor permeability of the multilayer composite should be between 10 and 3000 g/m 2 d, preferably, between 100 to 1500 g/m 2 d, with any individual value and any intermediate interval within the range boundaries being possible.
[0065] In the alternative named under 6b), the sealing layer is made in the form of a foam layer of a closed-cell elastic foam. The following features by themselves or in combination can also be implemented in conjunction with other aforementioned features:
The foam layer can be part of a multilayer composite, as has been described above. Reference is made expressly hereto. However, it is also fundamentally possible for several function layers to be combined in the foam layer. Thus, for example, a foamed TPE-U or TPE-E or even other layers can at the same time assume the function of the mechanical protective layer and/or the membrane and/or one or even several sealing layers. The material of the sealing layer is preferably a polymer foam layer which forms the seal to the fastener or the perforation means when the sheet is perforated/damaged. The polymer foam can consist of thermoplastic elastomers or blends, preferably of water vapor-permeable TPE-U or TPE-E which are foamed with chemical or physical propellants or by gases such as air, nitrogen, and/or carbon dioxide. The density of the material of the foam layer is between 1 and 2200 kg/m 3 , preferably between 5 and 500 kg/m 3 , with any individual value and any intermediate interval within the range boundaries being possible. The layer thickness of the material of the sealing layer is between 30 μm and 5000 μm, any individual value and any intermediate interval within the range boundaries being possible. The weight per unit of area of the foam layer is between 10 and 1000 g/m 2 , preferably between 50 and 500 g/m 2 , with any individual value and any intermediate interval within the range boundaries being possible. The water vapor permeability (WDD) is between 10 and 3000 g/m 2 d, preferably between 100 to 1500 g/m 2 d, with any individual value within the range boundaries being possible. The modulus of elasticity of the material of the sealing layer is between 0.01 and 20 kN/mm 2 , preferably between 0.05 and 1 kN/mm 2 , here any individual value and any intermediate interval within the range boundaries also being possible. In the implementation of a foamed elastomer layer, a perforation as mentioned above is otherwise possible. Here, the cell or pore diameter of the foam material should be smaller than the expected hole diameter due to the fastener. Preferably, alternatively, open-pore elastomer foam can be used, and thus, an additional perforation can be omitted.
[0076] In the embodiment described under 6c) the use of a viscoelastic gel as an elastic layer or sealing layer is provided. When the sheet is perforated or damaged, the flexible and highly elastic gel is displaced into the surface. In contrast to purely viscous media as described in the embodiment according to number 2, or a purely elastic layer, i.e., the use of an ideal elastomer, viscoelastic materials cover the transition region in which the properties of the two materials apply.
[0077] Even if an intermediate layer of a viscoelastic gel is not an ideal elastomer, it is still subsumed under the term “elastic layer”.
[0078] Due to their stability of shape, viscoelastic materials, such as gels, try to return to the initial shape and compared to pure elastomers thus provide for an additional flowing seal to the fastener or the perforation means. In this way, the viscoelastic gel has self-adhesive properties, and thus, provides for a further bond to the fastener/perforation means.
[0079] In conjunction with the use of a sealing layer of a viscoelastic material, the following features for themselves or in any combination with the aforementioned features of the other alternatives can also be used with one another:
Fundamentally, the sealing layer of a viscoelastic gel can be integrated in a multilayer composite according to alternative 6a), the layer of elastic material, as such, then being replaced by the gel layer. Reference is made expressly to the above described features. The viscoelastic gel for the sealing layer can also be binary or single-component polyurethane systems, silicone gels or PMMA-based gels. Instead of the aforementioned layer composites, the viscoelastic intermediate layer can also be combined with one or more (carrier) layers in order to increase stability. The carrier layers can be films, nonwovens, woven fabric, knits of materials such as thermoplastic polymers, for example, PE, PP, PES, EVA or the like. The gel film can be applied to a carrier, for example, by spraying, doctoring or rolling. The degree of hardness of the viscoelastic gel is in the range of Shore A 15 to Shore A 30, any individual value and any intermediate interval within the range boundaries being possible. The application weight of viscoelastic gel in the sealing layer is between 50 and 1000 g/m 2 , preferably, in the range between 100 and 400 g/m 2 , with any individual value and any intermediate interval within the interval limits being possible. To reduce the weight of the gel layer, fillers whose weight is less than that of the gel, such as, for example, hollow microspheres, can be used, or loading with air or other gases can be performed. The water vapor permeability of the gel layer, when the layer composite is to be completely permeable to water vapor, is between 10 and 3000 g/m 2 d, preferably, between 100 and 1500 g/m 2 d, any individual value and any intermediate interval within the range boundaries being possible. Fundamentally, the self-adhesive nature of the gel can also be used to cement the film sheets among other another. Thus, in the region of the edge of the sheet above the gel layer, the outer protective/carrier layer can be shortened on the side of the longitudinal edge so that a longitudinally running outer edge strip of the gel layer arises which is preferably covered by means of a protective film, for example, in the form of a polyurethane film or a polyurethane-enamel system. The protective film is removed for installation so that, on the edge side, the self-adhesive surface appears over which the following sheet can be cemented.
[0090] In this connection, it is fundamentally possible, on the opposing longitudinal edge, on the same or the other side of the sheet, to provide a corresponding formation in which the gel layer except for the protective film is likewise exposed on the edge side.
[0091] In all embodiments of the alternatives according to number 6, preferably, the following is provided by itself or in combination with one another or other of the aforementioned features:
The characteristic for the amount of sealing (MDA) of the sealing layer computed from the product of the restoring force F r [N/5 cm] and the thickness of the sealing layer d [μm] according to the following formula
[0000]
MDA=F
r
×D
[0000] is between 3 N/5 cm×μm and 10000 kN/5 cm×μm, and preferably, between 10 N/5 cm×μm and 5000 kN/5 cm×μm and especially between 50 N/5 cm×μm to 2000 N/5 cm×μm, with any individual value within the indicated value range being possible.
Preferably, the restoring force of the sealing layer should be in the range between 0.1 and 2000 N/5 cm, preferably, between 20 and 500 N/5 cm, with any individual value and any intermediate interval within the range boundaries being possible.
[0094] Furthermore, it is pointed out that, especially for alternatives 1 to 3, it is also possible to use corresponding unencapsulated material particles instead of microcapsules. In this connection, it should then be provided that these particles are embedded into the matrix of the sheet body, therefore are not freely accessible on the outside. Accessibility, and thus, the possibility of a reaction arise only in the case of a perforation. In this case, then, the reaction partners can be air or water. Therefore, it is also important that the microparticles, which preferably are made of a solid material in the unperforated state of the sheet, are completely incorporated into the sheet matrix and are not accessible on the outside.
[0095] In conjunction with the layers according to alternatives 4 and 5, it is pointed out that it is fundamentally possible, according to the execution of the microcapsules with different reaction partners, to provide two inner reaction layers which are then separated from one another via a separating layer. In the case of a perforation or damage to the sheet, the reaction partners of the individual layers, which have been separated beforehand via the separating layer, become joined to one another so that the above described reaction can occur.
[0096] Otherwise, it goes without saying that the above described sealing function layers, regardless of whether they are made as an intermediate layer or contain microcapsules or microparticles, can be combined with any other layers. The sheet body can therefore be easily built up from a multilayer material.
[0097] The chemical basis of the microencapsulated adhesives (core materials) is, for example, acrylates, polyesters, epoxy resins or polyurethanes.
[0098] A dedicated choice of the wall material, the core material and the method for microencapsulation can influence the desired properties of the microcapsules, such as the capsule diameter and wall thickness. Wall material and wall thickness are important characteristics for the mechanical, thermal and chemical stability. They also determine whether the core material is continuously or preferably suddenly released and dictate the storage stability of the material.
[0099] Thus, depending on the encapsulation technique which has been used, capsule diameters between 0.1 and 300 μm, preferably between 1 to 100 μm and especially between 10 and 50 μm can be used. Fundamentally, typical wall materials, such as, for example, amino resins, polyamides, polyurethanes, polyureas, polyacrylonitrile or gelatins are available.
[0100] The method used for producing sheets, such as extrusion, casting, coating or fiber spinning must be matched to the size and the stability of the microcapsules or particles, so that a premature release of the core material by excess mechanical, thermal or chemical stress in the sheet production process is avoided.
[0101] Furthermore, it must be considered that the concentration of the capsules (average number of capsules per unit of area) is chosen such that, in the case of diffusion-open sheets, the diffusion capacity of the sheet in the required magnitude is maintained.
[0102] Ageing of the sheet under the conditions which correspond to the application should not lead to damaging of the wall material of the capsules, and thus, to a planar distribution of the adhesive and to an associated general adverse effect on the diffusion capacity of the sheet.
[0103] Locally destroying the capsules and achieving the accessibility of the embedded parts or layers should only take place by relatively high mechanical pressure, for example, by perforation and damage as a result of nailing-through.
[0104] The adhesive which is released from the damaged capsules after the curing process establishes a water-impermeable bond to the perforation medium.
[0105] Swellable materials are preferably polymers of acrylic acid/acrylic salts (superabsorbers) and/or bentonites. However, polyurethanes, polyether esters, polyether block amides, polyacrylic acid esters, ionomers and/or polyamides with corresponding water absorption are also suitable.
[0106] The water absorption of the swellable materials at 23° C. in water when using superabsorbers and bentonites is between 10-1000 times. The water absorption for other polymers, especially for intermediate layers, is between 1 and 30%, preferably, between 3 and 15%, and more preferably, between 5 and 10%.
[0107] In one special case, the microcapsules are worked into a polymer (homopolymers or copolymers of polyethylene, polypropylene or polyester), this mixture is extruded and then stretched. In doing so, a microporous, diffusion-open membrane (breathable film) with self-sealing properties is formed. Some of the microcapsules can be replaced by conventional fillers such as chalk, talc, marble, limestone, titanium oxide or quartz powder.
[0108] The weights per unit of area of the sealing function layers or of the microcapsules/particles for an at least essentially uniform distribution over the surface of the sheet or in the diffusion-open case are between 5 to 150 g/m 2 , preferably, 10 to 100 g/m 2 , and more preferably, 20 to 80 g/m 2 . The respective weight per unit of area can depend especially on the respective application. Conversely the total weight per unit of area, i.e., the weight of the matrix material of the sheet body including the weight per unit of area of the sealing function layer/microcapsules/particles in the diffusion-closed case is between 30 to 1000 g/m 2 , preferably, 50 to 500 g/m 2 and more preferably 100 to 300 g/m 2 .
[0109] The concentration of the capsules/particles is between 5 to 70%, preferably, 10 to 50% and furthermore 20 to 30%. The aforementioned percentages can relate especially to the volume (% by volume) and also the weight (% by weight).
[0110] The sheet in accordance with the invention can be both open to diffusion and also closed to diffusion. For sheets open to diffusion, the sd value is in the range between 0.01 to 0.5 m, preferably, between 0.01 to 0.3 m, and furthermore, 0.02 to 0.15 m. In the diffusion-closed version, the sd value is between 0.5 to 1000 m, preferably, between 2 to 200 m.
[0111] In conjunction with this invention, it has otherwise been ascertained that the watertightness of the sheet in accordance with the invention after perforation with a nail or a screw is such that there is a tightness for a static water column>200 mm, preferably >500 mm, especially preferably >1000 mm, and furthermore, preferably, >1500 mm. Depending on the type and amount of the function material, the ratio of the watertightness of the sheet in accordance with the invention after perforation to the undamaged sheet is greater than 50%, preferably, greater than 70% and more preferably, greater than 90%. Ultimately, the invention can ensure almost a watertightness as in an undamaged sheet.
[0112] The sheets or strips of all alternatives outfitted, in this way, preferably, are used in the sealing of buildings, especially in the diffusion-open version, as an underlay sheet or as a facade sheet.
[0113] The diffusion-closed sheets are used as vapor brakes, vapor barriers, gas barriers (for example, against radon, methane), masonry barriers and vertical (walls) and horizontal seals (floors, flat roofs).
[0114] It is expressly pointed out that all of the aforementioned range data comprise all individual values and all intermediate vales within the indicated range limits, even if they are not given in particular. All unnamed individual values and intermediate ranges are regarded as critical to the invention.
[0115] Exemplary embodiments of the invention are described below. All described and/or illustrated features by themselves or in any combination form the subject matter of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0116] FIG. 1 is a schematic depiction of a first embodiment of a sheet in accordance with the invention,
[0117] FIG. 2 is a schematic depiction of a second embodiment of a sheet in accordance with the invention,
[0118] FIG. 3 is a schematic depiction of a microcapsule,
[0119] FIG. 4 is a schematic depiction of a third embodiment of a sheet in accordance with the invention,
[0120] FIG. 5 is a schematic depiction of a fourth embodiment of a sheet in accordance with the invention,
[0121] FIG. 6 is a schematic depiction of a fifth embodiment of a sheet in accordance with the invention,
[0122] FIG. 7 is a schematic depiction of a sixth embodiment of a sheet in accordance with the invention,
[0123] FIG. 8 is a schematic depiction of the sheet from FIG. 1 in the perforated state,
[0124] FIG. 9 is a schematic depiction of the sheet from FIG. 1 with a counter lath in place in the perforated state,
[0125] FIG. 10 is a schematic depiction of the sheet from FIG. 6 in the perforated state,
[0126] FIG. 11 is a schematic depiction of a seventh embodiment of a sheet in accordance with the invention without fasteners,
[0127] FIG. 12 is a schematic depiction of the sheet from FIG. 11 with fasteners,
[0128] FIG. 13 is a schematic depiction of an eighth embodiment of a sheet in accordance with the invention,
[0129] FIG. 14 is a top view of the sheet from FIG. 13 , with the uppermost layer removed,
[0130] FIG. 15 is a schematic cross sectional view of another embodiment of a sheet in accordance with the invention and
[0131] FIG. 16 is a perspective partial view of another embodiment of a sheet in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0132] FIGS. 1 & 2 as well as FIGS. 4 to 10 each show a respective embodiment of sheets 1 which are intended for use in the building sector. The sheets 1 can be, for example, sealing or facade sheets, air barriers and vapor barriers. Depending on the application, the sheets 1 can be open to diffusion or closed to diffusion. Here, the term “sheet” also includes strips or film products. In any case, the sheet 1 has a planar sheet body 2 which has an extrudable or castable plastic as a matrix material. Conventionally, the sheet body 2 has an elongated shape and is wound up when not in use for handling purposes. The length of the sheet body 2 , the width and the thickness are dependent on the application. Conventional thicknesses of the sheet body 2 are between 100 and 300 μm, and the thickness range can vary fundamentally between 50 μm and 2000 μm, any individual values between the aforementioned range limits being fundamentally possible.
[0133] In all embodiments, it is such that the sheet body 2 contains a material which is inactivate when not in use and which can be activated, and which, in the case of a perforation of the sheet body 2 , emerges from the sheet body 2 , and in doing so, is intended for closing or for sealing the perforation opening.
[0134] FIGS. 1 & 2 as well as FIGS. 4 to 7 show different embodiments of sheets 1 . In the embodiment as shown in FIG. 1 , in the matrix material of the sheet body 2 there are microcapsules 3 which contain a single-component adhesive. When the sheet body 2 is perforated by a fastener 4 , for example, in the form of a nail, the microcapsules 3 , which are located in the region of the perforation, are destroyed. In doing so, the adhesive emerges from the capsules 3 . Then, the adhesive can set physically or chemically. Reaction partners can be, for example, water which is penetrating from the outside, oxygen and/or reactive groups of the surrounding matrix material. Ultimately, a seal 5 ( FIGS. 8-10 ) is formed by the adhesive being released in the region of the perforation opening between the fastener 4 and the matrix material of the sheet body 2 ; the seal 5 seals the annular perforation opening between the fastener 4 and the surrounding matrix material of the sheet body 2 . In doing so, it can also be otherwise provided that the adhesive of the microcapsules 3 reacts with the material of the fastener 4 so that seal 5 occurs in that way.
[0135] In the embodiment according to FIG. 2 , there are two different types of microcapsules 3 which are identified here as light and dark. The two types of microcapsules 3 contain different reaction partners. When a fastener 4 is inserted, the microcapsules 3 are destroyed and the reaction partners emerge. In doing so, then, there is a reaction forming corresponding seal 5 , as is shown in FIG. 8 .
[0136] FIG. 3 schematically shows a microcapsule 3 . It has a core 6 of a first material and a shell 7 of a second material. The first material can be a resin, the second material a curing agent.
[0137] FIG. 4 shows an embodiment in which, instead of using microcapsules, solid particles 8 are embedded into the matrix material of the sheet body 2 . The particles 8 are a comparatively solid or grainy material. Since the particles 8 react when air and/or water enters, they are not located on the outside of the sheet body 2 , but in the middle region so that an unintentional reaction is precluded. A reaction takes place only when the sheet 1 is perforated.
[0138] FIG. 5 shows an alternative embodiment in which there are different particles 8 which are, likewise, embedded in the middle region of the matrix material of the sheet body 2 . The different particles are identified as light and dark. A reaction of the particles 8 of the different materials takes place only when air and/or water enters; this occurs only when the sheet 1 is perforated.
[0139] FIG. 6 shows an embodiment in which the sheet body 2 is built up in layers. Here, there are three layers, specifically an upper layer 9 , an intermediate layer 10 and a lower layer 11 . The sealing/swelling material is located in the inner intermediate layer 10 . The intermediate layer 10 can have a layer thickness between 0.1 to 300 μm, preferably between 1 to 100 μm and especially between 10 and 50 μm. When the sheet 1 is perforated by a fastener 4 , as is shown in FIG. 10 , the material of the intermediate layer 10 emerges in the region of the perforation opening, and in doing so, fills the region between the fastener 4 and the surrounding matrix material of the sheet body 2 so that a seal 5 is formed there, as is shown in FIG. 10 .
[0140] FIG. 7 shows an embodiment in which the sheet body 2 is made with five layers. Here the reactive intermediate layer 10 is composed of two reaction layers 12 , 13 and one separating layer 14 which is provided between the reaction layers 12 , 13 and which separates them. When the sheet body 2 is perforated the separating layer 14 is also perforated so that the materials of the reaction layers 12 , 13 react with one another and can assume their self-sealing or self-healing function in the region of the perforation opening.
[0141] FIG. 9 shows a situation as often occurs in the roof region. Wood 15 , for example, a counter lath which is connected to the undersurface via a fastener 4 , is placed on the sheet 1 . The fastener 4 goes through the wood 15 and the sheet 1 . In doing so, then, the effect of seal 5 shown in FIG. 8 arises via the material of the microcapsules 3 which has been destroyed during the perforation, the sealing 5 taking place between the fastener 4 and the surrounding matrix material of the sheet body 2 and in the region of the wood 15 .
[0142] In all embodiments, it is otherwise such that the microcapsules 3 /microparticles are distributed at least essentially uniformly over the base surface of the sheet body 2 . On the edge side, there should be no access to the capsules 3 /particles or exposure.
[0143] FIG. 11 shows one embodiment of a sheet 1 which has an intermediate layer 10 of a swelling material. The sheet body 2 is perforated, therefore has a perforation 16 . Air and/or water travels through the perforation 16 to the swelling material of the intermediate layer 10 so that this material swells into the perforation 16 and reduces the free diameter of the perforation relative to the diameter in the upper layer 9 or the lower layer 11 . The swelling of the material therefore provides for a narrowing of the cross section of the perforation which can even proceed so far that the perforation 16 in the region of the intermediate layer 10 is completely closed.
[0144] FIG. 12 shows an exemplary embodiment in which the fastener 4 is located in the perforation 16 . The material of the intermediate layer 10 has expanded in the region of the perforation opening or of the fastener 4 and presses against the fastener 4 which penetrates the sheet body 2 . In the region of the perforation 16 , the intermediate layer 10 thickens due to the swelling of the material in the intermediate layer 10 .
[0145] FIGS. 13 and 14 show another embodiment of the sheet 1 in accordance with the invention. The sheet body 2 here has an elastic layer as the sealing layer 17 which is provided with a plurality of through openings 18 . The diameter of the through openings 18 is smaller than the diameter of the fastener 4 . Since the through openings 18 have relatively large pores, the sheet body 2 has an upper layer 9 which is open to diffusion but which can also be closed to diffusion. Moreover, there is a lower layer 11 which can be, for example, a nonwoven layer which contributes to the planar stability of shape of the sheet body 2 .
[0146] If the sheet 1 is penetrated by the fastener 4 , due to the elastic properties of the elastic layer material and the use of through openings 18 whose diameter is smaller than the diameter of the fastener 4 , there is sealing contact of the elastic material with the fastener 4 .
[0147] It goes without saying that, for certain applications, it is fundamentally possible for the sheet body 2 , when using an elastic or sealing layer 17 , to be made only with one layer, so that it has only the sealing layer 17 . Fundamentally, the through openings 18 can also be omitted. For diffusion-open applications, the embodiment shown in FIG. 13 should be chosen, the lower layer 11 not being unconditionally necessary as a stability or support layer.
[0148] FIG. 15 shows an embodiment of a sheet 1 in which the sheet body 2 is made as a multilayer composite. There are an upper layer 9 and a lower layer 11 each of which forms a mechanical protective layer. Between the two protective layers 9 , 11 , there are a sealing layer 17 and a membrane layer 19 .
[0149] Otherwise, sheets are also possible in which the structure of the film composite is different.
[0150] Thus, the following exemplary embodiments of sheets and their respective production which are also possible.
Film Composite 1
[0151] A silicone gel of 50 μm is applied by means of a doctor blade to a calendared PP nonwoven material with a weight per unit of area of 150 g/m 2 and is laminated with a TPE-E film 90 μm thick.
Film Composite 2
[0152] A TPE-U film of 119 μm is extruded between two viscose nonwoven materials of 120 g/m 2 weight per unit of area each.
Film Composite 3
[0153] An EPDM film which has been perforated with holes (hole diameter 2 mm, open area 70%) is extrusion-coated with a TPE-E membrane of 134 g/m 2 . Then, cement lamination onto the membrane side is done with a heat-calendered PET nonwoven material.
Film Composite 4
[0154] A perforated PP foam film 200 μm thick with an open area of 47% is extrusion coated with a TPE-E membrane of 91 μm. This composite is cement-laminated on both sides with PP nonwovens of 120 g/m 2 each.
Film Composite 5
[0155] A mixture of an adhesive and superabsorber-filled microcapsules is applied to a PP nonwoven material that is 89 μm thick and then cemented by means of a second PP nonwoven material that 67 μm thick.
[0156] FIG. 16 shows an embodiment in which the sealing layer 17 is located between an upper layer 9 and a lower layer 11 which each form carrier layers. The three-ply layer composite of the sheet 1 is shortened on at least one longitudinal edge in the region of the upper layer 9 . In the same way, the lower layer can be shortened on the opposite longitudinal edge. The sealing layer 17 is made of a viscoelastic gel which has self-adhesive properties. On the exposed edge region of the gel layer, there is a covering protective film 20 which is pulled off for installation of the sheet. The self-adhesive properties of the gel layer 17 easily enable cementing of the sheet to an adjacent sheet in the edge region. In this embodiment, the sealing layer 17 has a dual function, specifically, on the one hand, the sealing action in the case of damage/perforation, and on the other hand, the function of joining to the next sheet which is to be installed.
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A sheet ( 1 ), preferably for use in the building sector, and in particular, for sealing the shell of a building, comprising a planar sheet body ( 2 ) that has at least one elastic layer as a sealing layer ( 17 ) made of a material of such elasticity and such restoring force that, when the sealing layer ( 17 ) is penetrated by a fastener ( 4 ), the material of the sealing layer ( 17 ) surrounding the fastening means ( 4 ) encloses the fastener ( 4 ) and provides sealing in the region of the fastener ( 4 ). Alternatively, the sheet body contains a sealing material which, upon perforation of the sheet body, is able to automatically emerge or swell to an extent sufficient to close or seal the perforation.
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TECHNICAL FIELD
[0001] This invention relates generally to drill bit and drill bit stabilizing systems and methods for use in borehole forming operations wherein a drill bit is connected to a drill string and rotated while drilling fluid flows down the drill string to the drill bit for circulating cuttings up the borehole as the hole is drilled. More particularly, the invention relates to stabilizing systems and methods for stabilization of a drill bit so as to minimize vibration and possible damage to the drill bit or other structures.
BACKGROUND OF THE INVENTION
[0002] My prior U.S. Pat. Nos. 4,842,083; 4,856,601; and 4,690,229, which are hereby incorporated by reference, are directed to drilling systems and methods providing distinct advantages. U.S. Pat. No. 4,842,083, entitled “Drill Bit Stabilizer”, is directed to a stabilizing system to stabilize the drill bit and drilling string in a down hole system, and the present invention is directed to improvements in the system and methods described therein. Although the prior system and methods provide the desired stabilization of the drill bit under most circumstances, it has been found to be desirable to minimize the actuating forces required on the wedge shaped stabilizing members in order to affect the frictional blocking action needed for radial stability. Also, it has been found to be desirable to account for high down hole drilling pressures, particularly where the stabilizing members are spring actuated, such that the drilling fluid pressure does not adversely interfere with the spring action of the stabilizing members. Blockages of various orifices or recesses in the system can also cause problems, and the present invention is directed at reducing or eliminating such possible blockages, particularly around the stabilizing members. It has also been found that under certain conditions, the bit may not be properly stabilized by the stabilizing members, such as at the beginning of a drilling operation or where no pilot hole is formed in the borehole. In such situations, it would be desirable to provide stabilization for the bit face until sufficient hole has been drilled to allow the stabilizing members to engage the bore hole wall. Thus, it would be desirable to prevent vibration damage of PDC cutting elements on the bit which can occur during the start of drilling a bore hole, or to prevent harmful axis wobble of the assembly may occur during ongoing drilling operation.
[0003] As will be shown herein, the present invention includes improved means so as to overcome the deficiencies and problems mentioned above.
SUMMARY OF THE INVENTION
[0004] It is therefore an object of the present invention to provide a drill bit stabilizing system and methods which overcome the above noted problems.
[0005] The structure of the present invention may be generally similar to that shown in prior U.S. Pat. No. 4,842,083; except that the various improvements have been provided, both as to the methods and stabilizing system of the invention. In one aspect, the invention is directed to a drill bit stabilizing system comprising a body member having an axis, and at least one recess formed in the body member for housing at least one stabilizing member when in a first retracted position. The at least one stabilizing member is biased to a second extended operating position. The body member further comprises at least one fixed stabilizing surface positioned in axially spaced relationship to the at least one movable stabilizing member. In another aspect, the invention is directed to a drill bit stabilizing system comprising a body member and at least one stabilizing member, being moveable from an extended operating position to a retracted position within the body member. The at least one stabilizing member comprises outer contact faces adapted to engage the wall of a bore hole when in an operating position, and an inner slide surface adapted to slidingly engage a corresponding slide surface formed in the body member. The inner slide surface comprises at least one relief groove to facilitate the reduction of the surface area of the surface and thereby provide a predetermined increase in the contact pressure per square inch between the inner slide surface and corresponding slide surface associated with the body member. In a further aspect, the slideable, wedge shaped stabilizing members are entirely spring actuated and the at least one stabilizing member comprises a plunger portion provided in a spring chamber formed in the body member. The spring chamber comprises an amount of incompressible fluid therein, and a fluid displacement system in fluid communication with the spring chamber to provide pressure equalization upon movement of the plunger within the spring chamber. The invention is also directed to a drill bit for forming a bore hole wherein the drill bit is attached to a rotary drill string having an axial passageway through which drilling fluid flows to the bit face. The bit comprises a plurality of wear ridges and a plurality of cutters in association with the bit face, the plurality of wear ridges characterized in providing an initial support surface for the weight applied to the bit during a drilling operation. There is also provided a method of drilling a bore hole using a drill bit rotated in conjunction with a drill string. The method comprises the steps of providing a drill bit having a plurality of wear ridges on the bit face along with a plurality of cutting elements. The plurality of wear ridges initially extend outwardly from the bit face to a greater extent than the plurality of cutting elements. The drill bit is rotated along with the drill string to initiate a drilling operation or in an existing full gauge hole to form a pilot hole. Upon rotation of the drill bit, the plurality of wear ridges will allow rotation of the drill bit and drill string for a period of time before engagement of the plurality of cutting elements.
[0006] Other objects and advantages of the present invention will be apparent upon consideration of the following specification, with reference to the accompanying drawings in which like numerals correspond to like parts shown in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a longitudinal, partially sectioned view of the preferred embodiment;
[0008] [0008]FIG. 2 is a straight-on bottom view of the embodiment;
[0009] [0009]FIG. 3 is a cross sectional view taken along line 3 - 3 of FIG. 1;
[0010] [0010]FIG. 4 is an enlarged partial side view taken along line 4 - 4 of FIG. 1;
[0011] [0011]FIG. 5 is a multi-view illustration of the item shown in FIG. 4;
[0012] [0012]FIG. 6 is a flattened partial side view taken along line 6 - 6 of FIG. 2;
[0013] [0013]FIGS. 7 through 14 are partial sectional views of various portions of items shown in FIG. 2;
[0014] [0014]FIG. 15 is an enlarged partial sectional view of FIG. 1;
[0015] [0015]FIG. 16 is a schematic, part sectional view of a drilling operation with the present invention included therewith.
DETAILED DESCRIPTION
[0016] Referring to the figures of the drawings, the embodiment comprises an improved stabilizer and drill bit, generally indicated by the numeral 100 . The invention in one aspect is generally directed to a drill bit stabilizer having a main body of generally cylindrical configuration and a pin end opposed to a lower drilling end. The system is attachable to or includes a drill bit for making a borehole when rotation occurs. A throat is formed longitudinally through the main body of the stabilizer for passage of drilling fluid from a drill string, through the body, and through nozzles of the bit. The drilling fluid exits the bit and returns up the borehole annulus. A plurality of circumferentially arranged wedge shaped pockets or recesses are formed about the main body from the outer surface of the main body inward to slideably receive corresponding wedge shaped stabilizing members. Means are provided by which the stabilizing members are spring actuated. The stabilizing members are each therefore reciprocatingly received in a slideable manner, as they are spring actuated within each respective pocket. Each of the stabilizing members has an outer face which can be retracted into alignment with the outer surface of the main body, and which can be extended outwardly from the surface of the main body and into abutment with the wall of a borehole. Flushing orifices are provided to allow a limited volume of drilling fluid to flow from the throat through the pockets so as to prevent jamming of the stabilizing members by detritus material.
[0017] The before mentioned spring means are incorporated into the main body in a manner such that each of the stabilizing members is forced to move in an angular direction downwardly and outwardly of the main body. The spring means forces the stabilizing members towards the extended configuration and, as the face of the stabilizing member, or the borehole wall, is worn, the face of the member is further extended to maintain abutment with the borehole wall. Frictional means is provided to lock, or block, the stabilizing members in any one of a range of extended positions. The frictional means is the friction between the sliding surfaces of the wedge shaped stabilizing members and the corresponding surfaces of the pockets within which the wedges are received.
[0018] More particularly, and with respect to the embodiments shown in the drawings, the stabilizer comprises a main body 1 made of a suitable material such as steel. The main body 1 is generally cylindrical in shape and the upper end thereof is threaded in the conventional manner or is otherwise provide with a known means for attachment to the end of a drill pipe or “drill string”. The main body 1 has a central fluid passage or throat 15 extending from the top end, axially along the central axis towards the lower end. The lower marginal end of the main body 1 may be an integral part of a drill bit 110 , as shown in FIG. 1, or it may be a separate member suitably attachable to a drill bit with the throat 15 arranged to provide a flow of fluid therethrough to the drill bit, as described in my previous U.S. Pat. No. 4,842,083, of which this invention is a continuation in part.
[0019] The embodiment 100 includes a plurality of moveable and radial stabilizing wedges 29 installed in complementary radial pockets 3 formed into the main body 1 in spaced relationship respective to the throat 15 . The pockets 3 , with the respective wedges 29 installed therein, are symmetrically arranged circumferentially about the central longitudinal axis of the main body 1 , as shown in FIGS. 1 and 3. The embodiment 100 of FIGS. 1 and 3 includes three such pockets 3 and three corresponding wedges 29 ; however, any suitable number may be employed.
[0020] The pockets 3 are each shaped and arranged to provide a mated slide surface 45 which is inclined downward and outward relative to the central axis of the main body 1 . The upper end surface 45 ′ of each pocket 3 is generally perpendicular to the inclined slide surface 45 , as seen in FIG. 15. Each wedge 29 is correspondingly shaped and arranged so that the outer surface of each wedge 29 is flush or aligned with the outer surface of the main body 1 when the wedges 29 are fully seated into the pockets 3 . Each wedge has an inner slide surface 44 which is mated to and arranged to slide against the slide surface 45 .
[0021] The outer faces of the wedges 29 are provided with suitably thick wear resistant tungsten carbide surfaces 36 formed onto the outer faces of the wedges 29 so that the wear resistant surfaces 36 are flush or aligned with the outer faces of the wedges 29 , thereby making the outer faces of the wedges 29 wear resistant. The wedges 29 may alternatively be made entirely of a wear resistant material, such as ceramic, or may be made wear resistant by other known expedients, such as applying PDC diamond to the faces.
[0022] Corresponding plungers 32 are attached to the upper end of each wedge 29 and extend upward and inward parallel to the slide surface 45 of each pocket 3 . To facilitate proper operation, the coupling between the wedge 29 and corresponding plungers 32 is preferably non-rigid or has some flexibility to allow some movement between these members. Such a connection will avoid the formation of a high stress point at this location. In the embodiment shown, to attach the wedges 29 to the plungers 32 , a bore 8 is formed in the large end of each wedge, as shown in FIG. 5; with an annular groove 9 formed therein. As shown in FIG. 15, the lower ends of plungers 32 are formed to correspond to bores 8 and have grooves formed thereon to match with grooves 9 . As shown in FIG. 5, an access hole 10 is drilled tangent to groove 9 in each wedge 29 to allow insertion of metal balls 48 , of metal such as stainless steel, so the matching grooves are filled with metal balls to thereby attach the wedges 29 to the plungers 32 , as seen in FIG. 15. The access holes 10 are tapped to receive plugs to retain the metal balls in place.
[0023] Complementary bores 46 ′, which do not communicate with the throat 15 , are provided to receive each plunger 32 . Each bore 46 ′ has an enlarged section to form a spring chamber 46 and to accommodate seal bushing 33 . The seal bushings 33 are installed in fixed relationship within the lower marginal end of spring chambers 46 and reciprocatingly receive the plungers 32 in sealed relationship therewith by means of the illustrated o-rings 31 . Wipers 43 are also added to prevent debris from harming the o-rings 31 during reciprocating movements of the plungers 32 . The seal bushings 33 are sealed to the spring chambers 46 by o-rings 49 and are affixed therein by locking rings 35 , or by other suitable known means. Springs 34 , such as Belleville washers, and preferably of the stacked disk type, are received about each plunger 32 between the seal bushing 33 and the upper end of spring chambers 46 . The springs 34 are thus respectively confined and sealed within the chambers 46 at a location between the upper end of chamber 46 and seal bushing 33 . To prevent harmful effects from high static pressures encountered down hole during operation, the spring chambers 46 must be filled with an incompressible fluid, such as hydraulic oil, which is sealed therein by plugs 51 ; and all air or gas bubbles should be removed.
[0024] In addition, since any reciprocating movement of plungers 32 will produce a displacement of fluid in chambers 46 , complementary bores 46 ′ extend upward to intersect and provide fluid communication with corresponding radial bores 4 , as shown in FIG. 1. A moveable sealing member 5 , such as a free traveling piston is installed in each bore 4 and moveably sealed therein by an o-ring 6 so as to keep fluid within chamber 46 , bore 46 ′ and the inner portion of bore 4 . The moveable sealing member 5 could be of a different character, such as a sealed diaphragm or the like, while accommodating fluid displacement. Thus, as plunger 32 moves in or out during operation, corresponding moveable sealing member 5 , such as a piston, freely moves in or out to accommodate the change in fluid volume within chamber 46 . A retaining ring 7 is installed in bore 4 to keep piston 5 from inadvertently traveling too far outward in bore 4 . Thus, the in or out travel of plunger 32 and wedge 29 is not hindered nor affected by static down hole pressure nor by fluid pressure within throat 15 .
[0025] A suitable flange 11 is formed on each plunger 32 to provide contact with springs 34 ; and to abut against the seal bushings 33 so as to limit the outward travel of each plunger 32 at the appropriate distance. The springs 34 are arranged to press against the flanges 11 and thereby bias the plungers 32 , and the wedges 29 attached thereto, outward. As will be explained later herein, the wedges 29 and plungers 32 are to be retracted inward by other force means, such as by thrust of the wedges 29 against the rim of the pilot hole formed by the bit 110 .
[0026] As seen in FIGS. 1 and 15, flushing orifices 54 are positioned to provide fluid communication between throat 15 and each pocket 3 and are sized and arranged to provide an effectual flow of fluid through each pocket 3 so as to prevent detritus material from packing or jamming around the wedges 29 . As shown in FIGS. 1 and 15 of embodiment 100 , orifice 54 may be in the form of a disk made of abrasion resistant material, such as tungsten carbide, having an aperture 40 approximately 0.100 inch to 0.125 inch in diameter. As shown in FIG. 15, aperture 40 is preferably tapered and flared outward downstream so as to minimize the velocity of fluid exiting therethrough. Orifice 54 is retained in a suitably formed port 30 by means of a hollow screw 41 and sealed therein by an o-ring 42 . Each port 30 intersects throat 15 and provides fluid communication therethrough between throat 15 and each corresponding orifice 54 . Thus, flushing fluid, such as drilling fluid passing under pressure within throat 15 , can pass outward through each orifice 54 , outward through each pocket 3 and around each wedge 29 so as to remove detritus material or debris which might otherwise pack around the wedges 29 and jam proper movement thereof.
[0027] In order to prevent orifices 54 from becoming clogged by foreign material which might be present in drilling fluid passing through throat 15 , a strainer sleeve 26 is installed in throat 15 adjacent ports 30 , as shown in FIGS. 1 and 15. The outer surfaces of strainer sleeve 26 are formed so that the upper and lower end portions fit closely within throat 15 , but the intermediate portion is smaller in diameter so that a small but adequate annular space 28 is provide between the sleeve 26 and the wall of throat 15 adjacent to the ports 30 . The inner surface of sleeve 26 is cylindrical. A plurality, preferably up to 200, strainer holes 37 are drilled in sleeve 26 within the region of annular space 28 , but sufficiently above the vicinity of ports 30 , as shown in FIG. 15. The holes 37 are positioned above and away from ports 30 so as to prevent erosion of the holes 37 due to the swirl of fluid entering ports 30 . Thus, drilling fluid is permitted to pass from throat 15 through holes 37 , through annular space 28 , through ports 30 and through orifices 54 into pockets 3 . The strainer holes 37 are approximately 0.050 inch to 0.070 inch in diameter so as to be smaller than the apertures 40 . Thus, foreign material large enough to clog orifices 54 cannot pass through strainer sleeve 26 when passing through throat 15 . The annular space 28 is, preferably, made no wider than 0.070 inch so that it too prevents clogging of orifices 54 . Notice that the apertures 40 are sized to provide a flow rate through each of approximately 10 gpm to 15 gpm at the usual operating pressures.
[0028] In tests, it has been found that flushing fluid exiting orifices 54 and passing through pockets 3 can cause erosion damage to the sealing surface of plungers 32 . To prevent such erosion damage, a clearance notch 50 is formed on the inner, upper end of each wedge 29 , as shown in FIGS. 5 and 15; and ports 30 and orifices 54 are positioned so that fluid exiting orifices 54 impinges against notches 50 so as to deflect the fluid in a manner that does not erode the surface of plungers 32 .
[0029] In normal operation, the main flow of drilling fluid through throat 15 is to the nozzles of the bit 110 , so that foreign material or debris cannot clog the strainer holes 37 because the main flow through throat 15 will wash them away towards the nozzles of the bit 110 . To further enhance this washing action, throat 15 , in the vicinity of sleeve 26 , along with sleeve 26 , is made small enough in diameter so that a relatively high fluid velocity is achieved therethrough during normal operation. For example, when around 300 gpm of drilling fluid is provided, 1¼ to 1½ inch inside diameter of sleeve 26 seems to produce sufficient fluid velocity for effective washing action. To prevent undue erosion of sleeve 26 , preferably, sleeve 26 should be made of case hardened steel, or some harder material.
[0030] As shown in FIGS. 1, 2, and 15 , the bit 110 is equipped with a plurality of nozzles 25 , similar to the arrangement described in my prior U.S. Pat. No. 4,856,601, which are arranged to provide optimum fluid flow restriction and appropriate fluid output velocity. The nozzles 25 are installed in corresponding nozzle ports 24 which are formed and arranged to communicate with throat 15 . The nozzles 25 are retained in ports 24 by means of threaded retainers 52 and sealed against leak-by by means of o-rings 38 . Nozzles 25 will usually be made of abrasion resistant material such as tungsten carbide.
[0031] As shown in FIGS. 1, 2 and 3 , a plurality of flow slots 27 are formed in the face of bit 110 and along the outside of main body 1 to permit the return flow of drilling fluid exiting nozzles 25 during operation and to thereby evacuate drilled cuttings from the bore hole. Also, a plurality of cutting elements 18 , usually the PDC type, are installed, positioned and arranged on bit 110 so as to cut rock from the bottom of the borehole as bit 110 is rotated during operation.
[0032] As seen in FIG. 1, the portion of the main body 1 immediately above the wedges 29 is slightly larger in diameter than the bore hole produced by the drill bit 110 and has installed therein a plurality of secondary gauge cutting elements 85 which are similar to the cutting elements 18 on the face of bit 110 .
[0033] Notice that the gauge cutters 85 are shown in hidden lines and are artificially rotated into the positions shown so as to illustrate their cutting profile. The secondary gauge cutters 85 are positioned and arranged to produce a borehole large enough in diameter for the entire assembly to pass upward therethrough even when the wedges 29 are fully extended, as shown in FIG. 1. Thus, the drill bit 110 and the primary gauge cutters thereof forms a pilot hole which is intended to be enlarged by the secondary gauge cutters 85 to the final desired diameter.
[0034] In order to further prevent packing of detritus material behind or under the wedges 29 , vent holes 80 are formed to extend from the deeper end of each pocket 3 into each corresponding slot 27 . As shown, two such vents 80 may be employed for each pocket 3 .
[0035] In testing, it has been learned that forces generated by cutters 18 in the bit face, combined with forces generated by gauge cutters 85 , can tend to cause the axis of the assembly to wobble relative to the axis of the borehole being drilled. Such axis wobble can cause damage to the gauge cutters 85 or to the bit face cutters 18 . Therefore, as seen in FIG. 1, upper fixed stabilizing surfaces 12 , such as gauge pads, are formed on body 1 or provided on a separate body member attached to the stabilizing system. As an example, the fixed stabilizing surfaces 12 could be formed as part of the body member 1 , or could be provided by means of a suitable additional body member having fixed stabilizing surfaces thereon, which is coupled to the main body 1 . The fixed stabilizing surfaces 12 are preferably provided in corresponding relationship to each pocket 3 , and in positions axially behind gauge cutters 85 and radial bores 4 , so as to be located at a predetermined axial distance behind wedges 29 . In an example, the fixed stabilizing surfaces are positioned such that they are spaced from the corresponding moveable stabilizing members an axial length of not more than three times, and preferably not more than twice the gauge diameter of assembly. The fixed stabilizing surfaces 12 may also be provided with wear resistant surfaces 14 , which can be integral to or can be installed in the surface of each pad 12 to provide wear resistance. Surfaces 14 may be solid tungsten carbide, or may be impregnated or coated with diamond to achieve maximum wear resistance; or, the pads 12 may be made wear resistant by some other expedient method. The fixed stabilizing surfaces in conjunction with the moveable stabilizing members provide distinct advantages in operation to avoid detrimental wobble and vibration at the drill bit tip.
[0036] The pads 12 , with surfaces 14 provided or installed thereon, are sized and positioned to very nearly coincide with the borehole diameter cut by gauge cutters 85 so that only minimal clearance between the surfaces 14 and the borehole wall is allowed. Notice that the axial distance between wedges 29 and surfaces 14 is relatively short, and configured to prevent axis wobble of the assembly during drilling operation. The gauge pads 12 are effectively integral to the body 1 . Of course, pads 12 could be made as part of a short profile body, commonly called a “sub”, which could be weldable or otherwise attachable to main body 1 so as to be effectively integral thereto. Nevertheless, as shown in FIG. 1, pads 12 and main body 1 are a single continuous piece in the preferred embodiment.
[0037] As seen in FIG. 16, a borehole 60 has a drill string 62 and a drill collar 64 therein; with the stabilizer 100 attached to the lower end thereof. A drill bit 110 is integrally attached to the lower end of the stabilizer 100 . A drilling rig 70 manipulates the drill string 62 . The drill string 62 , drill collar 64 , together with the stabilizer 100 and drill bit 110 attached, are inserted in a bore hole 60 and rotated in the conventional manner during a drilling operation. In operation, drilling fluid flows at 72 into the drill string 62 , through the drill string 62 , through the throat 15 of the present stabilizer 100 , out of the drill bit 110 , back up the bore hole annulus outside the drill string 62 and returned through a blowout preventer 74 in the usual manner. A shown in FIGS. 1, 2 and 3 , flow slots 27 permit passage of the drilling fluid and, thereby, removal of drilled cuttings from the borehole.
[0038] In the above mode of operation, the wedges 29 will run in a pilot hole formed by drill bit 110 and the primary gauge cutters thereof, while the secondary gauge cutters 85 enlarge the bore hole to the desired final diameter.
[0039] In a usual operation, drilling fluid flowing through the present stabilizer 100 is at a relatively elevated pressure within throat 15 , because of the usual pressure drop measured across the nozzles 25 of the drill bit 110 . However, neither the fluid pressure in throat 15 nor the fluid pressure outside of stabilizer 100 will have any effect on the plungers 32 . Due only to the thrust of the springs 34 , the plungers 32 will thrust downward. The wedges 29 will thus be caused to move downward and outward along the slide surface 45 until the outer face of the wedges 29 abuts the wall of the pilot hole. The wedges 29 thus are held in contact with the wall of the pilot hole so long as sufficient spring tension is maintained. Also, as the outer surface of wedges 29 , or the borehole wall, slowly wear due to friction against the wall of the pilot hole; the thrust of springs 34 will continually force plungers 32 and wedges 29 downward and outward to maintain the outer face of wedges 29 in constant rotating abutment with the stationary wall of the pilot hole.
[0040] The angle of the slide surfaces 44 and 45 , with respect to the axis of main body 1 , is of a selected value so that inward radial force exerted on the outer face of each wedge 29 produces sufficient friction between the mated slide surfaces 44 and 45 to overcome the resultant upward sliding vector force on the wedges 29 , so that the wedges 29 cannot be made to retract by radial force during drilling operation. This is called “radial blocking action” which prevents radial movement of the central axis of stabilizer 100 and bit 110 . The relative angle and arrangement of the slide surfaces 44 and 45 is such to block any radial inward movement of the wedges 29 at any extended position thereof when an inward radial force is exerted on the wedges 29 . This is so even if such inward radial force is of a magnitude that would overcome the thrust of springs 34 in the absence of the frictional interaction of the slide surfaces 44 and 45 .
[0041] The frictional interaction between surfaces 44 and 45 depends, of course, on the prevailing coefficient of friction. It has been learned that, due to the relatively large area of surface 44 on each wedge 29 , as described in my prior U.S. Pat. No. 4,842,083, the coefficient of friction is sometimes reduced by conditions of the drilling fluid or other materials present during operation. Since the coefficient of friction tends to increase with the amount of contact pressure per square inch, a shallow but relatively wide relief groove 47 , as shown in FIGS. 5 and 15, is formed longitudinally through the middle of slide surface 44 on each wedge 29 to reduce the effective area of each surface 44 , by one half or more, and thereby increase the contact pressure per square inch between slide surfaces 44 and 45 ; and thus increase the coefficient of friction and frictional interaction between the slide surfaces 44 and 45 . This reduces the amount of spring thrust required in order to affect the “blocking action” previously described; and also reduces the outward force and frictional drag between the outer surface of wedges 29 and the wall of the pilot hole. In addition, the longitudinal groove 47 provides a flow path for drilling fluid traveling back up the borehole annulus to flow under and behind each wedge 29 and thereby aid in removing detritus material from each pocket 3 .
[0042] As shown in FIG. 2 and in FIGS. 6 through 14, the face of bit 110 has wear ridges 39 integrally formed thereon immediately trailing and corresponding to the pattern of cutting elements 18 . The cutters 18 are deeply installed, and the ridges 39 are so formed, that the tips of cutters 18 initially do not extend beyond the surface profile of the ridges 39 , before any wear occurs on the ridges 39 . Notice that the ridges 39 of the present invention are similar to the fluid flow isolating ridge 39 of my prior U.S. Pat. No. 4,856,601, however, the ridges 39 of the present invention are much wider and stronger, so as to be able to actually support the weight applied to the bit 110 during typical drilling operation, without wearing too fast. For example, the ridges 39 of the present invention will normally be formed of high grade, hardened steel so as to be at least one-half inch wide, or more, and so as to be quite resistant to wear when rotated against the bottom of a bore hole; and wear resistant materials, such as tungsten carbide, may be applied to the ridges 39 to further increase wear resistance. This provides needed stabilization of bit 110 during the start of drilling a borehole.
[0043] For instance, when starting to drill a bore hole, either at the surface or at the bottom of a preliminary, full gauge hole drilled with a conventional drill bit, where no pilot hole exists, the wedges 29 cannot engage the wall of the full gauge hole and cannot provide any stabilization, initially. In such an instance, if the cutters 18 are allowed to fully engage, or cut into the bottom of the bore hole, the cutting forces will cause chatter or other vibrations that will damage the cutters 18 , especially when the rock or other material being drilled is relatively hard.
[0044] Hence, in the ridge and cutter arrangement of the present invention, the strong ridges 39 support the normal weight-on-bit and prevent the cutters 18 from engaging until the ridges 39 wear to expose them. As rotation begins with weight-on-bit applied, the ridges 39 will normally abrade the borehole bottom sufficiently to form a matching profile pattern thereon. The ridges 39 , being held against the matching profile of the borehole bottom by the weight-on-bit, will maintain stability of the bit axis. As rotation continues, the ridges 39 will slowly wear and allow the cutters 18 to begin to engage the borehole bottom, which will proportionately increase the drilling and penetration. Notice that, as the lower nose end of each wedge 29 contacts the rim of the pilot hole formed by the bit 110 , the wedges 29 and the respective plungers 32 will be easily pushed upward and inward as the main body 1 and bit 110 continue to rotate, drill and descend while making hole. As drilling continues, a pilot hole will be formed by the bit 110 , which will facilitate full engagement and stabilizing action of the wedges 29 against the wall of the pilot hole.
[0045] The ridges 39 are formed and arranged so that, before the wedges 29 are fully engaged and activated, the ridges 39 continue to bear most of the weight-on-bit. After the wedges 29 are fully engaged and activated, after about two feet of hole is drilled, the ridges 39 continue to wear, usually for two hours or longer, until the ridges 39 no longer bear any of the weight-on-bit; and practically all the weight-on-bit is then borne by the cutters 18 . Thus, the ridges 39 provide temporary stabilization; at least until the wedges 29 are able to fully engage the pilot hole formed by the bit 110 .
[0046] Since the ridges 39 are made of tough steel, which is harder than the materials typical casing plugs are made of, a drill bit and stabilizer assembly made according to the present invention can be used to effectively drill out casing plugs, without experiencing damage to the cutters 18 . This is a distinct benefit, because conventional PDC bits often experience damaged cutters when drilling out casing plugs at the start of drilling oil or gas wells. Of course, hard materials, such as tungsten carbide, may be applied to the ridges 39 so as to predetermine their wear rate or abrasive characteristics.
[0047] It should be made clear that the ridges 39 of the present invention are arranged and intended so as to wear sufficiently, in due course, so that, after drilling has progressed sufficiently, the ridges 39 no longer bear any of the weight-on-bit nor any longer retard the cutting and penetrating action of the cutters 18 .
[0048] During ongoing drilling operation, axis wobble of the assembly is prevented by virtue of the axial spacing between the wedges 29 and the gauge surfaces 14 and by the limited, or nonexistent, clearance between the surfaces 14 and the bore hole wall. Also, in the event that detritus material accumulates in pockets 3 behind the wedges 29 , the detritus material can be forced out of the pockets 3 through vents 80 and into slots 27 upon upward movement of wedges 29 .
[0049] Also, even under extremely high down hole static pressure, the hydraulic force on plungers 32 will be equalized by the action of pistons 5 freely moving in bores
[0050] Now, it can be seen from the foregoing that the present invention provides improved means for radial stabilization of a drill bit; such that whirl, chatter and other forms of radial vibration are prevented under a wide range of drilling conditions; and such that the drilling, penetrating and endurance capabilities of a PDC drill bit is maximized.
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The present invention relates to providing a drill bit stabilizing system and methods which overcome the above noted problems. The at least one stabilizing member is biased to a second extended operating position. The body member further comprises at least one fixed stabilizing surface positioned in axially spaced relationship to the at least one movable stabilizing member. In another aspect, the invention is directed to a drill bit stabilizing system comprising a body member and at least one stabilizing member, being moveable from an extended operating position to a retracted position within the body member. The at least one stabilizing member comprises outer contact faces adapted to engage the walls of a bore hole when in an operating position, and an inner slide surface adapted to slidingly engage a corresponding slide surface formed in the body member. There is also provided a method of drilling a bore hole using a drill bit rotated in conjunction with a drill string. The method comprises the steps of providing a drill bit having a plurality of wear ridges on the bit face along with a plurality of cutting elements. The plurality of wear ridges initially extends outwardly from the bit face to a greater extent than the plurality of cutting elements. The drill bit is rotated along with the drill string to initiate a drilling operation or in an existing full gauge hole to form a pilot hole. Upon rotation of the drill bit, the plurality of wear ridges will allow rotation of the drill bit and drill string for a period of time before engagement of the plurality of cutting elements.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None.
FIELD OF THE INVENTION
[0003] This invention relates to strikes or striker plates used for locking doors. A strike or striker plate is typically installed in the jamb of a door to receive a bolt latch of a lock such as a deadbolt so that together, they securely hold the door closed.
BACKGROUND OF THE INVENTION
[0004] To securely lock a door, one needs or wants a strong door, a strong door frame, a strong latch and a strong strike or striker plate. Like a chain, the combined strength of the locked door is limited by the strength of the weakest of the these elements.
[0005] Focusing on the strike or striker plate, at an outside door to be securely locked, it is common to have a strong striker plate comprised of steel that is screwed into and maybe through the door jamb into the underlying supporting structure. One might use extra-long screws to hold the striker plate not just to the jamb, but also to a 2×4 stud behind the jamb that is part of the structure of the wall. However, even thicker steel striker plates with extra-long screws may be quickly defeated by a motivated thief that is able to apply a powerful kick to the door near the lock and the striker plate. The screws may hold firm to the 2×4 stud, but the striker plate is typically spaced about an inch from the 2×4 stud. The screws may have a lot of tensile strength, but they do bend. With the screws extending an inch out from the stud, such impacts from kicking the door may bend the screws sufficiently to allow the striker plate to pivot inwardly so that latch may slip out of the hole in the striker plate. The bending screws also are levers to break apart the jamb and the 2×4 studs, which is a second mode of failure of the striker plate. Regardless of the strength of the door and the strength of the latch, if the striker plate fails, the doorway may be breached based on the failure of the simplest and smallest element for an outside security door.
[0006] While stronger materials are being continually developed, there is a need for a simple, but effective strike or striker plate to work with stronger doors and stronger latches to provide better security for people and things. There is a need for an improved design for a striker plate to take better advantage of the underlying structure of a doorway opening.
BRIEF SUMMARY OF THE DISCLOSURE
[0007] The invention relates to a striker box assembly comprising a box, a cover plate and a boot. The box comprises four connected lateral walls where a first lateral wall is an inner wall, a second lateral wall is a back wall that is opposite the inner wall, a third lateral wall is an upper wall and the fourth of the four lateral walls is a lower wall. The four lateral walls are connected end to end to form a generally rectangular shape. The box further has an open front and a boot flange opposite the open front of the box and which is attached to at least three of the four connected lateral walls at a bottom of the box and arranged generally perpendicular to all four lateral walls. The box further includes a jack flange attached at or near the bottom of the inner wall and arranged to extend away from the open front of the box beyond the jack flange of the box. An upper wing of the box is attached to the upper wall at or near the open front of the box and arranged to extend away from the lower wall. A lower wing of the box is attached to the lower wall at or near the open front of the box and arranged to extend away from the upper wall and away from the upper wing. A base wing of the box is attached to the inner wall at the open front and arranged to extend away from the back wall, wherein the wings are generally arranged to be in a common plane that is generally parallel to the boot flange. The cover plate is attached to the wings of the box wherein the cover plate comprises a face plate and a back flange oriented generally perpendicular to the face plate. The face plate further has a hole arranged to receive a latch of a door locking system wherein the latch may enter into the hole and into the box such that the box and cover plate together resist against lateral movement of the latch which would occur when the door is to be opened. The boot is attached to the boot flange and has a foot side for being positioned flush against a structural element such as a stud within wall at the frame of a door in which the box is suited for installation.
[0008] The invention may also be described as related to an installed striker box assembly comprising a jack stud, a door jamb arranged generally flush against the jack stud, a box attached into the door jamb and to the jack stud, and a cover plate attached to the box. The box comprises four connected lateral walls where a first lateral wall is an inner wall, a second lateral wall is a back wall that is opposite the inner wall, a third lateral wall is an upper wall and the fourth of the four lateral walls is a lower wall, wherein the four lateral walls are connected end to end to form a generally rectangular shape. The box has an open front and a boot flange positioned opposite the open front and attached to at least three of the four connected lateral walls at a bottom of the box and arranged generally perpendicular to all four lateral walls. The boot flange is particularly arranged to have firm contact directly or indirectly with the jack stud. The box further includes a jack flange attached at or near the bottom of the inner wall and arranged to extend away from the open front of the box beyond the jack flange of the box. An upper wing of the box is attached to the upper wall at or near the open front of the box and arranged to extend away from the lower wall. A lower wing of the box is attached to the lower wall at or near the open front of the box and arranged to extend away from the upper wall and away from the upper wing. A base wing is attached to the inner wall at the open front and arranged to extend away from the back wall. All of the wings are generally arranged to be in a common plane that is also generally parallel to the boot flange. The cover plate is attached to the wings wherein the striker plate comprises a face plate and a structural flange oriented generally perpendicular to the face plate wherein the face plate has a hole arranged to receive a latch of a door locking system wherein the latch may enter into the hole and into the box such that the box and cover plate resist against lateral movement of the latch. The assembly further includes machine screws holding the cover plate to the box, a primary screw through the boot flange into the jack stud, at least one jack screw through the jack flange into the jack stud at substantial angle to the primary screw and at least two secondary screws holding the cover plate to the box and firmly to the jack stud.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A more complete understanding of the present invention and benefits thereof may be acquired by referring to the follow description taken in conjunction with the accompanying drawings in which:
[0010] FIG. 1 is a perspective view of a door having a door knob and a deadbolt lock each of which are arranged to latch into conventional prior art striker plates;
[0011] FIG. 2 is a top sectional view of the door closed with the latch of the deadbolt extended into and engaged with the conventional striker plate in the door jamb while the door is closed against the door stop;
[0012] FIG. 3 is a second top cross sectional view showing the failure of a conventional striker plate when the door has been kicked open;
[0013] FIG. 4 is an exploded view of the striker box and the cover plate oriented to be installed into a door jamb;
[0014] FIG. 5 is a perspective view of the box according to the present invention;
[0015] FIG. 6 is front view of the box of the present invention;
[0016] FIG. 7 is a bottom perspective view of the box providing an alternative angle to better understand the structure of the box;
[0017] FIG. 8 is a top cross sectional view of the box and cover plate attached firmly to the stud;
[0018] FIG. 9 is a top cross sectional view like FIG. 8 showing the jamb spaced from the stud, but where the box and cover plate are installed firmly to the stud using a shim or pair of shims to fill the space between the back wall of the box and the stud;
[0019] FIG. 10 is a top cross sectional view of an embodiment of the box with an adjustable boot installed therein for adapting the box to fit various door installations with the normal varying dimensions of spacings between the jamb and the supporting stud;
[0020] FIG. 11 is a perspective view of the boot;
[0021] FIG. 12 is a top cross sectional view like FIG. 8 showing the boot filling the space between the back wall of the box and the stud; and
[0022] FIG. 13 is a top cross sectional view like FIG. 8 showing the finish carpentry including drywall and trim around the doorway.
DETAILED DESCRIPTION
[0023] Turning now to the detailed description of the preferred arrangement or arrangements of the present invention, it should be understood that the inventive features and concepts may be manifested in other arrangements and that the scope of the invention is not limited to the embodiments described or illustrated. The scope of the invention is intended only to be limited by the scope of the claims that follow.
[0024] Turning now to FIG. 1 , a conventional door D is shown that swings closed to a door jamb J and stops against door stop S. Once closed, a spring latch 11 engages a strike or striker plate 21 attached to the jamb by descending into the opening 25 in the striker plate 21 . The door D may be re-opened by turning the knob 10 to pull the spring latch 11 from the striker plate 21 . However, to securely lock the door D, a deadbolt 15 having a bolt latch 16 engages striker plate 22 by descending into opening 26 in the striker plate 22 . The bolt latch may be hardened steel and the deadbolt is designed to prevent the withdrawal of the bolt latch 16 unless the cylinder is properly engaged by a key or the inside thumb switch (neither of which is shown).
[0025] Referring to FIG. 2 , the bolt latch 16 is shown fully extended into the opening 26 in the striker plate 22 to resist opening of the door. As shown in FIG. 3 , if a powerful force is applied from the outside of the inwardly swinging door D, such as from a person kicking or charging the door or by some type of battering ram, the screws 23 holding the striker plate to the jamb J and perhaps the jack stud 31 tend to bend inwardly. Eventually, the jamb J breaks and the bolt latch 16 pops loose from the striker plate 22 as the striker plate rolls away from the door stop S. The length that the screws extend out from the jack stud 31 also tends to give leverage to the forces being applied to the striker plate and tears up the jamb J and the jack stud 31 , especially if the screws 23 are installed close to the edge or inside lateral face of the stud 31 .
[0026] It should be noted that most conventional doors are framed with jack studs on either side of the opening with a header spanning across the top of the rough opening. Flush against the jack studs are king studs which extend fully to the top plate.
[0027] FIGS. 1-3 are prior art arrangements.
[0028] Turning now to the present invention shown in FIGS. 4, 5, 6 and 7 , a striker box assembly is shown comprising a cover plate 40 and a box 50 . The box 50 is the central element in the striker box assembly and comprises a number of elements that are best shown in FIGS. 5, 6, 7 and 10 . It should first be understood that the box 50 should be made of strong and robust material. It would be expected that the box 50 would be made of steel and that the walls would have a robust dimension. For example, the thickness of the walls of the box 50 might be between about 1/32″ and about 3/16″ steel depending on the security desired for the door D.
[0029] The box 50 includes four connected lateral walls 61 , 52 , 54 and 55 . The first lateral wall 61 is also an inner wall 61 . A second lateral wall 53 is also a back wall 52 that is opposite the inner wall 61 . A third lateral wall 54 is also an upper wall 54 and the fourth lateral wall 55 of the four lateral walls is a lower wall 55 . The four lateral walls are connected end to end to form a rectangular shape. The box 50 has an open front or top and a bottom wall 58 that at least partially closes the bottom of the box 50 . The bottom wall 58 may optionally extend fully across that bottom of the box so that it is closed on five sides and open on the front or top, but in the preferred embodiment, it is partially closed on the bottom. The bottom wall 58 is also called the boot flange 58 and is arranged generally perpendicular to the four lateral walls 61 , 52 , 54 and 55 .
[0030] The back wall 52 , the upper wall 54 and lower wall 55 all have a common depth dimension when considering the dimension from the front or top of the box 50 to the bottom. However, inner wall 61 includes a portion that extends beyond the bottom wall 58 . This extended portion may be called a jack flange. It may be viewed by some that it is not clear where the inner wall 61 ends and the jack flange begins, but it may be viewed or understood that the jack flange begins about where the plane of the bottom wall 58 intersects the inner wall 61 . The function of the jack flange 61 will be explained below.
[0031] The box 50 further includes an upper wing 62 attached to the upper wall 54 and which extends generally flush with the open top of the box 50 and generally perpendicular to the upper wall 54 . Similarly, a lower wing 63 is attached to the lower wall 55 and which extends generally flush with the open top of the box and generally perpendicular to the lower wall 55 . It should be noted that these wings 62 and 63 extend away from the interior of the box.
[0032] The box 50 further includes a base wing 65 that is somewhat similar to the upper and lower wings 62 and 63 , but attaches to the inner wall 61 and which extends generally flush with and away from open front of the box 50 and generally perpendicular to the inner wall 61 . Preferably, the three wings 62 , 63 and 65 generally lie in a common plane.
[0033] Looking back at FIG. 4 , the cover plate 40 includes a face plate 41 and a back flange 42 . The face plate 41 is arranged to cover the open top or front of the box 50 and includes a main opening 43 and two sets or pairs of screw holes 44 and 45 (for a total of four screw holes). The box 50 includes two sets or two pairs of screw holes 74 and 75 in the wings 62 , 63 and 65 which are arranged to align with screw holes 44 and 45 , respectively, of the cover plate 40 . The screw holes 74 in the base wing 65 are preferably provided with threads for securely receiving machine screws 83 . Once assembled, the cover plate 40 is attached to the box 50 by the machine screws through the holes 44 and threaded into the holes 74 . Screw holes 45 and 75 do not have screw threads but are arranged to have secondary long screws 85 secure the cover plate 40 and box 50 together and to the door jamb J.
[0034] Still focusing on FIG. 4 , prior to installation of the striker box assembly, a portion of the door jamb J is cutout exposing the jack stud 31 . A similar cutout is made in the drywall 28 exposing the side or lateral face of the jack stud 31 and possibly part of the king stud 32 , into this cutout, the box 50 is positioned for installation. Typically, a surface portion of the door jamb J would also be removed with a chisel by mortising a recess M both above and below the cutout C to let the upper and lower wings 62 and 63 recess below the face surface of the door jamb J at a sufficient depth so that the cover plate 40 ends up generally flush with the same face surface of the door jamb J.
[0035] As shown in FIG. 8 , the box 50 would first be attached to the jack stud 31 by a primary screw 81 through a screw hole 94 or by a pair of primary screws 81 through screw holes 77 in the bottom wall 58 . The attachment of the box 50 to the jack stud 31 will be strongest if the bottom wall 58 is flush against the jack stud 31 as shown in FIG. 8 . However, in most situations, the door jamb J is spaced somewhat from the jack stud 31 to make the door jamb J square, straight and vertical. Also, the frame for the door (which includes door jamb J) is typically slightly smaller than the rough opening in the wall for the door. Centering the frame in the door creates space between the door jamb J and the jack stud 31 . Typically, shims are used to fill the space and firmly attach the jamb J to the jack stud 31 . In the present invention as shown in FIG. 9 , a shim 91 is also used to fill the space between the bottom wall 58 and the jack stud 31 providing firm support to the box 50 and the striker assembly from the jack stud 31 . A shim is a thin wedge typically made of wood, but may be plastic or metal and is inserted into the space between the bottom wall 58 and the jack stud 31 until the shim 91 is in contact with both at the same time. With the shim 91 in place, the primary screw or screws 81 is/are installed through the shim 91 to hold the box 50 in position.
[0036] A third alternative installation arrangement is shown in FIGS. 10, 11 and 12 where hole 94 in bottom wall 58 is a threaded hole and a boot 92 having screw threads 93 is arranged to engage the threads of the threaded hole 94 and extend to from the bottom wall 58 to the jack stud 31 . It is this configuration where the bottom wall 58 is sometimes called a boot flange 58 as it provides the connection of the boot 92 to the box 50 and gains the support of the jack stud 31 for the box 50 and the striker box assembly. By simple rotation of the boot 92 , the distance between the bottom surface 95 of the boot 92 and the bottom face 58 f of the bottom wall 58 may be adjusted. The boot, as shown in FIG. 11 has a slot 96 suitable for turning with a straight bladed screw driver. By trial and error, the depth of the boot is adjusted until the box 50 may be positioned in the cutout at the right depth with respect to the door jamb J and the bottom surface 95 of the boot 92 is flush to the jack stud 31 . It is preferred that the boot have the same diameter as the threaded portion 93 so that the boot may fully or nearly fully recessed into the box 50 in the event that the door jamb J is quite close or flush with the jack stud 31 . Center bore 98 within the boot 92 is arranged to receive the primary screw 81 to hold the boot 92 to the jack stud 31 and thereby secure the box 50 firmly in place within the cutout.
[0037] For all the embodiments, a set of jack screws 82 are used to attach the inner wall or jack flange 61 to the jack stud 31 via screw holes 76 . It should be noted that jack screws 82 are oriented generally perpendicular to the primary screw 81 . Having these screws at such strongly divergent angles makes it so only one screw is oriented in a weaker orientation for failure under a destructive load while the other screw is in a stronger orientation to resist failing. For example, if a fully inserted screw is weakest in pure tension, then if the box 50 were being pulled straight out from the door jamb J, jack screw 82 would strongly resist that load and tend to provide support for primary screw 81 preventing he primary screw 81 from failing. If the load were shifted to push the box 50 inwardly into the room in which the door would swing when opened, the jack screw 82 would be in tension, but the primary screw 81 would be in an orientation to the load that would be able to provide the additional resistance to this second type of load or force. Secondly, with the box 50 secured by a jack flange 61 to the side of the jack stud 31 , the box 50 is better prevented from rolling or rotating in the cutout while the door D is being forced open.
[0038] After the box 50 is attached to the jack stud 31 by primary screw or screws 81 and jack screws 82 , cover plate 40 is attached to the box by machine screws 83 . A third way of attaching the box 50 along with the cover plate 40 to the jack stud 31 is with secondary screws 85 that extend through screw holes 45 in the cover plate 40 and screw holes 75 in the box 50 and then through the jack stud 31 and into king stud 32 . The screw holes 45 and 75 align such that the screws 85 hold the cover plate 40 and the box 50 together while attaching to the jack stud 31 and king stud 32 . It should be noted that the screw holes 75 are off center relative to the box 50 (as identified by centerline 51 in FIGS. 5 and 6 ) and especially with respect to the main opening 43 in the cover plate 40 so that the secondary screws 85 will be positioned closer to the center of the jack stud 31 as shown in FIGS. 8, 9, 12 and 13 and further away from the edge of the jack stud 31 to avoid the vulnerability of tearing up the jack stud as described when discussing FIGS. 2 and 3 above. Focusing on FIG. 6 , the center line 51 is shown extending vertically across the face or front opening of the box 50 and the holes 75 are positioned on the opposite side of the centerline from the jack flange 61 and closer to the inner wall 52 . It should also be noted that the center bore 98 is arranged to be outside the alignment of the screw holes 75 and 77 to reduce the probability that all three screws will hit the same grain line in the wood. If all three screws hit the same grain line, the stud would be likely to split and be seriously weakened.
[0039] One feature of the invention that provides additional strength to the striker box assembly is the way the inner wall 61 , the base wing 65 and the back flange 42 are arranged to create a U-channel as seen in FIGS. 8, 9, 12 and 13 . This U-channel provides resistance to distortion of the striker box assembly under a severe load in a manner similar to the way an I-beam or a piece of channel iron resists bending.
[0040] Another aspect of the striker box assembly is that the boot 92 is arranged to be offset from where the latch 16 may set into the box 50 . The box 50 is generally preferred to be about 5 / 8 ″ in depth to work with a conventional jamb dimension of 11 / 16 ″.
[0041] When the drywall 28 and door trim 99 are attached as shown in FIG. 13 , the striker box assembly will appear to be reasonably similar to conventional systems and the cutout will not be visible.
[0042] Ultimately, the striker box assembly will only be as strong as the materials from which it is constructed and to which it is attached. This invention is intended to take as much advantage of the available structure within the wall surrounding the door as possible in a cost considered manner and reduce the likelihood of failure of the door system based on the striker being the weak link.
[0043] In closing, it should be noted that the discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. At the same time, each and every claim below is hereby incorporated into this detailed description or specification as a additional embodiments of the present invention.
[0044] Although the systems and processes described herein have been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the spirit and scope of the invention as defined by the following claims. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described herein. It is the intent of the inventors that variations and equivalents of the invention are within the scope of the claims while the description, abstract and drawings are not to be used to limit the scope of the invention. The invention is specifically intended to be as broad as the claims below and their equivalents.
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A striker box assembly provides enhanced security when locking a door where the assembly includes a box and a cover plate which are secured to a stud in the frame around the doorway in at least three ways. The first way of securing the assembly is with screws in a jack flange that extends along a lateral side of the stud in flush contact therewith. The second manner is with a screw in the bottom of the box to hold the box firmly against the stud or through shims or a boot that solidly fills any gap between the bottom of the box and the stud. The third way is with offset screws that extend through the cover plate and the box into the stud. The cover plate includes a flange that provides additional strength to resist destructive forces involved when a person attempts to break down a door.
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This application is a continuation of application Ser. No. 09/664,281, filed on Sep. 18, 2000 now U.S. Pat. No. 6,412,431, which is a continuation-in-part- of application Serial No. 09/360,281, filed on Jul. 22, 1999, now U.S. Pat. No. 6,204,014, which is incorporated herein by this reference.
BACKGROUND
The present invention relates to cushioning devices for wharfs and docks to which shipping vessels are docked at shipping terminals.
A prior art fender installation on a vertically oriented stationary wharf face includes one or a vertically spaced plurality of resilient support members to which is fastened a plate having resilient tiles thereon. In one configuration, each support member is a conically shaped molding having steel flange reinforcements at opposite ends and having openings therein for receiving threaded fasteners. In another configuration, the support members have generally V-shaped configuration including a pair of diverging vertically oriented flexible web portions diverging from proximate the plate and having respective outwardly projecting flanges that are fastened to the wharf face. Such devices provide resilient lateral support for large ships. However, they exhibit a number of disadvantages. For example:
1. They are expensive to provide in that the resilient tiles require a large number of fasteners for anchoring to the plates;
2. The plates and fasteners are subject to corrosion;
3. The plates are excessively heavy and/or insufficiently strong for resisting expected side loading, particularly at corners of the plates.
Thus there is a need for a composite fender that overcomes the disadvantages of the prior art.
SUMMARY
The present invention meets this need by providing a fender panel and assembly that is particularly effective in protecting wharfs from damage by passing or docking ships. In one aspect of the invention, the fender panel includes a resilient body member having a front surface and a rear mounting surface; and a cage frame encapsulated within the body member, the cage frame including an attachment structure connected to plural spaced apart locations of the cage frame, the attachment structure defining a spaced plurality of attachment elements for connecting to supporting structure. The cage frame is spaced from the front face by not less than 10 percent of a panel thickness of the body member between the front face and the rear mounting surface for cushioning the impact of contacting ship hulls. The cage frame preferably includes a grid of rod members for forming a light-weight, high-strength matrix reinforcement of the body member.
The rod members of the cage frame can be steel reinforcing rods having gripping projections formed thereon. Preferably the rod members have a nominal cross-sectional diameter that is not more than 10 percent of the panel thickness for efficient utilization of the steel material. Preferably the grid of the cage-frame has welded connections at respective intersections thereof for enhanced rigidity. The grid can be a front grid, the cage frame further including a rear grid of rod members and a spacer structure connecting portions of the grids in rigidly spaced relation.
The attachment structure can be rigidly connected to the spacer structure, and can include a plate member having respective fastener openings extending through the plate member to form the attachment elements. The plate member can be parallel-spaced from the mounting surface, the attachment structure also including a plurality of tubular spacers extending between the plate member and the mounting surface in alignment with the fastener openings for receiving corresponding threaded fasteners. The spacer structure can be a rectangular frame having pairs of side and end frame members, and the plate member can be welded between the side frame members. The frame members can be formed having a uniform cross-section including spaced pairs of flange portions and connecting web portions, the flange portions forming front and rear faces of the frame.
The grids can include respective pluralities of lateral and longitudinal rods, with some of the lateral rods being connected to the side frame members, and the longitudinal rods being connected to the lateral rods in spaced relation opposite the frame.
The front surface can include a planar main portion and a tapered perimeter portion, a cushion thickness of the resilient body between the main portion of the front surface and the cage frame preferably being at least 30 percent of the panel thickness for enhanced cushioning of impacting vessel hulls. Regardless of the panel thickness the cushion thickness is preferably at least 0.15 meters. Preferably, the resilient body consists of a main polymeric component and an additive component, the main polymeric component being low-density polyethylene of which at least 35 percent is linear low-density polyethylene for preventing cracking and preserving uninterrupted coverage of the cage frame by the resilient body, the additive component including an effective amount of an ultraviolet inhibitor. Preferably the main polymeric component is at least 90 percent of the resilient body, the resilient body including not more than 5 percent by weight of high-density polyethylene. It is also preferable that the main polymeric component be at least 65 percent linear low-density polyethylene.
The cage frame can include a frame having pluralities of first and second beams that are rigidly connected in orthogonal relation, and the cage frame can include the grid of first and second rod members wherein the first rod members are connected between the second rod members and a front face of the frame. The first and second beams can be joined in coplanar relation. The at least some of the second beams can be segmented with each segment extending between a pair of the first beams. The beams can each be formed having a uniform cross-section including front and rear flange portions and a connecting web portion, the flange portions forming respective front and rear faces of the frame.
The attachment elements can be formed in respective boss members that are rigidly connected between respective front and rear flanges of one of the beams. The boss members can be threaded for engaging threaded fasteners. Preferably each of the boss members projects rearwardly from the rear flanges of the beams for reinforcing respective threaded fastener. More preferably, the boss members are formed of corrosion resistant steel and extend flush with the rear mounting surface of the body member for enhancing the reinforcement and for preventing corrosion in case of water leakage between the support and the rear mounting surface of the composite fender panel.
Alternatively, the boss members can be spaced from the mounting surface with a passage being formed for the fastener between the boss member and the mounting surface whereby, when the fasteners are tightened against a support that contacts the mounting surface, the body member is compressed about the fasteners between the mounting surface and the bosses for sealing same. Also, or in the alternative, the boss members can be formed with passages therethrough for receiving threaded fasteners, a cavity being formed between the boss and the front surface of the resilient body for receiving a head of the fastener and a plug for encapsulating the head of the fastener.
The frame can include front and a rear portions that are connected in parallel-spaced relation by a plurality of third beams for imparting added strength to the cage frame.
A composite fender assembly can be formed from the composite fender panel and a resilient support member for mounting the fender panel in resiliently spaced relation to a wharf face, the support member having a plurality of threaded fastener cavities formed in a support surface thereof, the fender panel being attached by a plurality of threaded fasteners that connect respective fastener elements of the fender panel to the support member for rigidly holding the mounting surface of fender panel against the support surface of the support member. The resilient body can be initially formed with head cavities extending between respective fastener openings and the front face, the head cavities being tapered continuously inwardly between the front face and the fastener elements, a resilient plug member being subsequently sealingly bonded within the cavity and forming a portion of the front face. The plug member can adhesively bonded or thermally fused within the cavity.
In another variation, the fastener elements can be formed as threaded openings in the attachment structure for engaging corresponding ones of the threaded fasteners when there is access to heads of the fasteners opposite a flange of the support member.
In another aspect of the invention, a method for forming a composite fender panel includes:
(a) forming a cage frame including a spaced plurality of attachments; and
(b) encapsulating the cage frame in a resilient material forming a resilient body having a front surface and a rear mounting surface, the resilient material being formed for accessing the attachment elements.
The method can further include providing an openable mold assembly having front and rear mold elements for respectively defining the front surface and the rear mounting surface, and supporting the cage frame within the mold assembly by a plurality of threaded fasteners engaging respective ones of the fastener openings. The fastener openings can be threaded, the fasteners threadingly engaging the fastener openings during the encapsulating.
The cage frame can include the grid of reinforcing rods on a front face of the frame, with first rods being connected to the front face and second rods connected to front edges of the first rods. The cage frame can include the frame having intersecting beam members, and the attachment elements can have respective fastener openings.
The method can further include, prior to the encapsulating, assembling respective spacer sleeves against the frame in registration with corresponding ones of the fastener openings, the spacer sleeves being encapsulated flush with the mounting surface in the encapsulating of the cage frame. Also or alternatively, the encapsulating includes forming respective passages extending from the mounting surface to the fastener openings. Also, the encapsulating can include forming respective head cavities in the body between the front surface and the fastener openings for accessing the fastener openings.
The invention also provides a method for making a composite protective fender assembly, including forming the composite fender panel; providing a resilient support member having a plurality of threaded fastener cavities formed in a supporting surface thereof; fastening the fender panel against the supporting surface using headed fasteners extending from respective head cavities, through the mounting plate, and into engagement with corresponding ones of the threaded cavities; and sealingly filling the head cavities using respective resilient plug members.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
FIG. 1 is a side elevation view of a fender assembly including a composite fender panel according to the present invention;
FIG. 2 is a front elevation view of the fender panel of FIG. 1;
FIG. 3 is a front view showing the fender panel of FIG. 1 partially cut away;
FIG. 4 is a side view showing the fender panel of FIG. 1 cut away as in FIG. 3;
FIG. 5 is a fragmentary sectional detail view within region 5 of FIG. 1 showing the fender panel in final stages of assembly;
FIG. 6 is a plan sectional view showing a fender assembly including an alternative configuration of the composite fender panel of FIG. 1;
FIG. 7 is a front view of the composite fender panel of FIG. 6 showing an front grid portion of an internal cage-frame thereof;
FIG. 8 is a rear view of the composite fender of FIG. 6, showing a frame portion of the internal cage-frame thereof;
FIG. 9 is a plan sectional view showing an alternative configuration of the composite fender panel of FIG. 6;
FIG. 10 is a plan view of a mold assembly for forming the composite fender panel of FIG. 6;
FIG. 11 is a front view of the mold assembly of FIG. 10;
FIG. 12 is a rear view of the mold assembly of FIG. 10;
FIG. 13 is a flow chart for a process of fabricating the composite fender panel of FIG. 6;
FIG. 14 shows an alternative configuration of the flow chart of FIG. 13; and
FIG. 15 is a fragmentary sectional view showing an alternative configuration of a boss portion of the composite fender panel of FIGS. 6 - 8 .
DESCRIPTION
The present invention is directed to a composite fender that is particularly suited for protecting wharfs and other structures at and in the vicinity of shipping terminals. With reference to FIGS. 1-5 of the drawings, a fender assembly 10 includes a composite fender panel 12 that is spaced from a wharf face 14 by a resilient support 16 . According to the present invention, the fender panel 12 includes a cage-frame 18 that is encapsulated within a resilient body 20 . In an exemplary configuration, the cage-frame 18 incorporates a rectangular frame 21 having grid reinforcements on opposite faces as described below, the frame 21 including a plate 22 having fastener openings 24 therein for attachment by respective threaded fasteners 25 to the support 16 as also described below. Opposite edges of the plate 22 are welded to a pair of longitudinal frame members 26 which can be channel members as shown in FIG. 3, the channel members each having an inwardly facing web 28 and outwardly facing flanges 30 that are individually designated front flange 30 F and a rear flange 30 R. A pair of cross members 32 are welded to opposite ends of the frame members 26 , the cross members 32 having counterparts of the web 28 and the flanges 30 as best shown in FIG. 4, being formed of the same material, the frame 21 having respective front and rear faces 34 F and 34 R, the plate 22 being flush with the front face 34 F.
The cage-frame 18 also includes at least one grid 36 of reinforcing members 38 including a plurality of lateral reinforcing members 38 A and a plurality of longitudinal reinforcing members 38 B. Preferably a front grid 36 F is located against the front face 34 F and a rear grid 36 R is located against the rear face 34 R of the frame 21 , the lateral reinforcing members 38 A being welded directly to the frame members 26 at a spacing S 1 , the longitudinal reinforcing members 38 B having a spacing S 2 and being welded to opposite sides of the lateral reinforcing members 38 A in spaced relation to the frame 21 . The lateral and longitudinal reinforcing members 38 A and 38 B are preferably formed of steel reinforcing bar, commonly known “re-bar”, which has a ribbed surface configuration that facilitates the transfer of shear loading between the members 38 and an encapsulating medium. Also, opposite ends of the reinforcing members 38 can be formed at right-angles to extend between the front and rear flanges 30 F and 30 R of the frame members 26 and the cross members 32 , thereby augmenting the structural integrity of the encapsulating resilient body 21 as best shown in FIGS. 1 and 3. It will be understood that separate lengths of reinforcing material can be attached between the flanges 30 F and 30 R in place of formed extensions of the reinforcing members 38 .
The cage-frame 18 , which is typically a welded assembly, is encapsulated in a polymeric material that does not form voids and cracks due to tensile thermal strains being generated during solidification. A particularly suitable composition for forming the plastic body 14 as an uninterrupted covering of the cage-frame 18 is discloses in this inventor's U.S. Pat. No. 6,244,014. Initially, and prior to assembly with the resilient support 16 , the body 20 is formed with respective conically shaped cavities 46 extending from the front surface 42 to the plate 22 in regions surrounding the fastener openings 24 , the cavities being subsequently filled as described below. The composition includes a main first quantity of low density polyethylene of which at least 35 percent and preferably 65 percent is linear low-density polyethylene (LLDPE), the balance being regular low-density polyethylene (LDPE), and a process additive second quantity including an effective amount of UV inhibitor, the composition not having any significant volume of filler material such as calcium carbonate. Preferably, the first quantity is at least 90 percent of the total volume of the plastic body 14 , approximately 5 percent of the total volume being a mixture of coloring, foaming agent, and IN inhibitor. Preferably the composition is substantially free (not more than 5 percent) of high density polyethylene.
Thus the composition of the resilient body 20 has polymeric elements being preferably exclusively polyethylene as described above (substantially all being of low-density and mainly or at least 50 percent being linear low-density), together with process additives as described below. As used herein, the term “process additive” means a substance for enhancing the properties of the polymeric elements, and does not include filler material such as calcium carbonate. The composition preferably contains a process additive which can be a foaming or blowing agent in an amount of up to about 0.9% by weight to insure than when the plastic body 14 is made by extruding the plastic composition into a mold, the mold is completely filled. The foaming agent can be a chemical blowing agent such as azodicarbonamide. A suitable chemical blowing agent is available from Uniroyal of Middlebury, Conn., under the trade name Celogen AZ 130.
Other process additives of the composition can include a coupling agent, preferably a silane, for improved bonding between the plastic body 14 and the cage 12 .
The plastic composition can also include a fungicide, typically in an amount of about 0.25% by weight, and an emulsifier, in an amount of from about 0.1% to 0.3% by weight. The use of emulsifier improves surface appearance of the product.
The composition can also contain a carbon black, generally a furnace black, as a colorant, to improve the physical properties, and as a UV stabilizer. The amount of carbon black used is generally about 2.5% by weight.
In a typical configuration, the composite panel 12 is generally rectangular and having a width W, a height H, and a thickness T as shown in FIGS. 1 and 2. A rear surface 40 of the panel is generally planar, a front surface 42 having a planar central region 42 C and beveled perimeter region 412 . The resilient body 20 has a thickness T 1 between the front surface central region 42 C and the longitudinal reinforcing members 38 B of the front grid 36 F. Also encapsulated in the composite panel 12 are respective stand-off spacer sleeves 44 that are aligned with corresponding ones of the fastener openings 24 as shown in FIG. 5, each of the spacer sleeves 44 extending between the plate 22 and the rear surface 40 for rigidly spacing the frame 21 from the support 16 when the composite panel 12 is attached thereto by the fasteners 25 . The resilient body 20 is formed with cone-shaped cavities 46 concentric with the mounting holes 24 and extending from the plate 22 and the front surface 42 for receiving the fasteners 25 during assembly with the support 16 . After the fasteners 25 have been securely tightened, each of the cavities 46 is filled with a plug 47 of resilient material which can be the same material as that of the body 20 . In the assembled condition of the fender assembly 10 , a substantially effective seal is formed at the rear surface 40 of the composite panel 12 by pressure contact against the support 16 when the fasteners 25 are tightened. Thus the fasteners 25 and the entirety of the cage-frame 18 are fully encapsulated by the material of the resilient body 20 in combination with the support 16 (to the extent that the support 16 sealingly engages threaded extremities of the fasteners 15 ). In that respect, it is contemplated that the support 16 includes a metal collar having threaded engagement with the fasteners 25 , the collar being encapsulated within resilient material of the support except for openings to respective threaded holes of the collar for receiving the fasteners 25 .
In the exemplary configuration shown in the drawings, the height H is on the order of 3 meters, the width W is on the order of 1.6 meters, and the thickness T is on the order of 0.4 meters, the frame 21 incorporating a spaced pair of the plates 22 for support of the composite panel 12 by a vertically spaced pair of the supports 16 . The frame members 26 and the cross members 32 are formed off 4-inch standard structural steel channel, and the reinforcing members 38 are lengths of 1-inch diameter reinforcing bar, the spacings S 1 and S 2 being on the order of 0.3 meter. The thickness T 1 of the resilient body 20 between the front surface central region 42 C and the front grid 36 F is approximately 18 cm, being approximately 45 percent of the thickness T. It will be understood that the actual dimensions of the various components of the cage-frame 18 are determined by expected impact loading to be encountered, and the thickness T 1 can range from approximately 5 cm up to approximately 1.5 meters.
With further reference to FIGS. 6-8, an alternative configuration of the fender assembly, designated 10 ′, has a counterpart of the composite panel, designated 12 ′ mounted on a counterpart of the support, designated 16 ′. Stainless-steel counterparts of the fasteners, designated 25 ′, are inverted and extend forwardly through an outwardly projecting flange 50 of the support 16 ′, threadingly engaging respective threaded sleeves 52 that are rigidly supported within a counterpart of the cage-frame, designated 18 ′ as further described below. As also shown in FIG. 6, the cage-frame 18 ′ includes a counterpart of the front grid 36 F, but not the rear grid 36 R, a counterpart of the frame, designated 21 ′, being augmented by a plurality of beam members 54 including vertical beam members 54 V and horizontal beam members 54 H that are rigidly supported within counterparts of the longitudinal frame members 26 and the cross members 32 . As in the configuration of FIGS. 1-5, the frame members 26 and the cross members 32 can be structural steel channels that define respective front and rear faces 34 F and 34 R. The beam members 54 can be structural beams such as I-beams and WF beams, WF beams being shown in the drawings as standard W4×13 members, the various members being rigidly welded together. Also, the horizontal beam members 54 H are segmented and notched for projecting between respective flanges of the vertical beam members 54 V to be flush with the front and rear faces 34 F and 34 R of the frame 21 ′. It will be understood that the vertical frame members 54 V can be segmented instead of the horizontal frame members 54 H, and that the beam members 54 can be arranged in two layers without segmenting. The threaded sleeves 52 project through respective openings that are formed in flanges of the beams 54 , being securely welded in place.
With further reference to FIG. 9, another alternative configuration of the fender assembly, designated 10 ″, has greatly enhanced strength for resisting more severe lateral loading by contacting large vessels. A counterpart of the composite panel 12 ′, designated 12 ″ and having increased thickness, is mounted to a counterpart of tee support 16 ′ of FIG. 6. A counterpart of the cage-frame 18 ′, designated 18 ″, includes a space-frame 21 ″ having a front frame section 21 A and a rear frame section 21 B that is rigidly connected thereto in parallel-spaced relation by a plurality of diagonal frame members 54 D. The front frame section 21 A corresponds to the frame 21 ′ of FIGS. 6-8 but without the threaded sleeves 52 , whereas the rear frame section 21 B corresponds to a central portion of the frame 21 , including the threaded sleeves 52 . The spacing between the frame sections 21 A and 21 B is selected such that the combination of the frame 21 ″ with the front grid 36 F provides an effective bending strength of the panel 12 ″ sufficient to transmit the more severe loading contemplated for the fender assembly 10 ″.
With further reference to FIGS. 10-12, a mold assembly 60 for encapsulating the cage-frame 18 ′ to form the composite panel 12 ′ of FIGS. 6-8 includes a flanged front mold shell 62 , and a flanged rear mold wall 64 , the shell 62 and the wall 64 being sealingly joined by a set of mold fasteners 66 . The mold assembly 60 is characterized by robust construction in view of anticipated molding pressures on the order of 350 psi. The mold assembly 60 also incorporates a conventional extruder inlet and an air exhaust port (not shown). In an exemplary configuration as shown in the drawings, the mold shell 62 and wall 64 are each weldments of steel mold plates 68 , reinforcing beams 70 , and flange members 72 , the shell 62 also having reinforcing plates 72 in areas forming the perimeter region 42 P of the panel 12 P. The inside dimensions of the mold assembly 60 correspond to like dimensions of the panel 12 ′, but with suitable allowances for shrinkage of the material forming the body 20 . Counterparts of the fastener openings, designated 24 ′, are formed on the plate 68 of the rear mold wall for supporting the cage frame 18 ′ during molding. If necessary, portions of the reinforcing beams 70 can be removed for clearing fasteners used for that purpose. Suitable material for the plates 68 is mild steel of 0.5 inch thickness; the reinforcing beams 70 can be conventional steel beams, A.I.S.C. 4 WF 13 shapes (having a 4.0 inch section depth and weighing 13 pounds per foot) being shown. The flange members 72 can be 1-inch by 2-inch mild steel bars, and the reinforcing plates 72 can be mild steel of 0.5 inch thickness, approximately 12 inches long and 4 inches wide. It will be understood that other configurations of the mold assembly 60 can provide the needed stiffness and strength against molding pressure, including different thicknesses of the plates 68 and other arrangements of the reinforcing beams 70 , which can also extend diagonally in place of the reinforcing plates 72 .
Also shown in FIG. 10 is the cage 18 ′ centered within a main cavity 74 of the mold assembly 60 , being supported by counterparts of the fasteners, designated 25 ″ that are inserted through the fastener openings 24 ′. More particularly, the mold assembly is preferably inverted so that the cage frame 18 ′ is suspended in spaced relation to the rear mold wall by the fasteners 25 ″. It will be understood that when molding the composite panel 12 of FIGS. 1 - 5 , the fasteners 25 ″ also locate the spacer sleeves 44 during molding; also, the fasteners 25 ″ can threadingly engage respective mold inserts (not shown) for forming the cavities 46 .
With further reference to FIG. 13, a molding process 100 for forming the panel 12 includes a load mold step 102 wherein the cage-frame 18 ′ is mounted to the rear mold wall 64 using the fasteners 25 ″. Then, the mold shell 62 is fastened to the mold wall 64 in a close mold step 104 and, optionally in an incline mold step 106 , the mold assembly 42 is propped up on a suitable support for elevating one or more exhaust vents (not shown).
Next, the material of the resilient body 20 is fed into the main cavity 60 in an inject body step 108 . Then in a cooling step 110 , the mold assembly 60 with its contents is submerged in cooling water for solidifying the material of the plastic body 20 , after which the assembly 60 is removed from the water (step 112 ), and the mold assembly 60 is opened (step 114 ). The fasteners 25 ″ are removed, and the substantially complete fender panel 12 ′ is taken from the rear mold wall 64 (step 116 ); and the panel 12 ′ is assembled with the resilient support 16 (step 118 ).
With further reference to FIG. 14, an alternative counterpart of the molding process for the configuration of the fender assembly 10 of FIGS. 1-5 is designated 100 ′, wherein, following the fastening step 118 , exposed head portions of the fasteners 25 and adjacent portions of the plate 22 are sealed in a fill cavities step 120 by first surface-heating the plugs 47 and the cavities 46 using suitable means such as the flame of an acetylene torch, and pressing the plugs 47 into the cavities 46 flush with the front surface 42 of the fender panel 12 .
As described above, FIG. 5 shows one of the cavities 46 prior to filling, and others of the cavities having been filled with corresponding plugs 47 .
If desired or needed, the cage-frame 18 ( 18 ′ or 18 ″) and/or the mold assembly 60 can be preheated to be certain that the plastic material of the resilient body 20 flows to the exhaust port(s) of the mold assembly 60 and completely fills the main cavity 74 .
With further reference to FIG. 15, alternative counterparts of the threaded sleeves, designated 52 ′, are extended to the rear of the rear flanges 30 R for augmenting lateral stability of the fender assembly 10 ′ by reinforcing the fasteners 25 ′. In the exemplary and preferred configuration of FIG. 15, the sleeves 52 ′ are fully flush with the rear surface 40 , it being further preferred that the sleeves 52 ′ be formed of stainless steel for preventing corrosion in case of water leakage between the support 16 ′ and the rear surface 40 . Similarly, the spacer sleeves 44 in the configuration of FIGS. 1-5 can also be formed of stainless steel.
The fender assembly 10 of the present invention is immune to marine borer attack, and thus requires no further protection, such as creosote or plastic sheathing, being practically maintenance free. The fender panel 12 is abrasion resistant, and thus has excellent effectiveness as a marine fender without any added protective covering.
The composite fender panel 12 is chemically inert, so it can last indefinitely. It does not react with sea water, is corrosion free, is substantially immune to the effects of light, is not bothered by most petroleum products, and is not subject to dry rot. Because it can be made with recycled plastic, it is an environmentally sound investment.
In some military based naval applications, it is undesirable for a wharf fender to be electro-magnetically sensitive. In such applications the cage-frame 18 can be formed with non-magnetic materials, such as carbon-reinforced plastic. The cage-frame 18 can also be developed by using fiberglass reinforcing rods and shapes, with reinforced epoxy joints at points of contact between the reinforcing members 38 , between the lateral members 38 A and the frame 21 , as well as between elements of the frame 21 .
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, the plate 22 in the configuration of FIGS. 1-5 can be displaced rearwardly to the rear face 34 R of the frame 21 . Also, the composite panel can have other shapes than rectangular, including hexagonal, octagonal, trapezoidal, and rounded, for example. Therefore, the spirit and scope of the appended claims should not necessarily be limited to the description of the preferred versions contained herein.
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A composite fender panel for protecting a harbor structure includes a resilient body member having a front surface and a rear mounting surface spaced by a panel thickness from a main portion of the front surface. Encapsulated within the body member is a cage frame including a frame having a plurality of intersecting beams of uniform cross-section including front and rear flange portions and a connecting web portion, at least some of the flange portions forming respective front and rear faces of the frame; a grid of steel reinforcing rods having gripping projections formed thereon, the rods also having a nominal cross-sectional diameter being not more than 10 percent of the panel thickness, a first plurality of the rods being welded to the front face of the frame, a second plurality of the rods having welded connections to the first rods in spaced relation opposite the front face of the frame; and an attachment structure defining a spaced plurality of attachment elements formed in respective boss members, each of the boss members being rigidly connected between respective front and rear flanges of one of the beams.
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BACKGROUND OF THE INVENTION
[0001] A fuller understanding of the operation of the demolition apparatus of the present invention may be achieved by studying U.S. Pat. Nos. 4,519,135 and 6,061,911, hereby incorporated by reference. This invention relates to a heavy duty demolition apparatus, especially adapted to be mounted on a rigid boom of a mobile vehicle and particularly adapted to be mounted on the dipper stick of an excavator, with a blade stabilizing device or puck to keep the upper jaw of the apparatus from moving laterally relative to the lower jaw and breaking during the shearing operation on a workpiece.
[0002] Heavy duty shears of the type that are powered by hydraulic cylinders are proving more and more useful in handling scrap and especially metal scrap of all sorts. Such scrap comes in many different forms, and may be in the form of pipes made of steel or soft iron or cast iron, ranging in sizes from 2 inches or smaller, and up to 8 or 10 inches in diameter or larger; structural beams such as I-beams, channels, angle beams in a large range of sizes, up to 8 or 10 inches across and larger; rods and heavy cables having diameters of 2 to 3 inches and larger, metal sheets and plates and formed metal of all sorts including wheels and automobile and truck frames, and a myriad of long and short pieces of stock and metal pieces that are cast, rolled, stamped or otherwise formed, both singly and in various types of assembly.
[0003] The prior art has included numerous shears such as that illustrated in U.S. Pat. Nos. 4,198,747; 4,188,721; 4,897,921; 4,543,719; 4,558,515 and 4,104,792. Typically, these heavy duty shears mount on the dipper stick of an excavator so that the shears may be controlled fairly well in handling various types of scrap and cutting the scrap into smaller pieces and lengths.
[0004] Typically, these shears have a fixed lower jaw and a movable upper jaw that pivots on the lower jaw, with shear blades of hardened steel on both the upper jaw and the lower jaw. The workpiece is sheared by closing the upper jaw against the lower jaw under hydraulic pressure, with the shear blades cutting the workpiece.
[0005] Unfortunately, great lateral as well as vertical pressure develops against the movable upper jaw as it contacts and proceeds to cut the workpiece. This lateral pressure can cause the upper jaw to crack or otherwise experience structural failure. This lateral pressure exists from the moment the upper jaw contacts the workpiece until the workpiece is cut and the upper jaw meets the lower jaw and becomes supported by the lower jaw in a slot in the lower jaw. This lateral force develops analogously to when a person tries to cut too heavy an object with a pair of scissors. The scissors' blades are forced laterally apart and may break.
[0006] There is a need for a heavy duty demolition shear with a blade stabilizing device that prevents lateral movement of the upper jaw relative to the lower jaw and which supports the upper jaw against this lateral pressure.
[0007] In rebuilding highways for motor vehicle travel, and in the demolition of structures which are largely made of or incorporate reinforced concrete as structural members, the disposal of large pieces of concrete paving or reinforced concrete structure becomes a significant problem. Many governmental regulations and practical considerations relating to the operation of landfills prohibit the disposal of concrete slabs and large reinforced concrete structures by simply burying them in the landfills. Accordingly, it becomes necessary to dispose of such concrete material in other ways.
[0008] Crushing of the concrete is one alternative so that the concrete slabs and structures may be reduced to smaller particle sizes which accommodates the reuse of such concrete as fill and as aggregate base for roadways and the like.
[0009] It has been possible in the past to reduce concrete into particles and chunks by use of heavy duty shears, but such shears which are primarily designed for shearing steel and other metallic and wood structures have sharpened blades and are rather expensive for the purpose of reducing concrete slabs and structures which is thought to be accomplished in other ways. Such crushers are shown in U.S. Pat. Nos. 5,478,019; 4,512,524; 5,183,216; 5,044,569; and 4,951,886.
[0010] Furthermore, crushing concrete may result in the development of lateral pressure against the movable upper jaw of a demolition shear in the same way that shearing metal does.
[0011] There is a need for a demolition apparatus with a blade stabilizing device that prevents lateral movement of the upper jaw relative to the lower jaw and which supports the upper jaw against this lateral pressure.
SUMMARY OF THE INVENTION
[0012] A blade stabilizer device for a heavy-duty material handling demolition tool for shearing and crushing scrap material which includes a lower jaw connected to the boom structure of a hydraulic system of an excavator and has an upper jaw pivotally connected and closeable upon the lower jaw beginning at the pivot point. The blade stabilizing device consists of a wear guide supported by the lower jaw adjacent the pivot point slidably engaging the upper movable jaw to keep the upper jaw in close engagement with the lower jaw. The wear guide is mounted behind the pivot point. A second wear guide may be mounted in front of the pivot point on the opposite side of the upper jaw to cross-brace the upper jaw.
[0013] An object and advantage of the invention is to provide an improved heavy-duty material handling demolition tool for shearing and crushing scrap material with a blade stabilizing device which prevents the upper jaw from moving laterally relative to the lower jaw, thus improving the cutting ability of the tool for heavy scrap material.
[0014] Another object and advantage of the present invention is to provide a blade stabilizing device for a heavy-duty demolition tool which reduces lateral stress on the upper jaw caused due to shearing the workpiece.
[0015] Another object and advantage of the present invention is that the blade stabilizing device is removable and replaceable when worn due to friction with the upper jaw.
[0016] Another object and advantage of the present invention is that the clearance between the blade stabilizing device and the upper jaw is adjustable to compensate for wear.
[0017] Another object and advantage of the present invention is that the blade stabilizing device contacts a wear surface on the upper jaw and the wear surface is dimensioned such that the blade stabilizing device does not contact the wear surface once the upper jaw is securely received in the lower jaw.
[0018] Another object and advantage of the present invention is that the blade stabilizing device may comprise a first stabilizer or puck mounted to the rear of the pivot point and a second stabilizer or puck mounted in front of the pivot point, thereby providing cross-bracing to the upper jaw.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a right-side perspective view of the heavy-duty demolition apparatus of the present invention.
[0020] FIG. 2 is a cross-section of the heavy duty demolition apparatus of the present invention at approximately the lines 2 of FIG. 1 .
[0021] FIG. 3 is a right-side elevational view of the heavy-duty demolition apparatus of the present invention with some internal structure shown in phantom.
[0022] FIG. 3A is a left side elevational view of the apparatus.
[0023] FIG. 4 is the same as FIG. 3 , showing the upper jaw partially closed.
[0024] FIG. 5 is the same as FIG. 3 , showing the upper jaw fully closed.
[0025] FIG. 6 is a left-side perspective view of the heavy duty demolition apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The heavy-duty demolition apparatus of the present invention is generally referred to in the Figures as reference numeral 10 .
[0027] Referring to FIGS. 1 through 6 , the heavy-duty demolition apparatus 10 comprises a lower jaw 12 , an upper jaw 14 , pivot means 16 interconnecting the lower jaw 12 and upper jaw 14 , and means 18 for attachment to the excavator (not shown). The means 18 may further include a rotator unit 20 allowing rotation of the demolition unit 10 about a longitudinal axis. The apparatus 10 also includes means 30 for attachment to the hydraulic system of an excavator (not shown) for closing and opening the upper jaw relative to the lower jaw. More specifically, the means 30 includes a cylinder 30 a having a reciprocating piston 30 b within the cylinder 30 a . The cylinder 30 a is connected to the hydraulic system of the excavator (not shown). The piston 30 b connects to the upper jaw 14 at a knuckle 32 .
[0028] The upper jaw 14 has a first side 22 , and a second side 24 . The lower jaw 12 has a first mounting plate 26 adjacent the first side 22 , and a second mounting plate 28 adjacent the second side 24 . The first mounting plate 26 and second mounting plate 28 receive the pivot means 16 between them.
[0029] The upper jaw 14 has upper shear blades 34 and the lower jaw 12 has lower shear blades 36 extending along each other for shearing a workpiece when the upper shear blades 34 are closed upon the lower shear blades 36 . Preferably, the shear blades 34 , 36 are replaceable.
[0030] A blade stabilizing device 38 for the apparatus 10 engages the upper jaw 14 to prevent the upper jaw 14 from moving laterally with respect to the lower jaw 12 while shearing the workpiece.
[0031] Preferably, the blade stabilizing device 38 further comprises a first blade stabilizer 40 attached to the first mounting plate 26 and slidably engaging the upper jaw 14 on the first side 22 of the upper jaw 14 . Optionally, a second blade stabilizer 42 may be attached to the second mounting plate 28 and slidably engaging the upper jaw 14 on the second side 24 of the upper jaw 14 .
[0032] Preferably, the apparatus 10 further comprises a first arcuate wear surface 44 on the first side 22 and contacting the first blade stabilizer 40 and a second arcuate wear surface 46 on the second side 24 and contacting the second blade stabilizer 42 . The second arcuate wear surface 46 may be on a hub or reinforced section of the upper jaw 14 . The wear surfaces 44 , 46 may preferentially be constructed of a different material from the upper jaw 14 in order to better resist sliding friction cause by the first blade stabilizer 40 and second blade stabilizer 42 .
[0033] Preferably, the apparatus 10 further comprises a guide blade 48 on the lower jaw 12 lying along the lower shear blade 36 and in spaced relation therewith, the outer end 50 of the guide blade and outer end 52 of the shear blade being adjacent each other, and rigid means 54 securing the outer ends 50 , 52 together. The rigid means 54 is preferably a tie plate 56 .
[0034] An open slot 58 preferably exists between the lower shear blade 36 and the adjacent guide blade 48 to receive the upper shear blade 34 therein, the open slot 58 having a width wider than the thickness of the upper shear blade 34 to maintain open space between the upper shear blade 34 and the guide blade 48 when the upper shear blade 34 is in the open slot 58 . Preferably, the first arcuate wear surface 44 and second arcuate wear surface 46 are of such dimensions that the first blade stabilizer or puck 40 and also perhaps the second blade stabilizer or puck 42 move off the first arcuate wear surface 44 and second arcuate wear surface 46 , respectively, when the upper shear blade 34 is received in the open slot 58 . This is because the first blade stabilizer 40 and second blade stabilizer 42 are no longer needed to brace the upper jaw 14 once the upper shear blade 34 is received in the slot 58 .
[0035] Preferably, the first blade stabilizer 40 and second blade stabilizer 42 are removable and replaceable when they become worn due to frictional contact with the upper jaw 14 . The first blade stabilizer 40 and second blade stabilizer 42 may also be adjustable to provide variable clearance between them and the upper jaw 14 , as for example as the blade stabilizers become worn.
[0036] In the preferred embodiment, the first blade stabilizer 40 is located rearwardly of the pivot means 16 . FIGS. 1 and 2 show the details of the first blade stabilizer 40 . Most preferably, the first blade stabilizer 40 comprises a first guide 66 engaging the upper jaw 14 , means 70 for attaching the first guide 66 to the first mounting plate 26 , and a shim 76 for adjusting the clearance between the first guide 66 and the upper jaw 14 . The means 70 may most preferably be threaded bolts 72 with washers 73 , but it will be recognized that any equivalent fasteners such as screws or pins could also be used. Threaded bolts 70 preferably engage the first mounting plate 26 through recessed apertures 74 . The first blade stabilizer 40 may optionally further comprise an adjustment plate 80 between the first mounting plate 26 and the shim 72 . The first guide 66 may preferably further comprise a grease channel 82 opening onto the upper jaw 14 and a grease fitting 84 for delivering grease to the grease channel 82 for lubricating the engagement between the first guide 66 and the upper jaw 14 . The upper jaw 14 preferably has a pocket 86 in the first mounting plate 26 for receiving the first guide 66 .
[0037] In the preferred embodiment, the second blade stabilizer 42 is located forwardly of the pivot means 16 . FIGS. 2 and 6 show the details of the second blade stabilizer 42 . Most preferably, the second blade stabilizer 42 comprises a second guide 90 engaging the upper jaw 14 , means 70 for attaching the second guide 90 to the second mounting plate 28 , and a shim 76 for adjusting the clearance between the second guide 90 and the upper jaw 14 . The means 70 may most preferably be threaded bolts 72 with washers 73 , but it will be recognized that any equivalent fasteners such as screws or pins could also be used. Threaded bolts 70 preferably engage the second mounting plate 28 through recessed apertures 74 . The second blade stabilizer 42 may optionally further comprise an adjustment plate 80 between the second mounting plate 28 and the shim 76 . The second guide 90 may preferably further comprise a grease channel 82 opening onto the upper jaw 14 and a grease fitting 84 for delivering grease to the grease channel 82 for lubricating the engagement between the second guide 90 and the upper jaw 14 . The upper jaw 14 preferably has a pocket 92 in the second mounting plate 28 for receiving the second guide 90 .
[0038] Operation of the present invention may best be seen by viewing FIGS. 3-5 . In FIG. 3 , the upper jaw 14 is in the open position, preparatory to shearing the workpiece. It will be seen that the guide or pad or guide pad 66 rests at one end of the first arcuate wear surface 44 and the second guide or pad or guide pad 90 rests at one end of the second arcuate wear surface 46 . In FIG. 4 , the upper jaw has partially closed on the workpiece (not shown) and has begun to shear the workpiece. The guides 66 , 90 are still supported by the wear surfaces 44 , 46 respectively. In FIG. 5 , the upper shear blade has been entirely received in the slot 58 . Consequently, the support of the guide pads 66 , 90 is no longer required and the guide pad 66 has moved off the first arcuate wear surface 44 . Although not shown in the Figure, the second arcuate wear surface could also be dimensioned so that the guide pad 90 has moved off it at this point.
[0039] Before beginning operation, the operator uses a feeler gauge or a shim to measure the clearance (typically 0.003 to 0.010 inches) between the guides 66 and 90 wear surfaces 44 and 46 respectively. If the measurement is within the range of 0.003 to 0.010 inches, no adjustments are needed. If the measurement is below this range, shims 76 or 72 are either removed entirely or replaced with thinner shims to bring the arrangement within operating tolerances of 0.003 to 0.010 inches. After the pucks or guides 66 or 90 wear and the clearance is larger than 0.010 of an inch, and appropriate shim size is determined. The upper jaw 14 is then closed, the threaded bolts 70 are loosened, the shims 76 are inserted, and the bolts 70 are re-tightened. Unlike previous designs, the guides 66 , 90 are very durable with fewer maintenance problems. The clearance between the upper jaw 14 and the guides 66 , 90 may be adjusted as the guides 66 , 90 wear by adding additional shims. The grease fitting allows the engagement between the guides 66 , 90 and the upper jaw to be lubricated, reducing wear. As no fasteners traverse the mounting plates 26 , 28 in this design, it is unlikely that the mechanism will seize, which previously required cutting out the damaged assembly and welding in a new assembly. Also, the simpler design reduces manufacturing costs. The adjustment plates 80 can be used to adjust for manufacturing variances and customized to each apparatus, but are not required for all applications.
[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. In case of conflict, the present specification, including definitions, will control.
[0041] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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A blade stabilizer device for a heavy-duty material handling demolition tool for shearing and crushing scrap material which includes a lower jaw connected to the boom structure of a hydraulic system of an excavator has an upper jaw pivotally connected to and closable upon the lower jaw at a pivot point. The blade stabilizing device consists of a wear guide pad supported by the lower jaw adjacent the pivot point slidably engaging the movable upper jaw to keep the upper jaw in close engagement with the lower jaw. The wear guide pad is mounted behind the pivot point. A second wear guide pad may be mounted in front of the pivot point on the opposite side of the upper jaw to cross-brace the upper jaw.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
REFERENCE TO CONCURRENTLY-FILED DESIGN APPLICATION
[0001] Reference is made to a design patent application entitled MASON'S GUIDE LINE HOLDERS OR SIMILAR ARTICLES (Attic's Docket No. 6-491) filed concurrently herewith by the inventor hereof, Ser. No. (not known), the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to line holders of a type used by bricklayers and stone masons to support intermediate portions of tautly stretched guide lines along which courses of bricks, blocks and stones are to be laid in proper alignment as walls are built. The line holder, also known as a “trig,” positions an intermediate reach of a guide line, also known as a “trig line,” to correspond with a top surface height at which, and the location of a front surface plane along which, bricks, blocks and stones are to be accurately laid as masonry walls are erected.
[0003] Over the years, a variety of line holders or trigs have been proposed, some being more complexly configured than others, and some being more difficult to employ than others. An unduly complex and clumsy to employ trig line holder intended to support an intermediate reach of a trig line is disclosed in U.S. Pat. No. 3,148,453—which has gained little acceptance due to its complexity and relatively high cost of manufacture, and its lack of ease of use.
[0004] A much simpler trig line holder formed from a folded metal strip that has gained a reasonable degree of acceptance is disclosed in U.S. Pat. No. 3,961,387—but provides a design employing overlying components that are difficult to separate when a trig line must be inserted between the overlying components to put the holder into use. Drawbacks commonly encountered with this form of line holder are the ease with which it quickly becomes bent beyond being reused, and the loosening of its grip on guide lines—both of which problems are commonly encountered after relatively few uses of this line holder.
[0005] A simpler, repeatedly reusable, easier-to-employ line holder or “trig” has long been needed. The line holder or trig of the present invention cleverly addresses, and is quite well suited to fill, this long-standing need.
SUMMARY
[0006] The present invention provides line holders or trigs of simple, compact and lightweight construction, that are inexpensive to manufacture, that are repeatedly reusable without likelihood of becoming bent or otherwise being damaged during normal use, and that are conveniently carried in a bricklayer's or stone mason's pocket so as to be ready for use when needed. If one should be lost, the low cost of a replacement is negligible.
[0007] Of primary importance is the accuracy with which line holders or trigs embodying the invention are capable of reliably supporting and positioning a guide line, without introducing even an error that corresponds to a thickness of the material from which the line holder or trig is formed.
[0008] Some embodiments preferably take the form of a relatively thin, stiff and substantially flat member that has a centrally located body portion and a forwardly projecting guide line support portion. The body portion is postponable atop a flat surface to support the line holder at a proper height to be met as masonry elements are added to a wall. When the line holder is properly positioned, the forward line support portion defines a pair of passages that open downwardly in a front surface plane of the wall along which added masonry elements are to extend. Slot formations defined by the support portion permit a loop of guide line to be introduced into the passages so the guide line can be supported by the line holder when the guide line is stretched tautly in opposite directions along the front surface plane of the wall and at the proper height.
[0009] In some embodiments, a line holder includes a thin, elongate, generally rectangular member having two side-by-side passages that extend through the member at locations spaced short distances from one end surface of the member, having a single passage extending through the member at a location spaced a short distance from an opposite end surface of the member, having a pair of side-by-side slots each communicating with a different one of the side-by-side passages and extending through the one end surface, and having a single slot communicating with the single passage and extending through the opposite end surface.
[0010] In some embodiments, a line holder includes a thin, flat, relatively stiff member having a centrally located body portion postponable atop a horizontal surface at a desired height, and a forwardly projecting guide line support portion adapted to extend forwardly from the front surface plane 1) to define passage means configured to open downwardly through a bottom surface of the support portion at two side-by-side locations along a path extending at the desired height adjacent the front surface plane, and 2) to define slot means communicating with the passage means and configured to permit insertion of the loop into the downwardly opening passage means so the loop is supported by the line holder when the guide line is drawn taut in opposite directions extending along the path.
[0011] In some embodiments, a line holder includes a stiff, flat strip having an end region that defines two side-by-side passages extending through the strip at locations spaced a relatively short distance from an end surface of the end region, and that defines two side-by-side elongate slots each having a slot portion located adjacent to and communicating with a different one of the passages, with the slots extending in a length direction to open through the end surface, and with the passages having widths measured transverse to the length direction that are greater than are widths of slot portions located adjacent to and communicating with the passages.
[0012] In some embodiments, a line holder includes a stiff, flat, elongate strip having two side-by-side passages extending through the strip at locations spaced substantially equidistantly from an end surface of the strip, wherein the passages each communicate with a different one of two slots extending through a thickness of the strip and in a length direction to open through the end surface, wherein the openings are transversely wider than are portions of the slots located adjacent to and communicating with the openings.
[0013] In some embodiments, a line holder for supporting and positioning an intermediate reach of a mason's guide line when drawn taut to extend away from the line holder in opposite directions along a linear path at a desired height within a front surface plane of a wall being built, includes a thin, stiff, elongate member having a centrally located body portion postponable atop a horizontal surface at the desired height, and having a guide line support portion formed integrally with and projecting forwardly from the body portion 1) to define passage means opening downwardly through a bottom surface of the support portion at two locations along the linear path within the front surface plane, and 2) to define slot means communicating with the passage means and opening through an edge surface of the elongate member to provide a track that can be followed when inserting a loop of the reach into the passage means to depend through the bottom surface at said locations.
[0014] In some embodiments, a line holder is formed as a stamping from a thin, stiff, flat, elongate strip of metal having one and opposite end regions that define one and opposite end surfaces, respectively, having two side-by-side passages extending through a thickness of the one end region, having a single passage extending through a thickness of the opposite end region, with separate slots extending through the thickness of the one end region from each of the side-by-side openings and through the one end surface, and with another slot extending through the thickness of the opposite end region from the single passage and through the opposite end surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other features, and a fuller understanding of the invention may be had by referring to the following description and claims, taken in conjunction with the accompanying drawings, wherein:
[0016] FIG. 1 is a perspective view of a portion of a brick wall being erected, with a guide line shown extending along a linear path adjacent a front surface plane of the wall at a desired height to be met by bricks being added to the wall, with an intermediate portion of the guide line being supported and held properly in position by a line holder or “trig” embodying features of the invention that, in turn, is held in place by an overlying brick;
[0017] FIG. 2 is a vertical cross-sectional view on an enlarged scale, as seen from a plane indicated by a line 2 - 2 in FIG. 1 ;
[0018] FIG. 3 is a perspective view on an enlarged scale of a relatively thin, stiff and substantially flat line holder or “trig” depicting one form that can be taken by the invention;
[0019] FIG. 4 is a cross-sectional view on a still more enlarged scale, as seen from a plane indicated by a line 4 - 4 in FIG. 3 ;
[0020] FIG. 5 is a cross-sectional view similar to FIG. 4 and showing how a guide line loop preferably extends through passages and across the top of a central portion of the line holder of FIGS. 3 and 4 ;
[0021] FIG. 6 is an exploded perspective view showing the guide line loop ready to be inserted along a track defined by slots formed in a forward end region of the line holder of FIG. 3 , with a spare brick ready to be lowered onto a central body portion of the line holder to retain the line holder in position atop a flat upper surface of the masonry wall under construction;
[0022] FIG. 7 is a perspective view showing the guide line loop inserted through the slots into side-by-side passages of the line holder shown in FIG. 6 , with the spare overlying brick lowered onto the central body portion of the line holder to retain the line holder in place atop the flat upper surface of the masonry wall;
[0023] FIG. 8 is a perspective view showing bottom surface portions of the line holder together with brick portions that engage top and bottom surfaces of the line holder to sandwich and clamp the line holder in position, and showing how the guide line loop exits from two bottom openings defined where the side-by-side passages open through the bottom surface of the front portion of the line holder, wherefores the guide line extends tautly in opposite directions along a linear path adjacent a front surface plane of the wall being erected;
[0024] FIG. 9 is a cross-sectional view of a pair of spaced portions of a brick wall being built, showing how a pair of the rear end portions of two of the line holders of FIG. 3 may be utilized to support an intervening portion or reach of guide line at a desired level at the same height as a flat upper surface of the wall on which the two line holders are supported to indicate a height to be matched by bricks being added to the wall;
[0025] FIG. 10 is a perspective view showing a first step in a three-step procedure for properly installing a guide line reach through the side-by-side slots of a front portion of the guide line holder of FIG. 3 and into the associated side-by-side passages formed through the front portion, with the view showing the line holder turned on edge to receive the guide line reach in an upper one of the two slots;
[0026] FIG. 11 is a perspective view similar to FIG. 10 showing a second step in the three-step procedure, depicting how the line holder may be turned clockwise to cause the guide line reach to extend across a top surface of a central part of the line holder;
[0027] FIG. 12 is a perspective view similar to FIGS. 10 and 11 showing a third step in the three-step procedure, depicting how the guide line reach may be passed through the second of the side-by-side slots and into the second associated passage as the line holder is turned to extend substantially horizontally;
[0028] FIG. 13 is a top view of a first alternate form that can be taken by the front portion of the line holder of FIG. 3 ;
[0029] FIG. 14 is a top view of a second alternate form thereof;
[0030] FIG. 15 is a top view of a third alternate form thereof;
[0031] FIG. 16 is a top view of a fourth alternate form thereof;
[0032] FIG. 17 is a top view of a fifth alternate form thereof;
[0033] FIG. 18 is a top view of a sixth alternate form thereof;
[0034] FIG. 19 is a top view of a seventh alternate form thereof;
[0035] FIG. 20 is a top view of an eighth alternate form thereof;
[0036] FIG. 21 is a top view of a ninth alternate form thereof;
[0037] FIG. 22 is a top view of a tenth alternate form thereof; and,
[0038] FIGS. 23 and 24 are cross-sectional views as seen from planes indicated by lines 23 - 23 and 24 - 24 , respectively, in FIG. 22 .
DETAILED DESCRIPTION
[0039] Referring to FIG. 1 , a brick wall being built or erected is indicated generally by the numeral 40 . A front surface plane of the wall 40 is indicated by the numeral 50 . A guide line drawn taut to extend along a linear path 61 closely adjacent the front surface plane 50 of the wall 40 at a desired height to be met by bricks being added to the wall 40 is indicated by the numeral 60 .
[0040] A left end region 70 of the guide line 60 may be supported by any of a variety of conventional guide line holders 80 , examples of which are disclosed in U.S. Pat. Nos. D-347,798, D-198,813, 6,412,184, 5,479,713 and 2,585,160, the disclosures of which are incorporated herein by reference, or by other conventional techniques well known to those skilled in the art. Likewise, a right end region of the guide line 60 (not shown) may also be supported by a conventional guide line holder such as is disclosed in the patents just mentioned, or by other conventional techniques well known to those skilled in the art. An intermediate portion 65 of the guide line 60 is supported by a line holder 100 that preferably embodies features of the present invention.
[0041] Referring to FIG. 3 , the line holder 100 is a one-piece, flat, thin, elongate, generally rectangular strip 105 that can be thought of as having three portions, namely a centrally located, relatively lengthy body portion 110 , a relatively stubby front end region referred to as a dual-passage guide line support portion 120 , and a similar, relatively stubby rear end region referred to as a single-passage guide line support portion 130 .
[0042] Novelty resides in the combination of the central body portion 110 and the uniquely configured front support portion, for previously proposed line holders have not provided such features; and, novelty resides in providing the central body portion 110 together with the odd combination of front and rear end regions 120 , 130 , respectively, that are capable in functioning in different ways to serve different guide line support needs found in different masonry wall erection applications, as will be explained later herein.
[0043] The embodiment of the line holder 100 shown in FIG. 3 has a top surface 102 , a bottom surface 104 , a forward end surface 106 , a rearward end surface 108 , and substantially parallel extending left and right edge surfaces 112 , 114 . Two side-by-side passages 140 , 142 are formed through the front end region 120 of the line holder 100 at locations spaced identical short distances from the forward end surface 106 . A single passage 144 is formed through the rear end region 130 of the line holder 100 at a location spaced a similar short distance from the rearward end surface 108 . Each of the passages 140 , 142 , 144 extends substantially vertically through the line holder 100 so as to open at one end through the top surface 102 , and at the other end through the bottom surface 104 .
[0044] Turning to FIG. 4 , where the passages 140 , 142 open through the top surface 102 , the side-by-side passages 140 , 142 define side-by-side openings 150 , 152 , respectively. Where the passages 140 , 142 open the bottom surface 104 , the side-by-side passages 140 , 142 define side-by-side openings 160 , 162 , respectively. Where the solo passage 144 opens through the top and bottom surfaces 102 , 104 , the passage 144 defines top and bottom surface openings 154 , 164 , respectively.
[0045] Referring again to FIG. 3 , a pair of side-by-side slots 170 , 172 communicate with the side-by-side passages 140 , 142 , respectively, and open through the forward end surface 106 . Similarly, a slot 174 communicates with the passage 144 , and opens through the rearward end surface 108 .
[0046] In FIGS. 1 , 2 and 6 - 8 , the line holder 100 is shown in a proper position to enable the front end support portion 120 to support an intermediate reach 65 of the guide line 60 extending along and closely adjacent to the front surface plane 50 of the wall 40 at a height to be met by new bricks being added to the wall 40 . When positioned as shown in FIG. 2 , the line holder 100 is held in place by a spare brick 45 turned on edge and resting atop the central body portion 110 to clamp the central body portion 110 into firm engagement with the flat, upwardly facing wall surface 75 —which causes the bottom surface 104 of the line holder 100 to extend at the desired height to be met by bricks being added to the wall 40 .
[0047] When the line holder 100 is positioned as shown in FIGS. 1 , 2 and 6 - 8 , the front support portion 120 projects forwardly from the front surface plane 50 of the wall 40 , and the bottom surface openings 160 , 162 open downwardly adjacent the front surface plane 50 (as is best seen in FIG. 8 ) so that, when a loop 62 of an intermediate reach 65 of the guide line 60 (such as is shown in FIG. 6 ) is inserted through the slots 170 , 172 and into the passages 140 , 142 (as shown in FIGS. 7 and 8 ), portions of the loop 62 are caused to exit through the bottom surface openings 160 , 162 adjacent the front surface plane 50 at spaced locations so that, as the guide line 60 is drawn taut, lengthy portions or reaches 63 , 64 of the guide line 60 (that extend away from the intermediate portion or reach 65 supported by the line holder 100 ) are caused to extend in opposite directions (along a path designated by the numeral 61 in FIGS. 7 and 8 at a desired height to be met by bricks that are added to the wall 40 ) away from the bottom surface openings 160 , 162 at locations adjacent the front surface plane 50 of the wall 40 and at the same height as the bottom surface 104 of the line holder 100 . As a result, the intermediate reach 65 of the guide line 60 is supported by the line holder 100 at a height to be met by new bricks as they are added to the wall to advance the erection of the wall 40 .
[0048] What FIG. 9 shows is how the rear end region 130 of the line holder 100 of FIG. 3 can be put to use. Depicted in FIG. 9 are spaced-apart left and right portions 41 , 42 of a brick wall 40 that is being built or erected. The depicted wall portions 41 , 42 have flat top surfaces 75 that (in the same manner that the flat top surface 75 shown in FIGS. 6-8 underlies and supports a central body portion 110 of the line holder 100 shown in FIGS. 6-8 ) underlies and supports the central body portion 110 of a left line holder 100 atop the surface 75 of the left wall portion 41 , and underlies and supports the central body portion 110 of a right line holder 100 atop the surface 75 of the right wall portion 42 . Spare bricks 46 , 47 laid atop the left and right line holders 100 , respectively, hold the left and right line holders 100 in position atop the flat surfaces 75 of the left and right wall portions 41 , 42 just as a spare brick 45 laid atop the line holder 100 shown in FIGS. 7 and 8 holds the line holder 100 in place atop the flat surface 75 of the wall portion 40 shown in FIGS. 7 and 8 . Rear portions 130 of the left and right line holders 100 shown in FIG. 9 are positioned to project forwardly beyond a front surface plane 50 of the portions 41 , 42 of the wall 40 in the same manner that the front portion 120 of the line holder 100 shown in FIGS. 6-8 projects forwardly beyond a front surface plane 50 of the wall portion 40 shown in FIGS. 6-8 ).
[0049] As can be seen in FIG. 9 , a guide line portion 67 overlies an upper surface portion 102 of the left line holder 100 before extending through the rear passage 144 of the left line holder 100 to provide another guide line portion 66 that extends rightwardly along a bottom surface portion 104 of the left line holder 100 toward the right line holder 100 . In a mirror-image manner, a guide line portion 68 overlies an upper surface portion 102 of the right line holder 100 before extending through the rear passage 144 of the right line holder 100 to provide another guide line portion 66 that extends leftwardly along a bottom surface portion 104 of the right line holder 100 toward the left line holder 100 .
[0050] When the guide line 60 shown in FIG. 9 is pulled taut, the guide line portion 66 that extends between the left and right line holders 100 is held by the line holders 100 at a correct height (even with the top surface portions 75 of the left and right wall portions 41 , 42 ) that is to be matched as bricks are added to the wall 40 at locations (not shown) situated between the left and right line holders 100 that are shown in FIG. 9 (just as the guide line portions 63 , 64 shown in FIGS. 7 and 8 are held at a correct height to be matched as bricks are added to the wall 40 at locations on opposite sides of the line holder 100 shown in FIGS. 7 and 8 ).
[0051] What is shown in the sequence of three views provided by FIGS. 10 , 11 and 12 are three simple steps that can be followed to properly install an intermediate reach 65 of guide line 60 along tracks defined by the slots 170 , 172 and into the passages 140 , 142 to enable the intermediate reach 65 of the guide line 60 to be properly supported by the line holder 100 . As is shown in FIG. 10 , a first step is taken by turning the line holder 100 vertically (i.e., on edge), so that one of the slots 170 , 172 (in this case, the slot 172 ) is located above the other of the slots 170 , 172 . The guide line portion 65 to be supported by the line holder 100 is then passed through the upper slot 172 and into the associated upper passage 142 .
[0052] As is shown in FIG. 11 , a second step is taken by turning the line holder 100 in either a clockwise or a counter-clockwise direction (in this case, in a clockwise direction as indicated by an arrow 99 ) to bring the unoccupied slot 170 and the unoccupied passage 140 near the guide line portion 65 that is to be supported by the line holder 100 . And, as is shown in FIG. 12 , a third step is taken by slipping a nearby part of the guide line portion 65 along the slot 170 and into the associated passage 140 —which, with a minimum of fuss causes the guide line portion 65 to be properly supported by the front end region 120 of the line holder 100 , in the manner shown in FIGS. 7 and 8 .
[0053] Although the shape defined by the perimeter of the elongate strip 105 shown in FIG. 3 is generally rectangular, the exterior shape of the line holder 100 need not always be either elongate or rectangular, which will become more clear as this description concludes with reference to FIGS. 13-20 . The line holder 100 merely needs to provide a relatively sizable centrally located body portion 110 atop which a spare brick (such as the brick 45 shown in FIGS. 1 , 2 and 6 - 8 , or the bricks 46 , 47 shown in FIG. 9 ) can rest to retain the line holder 100 in position atop a flat wall surface 75 , and needs to provide a front end portion 120 that defines two spaced passages 140 , 142 that can receive the loop 62 of the intermediate reach 65 of the guide line 60 .
[0054] Likewise, although the passages 140 , 142 are depicted in FIG. 3 as being transversely elongate (i.e., elongate in directions paralleling the front surface plane 50 of the wall 40 ); and although the slots 170 , 172 are shown in FIG. 3 as being of uniform width along their lengths, as extending parallel to each other and to the length of the line holder 100 , and as extending through the forward end surface 106 , the passages 140 , 142 need not be transversely elongate in shape; and the slots 170 , 172 need not be of uniform width along their lengths, nor do they need to extend in side-by-side parallel relationship, nor do the slots 170 , 172 need to extend parallel to each other or to the length of the strip 105 , nor do the slots 170 , 172 need to exit through the forward end surface 106 of a line holder that is of generally rectangular configuration.
[0055] The passages 140 , 142 (or “passage means” reasonably equivalent thereto) need merely be capable of receiving and retaining the loop 62 of the intermediate reach 65 of the guide line 60 ; and the slots 170 , 172 (or “slot means” reasonably equivalent thereto) need merely be capable of providing a track or tracks along which portions of the guide line loop 62 can be moved into the passages 140 , 142 . Accordingly, the passages 140 , 142 (or a reasonably equivalent “passage means”) and the slots 170 , 172 (or a reasonably equivalent “slot means”) may take a variety of sizes and shapes, and the slots 170 , 172 may differ in where they exit through an edge surface of the line holder 100 .
[0056] Examples of the many ways in which the passages 140 , 142 (or a reasonably equivalent “passage means”), and the slots 170 , 172 (or a reasonably equivalent “slot means”) can take on different sizes, shapes and edge surface exit locations are provided in FIG. 13 through FIG. 24 —and yet, the resulting front end portions 120 of the depicted line holders 100 can still function in much the same way as has been described in considerable detail in conjunction with FIGS. 6 - 8 —so that downwardly opening passage openings position portions of a loop 62 of a guide line 60 to be supported to extend along a linear path 61 closely adjacent a front wall plane 50 of a wall 40 being built or erected, and at a desired height to be met by bricks or other masonry elements being added to the wall being built or erected.
[0057] Referring to FIG. 13 , the forward end portion 120 of a guide line holder 100 may have a pair of slot portions 171 , 173 that join with a single slot portion 175 to form a Y-like track or tracks along which portions of a loop 62 of an intermediate reach 65 of a guide line 60 (as depicted, for example, in FIG. 6 ) can travel to pass into a pair of side-by-side passages 141 , 143 that, in this embodiment, are of round cross-section instead of being of elongate cross-section like the passages 140 , 142 of the line holder 100 of FIG. 3 . Corner regions 107 , 108 of the end surface 106 are more rounded than are corresponding corner regions of the line holder 100 shown in FIG. 3 —which does nothing to alter how the line holder 100 of FIG. 13 functions in comparison to the line holder 100 of FIG. 3 .
[0058] Referring to FIG. 14 , a pair of slots 181 , 183 of a front end portion 120 of a line holder 100 are of relatively wide width until they reach choke points 191 , 193 located adjacent two elongate passages 140 , 142 (which may, in some applications, help to retain portions of a guide line loop 62 within the passages 140 , 142 ). The slots 181 , 183 have corner region openings 117 , 118 that are situated at opposite ends of the end surface 106 —and still a line holder 100 is provided that performs well, in substantially the same manner described in conjunction with the line holder depicted in FIGS. 6-8 .
[0059] Referring to FIG. 15 , slots 182 , 184 communicate with elongate passages 192 , 194 to provide P-shaped openings through the front end portion 120 of a line holder 100 .
[0060] Referring to FIG. 16 , a pair of curved slot portions 221 , 223 communicate with a single, centrally located slot portion 225 before opening into a pair of elongate passages 140 , 142 , respectively. The slot branches 221 , 223 , 225 provide a track or tracks along which portions of a loop 62 of guide line 60 (such as is shown in FIG. 6 ) can be moved to deliver a portion of a guide line loop 62 into the passages 140 , 142 where the guide line loop portion 62 is retained while other portions of the guide line loop exits downwardly through bottom openings of the passages 140 , 142 just as described previously in conjunction with FIGS. 7 and 8 , to support an intermediate reach 65 of the guide line 60 .
[0061] Referring to FIG. 17 , two relatively wide slot branches 221 , 223 join with a relatively thin central slot branch 225 enabling portions of a guide line loop 62 to be moved a pair of rounded passages 217 , 219 defined by a forward end region 120 of a line holder 100 .
[0062] In FIGS. 18-20 , however, slots 170 , 172 that open through different edge surface regions of forward end portions 120 of line holders 100 communicate with transversely elongate passages 140 , 142 to enable portions of a guide line loop 62 such as is shown in FIG. 6 to travel along slot-defined tracks into the passages 140 , 142 to be retained and supported by the associated guide line holders 100 .
[0063] Referring to FIG. 21 , a front end portion 120 of a line holder 100 is shown that employs passages 240 , 242 connected by a C-shaped slot 270 that does not open through any edge surface of the line holder 100 . Configurations such are exemplified by the line holder front end portion 120 shown in FIG. 21 provide still another type of approach that can be taken by the present invention to use what can be referred to as “slot means” that communicates with “passage means” to permit a loop 62 of a guide line 60 (such as is shown in FIG. 6 ) to be moved along one or more tracks defined by the “slot means” and into the “passage means” to be retained so the line holder 100 performs in substantially the same way as the line holder 100 depicted in FIG. 8 .
[0064] Finally, referring to FIGS. 22-24 , a front end portion 120 of a line holder 100 is shown that employs passages 140 , 142 and communicating slots 170 , 172 that do not extend straight through the line holder 100 (i.e., not extending perpendicular to the top and bottom surfaces 102 , 104 , as do the many other slots and passages of the various line holder forms that are shown in other drawing views). Instead, the slots 170 , 172 and the passages 140 , 142 shown in FIGS. 22-24 are inclined relative to the top and bottom surfaces 102 , 104 , respectively—as is made clear in the cross-sectional views provided by FIGS. 23 and 24 . Slot or passage inclination alterations of this type may also be applied to the various other slot and passage configurations employed by the various other types of line holder configurations disclosed herein without departing from the spirit and scope of the present invention.
[0065] As those who are skilled in the art will readily understand, line holders 100 that embody features of the present invention may be formed from a wide variety of materials including but not limited to metals such as steel, tin, brass and aluminum; from plastics materials including but not limited to nylon, thermoplastic materials such as PVC, TPU, PP, TPE and ABS, and the like; and even from organic materials such as strips of wood, bamboo and the like, and other stiff, thin, flat, durable materials, some of which may not even be known at present.
[0066] Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form shown in FIG. 3 has been made only by way of example, and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. It is intended to protect whatever features of patentable novelty exist in the invention disclosed.
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A relatively thin, stiff, flat guide line holder or “trig” for accurately supporting and positioning intermediate portions of tautly stretched guide lines such as are used by bricklayers and stone masons in laying courses of bricks, blocks and stones during the erection of masonry walls has a centrally located body portion, and an integrally formed, forwardly projecting guide line support portion. During use, the body portion is positioned atop a flat surface of a wall being erected to support the line holder at a desired height to be met by masonry elements added to the wall, with the support portion projecting forwardly beyond a front surface plane of the wall being erected. Passage formations defined by the support portion open downwardly through a bottom surface of the support portion at two spaced locations along the front surface plane when the line holder is properly positioned. Slot formations defined by the support portion provide a track, or tracks, along which a loop of the guide line can be moved into the passage formations so lengthy portions of the guide line located on opposite sides of the loop can extend along the front surface plane in opposite directions away from the line holder when the guide line is drawn taut at the desired height.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CITATION TO PRIOR APPLICATION
[0001] This is a continuation-in-part with respect to U.S. patent application, Ser. No. 11/041,525, filed on Jan. 24, 2005; which is a continuation-in-part with respect to U.S. patent application, Ser. No. 10/763,568, filed on Jan. 23, 2004; which is a continuation-in-part with respect to issued U.S. Pat. No. 6,681,859, filed on Oct. 22, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to systems and methods for producing or delivering heat at or near the down hole end of production tubing of a producing oil or gas well for improving production therefrom.
[0004] 2. Background Information
[0005] Free-flowing oil is increasingly difficult to find, even in oil wells that once had very good flow. In some cases, good flowing wells simply “clog up” with paraffin. In other cases, the oil itself in a given formation is of a viscosity that it simply will not flow (or will flow very slowly) under naturally ambient temperatures.
[0006] Because the viscosity of oil and paraffin have an inverse relationship to their temperatures, the solution to non-flowing or slow flowing oil wells would seem fairly straight forward—somehow heat the oil and/or paraffin. However, effectively achieving this objective has proven elusive for many years.
[0007] In the context of gas wells, another phenomena—the buildup of iron oxides and other residues that can obstruct the free flow of gas through the perforations, through the tubing, or both—creates a need for effective down hole heating.
[0008] Down hole heating systems or components for oil and gas wells are known (hereafter, for the sake of brevity, most wells will simply be referred to as “oil wells” with the understanding that certain applications will apply equally well to gas wells). In addition, certain treatments (including “hot oil treatments”) for unclogging no-flow or slow-flow oil wells have long been in use. For a variety of reasons, the existing technologies are very much lacking in efficacy and/or long-term reliability.
[0009] The present invention addresses two primary shortcomings that the inventor has found in conventional approaches to heating oil and paraffin down hole: (1) the heat is not properly focused where it needs to be; and (2) existing down hole heaters fail for lack of design elements which would protect electrical components from chemical or physical attack while in position.
[0010] The present inventor has discovered that existing down hole heaters inevitably fail because their designers do not take into consideration the intense pressures to which the units will be exposed when installed. Such pressure forces liquids (including highly conductive salt water) past the casings of conventional heating units and causes electrical shorts and corrosion. Designers with whom the present inventor has discussed heater failures have uniformly failed to recognize the root cause of the problem—lack of adequate protection for the heating elements and their electrical connections. The down hole heating unit of the present invention addresses this shortcoming of conventional heating units.
[0011] Research into the present design also reveals that designers of existing heaters and installations have overlooked crucial features of any effective down hole heater system: (1) it must focus heat in such a way that the production zone of the formation itself is heated; and (2) heat (and with it, effectiveness) must not be lost for failure to insulate heating elements from up hole components which “draw” heat away from the crucial zones by conduction.
[0012] However subtle the distinctions between the present design and those of the prior art might at first appear, actual field applications of the present down hole heating system have yielded oil well flow rate increases which are multiples of those realized through use of presently available down hole heating systems. The monetary motivations for solving slow-flow or no-flow oil well conditions are such that, if modifying existing heating units to achieve the present design were obvious, producers would not have spent millions of dollars on ineffective down hole treatments and heating systems (which they have done), nor lost millions of dollars in production for lack of the solutions to long-felt problems that the present invention provides (which they have also done).
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide an improved down hole heating system for use in conditioning oil and gas wells for increased flow, when such flow is impeded because of viscosity and/or paraffin blockage conditions.
[0014] It is another object of the present invention to provide an improved design for down hole heating systems which has the effect of more effectively focusing heat where it is most efficacious in improving oil or gas flow in circumstances when such flow is impeded because of oil viscosity and/or paraffin blockage conditions.
[0015] It is another object of the present invention to provide an improved design for down hole heating systems for oil and gas wells which design renders the heating unit useful for extended periods of time without interruption for costly repairs because of damage or electrical shorting caused by unit invasion by down hole fluids.
[0016] It is another object of the present invention to provide an improved method for down hole heating of oil and gas wells for increasing flow, when such flow is impeded because of viscosity and/or paraffin blockage conditions.
[0017] In satisfaction of these and related objects, the present invention provides a down hole heating system for use with oil and gas wells which exhibit less than optimally achievable flow rates because of high oil viscosity and/or blockage by paraffin (or similar meltable petroleum byproducts). The system of the present invention, and the method of use thereof, provides two primary benefits: (1) the involved heating unit is designed to overcome a previously unrecognized problem which leads to frequent failure of prior art heating units—unit invasion by down hole heating units with resulting physical damage and/or electrical shortages; and (2) the system is designed to focus and contain heat in the production zone to promote flow to, and not just within, the production tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Applicant's invention may be further understood from a description of the accompanying drawings, wherein unless otherwise specified, like referenced numerals are intended to depict like components in the various views.
[0019] FIG. 1 is an elevational view of a producing oil well with the components of the present down hole heating system installed.
[0020] FIG. 2 is cross-section view of the heating unit connector of the preferred embodiment of the present invention.
[0021] FIG. 3 is a cross-section view of the heating unit connector of an alternative embodiment of the present invention.
[0022] FIG. 4 is a cross-section view of the heating unit connector of a second alternative embodiment of the present invention.
[0023] FIG. 5 is a cross-section view of the female segment of the heating unit connector of the second alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring to FIG. 1 , the complete down hole heating system of the present invention is generally identified by the reference numeral 10 . System 10 includes production tubing 12 (the length of which depends, of course, on the depth of the well), a heat insulating packer 14 , perforated tubing 16 , a stainless steel tubing collar 18 , and a heating unit 20 .
[0025] Heat insulating packer 14 and stainless steel collars 18 are included in their stated form for “containing” the heat from heating unit 20 within the desired zone to the greatest practical degree. Were it not for these components, the heat from heating unit 20 would (like the heat from conventional down hole heater units) convect and conduct upward in the well bore and through the production tubing, thereby essentially directing much of the heat away from the area which it is most needed—the production zone.
[0026] Perhaps, it goes without saying that oil that never reaches the pump will never be produced. However, this truism seems to have escaped designers of previous down-hole heating schemes, the use of which essentially heats oil only as it enters the production tubing, without effectively heating it so that it will reach the production tubing in the first place. Largely containing the heat below the level of the junction between the production tubing 12 and the perforated tubing 16 , as is achieved through the current design, has the effect of focusing the heat on the production formation itself. This, in turn, heats oil and paraffin in situ and allows it to flow to the well bore for pumping, thus “producing” first the viscous materials which are impeding flow, and then the desired product of the well (oil or gas). Stainless steel is chosen as the material for the juncture collars at and below the joinder of production tubing 12 and perforate tubing 16 because of its limited heat conductive properties.
[0027] Physical and chemical attack of the electrical connections between the power leads and the heater rods of conventional heating systems, as well as shorting of electrical circuits because of invasion of heater units by conductive fluids is another problem of the present art to which the present invention is addressed. Referring to FIG. 2 , the present inventor has discovered that, to prevent the aforementioned electrical problems, the internal connection for a down hole heating unit must be impenetrably shielded from the pressures and hostile chemical agents which surround the unit in the well bore.
[0028] The patent which serves as a priority basis for the present invention discloses an embodiment that tremendously increases down hole wiring connection integrity. However, referring to FIG. 2 , the present invention is even better at preventing the aforementioned problems. In fact, the unique combination of materials, particularly ceramic cement, a highly durable insulation means, and the use of connector pins, provides protection against shortage and other connection damage not previously possible. Such an improvement is of great significance as the internal connection for a down hole heating unit must be impenetrably shielded from the pressures and hostile chemical agents that surround the unit in the well bore.
[0029] Referring in combination to FIG. 1 and FIG. 2 , heating unit 20 includes heating unit connector 30 . Heating unit connecter 30 is largely responsible for ensuring the integrity of the connection between surface wiring leads 24 and heater rod wiring leads 25 . The electrical current for heater rod 26 is supplied by cable 22 , which runs down the exterior of production tubing 12 and connects to surface wiring leads 24 at the upper end of heating unit 20 .
[0030] As shown in FIG. 2 , heating unit connector 30 is comprised of two substantially identical pieces. The upper piece (nearest surface), generally designated by numeral 32 , houses surface wiring leads 24 . The lower piece (nearest downhole), generally designated by numeral 34 , houses heater wiring 26 .
[0031] Heater unit connector 30 also contains two connector pins (male and female), wherein each connector pin has a distal and medial end. The union between male connector pins 40 and female connector pins 42 occurs about the medial end of each connector piece 40 and 42 , and further about the medial portion of heater unit connector 30 . Male connector pins 40 , have female receptacles that receive male extensions from wiring leads 25 . At its medial portion, male connector pins 40 have male extensions that may be plugged into the medial portion of female connector pins 42 .
[0032] Female connector pins 42 contain female receptacles about both their medial and distal portions. At their distal portion, female connector pins 42 receive male extensions from surface wiring leads 24 . At their medial portions, each female connector pin 42 receives a corresponding male connector pin 40 . Importantly, the improvements provided by the present invention do not depend on any specific pin connector configuration. In fact, as will be apparent to those skilled in the art, different connector pin configurations or different pin types may work equally as well.
[0033] Connector pieces 32 and 34 each contain, in their distal portion, a high temperature ceramic-filled region, generally designated by numeral 36 . The ceramic cement of region 36 serves to enclose the junction between each connector pin and the respective wiring of each piece. In the preferred embodiment, the high temperature ceramic cement is an epoxy material which is available as Sauereisen Cement #1, which may be obtained from the Industrial Engineering and Equipment Company (“INDEECO”) of St. Louis, Mo., U.S.A. However, as will be apparent to those skilled in the art, other materials may serve to perform the desired functions.
[0034] Upon drying, the high temperature ceramic cement of region 36 becomes an essentially glass-like substance. Shrinkage is associated with the cement as it dries. As such, in the preferred embodiment, each heater unit connector pieces contains a pipe plug 38 . Pipe plug 38 provides an access point through which additional ceramic cement can be injected into each piece, thereby filling any void which develops as the ceramic cement dries. Further, pipe plug 38 may be reversibly sealed to each piece so that epoxy can be injected as needed while the strength of the seal is maintained.
[0035] Connector pieces 32 and 34 further contain, in their medial portion, an insulator block region, designated by numeral 39 . Insulator region 39 houses each connector pin so that the union between male connector pins 40 and female connector pins 42 is suitably insulated from any outside electrical or chemical agent.
[0036] In order to withstand the corrosive chemicals and enormous external pressure, the outer surface of heater unit connector 30 must be incredibly strong. The aforementioned elements of connector 30 are substantially encased in a fitting assembly 50 , preferably made of steel (“encasement means”). Each components of assembly 50 is welded with continuous beads, preferably using the “TEG” welding process, to each adjoining component. The TEG welding process is preferred as it allows the seams of joined components to withstand extreme conditions in the well bore. Finally, in the preferred embodiment, the outer surface of connector 30 is comprised of stainless steel.
[0037] Each connector piece is secured to the other by fitting assembly 60 . Fitting assembly 60 and sealing fitting 62 are, as would be apparent to those skilled in the art, designed to engage one another so as to form a sealed junction. In the preferred embodiment, this union is a standard two inch union that is modified by the “TEG” welding process mentioned above. That is, the union is welded using the TEG process so that it will withstand the extreme environmental condition of the well bore.
[0038] The shielding of the electrical connections between surface wiring leads 24 and heater wiring leads 25 is crucial for long-term operation of a down hole heating system of the present invention. Equally important is that power is reliably delivered to that connection. Therefore, solid copper leads with KAPTON insulation are used, such leads being of suitable gauge for carrying the intended 16.5 kilowatt, 480 volt, and associated current for the present system with its 0.475 inch diameter INCOLOY heater rods 26 (also available from INDEECO).
[0039] Referring to FIGS. 3 and 4 , an alternative embodiment of the present invention includes a heater assembly 112 connected to a surface assembly 114 by a connector assembly 116 . In one alternative embodiment, connector assembly 116 sealably connects to heater assembly 112 via a welded connection as shown in FIG. 3 . Alternatively, as shown in FIG. 4 , connector assembly 116 is further characterized by a male connector pin section 118 and a female connector pin section 120 . Male connector pin section 118 sealably connects to heater assembly 112 via a welded connection; however, female connector section 120 sealably connects to male connector section 118 via coupling ring 122 . In the preferred embodiment, coupling ring 122 is made of aluminum bronze, but coupling ring 122 may also be made of other suitably corrosion resistant materials as known in the art. Referring to FIGS. 3 and 5 , in both embodiments, connector assembly 116 is further characterized in its connection to surface assembly 114 by pigtails 124 as generally known in the art. These pigtails are made by vulcanizing a connector portion directly to a length of cable. The pigtail is then spliced to the pump cable. In each alternative embodiment, the connection is further secured by a collar, as known in the art, at location 126 .
[0040] The general connector arrangement, and other beneficial variations thereof, are known to be manufacture by KEMLON, of Pearland, Tex., U.S.A. These connectors produced at KEMLON are held out as being particularly effective as they can withstand enormous pressures and are known by those skilled in the art to be particularly effective in various hostile environments including subsurface oil wells and high temperature surroundings. Further, sound construction of these connectors makes for especially beneficial use. For instance, these components are made of excellent material, having an alloy steel, cadmium plated bod; a copper, gold plated contact; and KN-01 NEOPRENE standard insulation. In particular, connectors of the SL-5000 series, manufactured by KEMLON are thought to serve as particularly suitable components for the present system.
[0041] Various embodiments of the present invention include the method for use of the above-described system for heat treating an oil or gas well for improving well flow. The method includes use of a down hole heating unit with suitably shielded electrical connections substantially as described, along with installation of the heat-retaining elements also as described to properly focus heat on the producing formation.
[0042] In addition to the foregoing, it should be understood that the present method may also be utilized by substituting cable (“wire line”) for the down hole pipe for supporting the heating unit 20 while pipe is pulled from the well bore. In other words, one can heat-treat a well using the presently disclosed apparatuses and their equivalents before re-inserting pipe, such as during other well treatments or maintenance during which pipe is pulled. It is believed that this approach would be particularly beneficial in treating deep gas wells with an iron sulfide occlusion problem.
[0043] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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A down hole heating system for use with oil and gas wells which exhibit less than optimally achievable flow rates because of high oil viscosity and/or blockage by paraffin (or similar meltable petroleum byproducts). The heating unit the present invention includes shielding to prevent physical damage and shortages to electrical connections within the heating unit while down hole (a previously unrecognized source of system failures in prior art systems). The over-all heating system also includes heat retaining components to focus and contain heat in the production zone to promote flow to, and not just within, the production tubing.
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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 building structures generally and more particularly to building structures which are based on web materials.
BACKGROUND OF THE INVENTION
Building structures based on web materials are well known in the art. The most basic structures of this type are tents wherein a web material is secured over a frame and tensioned with respect thereto. More complex building structures are also known employing web materials. These are generally characterized in that the web is tensioned so as to lie in a plane and is surrounded by structural elements with respect to which it is tensioned.
Complex geometrical shapes have been realized in building structures formed of tensioned webs by combining a plurality of discrete planar webs, each surrounded by its supporting structure, in a three-dimensional geometrical arrangment. Such structures have also been realized by the use of rigid materials instead of tensioned web materials.
Building structures based on web materials which are arranged in strips and tensioned along vertically disposed arcs are also known. These suffer from significant difficulties associated with difficulties in maintaining the webs at a required tension.
SUMMARY OF THE INVENTION
The present invention seeks to provide a building structure based on web materials and having a relatively large uninterrupted web surface defining a complex geometrical shape, formed of a plurality of identical modular elements.
There is thus provided in accordance with an embodiment of the present invention a building structure comprising at least one polyhyparic surface formed of a continuous tensioned web.
Further in accordance with an embodiment of the present invention the continuous tensioned web is coupled to structural members only along its periphery.
Additionally in accordance with an embodiment of the present invention the building structure is formed of a plurality of polyhyparic surfaces arranged to have common structural members along their periphery.
Further in accordance with an embodiment of the present invention the polyhyparic surface is formed of a plurality of identical modular elements each of which is a hyparic surface.
Additionally in accordance with an embodiment of the present invention the identical modular elements are formed of commercially available widths of web material by a technique of tapering while seaming.
Further in accordance with an embodiment of the present invention there is provided for use with building structures in which parallel webs are arranged and mounted between arc type ribs, selectable ventilation apparatus comprising web material disposed over the ribs and movable parallel thereto such that selectable positioning of the web material provides a selected amount of exposure in the region of the ribs.
Additionally in accordance with an embodiment of the present invention there is provided apparatus for securing web material under tension comprising an elongate member arranged with respect to the web material such that forces transmitted along the web material are transmitted thereto substantially continuously therealong and perpendicularly thereto and apparatus for anchoring the elongate member at discrete locations therealong.
Further in accordance with an embodiment of the invention, the elongate member is sufficiently rigid such that it does not deform in response to the forces applied thereto at the discrete locations.
Additionally in accordance with an embodiment of the present invention the elongate member is inserted into a sleeve formed in the web and the sleeve is slidable with respect to the elongate member so as to arrange itself such that forces therealong are equalized and arranged perpendicular to the elongate member.
Further in accordance with an embodiment of the present invention wherein the securing apparatus described above is used in a building structure, a flap member is associated with the web and extends therebelow to a bottom surface for enclosing the building structure. The flap member may be suitably weighted if desired.
Still further in accordance with an embodiment of the present invention there is provided a building structure which employs web material including web material of a first higher tensile strength arranged along lines wherein significant tensile forces are applied and web material of a second lower tensile strength arranged wherein significant tensile forces are not applied.
Additionally in accordance with the present invention reinforcing ribs for a building structure employing web material are constructed integrally with the web material by reinforcement thereof with additional layers of web material along desired axes.
Further in accordance with an embodiment of the present invention there is provided a technique for producing curved rigid building structures comprising the steps of providing a building structure comprising a continuous tensioned web; and applying a coating to the web for providing a rigid building structure including the web.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood and appreciated from the following detailed description taken in conjunction with the drawings in which:
FIGS. 1A and 1B are pictorial illustrations of a building structure comprising a plurality of polyhyparic surfaces;
FIGS. 2A, 2B and 2C are respective top view and sectional view illustrations of the building structure of FIGS. 1A and 1B, which illustrate the construction from a plurality of identical modular elements;
FIGS. 3A, 3B and 3C are respective plan and pictorial view illustrations of a modular hyparic surface employed in the invention;
FIGS. 4A and 4B illustrate the construction of a portion of the hyparic surface of FIGS. 3A-C;
FIG. 5 is an illustration of a building structure comprising a plurality of parallel webs and employing various embodiments of the present invention;
FIGS. 6A and 6B are respective pictorial and sectional views of the top of the structure of FIG. 5 illustrating one type of ventilating apparatus;
FIGS. 7A and 7B are respective pictorial and sectional views of the top of the structure of FIG. 5 illustrating another type of ventilating apparatus;
FIG. 8 is a partially sectional pictorial illustration of web material securing apparatus constructed and operative in accordance with an embodiment of the present invention; and
FIG. 9 is a pictorial illustration of a knot and a securing pin useful in the securing apparatus of FIGS. 8A and 8B.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIGS. 1A and 1B which illustrate a building structure comprising a plurality of polyhyparic surfaces. Generally speaking, the building structure comprises support struts, typically in the form of poles which support the raised corners as well as the edges of the individual polyhyparic surfaces. These poles are indicated by reference numeral 10, while the web material which is supported thereonto is indicated by reference numeral 12.
The unit structure from which building structures are constructed according to the present invention is a polyhypar, otherwise known as a hyperbolic paraboloid or alternatively as a parabolic hyperboloid. This geometrical configuration is well known although not in the area of building structures. There are a variety of different possible configurations for the polyhypar, all of which are considered to be within the scope of the present invention.
The particular configuration of polyhypar employed in the illustrated preferred embodiment is a six cornered surface having three raised corners interspersed with three low corners. The modular construction of the building structure of FIGS. 1A and 1B can be seen clearly in FIG. 2A in which the individual polyhypars are indicated by reference numeral 14.
The sectional illustrations of FIGS. 2B and 2C taken along respective lines B--B and C--C indicate the overall configuration of the building structure at these locations. It is appreciated that the lines in FIG. 2A which outline the individual polyhypars 14 represents struts 10 onto which the web material 12 is secured. FIG. 2A also indicates for a single polyhypar 16 the seams of web material which is joined to define the polyhyparic surface. This construction will now be described in greater detail with reference to FIGS. 3A-3C.
FIG. 3A shows a polyhypar in plan view and indicates that it is formed in the illustrated embodiment of six identical sections 18. It is a particular feature of the present invention that the polyhypar is formed of a continuous, albeit seamed, expanse of web material and does not require any rigid structure except at its periphery. The configuration and curved nature of the polyhypar and of curved sections 18 may be appreciated from the illustrations of FIGS. 3B and 3C.
It is noted from a consideration of FIGS. 3A-3C that each of identical sections 18 is formed of a plurality of strips of web material. FIG. 4A shows a section 18 in perspective view, indicating its curvature. FIG. 4B illustrates the four components of each section 18 and indicates how they are cut from strips 20 of web material. It is noted that while triangular outer components 22 and 24 extend to the full width of the strip, the interior components 26 and 28 are tapered along both their side seams, indicated by reference numerals 30 and 32 respectively on each of components 26 and 28. This tapering provides the desired curvature to sections 18 when components 22 and 24 are joined together along the indicated seams.
Each of sections 18 is a hyparic surface. Sections 18 and indeed all of web material 14 may be formed of any suitable web material such as canvas, plastic or a composite material.
Reference is now made to FIG. 5 which illustrates a building structure 40 comprising a plurality of parallel webs 42 which are mounted and arranged between generally parallel arc-type ribs 44. It is a particular feature of the embodiment of the invention illustrated in FIG. 5 that the webs 42 may be formed of different strengths of web material in order to realize net economy in web material. Thus in accordance with the present invention webs 42 comprise a relatively weak web material 45 along which are sewn at predetermined intervals reinforcing strips 46 of the same or different materials for handling expected loads in terms of the weight of the web material and externally generated forces such as wind. As seen in FIG. 5, the reinforcing strips may extend in a grid arrangement.
Reference is now made to FIGS. 6A and 6B which illustrate details of a ventilating arrangement for the building structure of FIG. 5 constructed and operative in accordance with one embodiment of the present invention.
FIG. 6A shows two adjacent arc-type web supporting ribs 44, one of which is covered with an elongate cover 50 of a web material and the other of which is uncovered. FIG. 6B is a sectional illustration of the air flows in the two alternative arrangements. Where the web is uncovered, the transverse flow of air, i.e. wind, past the rib on the outside of the enclosure operates to draw air out of the enclosure by means of the Bernouilli effect. Where the web is covered no such occurance takes place.
In accordance with the embodiment of the invention illustrated in FIGS. 6A and 6B a movable cover formed of an elongate strip of web material may be movably secured over the ribs 44 and secured thereonto by tensioned cables 47 along the elongate sides of the cover. By drawing the cables, which extend beyond the covers in one direction or the other, the cover can be drawn over most of the rib or removed therefrom at will.
FIGS. 7A and 7B illustrate an alternative arrangement of movable cover for the ribs 44. Here there are provided two covers 50 and 52. The inner cover may conveniently be provided by a continuation of the two adjacent parallel webs and is thus fixed to the rib while the outer cover 52 is movable along the rib relative thereto in a manner similar to that described hereinabove in connection with FIGS. 6A and 6B. Both covers 50 and 52 are formed with ventilation apertures 54 such that when the apertures are in phase, ventilation is provided as indicated in FIG. 7B, and when the apertures are out of phase, no ventilation is provided. This arrangement has the advantage that a relatively small movement of the outer cover 52 relative to the inner cover 54 is required to effect a change from no ventilation to maximum ventilation.
Reference is now made to FIG. 8 which illustrates apparatus for securing the edge of web material constructed and operative in accordance with an embodiment of the present invention and comprising an elongate member 60, such as a rod or a cable, which is threaded into a sleeve 62 defined at the edge of a portion of web material. The arrangement is such that the sleeve of web material is slidable with respect to the elongate member such that it can arrange itself to equalize forces and allow the elongate member to be arranged generally perpendicular to the forces.
In the illustrated embodiment, where the securing apparatus is employed as part of a building structure, the elongate member 60 is mounted relatively high high from the ground surface and is connected to the ground surface by means of a plurality of spaced cables 64 arranged at discrete locations along the elongate member. The elongate member is selected to have sufficient rigidity so as not to become significantly deformed at the discrete locations.
In the illustrated embodiment a flap member 66 is mounted onto or adjacent the elongate member 60 and extends therebelow to the floor surface to provide desired environmental sealing. A weight 68 may be employed for maintaining the flap member 66 in desired tension and in sealing contact with the floor surface.
Reference is now made to FIG. 9 which illustrates an easy to tie slip knot 70 which is employed together with a retaining pin for securing tensioned cables together. One application of this knot and the retaining pin 72 is in securing the side cables of the arc rib cover 50.
It will be appreciated by persons skilled in the art that the invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined only by the claims which follow:
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A building structure comprising at least one polyhyparic surface formed of a continuous tensioned web. The continuous tensioned web may be coupled to structural elements which extend only along the periphery of the web. A building structure formed of a plurality of polyhyparic surfaces arranged to have common structural members along their peripheries is also described.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The present invention relates generally to pool sweeps and devices utilized with pool sweeps, and more specifically to a bag designed to collect refuse from the pool sweep during operation of the unit. More particularly, the bag includes means of attachment to an output of a pool sweep and at least a portion constructed of porous material having sufficiently sized holes to allow water to pass therethrough without allowing most debris to pass therethrough.
2. Description of the Prior Art.
In the past, inventors have directed their efforts toward the construction of pool sweep units which include bags constructed of somewhat porous material to collect leaves and other debris while allowing water to pass therethrough. Such bags for use with pool sweeps or pool cleaners have generally included at least one means of opening the bag aside from removing it from the pool sweep or pool cleaner to allow removal of debris held therein. Some of such bags have been constructed utilizing sufficiently flexible material to allow the bag to fold over when not in use, thereby minimizing the likelihood that refuse held in the bag will make its way back into the pool sweep to which the bag is attached. None of the prior art of which applicant is aware has taught a bag having the unique features of the present invention.
SUMMARY OF THE INVENTION
The present invention consists of a pool sweep bag for use with pool sweeps and pool cleaners, which are generally used to clean the bottom of swimming pools and to remove leaves and other debris therefrom. The main portion of the bag is constructed of a porous material having holes of sufficiently large size to allow water or other liquid to pass therethrough easily, but of sufficiently small size to restrict the passage of most debris collected from a pool. More particularly, the bag of the present invention includes a piece of porous material formed into the shape of a pool sweep bag having a top and a bottom and an opening positioned at the bottom to allow attachment of the pool sweep bag to the outlet of a pool sweep or pool cleaner, so that debris from the pool sweep or pool cleaner can enter the bag. The bag of the present invention further includes a joined section which is generally seamed, extending from the bottom end up to the top end. A second seam is positioned at the top of the pool sweep bag and oriented substantially perpendicularly to the vertical seam just mentioned. The second seam at the top of the pool sweep bag is constructed utilizing velcro hook material or equivalent on one piece of material and velcro loop material or equivalent on the other side of the seam to facilitate opening and closing of the top seam, thereby allowing removal of debris therefrom. While velcro was utilized herein, any attaching means capable of facilitating easy opening and closing of the second seam would be acceptable.
One of the objects of the present invention is to provide a pool sweep bag which is constructed of sufficiently porous material to allow water to pass therethrough, but having sufficiently small holes to prevent most debris from the pool from passing therethrough.
Another object of the present invention is to provide a pool sweep bag having an unique snout where it attaches to the outlet of a pool sweep or pool cleaner designed in such a way that, when no water is flowing through the output of the pool sweep or pool cleaner, the snout closes to prevent leaves and other debris captured inside the pool sweep bag from falling back into the pool sweep or pool cleaner.
Another object of the present invention is to provide a pool sweep bag having a top seam which is oriented substantially perpendicularly to the main vertical seam of the bag which is openable and closable to facilitate easy removal of debris captured in the bag.
A further object of the present invention is to provide a pool sweep bag having a collapsible snout which opens while water is flowing from the outside of the pool sweep into the snout of the pool sweep bag, which collapses to capture debris inside the pool sweep bag when no pressure is present, and which is designed to allow debris to collect around the outside of the snout inside the pool sweep bag.
The foregoing objects, as well as other objects and benefits of the present invention, are made more apparent by the descriptions and claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 of the drawings is a side view showing the construction of the pool sweep bag of the present invention.
FIG. 2 is a top view of the pool sweep bag of FIG. 1 showing the positioning of the seam and the loop for lifting and carrying the bag.
FIG. 3 is a top view of the pool sweep bag of FIG. 1 showing the top seam opened to facilitate removal of debris therefrom.
FIG. 4 is a side constructional view of the snout area of the pool sweep bag of FIG. 1 showing the position of the snout when water pressure is present at the input of the snout.
FIG. 5 is a side constructional view of the snout of the pool sweep bag of FIG. 1 showing the snout in a collapsed position, as it would be when no pressure is present at the snout.
FIG. 6 is a cross-sectional view of the top seam of the pool sweep bag taken along lines 6--6 of FIG. 2 of the drawings.
FIG. 7 is a cross-sectional view showing the construction of the seam taken along lines 7--7 of FIG. 1 of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 of the drawings is a side view showing the pool sweep bag 10 of the present invention in a semi-collapsed state. Pool sweep bag 10 is substantially constructed of porous material 28 which is chosen such that it is sufficiently porous to allow water or other liquid to pass therethrough relatively easily while restricting the flow of most debris collected by pool sweeps and pool cleaners. The main part of pool sweep bag 10 as shown in the present embodiment is constructed of a single piece of porous material 28 which is folded and seamed and sewn together to form vertical seam 12. While vertical seam 12 could be constructed to allow opening and closing thereof, in this particular embodiment it was permanently sewn. A second seam 11 is positioned at the top of pool sweep bag 10 and oriented substantially perpendicularly to seam 12. Seam 11 is constructed utilizing a velcro hook-type material or equivalent and a velcro loop-type material or equivalent to facilitate opening and closing thereof. The construction of seam 11 is shown in greater detail in FIGS. 3 and 6 of the drawings. Pool sweep bag 10 further includes a strap 13 positioned to allow an individual to remove pool sweep bag 10 from a pool sweep or pool cleaner by simply inserting the finger through strap 13 and lifting. At the bottom of pool sweep bag 10, a snout section 14 constructed of snout material 17 is provided. Further, an opening 15 is provided at the bottom of snout section 14 to allow attachment to a pool sweep or pool cleaner. A strap 16 wraps around snout section 14 and attaches by means of velcro hook-and-loop-type material or equivalent to create a snug fit of snout section 14 on the output of a pool sweep.
FIG. 2 of the drawings is a top view of the pool sweep bag 10 of FIG. 1. Seam 11 is positioned and oriented substantially perpendicularly to seam 12, and loop 13 is attached to pool sweep bag 10 at seam 12.
FIG. 3 is a top view of pool sweep bag 10 of FIG. 1 with seam 11 opened to show side 18 of seam 11, which is constructed utilizing hook-type velcro-type material, and side 19 of seam 11, which is constructed utilizing loop-type velcro-type material. Note also that snout material 17, of which snout section 14 is constructed, is here shown in a collapsed condition. When snout material 17 is in a collapsed condition as shown in FIG. 3, it is oriented substantially the same as is seam 12 of pool sweep bag 10.
FIG. 4 is a side constructional view of the snout section 14 of pool sweep bag 10. Snout section 14 is constructed of snout material 17, which is generally constructed of a heavy vinyl material, creased at 29 and sewn together to form seam 22. Seam 22 of snout section 14 and seam 12 of pool sweep bag 10 may be sewn together as desired. Snout material 17 is also sewn to porous material 28 along seam 23 to hold it in position at the bottom end of pool sweep bag 10. An outlet 50 of a pool sweep or pool cleaner, as shown in dashed lines in FIG. 4, is inserted into the end of snout section 14, and water flows through outlet 50 along arrows A into snout section 14, forcing water along arrow B through opening 20 at the end of snout material 17.
FIG. 5 is a side constructional view of the snout section 14 of pool sweep bag 10. In this view, snout material 17 is collapsed to prevent the debris 21 of FIG. 4 from sliding back through opening 20 and into a pool sweep or pool cleaner to which pool sweep bag 10 has been attached. Because of the way in which the porous material 28 of pool sweep bag 10 is cut, the edge of seam 12 extends outward from snout section 14 at an angle D of approximately 25 degrees, and snout material 17 is further angled and seamed at an angle C of approximately 25 degrees inward from the edge of snout section 14. As a result, there is an angle of approximately 50 degrees between the edge of snout material 17 of snout section 14 and seam 12 of pool sweep bag 10. Consequently, much of the debris 21 collected in pool sweep bag 10 is deposited in the area between seam 22 of snout section 14 and seam 12 of pool sweep bag 10.
FIG. 6 of the drawings is an expanded view of seam 11 of pool sweep bag 10 taken along lines 6--6 of FIG. 2 of the drawings. As here shown, porous material 28 is folded over, and a velcro-type loop-type material 26 is attached to seam section 19 and sewn together with thread 27 to provide one side of a velcro-type seam. At the other side, porous material 28 is folded over and sewn to a velcro-type hook-type material 25 by thread 27 to provide a seam section 18. Seam sections 18 and 19, when pressed together, attach to close the top of pool sweep bag 10.
FIG. 7 is a cross-sectional view of seam 12 taken along lines 7--7 of FIG. 1. Porous material 28 is folded over and attached together by means of thread 30 as shown to provide a strong, durable seam 12.
While the foregoing description of the invention has shown a preferred embodiment using specific terms, such description is presented for illustrative purposes only. It is applicant's intention that changes and variations may be made without departure from the spirit or scope of the following claims, and this disclosure is not intended to limit applicant's protection in any way.
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A pool sweep bag is provided for use in holding debris collected by pool sweeps and pool cleaners constructed of porous material and having a collapsible snout section at the bottom end and a closable seam at the top end.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
A precast concrete board fixing metal fitting characterized by the provision of a support metal member including at one side portion an upward and downward adjusting screw extending vertically therethrough and a horizontally forward and backward adjusting screw having at least two nuts threaded thereon, and means provided at the other side portion for fastening said support metal member to the precast concrete board; and an adjusting metal member including upstanding plates mounted on a base board, horizontally securable to a building structure, at three side portions thereof except for that side portion confronting the precast concrete board, said plate confronting thhe precast concrete board having a notch extending from its upper portion, rightward and leftward adjusting screws of which distal ends are opposed to each other extending respectively through said right- and left-side plates, disposed perpendicular to the precast concrete board.
DETAILED DESCRIPTION OF THE INVENTION
1. Field of Industrial Utility
This invention relates to a metal fitting for fixing a precast concrete board (hereinafter referred to as "PC board") to a building structure.
2. Prior Art
In most of the conventional PC board fixing metal fittings, for example, as disclosed in Japanese Utility Model Application (OPI) Nos. 134209/1977, 155806/1978 and 40507/1982, through holes are formed through a flange of an L-shaped metal part which is protruded horizontally from a surface of the PC board, and it is adapted to be fixed to a metal member, secured to a building structure such as a beam, by the use of bolts vertically inserted into the through holes.
PROBLEMS TO BE SOLVED BY THE INVENTION
In the installation of the PC board using the conventional fixing metal fittings, the adjustments of the vertically-disposed board in an upward/downward direction, a rightward/leftward direction parallel to the board surface and a forward/backward direction perpendicular to the board surface can not be made independently of one another. And, even in the case where the adjustment in one direction is only needed, the adjustments in all the directions have been required to be made from the beginning.
Therefore, the installation of the PC board using the conventional fixing metal fittings has required a lot of time and labor.
An object of this invention is to overcome the above problems of the prior art and to provide a fixing metal fitting which enables an easy adjustment of the position of a PC board when installing the PC board, thereby improving an installation efficiency.
MEANS FOR SOLVING THE PROBLEMS
This invention has been made in order to achieve the above object and is characterized by the provision of a support metal including at one side portion an upward and downward adjusting screw extending vertically therethrough and a horizontally forward and backward adjusting screw having at least two nuts threaded thereon, and means provided at the other side portion for fastening the support metal member to the precast concrete board; and an adjusting metal member including upstanding plates mounted on a base board, horizontally securable to a building structure, at three side portions thereof except for that side portion confronting the precast concrete board, the plate confronting the precast concrete board having a notch extending from its upper portion, rightward and leftward adjusting screws of which distal ends are opposed to each other extending respectively through the right- and left-side plates, disposed perpendicular to the precast concrete board.
OPERATION
The support metal member, which is fastened at the other side portion to the PC board and has the upward and downward adjusting screw and the forward and backward adjusting screw having at least two nuts threded thereon both of which screws are threadedly connected to the support metal at the one side portion thereof, is placed on the base board between the opposed distal ends of the rightward and leftward adjusting screws of the adjusting metal member in such a manner that the forward and backward adjusting screw is received in the notch formed in the plate confronting the PC board with the two nuts disposed respectively on the front and rear sides of the plate.
Then, the position adjustment in the vertical direction is carried out by turning the upward and downward adjusting screw. And, the position adjustment in the rightward/leftward direction is carried out by turning the rightward and leftward adjusting screws. Further, the position adjustment in the forward/backward direction is carried out by turning the nuts on the forward and backward adjusting screws to position the PC board in place, and the support metal member is clamped between the rightward and leftward adjusting screws, thereby firmly fixing the PC board in position relative to the building structure.
EMBODIMENT
The invention will now be described in detail by way of one embodiment thereof.
FIG. 1 is a plan view of one embodiment of this invention.
FIG. 2 is a partly cross-sectional, front elevational view.
FIG. 3 is a view taken along the line A--A of FIG. 2.
In FIGS. 1 to 3, the PC board fixing metal fitting 1 according to the present invention comprises a support metal member 2 and an adjusting metal member 3. Threadedly connected to the support metal member at one side portion thereof are an upward and downward adjusting screw 4 vertically extending therethrough, and a horizontally forward and backward adjusting screw 5 having two nuts 5a, 5a threaded thereon, with two washers 5b, 5b interposed between the two nuts. The support metal member has at the other side portion means for fastening it to a frame member 11a of the PC board 11, for example, by bolts 2a.
On the other hand, the adjusting metal member 3 includes upstanding plates mounted on a base board 6, horizontally securable, for example, to a beam 12 of a building structure, at three side portions thereof except for that side portion confronting the PC board. The confronting plate 7 confronting the PC board 11 has a notch 7a extending from its upper portion, and rightward and leftward adjusting screws 10, 10 are threadedly connected to and extending through the right- and left-side plates 9 and 8, disposed perpendicular to the PC board, with the distal ends of the rightward and leftward adjusting screws being opposed to each other.
The support metal member 2 is fastened to the PC board 11 beforehand. For the installation, as shown in FIG. 1, the side portion of the support metal member to which the upward and downward adjusting screw 4 and the forward and backward adjusting screw 5 are threadedly connected in place on the base board 6 between the distal ends of the rightward and leftward adjusting screws 10, 10 (At this time, one or both of the rightward and leftward adjusting screws 10, 10 have been loosened to increase the spacing therebetween) in such a manner that the forward and backward adjusting screw 5 is received in the notch 7a of the confronting plate 7. And, as shown in FIG. 2, the two washers 5b, 5b are disposed on the opposite sides of the confronting plate 7, and the nuts 5a, 5a are positioned on the outsides of the washers 5b, 5b, respectively.
In the case where the width of the notch 7a is narrow, the washers 5b may be omitted, but in the case where the width is large to obtain a large amount of adjustment in the rightward/leftward direction, it is better to interpose the washers 5b as is the case with this embodiment.
For effecting the position adjustments, the nuts 5a on the forward and backward adjusting screw 5 are loosened to be free from the confronting plate 7. Thereafter, first, for example, the upward and downward adjusting screw 4 is turned to carry out the position adjustment in the vertical direction. Then, one of the rightward and leftward adjusting screws 10, 10 is turned, and the other is turned in the opposite direction to carry out the position adjustment in the rightward/leftward direction. Then, one of the nuts 5a, 5a threaded on the forward and backward adjusting screw 5 is turned, and the other is turned in the opposite direction to carry out the position adjustment in the forward/backward direction, thereby positioning the PC board in place. With respect to the order of this positioning operation, the position adjustment may be started in any of the directions.
After the positioning is finished, the rightward and leftward adjusting screws 10 are tightened to firmly clamp the support metal member 2 therebetween, and the nuts 5a on the forward and backward adjusting screw 5 are tightened to firmly clamp the confronting plate 7 therebetween through the washers 5b, so that the PC board 11 is fixed in the above-mentioned position.
Owing to the weight of the PC board 11 and the tightening forces of the rightward and leftward adjusting screws 10 and nuts 5a of the forward and backward adjusting screw 5, a stable fixing on the base board 6 in the vertical direction is achieved.
Therefore, the PC board 11 can be readily and firmly installed in place.
ADVANTAGEOUS EFFECTS
As described above, with the use of the fixing metal fitting according to the present invention, the position adjustments in the upward/downward, rightward/leftward and forward/backward directions can be made independently of each other when the PC board is to be installed, which greatly improves the installation efficiency.
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A metal fitting for fixing a precast concrete board comprises: a supporting metal member with one end portion secured to the board and with the other end portion provided with a first screw to move the board upward and downward through the supporting metal member and a second screw to move the board backward and forward through the supporting metal member; and an adjusting metal member including a base board which is secured to a building's structure, and a pair of third screws for moving the board rightward and leftward through the supporting metal member, so that the position adjustments of the board in the three directions can be achieved independently of one another.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to basin type plumbing fixtures (especially bathtubs and sinks). More particularly it relates to controls useable with such basins that can both govern flow through a basin's lower drain outlet and the basin's overflow outlet.
It is conventional to have a drain outlet at the bottom of a bathtub, sink or the like, and an overflow outlet positioned adjacent an upper rim. If water is running into the basin, and the bottom drain is closed or clogged, continued flow could cause excess water to spill, absent such an overflow. As such, these overflows are typically designed so that if water rises too high in the basin, before reaching the rim and spilling the water will instead pass out the overflow outlet and go to a by-pass drain line. See e.g. U.S. Pat. No. 3,835,484.
The bottom drain outlet used with these basins is typically controlled by a plug or stopper that is remotely actuatable without the need to touch the plug itself. This is often achieved through the use of mechanical levers or cable linkages. See e.g. U.S. Pat. No. 6,637,051. It is also sometimes achieved where an actuator for the linkage is associated with a control mounted adjacent the overflow outlet. See e.g. U.S. Pat. No. 4,594,738.
Regardless, provision is typically made to always leave the overflow outlet open. Whatever benefits this has for avoiding spillage, it necessarily also prevents the tub from being filled up all the way to the rim. Hence, some volume capacity of the tub is “wasted”. This can make it difficult for large consumers to have their torso completely immersed during bathing when using standard size bathtubs.
There have therefore been some attempts to have a drain control that also provides an option to close off the overflow somewhat when extra water volume is desired in the tub. See e.g. U.S. Pat. Nos. 3,835,484 and 3,859,676. However, these prior designs could increase clogging potential by mounting linkages along the drain passageways, and in any event were non-intuitive and relatively expensive to produce.
In separate work there have been a variety of drain stoppers developed which act somewhat like a ballpoint pen. When stepped on once they will click to a closure position. When stepped on a second time they will click to an open position. Hence, using a foot (or optionally a hand) the bottom drain outlet can be controlled by direct contact. See e.g. U.S. Pat. Nos. 6,195,819, 6,442,770 and 6,880,179. However, this requires a willingness to have a foot or hand pass through standing water to open the bottom drain after use, may leave an uncomfortable projection in the tub, and in any event does not address control of the overflow outlet.
There is therefore a need for providing improved combined controls for basin bottom drains and overflow outlets.
SUMMARY OF THE INVENTION
One aspect of the invention provides a combined control for a basin overflow and basin drain. The controls of the present invention are particularly suitable for use with bathtubs such as standard bathtubs or whirlpools.
There is an operator mountable adjacent a basin overflow, a drain closure valve mountable adjacent a basin drain, and a linkage extending between the operator and the drain closure valve such that rotation of a portion of the operator can cause movement of the drain closure valve between an open and a closed position. There is also a seal portion of the operator mounted for axial movement between two axial positions, and a pop-out type activator portion of the operator linked to the seal.
When installed, a first push of the activator (e.g. on a handle portion thereof) will move the seal from a first of the two axial positions to a second of the two axial positions. This will close off the overflow. Then, a second push of the activator in the same direction will pop the seal back to the first of the two axial positions.
Preferably, the seal is in a form of an overflow stopper skirt which is annular, and the activator includes a post defining a cavity extending along an axis, a sleeve member telescoped over the post, and a spring positioned within the cavity.
Note that the term “seal” is not intended to require a complete closure. Rather, it is enough that the closure be sufficient to permit water to rise past the overflow towards the rim. Moreover, it is not required that a gasket-type seal be present.
In other preferred forms the actuator is linked to a rotatable handle that controls movement of the drain closure valve. One can then, in one rotational position, push the handle axially to cause the overflow seal to initiate, and a second push will end the overflow seal.
In especially preferred forms the construction is such that axial handle movement is precluded when the drain outlet is open, and can be precluded even when the drain outlet is closed (if desired). However, there is a third rotational position of the handle that permits axial handle movement when the drain outlet is closed. This can be facilitated with a projection and slot construction.
In one form rotation of the handle causes movement of a cam which in turn causes a cable linkage to open or close the primary drain. That same handle can be pushed to first close the overflow, and then pushed again in the same direction to open the overflow.
Hence, a single operator will govern flow through the basin's bottom drain outlet, will preclude the overflow from being closed in some rotational positions, and will permit the overflow to be closed in another rotational position. The operational mechanism is highly intuitive, and thus something that does not require extensive explanation to first-time users.
Moreover, the product can be manufactured at reasonably low additional cost (relative to a standard cable driven drain control which does not have overflow control). Also, as pop-up type valves have been shown to have long-term reliability in this type of environment as applied to bottom drains, it is highly likely that incorporating them into the present assembly will not trigger significant maintenance issues.
The foregoing and still other advantages of the invention will appear from the following description. In that description reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration a preferred embodiment of the invention. That embodiment does not represent the full scope of the invention. Rather, the claims should be looked to in order to judge the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partly in section, of a bathtub which has been installed with a combined control of the present invention;
FIG. 2 is a partially exploded perspective view focusing on the overflow area of the bathtub;
FIG. 3 is an enlarged, partially exploded assembly view of a portion of the control;
FIG. 4 is an enlarged, partially exploded view somewhat similar to FIG. 3 , but showing a further stage of assembly;
FIG. 5 is an exploded view of an actuating assembly of FIG. 4 ;
FIG. 6 is an enlarged sectional view of the overflow area, when both the drain and overflow outlets are open;
FIG. 7 is a view similar to FIG. 6 , but showing the configuration when the bottom drain outlet is closed and the overflow is open; and
FIG. 8 is a view similar to FIG. 6 , but showing the configuration when both the bottom drain out and overflow are closed.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1 , there is shown a bathtub generally 10 having a control 12 provided through an overflow opening 13 of the side wall 14 . There is also a drain outlet valve 16 positioned at a bottom opening 17 of a basin bottom wall 18 .
Housing 20 is mounted to the side wall 14 and an actuator handle 22 controls both drain closure and overflow closure. Housing 24 is mounted to the bottom wall 18 in communication with the drain outlet valve 16 . A T-shaped fitting 26 connects a cross channel 28 coupled to the housing 24 , and a down channel 30 couples to the housing 20 and also a sewer line 32 .
Referring now also to FIG. 2 , housing 20 has a cylindrical portion 34 , and retains an actuating assembly 36 and the beginnings of cable linkage 38 . There is also a drain flange/escutcheon 40 . Note that the handle 22 also has an edge 42 which functions as a stopper. The cylindrical portion 34 has an open front inlet end 44 , and includes an outlet port 46 .
Referring now also to FIG. 4 , a cross bar 48 is provided to enable the escutcheon 40 and cylindrical portion 34 to be coupled to secure the assembly to the bathtub 10 . The cross bar 48 includes posts 50 on radially opposite sides of a central aperture 52 . The central aperture 52 permits the cross bar 48 to be inserted into the cylindrical portion 34 over the actuating assembly 36 . The cross bar 48 is secured via fasteners 54 inserted through apertures 56 formed at ends of the bar 48 .
Referring now also to FIG. 6 , the escutcheon 40 has an inner rim 58 surrounding an opening 59 , sized to extend beyond an outer rim 60 when it is inserted into the opening 13 of the bathtub 10 . The escutcheon 40 has a frustoconical surface 62 extending outwardly to a lip 64 with a diameter larger than the drain opening 13 to prevent it from being pressed through.
A pair of apertures 66 are formed through the inner rim 58 of the escutcheon 40 . The lip 64 of the escutcheon 40 rests on the side wall 14 and the apertures 66 in the inner rim 58 are aligned with openings 68 in the vertical posts 50 of the crossbar 48 secured within the cylindrical portion 34 . Fasteners 70 extend through the openings 66 and are threaded into the vertical legs 50 . The fasteners 66 are tightened to draw the cylindrical portion 34 and escutcheon 40 towards each other and into contact with opposing sides of the side wall 14 . A rubber gasket 72 positioned on the outer rim 60 seals against the bathtub 10 .
Referring now also to FIGS. 3 and 5 , an actuating assembly 36 includes a cam 74 and cam linkage 76 coupled to a waste drain stopper 78 via the cable linkage 38 . As shown, the cable linkage 38 includes a movable cable 80 and a protective sheath 82 . The cable 80 enters the cylindrical portion 34 via an opening 84 and a barrel-shaped end 86 is received by a slotted aperture 88 in a first end 90 of the cam linkage 76 .
A second end 92 of the cam linkage 76 includes an aperture 94 that is positioned onto an integral pivot post 96 . An arcuate opening 98 extending across the cam linkage 76 receives a toe 100 projecting outwardly from the cam 74 when assembled within the cylindrical portion 34 . The cable linkage 38 , cable opening 84 , cam 74 , and cam linkage 76 are sealed within the cylindrical portion 34 via a gasket 102 and plate 104 fastened by screws 106 .
The actuating assembly 36 is rotatable, via the handle/stopper 42 , to effect pivotable movement of the cam linkage 76 . At a first angular position shown in FIG. 6 , the toe 100 is adjacent to the first end 90 of the linkage 76 and the waste drain stopper 78 is open. Moving the actuating assembly 36 to a second angular position, such as shown in FIG. 7 , causes the cam 74 to rotate, pivoting the cam linkage 76 and pulling the cable 80 .
Although not illustrated, the other end of the cable 80 is linked to an internal second pivot in the housing 24 which pivots a part under the waste drain stopper 78 to pull the stopper 78 closed. At a third angular position of the actuating assembly 36 shown in FIG. 8 , the handle/stopper 42 can be pressed into and out of the escutcheon 40 .
As seen best in FIG. 5 , the actuating assembly 36 includes a clicker assembly 108 to temporarily hold the handle/stopper 42 against the inner rim 58 of the escutcheon 40 to close the overflow opening 13 . The clicker assembly 108 includes a post 110 and a cylindrical sleeve 112 partially telescoped onto the post 110 . Axial movement of the sleeve 112 further onto the post 110 is resisted by a compression spring (not shown) captured between the post 110 and the sleeve 112 . A catch wire 114 ( FIG. 4 ) secures the sleeve 112 to the post 110 . Radial movement of the sleeve 112 relative to the post 110 is prevented by a groove 116 in the post 110 and a set screw 118 extending through the outer sleeve 112 .
A conventional clicker assembly 108 includes a circuitous groove (not shown) formed in the post 110 to guide an end of the catch wire 114 . The end of the catch wire 114 travels within the groove allowing the sleeve 112 to telescope between an open, intermediate, and closed position. When the post 110 is axially fixed in place, a pressing force causes the spring to compress and the sleeve 112 is moved from an open to an intermediate position. When the force against the sleeve 112 is released, the spring decompresses slightly, moving the sleeve 112 to the closed position. A subsequent pressing force moves the sleeve 112 back to an intermediate position and after the subsequent force against the outer sleeve 112 is released, the spring forces the sleeve 112 back to the open position.
Various other known clicker assemblies may be used. See e.g. clicker 2 of U.S. Pat. No. 6,442,770.
The actuating assembly 36 includes the aforementioned plate 104 which has a central boss 120 defining a cavity 122 and a telescoping sleeve 124 received over the boss 120 . The clicker assembly 108 is received within the central boss 120 with one end portion 126 of the post 110 extending through an opening 128 in the plate 104 with an integral flange 130 on the post 110 abutting against the plate 104 from inside the boss 120 .
An o-ring 132 on the end portion 126 of the post 110 prevents leakage into the sealed portion of the cylindrical portion 34 . The cam 74 is retained on the end portion 126 of the post 110 via a c-clip 134 inserted into a groove 136 and abuts the opposing side of the plate 104 . Together, the integral flange 130 and cam 74 keep the clicker assembly 108 affixed to the plate and within the boss 120 .
The clicker assembly 108 extends through the boss 120 and into the telescoping outer sleeve 124 . A beveled square-shaped portion 138 of the inner sleeve 112 passes through a similarly shaped opening 140 in an axial face 142 of the outer sleeve 124 . A c-clip 144 inserted into a groove 146 in the square-shaped portion 138 secures the outer sleeve 124 to the clicker assembly 108 .
Ribs 148 formed in the outer sleeve 112 are received in slots 150 in the handle 42 . A set screw 152 prevents the handle 42 from being pulled off of the outer sleeve 124 .
Rotation of the outer sleeve 124 translates into rotation of the clicker assembly 108 due to the interface between the square-shaped portion 138 of the clicker assembly sleeve 112 and the matching square-shaped opening 140 in the outer sleeve 124 . Likewise, the rotation of the clicker assembly 108 translates into rotation of the cam 74 due to the interface between the end portion 126 of the post 110 and a square-shaped opening 149 in the cam 74 .
Importantly, in the first (drain open) and second (drain closed, but overflow protection desired) angular positions, an axial projection 150 on the central boss 120 prevents axial movement of the outer sleeve 124 and handle/stopper 42 . However, in the third (more rotationally extreme) angular position, a slot 152 in the outer sleeve 124 is aligned with the projection 150 on the central boss 120 . Pressing against the handle 42 moves the handle 42 and sleeve 124 connected thereto into contact with the escutcheon 40 . The handle/stopper 42 is preferably disk-shaped and provided with an annular rubber gasket 154 . The gasket 154 and stopper 42 are sized to fit tightly against the inner rim 58 of the escutcheon 40 to make a water tight seal at the overflow opening 13 .
The clicker assembly 108 automatically holds the handle 42 in a closed position. Subsequently pressing the handle 42 releases the handle 42 back to an open position. The handle 42 may then be rotated back to the second or first angular position as desired.
Hence, a single control will remotely activate the bottom drain for the tub, and also provide an option for closing off the overflow. The assembly is designed so that normally the overflow won't be closed off (even when the tub bottom drain is closed). However, when a conscious decision is made to shutoff the overflow, further rotation of a handle, followed by a pushing motion, can intuitively cause the overflow shutoff.
While a specific embodiment of the present invention has been shown, various modifications falling within the breadth and scope of the invention will be apparent to one skilled in the art. For example, the assembly need not rely on cable linkage, as distinguished from mechanical leverage systems, to activate the bottom drain. Thus, the following claims should be looked to in order to understand the full scope of the invention.
INDUSTRIAL APPLICABILITY
Disclosed is a combined control for basin bottom drain and basin overflow, particularly where the bottom drain can be controlled separately from overflow control.
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A control is provided adjacent an overflow of a bathtub or sink. It both remotely controls operation of a basin bottom drain, and provides an option of shutting off flow through the overflow. Rotation of a handle of the control controls the bottom drain, and axial movement of the handle controls flow through the overflow. For example, a clicker-type pop-out valve can control overflow flow. Slot and projection structures restrict use of the overflow shutoff when the drain is not closed, and/or in some circumstances even when the drain is closed.
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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 building foundations and in, particular pile foundations.
BACKGROUND OF THE INVENTION
Alaska and the Northern Regions are besieged by permafrost and ice rich soils conditions that make the construction of effective and economical foundation systems very difficult and costly. Foundations constantly fail and cause extensive damage to housing and other structures. Although foundation systems have been designed to solve these problems, they are generally not economically feasible for homes, in particular, as well as many other buildings. The budgets available for the construction of housing is not adequate for the installation of elaborate piling or refrigerated systems used for large commercial structures. In fact, the majority of homeowners living in the permafrost regions of Alaska simply acquiesce to high maintenance and repair costs of their homes caused by foundation movement.
Two types of foundations are typically used for housing and light buildings constructed in areas having permafrost conditions. One is “post and pad” and the other is piling. Although the post and pad system may have many variations, it commonly consists of wood or steel posts designed and supported on treated timber footings. The houses using this system are subject to high vertical and differential movement. The annual freeze-thaw cycles and frost heaves under the pads cause movement resulting in structural stresses to the houses resulting in cracking wallboard, plumbing breaks, broken window seals and doors jamming and in some severe cases, almost total failure of the houses. Most post and pad systems are difficult to adjust once they have moved and trying to re-level the houses has been a major challenge.
Prior piling systems include wood piles, steel piles, round and H driven piles and thermopiles. Generally, these piling systems are far to expensive for housing and small projects because of high materials costs and the cost of heavy equipment such as augers and cranes to install piles at remote locations. Driven steel piles are generally the most economical of the pile systems but it has been costly to install reliable bond breakers on driven piles to prevent jacking. Jacking is characterized as a gradual uplift of the pile due to the freeze thaw action of the surrounding soil. The freeze thaw action causes the surrounding soil to grip the upper part of the pile and lifts it upward. The reason for this is that the soil near the surface has a much stronger adfreeze bond or grip on the pile than does the warmer soil at depth. Therefore, without bond breakers, steel piles can be problematic for use in foundations in permafrost regions. In these prior piling systems, when bond breakers are used, the top five to seven feet of soil around the pile has to be dug out or a large diameter hole is predrilled so the bond breaker can be attached after insertion of the pile into the soil, resulting in wasted time and expense.
In view of the foregoing it can be seen that there is a need for an effective and economical foundation system for housing and other buildings in permafrost regions.
OBJECTS AND SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide an anti-jacking pile for use in foundation systems.
Another object of the invention is to provide a pile having an anti-jacking covering thereon to resist the effects of freeze-thaw cycles in permafrost regions.
Still another object of the invention is to provide a collar for facilitating driving of a pile into soil.
Yet another object of the invention is to provide a collar attached to a pile for preventing damage to an anti-jacking covering on the pile.
Still another object of the invention is to provide a method of installing a pile having an anti-jacking covering thereon.
Yet another object of the invention is to provide an adjustable leveling system as a long-term contingency so that the house can be re-leveled in the event of vertical movement.
These and other objects, uses and advantages will be apparent from a reading of the description which follows with reference to the accompanying drawings forming a part thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of the method of the anti-jacking pile installed in the ground;
FIG. 2 is a top section view of the collar of the anti-jacking pile;
FIGS. 3 and 4 are fragmentary elevation section views of the connection of the adjustable leveling system and the upper portion of the anti-jacking pile;
FIG. 5 is a side view of the connection plate for connecting the adjustable leveling system to the anti-jacking pile, and;
FIG. 6 is a side view of the adjustment post.
In summary, the invention is directed to an anti-jacking pile solution particularly suited for use in permafrost and cold regions. The pile includes bond breaking material for preventing frozen soil from directly gripping a pile near the surface of the soil and pulling the pile upward. A collar is attached to the pile to prevent damage and/or displacement of the bond breaking material during driving of the pile. The pile may be attached to a structure by way of an adjustable connection system.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a pile 10 after it has been driven into place into the soil 12 . A connection portion 13 of the pile 10 extends above the surface 14 of the soil 12 . The diameter and thickness of a steel pile will vary according to the particular building or structure design.
A pilot hole 16 may be drilled into the soil 12 to facilitate driving of the pile 10 . A bond breaker material 18 , is applied to the pile 10 prior to driving of the pile into the soil 12 . The bond breaker material 18 , is preferably a plastic material such that marketed under the names PERMALON® or CANVEX CB12WB, both of which have good elastic qualities under subfreezing conditions. Preferably, the bond breaker material 18 comes in six and eight foot wide rolls having ten to twelve mil thickness and is fastened to pile 10 with an approximately two-inch wide tape. The bond breaker material 18 is wrapped around the pile 10 in two layers and the first layer has a ½ pipe circumference overlap. It should be understood that the width of the bond breaker material 18 could vary and other products having similar good elastic qualities under subfreezing conditions could be substituted. Seams between adjacent wraps are preferably taped full length of the wrap and the lower end 19 of the bond breaker material 18 should also be taped in a thickness necessary to provide a sufficient clamping surface. Alternatively, a layer of grease may be applied to the pile 10 prior to application of the bond breaker material to further facilitate movement of the bond breaker material 18 relative to the pile 10 during soil movement.
In regions of Alaska, the continuous permafrost 20 may extend 1800 feet below the surface 14 of the soil 12 . At the surface 14 , the soil 12 may unthaw and refreeze to a much colder temperature than the permafrost 20 . This area of the soil 12 between the surface 14 and the continuous permafrost 20 is known as the active layer 22 . This active layer 22 is the part of the soil 12 that acts to pull the pile 10 upwardly as the soil 12 expands during frost heaves. Therefore, it is the portion of the pile 10 that is to be permanently located the active layer 22 that needs to be covered by the bond breaker material 18 . The active layer 22 is generally less than five feet in depth and therefore it is preferred that the bond breaker material 18 be applied to that portion of the pile 10 and preferably extending a few inches above the surface 14 of the soil 12 to compensate for uplift of the soil during frost heaves. It should be understood by one skilled in the art that the depth of the pile 10 into the soil 12 will vary according to construction requirements, and it should be understood that the pile 10 will generally extend fifteen to twenty-five feet farther into the continuous permafrost 20 for conventional housing construction.
A collar 24 is attached to the pile 10 adjacent the lower end 19 of the bond breaker material 18 . The collar 24 is preferably constructed of steel. As shown looking at both FIGS. 1 and 2, the collar 24 extends circumferentially around the pile 10 preferably overlapping the bond breaker material 18 and tightly engaged thereto to hold the bond breaker material 18 in place during welding of the collar to the pile 10 . Prior to driving the pile 10 , the collar 24 is preferably fillet welded in place along its lower edge 25 . The collar 24 is generally constructed of ¼ inch in thickness and approximately four inches in height. Although these dimensions are preferred, they may be varied as long as the function of the collar 24 of protecting the bond breaker material 18 during driving of the pile 10 is performed. The diameter of the collar 24 will vary in accordance with the diameter of the pile 10 being driven. Piles 10 for typical housing construction are six inches to ten inches in diameter.
Now looking to FIGS. 3, 4 , 5 and 6 , the supporting beams 30 of a building (not shown) are connected to the pile 10 by an adjustable connection system 32 . The system uses a two-part telescoping sleeve 34 and post 36 which slides into pile 10 and is welded thereto. The sleeve 34 includes four plates 38 , 40 , 42 and 44 extending horizontally outwardly from the sleeve 34 to accept connection to support struts 46 , 48 , 50 and 52 . The opposite ends of support struts 46 , 48 , 50 and 52 are connected to brackets 54 , 56 , 58 and 60 which are in turn connected to the support beams 30 .
As shown in FIG. 5, a plate 62 is used to join sleeve 34 directly to support beam 30 . Plate 62 provides a larger surface to engage support beam 30 to allow for slight variations in alignment. Sleeve 34 slidably engages post 36 which slides into pile 10 and is welded thereto. The telescoping sleeve 34 and post 36 are adjustably connected by bolts. Post 36 includes a plurality of holes 64 to facilitate vertical adjustment of the telescoping sleeve 34 .
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, uses and/or adaptations of the invention following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains and as maybe applied to the central features hereinbefore set forth, and fall within the scope of the invention and the limits of the appended claims.
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An anti-jacking pile solution particularly suited for use in permafrost or cold regions. The pile includes bond breaking material for preventing frozen soil from directly gripping a pile near the surface of the soil and pulling the pile upward. A collar is attached to the pile to prevent damage and/or displacement of the bond breaking material during driving of the pile. The pile may be attached to a building by way of an adjustable connection system allowing for future adjustments in the event of vertical movement.
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FIELD OF THE INVENTION
The present invention is directed to a roll-up partition system assembly having a protective partition for covering a window or door opening that may be rolled up into a housing when not in use. More particularly, the present invention is directed to an assembly implementing a strap box and having an emergency opening mechanism.
BACKGROUND OF THE INVENTION
Roll-up partition systems protect portals such as windows and doors from break-ins or from wind gusts and flying debris in heavy storms. One type of roll-up partition system is a rolling protective shutter. Rolling protective shutters are conventional and are used to provide protection against extreme weather conditions and to deter theft, for example. Rolling shutters illustratively comprise a plurality of elongate slats that are interconnected by a plurality of hinges. When not in use, the shutter may be retracted into a casing that is usually situated either above or beside the portal, illustratively a window or door. Retracting involves rolling up the shutter onto a roller tube. The shutter is composed of a number of elongated slats that are articulated along their long edges. Forming the shutter out of articulated slats enables the shutter to be retracted compactly yet be strong enough to deter burglary and provide protection against flying debris.
Roll-up partitions in general, and rolling protective shutters in particular, sometimes incorporate one or more torsion spring assemblies to assist in rolling and unrolling the shutters manually or by a powered opening device. In one illustrative arrangement, the assembly is a self-contained modular unit having a spring shaft surrounded by a coiled torsion spring. One end of the spring shaft includes a spring shaft support that is rotatable about the spring shaft, and a spring plate rigidly fixed to the spring shaft and to the proximate end of the torsion spring to prevent rotation of the end of the torsion spring relative to the spring shaft. The other end of the spring shaft includes a spring drive that is rotatable about the spring shaft and rigidly fixed to the other end of the torsion spring. The assembly is inserted into the shutter support member with one end of the spring shaft rigidly fixed to the shutter housing. The spring shaft support and spring drive engage the interior of and rotate with the shutter support member. When the shutter is unrolled, the torsion spring is wound tighter, thereby providing for controlled deployment and providing additional torque to assist in lifting and rolling the shutter onto the shutter support member. During normal operation of the rolling protective shutters, the torsion spring exerts a minimum torque when the shutter is in the rolled position and a maximum torque when the shutter is in the unrolled position.
Taking as an example a shutter for a window opening with a casing located above the window, as the shutter is unrolled the weight of the deployed portion of the shutter tends to cause unrolling to accelerate uncontrollably. To prevent such uncontrolled deployment, with the accompanying noise and potential for injury, the torsion spring biases the roller tube toward the fully retracted position. Rotation of the roller tube about the spring shaft in the direction for deployment tightens the torsion spring, which resists further motion in the direction of rotation, thereby at least partially compensating for the accelerating effect of the ever increasing weight of the unrolled portion of the shutter as it is being deployed. When the roller tube is rotated in the opposite direction to retract the shutter, the bias force of the torsion spring assists the motive force to lift the shutter, and the assistance diminishes as rolling of the shutter onto the roller tube progresses. The degree of bias is determined by the choice of spring and/or any pretensioning there may be when the shutter is fully retracted. The degree of bias, in turn, determines whether a shutter of a predetermined weight will remain deployed or will retract when there is no braking force on the roller tube to prevent rotation. For safety reasons, roller shutters may be equipped with a sufficiently strong torsion spring to fully retract the shutter when there is no braking force applied to the roller tube.
The motive force behind retraction and deployment of the shutter may be provided manually, e.g. by an operator pulling a strap, or electro-mechanically, e.g. by a motor.
Some building code regulations require that manual and electro-mechanical shutters be able to be opened very quickly in the case of an emergency, such as during a fire. A safety mechanism enabling quick release of a roller tube that is engaged to an electric motor is discussed in commonly-assigned U.S. Pat. Nos. 5,975,185 and 6,244,325, the teachings of which are herein incorporated by reference.
In manually operated shutters employing a strap, there is typically a pulley at one end of the roller tube. Illustratively, the pulley is attached to the shutter support member, and the strap is connected between the pulley and a strap recoiler (or “strap box” mounted to one of the shutter tracks or to the wall surrounding the opening. The strap recoiler includes a take-up roll upon which the excess strap is stored and a locking mechanism with a brake tab that locks the strap in place when the strap is pulled tight between the pulley and the strap recoiler. The locking mechanism of the strap recoiler is configured to facilitate retraction and deployment of the strap to roll and unroll the shutter. Illustratively, to roll the shutter to the retracted position, the strap is pulled outwardly away from the shutter track and opening and pulled downwardly toward the strap recoiler. As the strap is pulled outwardly, the locking mechanism releases the strap and allows the force of a torsion spring within the take-up roll to wind the excess strap onto the take-up roll. At the same time, the control strap is unrolled from the pulley, thereby rolling the shutter onto the shutter support member. When the strap is released, the weight of the shutter rotates the pulley and pulls the strap tight between the pulley and the strap recoiler, thereby locking the locking mechanism. To unroll the shutter to the deployed position, the strap is pulled outwardly away from the shutter track and opening and pulled upwardly toward the pulley and shutter housing. As the strap is pulled outwardly, the locking mechanism releases the strap and allows the strap to unwind from the take-up roll. At the same time, the control strap is rolled onto the pulley as the shutter support member rotates due to the weight of the shutter. When the strap is released, the weight of the shutter and the tension in the torsion spring pull the strap tight between the pulley and the strap recoiler, thereby locking the locking mechanism.
To improve the safety of manually operated roller shutters for doors and windows and to meet regulatory objectives, it would be highly desirable to have a quick release mechanism for a manually operated roller shutter employing a strap recoiler.
SUMMARY OF THE INVENTION
The present invention provides a roller shutter having a quick release feature that the roller shutter to move to a desired position.
One embodiment of the present invention is a roll-up partition comprising:
a) a shutter assembly comprising:
i) a shutter assembly housing adapted to be mounted to a wall above or beside a portal, ii) a roller tube rotatably mounted in the shutter assembly housing, and iii) a rolling shutter connected to the roller tube and configured to move between a retracted position in which the rolling shutter is wrapped around the roller tube and an open position in which the rolling shutter is deployed within the portal,
b) a flexible strap having a proximal end and a distal end, the proximal end connected to the roller tube,
c) a tensioner external to the shutter assembly housing, the tensioner connected to the distal end of the flexible strap and comprising a locking mechanism configured to releasably lock the flexible strap in place and a quick release mechanism configured to release the locking mechanism upon activation of the quick release mechanism, to allow the rolling shutter to change positions.
Illustratively, the locking mechanism is a brake tab, and the quick release mechanism changes the angle between the strap and the brake tab or otherwise releases the brake tab from a bearing surface. In various embodiments, the quick release mechanism is a pin, the removal of which permits the tensioner to pivot toward the roller tube, thereby releasing the locking mechanism. In other embodiments, the quick release mechanism is a lever or knob operatively connected to the locking mechanism, the movement of which releases the locking mechanism.
In illustrative embodiments, the roll-up partition further comprises a torsion spring connected to the roller tube, the torsion spring biasing the roller tube to move the rolling shutter toward the retracted position, and wherein operation of the quick release mechanism results in the rolling shutter moving toward the retracted position.
Another aspect of the invention is directed to a strap recoiler for use with a roller shutter, the strap recoiler comprising a housing, a take-up roll mounted in the housing, the take-up roll configured for wrapping a strap there-around, a torsion spring biasing the take-up roll in a direction to wrap the strap around the take-up roll, a first mounting bracket connected to the housing configured for pivotally mounting the strap recoiler to a support, and a second mounting bracket connected to the housing configured for releasably mounting the strap recoiler to the support.
Yet another aspect of the invention comprises strap recoiler for use with a roller shutter comprising a housing, take-up roll mounted in the housing, the take-up roll configured for wrapping a strap there-around, a torsion spring biasing the take-up roll in a direction to wrap the strap around the take-up roll, a locking mechanism configured to lock the strap in place, and a quick release mechanism configured to release the locking mechanism upon activation of the quick release mechanism. Various quick release mechanisms are within the scope of this invention.
Additional features of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of a rolling shutter assembly that can implement the present invention;
FIG. 2 is a fragmentary perspective view of a portion of the shutter of the shutter assembly of FIG. 1 ;
FIG. 3 is a partial cross-sectional side view of the strap recoiler of FIG. 1 in the locked position;
FIG. 4 is a partial cross-sectional side view of the strap recoiler of FIG. 1 in the unlocked position;
FIG. 5 is a partial cross-sectional side view of the strap recoiler of FIG. 1 in the with the quick release mechanism deployed;
FIG. 6 is an isometric view of a strap recoiler of FIG. 1 ;
FIG. 7 is a cross-sectional view of the strap recoiler of FIG. 6 along line 7 - 7 ;
FIG. 8 is an isometric view of a take-up roll for the strap recoiler of FIGS. 3-6 ;
FIG. 9 is a partial cross-sectional side view of another strap recoiler in the locked position;
FIG. 10 is an isometric view of a strap recoiler of FIG. 9 ; and
FIG. 11 is an isometric view of an alternative embodiment of a strap recoiler of FIG. 9 .
DETAILED DESCRIPTION
Directional terms like “above” and “below” and “upper” and “lower” may be used in the description of the roller shutter and tensioner according to the invention. The spatial relationships of the elements are determined by the design and construction of the roller shutter and the portal it protects. Thus, these terms are not intended to limit the invention to a vertical arrangement of elements.
The embodiments disclosed herein illustrated the various aspects of the present invention applied to one particular type of roll-up partition system: rolling protective shutters formed from a plurality of interconnected slats. It will be apparent to those of ordinary skill in the art that the present invention has application in other systems wherein a partition member is coupled to and rolls up onto a support member within a housing, such as roll-up doors, roll-up grills, roll-up gates, fire doors and the like. The application of the present invention to the various types of roll-up partition systems is contemplated by the inventor.
One type of a rolling shutter assembly 10 that may implement the present invention is shown in FIGS. 1-2 . Referring to FIG. 1 , the shutter assembly 10 has a shutter housing 8 that includes a top wall 12 , a pair of side walls 14 , and a front wall 16 . A shutter support member 20 is mounted for rotation within the shutter housing. The support member 20 includes a generally cylindrical central roller tube 22 and a plurality of mounting members 24 fixed to the roller tube 22 .
The upper end of a rolling shutter 30 is coupled to the mounting members 24 . The shutter 30 is composed of a plurality of individual, elongate slats 32 . One example of a configuration of slats 32 is illustrated in FIG. 2 . The slats 32 , each of which is substantially flat, having two substantially planar side portions, and may be composed of steel, are interconnected by a plurality of hinges 34 , each of which joins together a pair of adjacent slats 32 . Each of the slats 32 includes an upward projection 35 extending longitudinally along the upper edge of the slat 32 and having a rearwardly and downwardly extending hook 36 at the top. Each of the slats 32 further includes a downward facing U-shaped recess 37 extending longitudinally along the lower edge of the slat 32 and having a forward horizontal projection 38 formed on the rear edge of the recess 37 . The hook 36 of a lower slat 32 and the recess 37 and projection 38 of an upper slat 32 interlock to form each hinge 34 . Other configurations of slats 32 and interconnecting hinges 34 are well known in the art and are contemplated by the inventor as having use with the present invention. Several such examples of configurations of slats 32 are illustrated in co-pending U.S. patent application Ser. Nos. 10/802,385 and 10/802,257, the disclosures of which are herein incorporated by reference.
Referring back to FIG. 1 , a torsion spring assembly 26 is provided to assist roll-up of the shutter. Further details on an exemplary torsion spring assembly are found in U.S. Pat. No. 5,975,185, already incorporated by reference. However, other torsion spring configurations, as are known in the art, are within the scope of this invention. Illustratively, torsion spring 26 is sufficiently strong to fully retract shutter 30 when no braking force is applied. Still referring to FIG. 1 , the ends of the slats 32 are disposed within a pair of shutter tracks 40 . The shutter assembly 10 has a pulley housing 42 that interconnects the rotatable roller tube 22 to one end of a strap 44 via a conventional pulley (not shown). The other end of the strap 44 is attached to a strap recoiler 46 , which is mounted to track 40 via mounting bracket 76 . When mounted to protect a window or other opening, the shutter tracks 40 of the shutter assembly 10 are positioned on either side of the opening and the shutter housing is positioned over the top of the opening. Alternatively, in some applications, the side tracks 40 and shutter housing are positioned within the opening.
An illustrative strap recoiler 46 is shown in greater detail in FIGS. 3-5 . Referring to FIG. 3 , the strap 44 enters the housing 48 of the recoiler 46 through an opening 50 in the top 51 . The strap 44 is attached to a take-up roll 52 disposed within the housing 48 . The take-up roll 52 is rotatably coupled to the housing 48 by a central shaft (not shown) and includes a torsion spring 27 that applies torque that rotates the take-up roll 52 counter-clockwise as shown in FIG. 3 , to wrap the strap 44 around the take-up roll 52 .
The strap recoiler 46 of FIG. 3 includes a locking mechanism formed by a brake tab 56 and a bearing surface, illustratively bearing pin 58 . The brake tab 56 is pivotally mounted to the housing 48 by a pivot pin 60 . The brake tab 56 pivots about the pivot pin 60 between a locked position ( FIG. 3 ) wherein the brake tab 56 bears upon the bearing pin 58 , and an unlocked position ( FIG. 4 ) wherein the brake tab 56 does not bear upon the bearing pin 58 . When the shutter 30 is partially or fully unrolled, the torsion spring tends to rotate the shutter support member 20 in the direction that rolls the shutter 30 . This results in a force on the strap 44 in the direction of the shutter housing as indicated by the arrow F. The tension on the strap 44 exerts a force on a tip 62 of the brake tab 56 that rotates an engagement surface 63 at the opposite end of the brake tab 56 into engagement with the bearing pin 58 . In this position, the frictional force between the engagement surface 63 , the bearing pin 58 and the strap 44 is sufficient to retain the strap 44 and prevent the shutter 30 from rolling or unrolling, depending on the weight of the shutter and relative strengths of the torsion spring in torsion spring assembly 26 and the torsion spring provided in strap recoiler 46 .
During normal operation of the shutter assembly 10 , the locking mechanism automatically releases the strap 44 when the strap 44 is pulled out to raise or lower the shutter 30 , as illustrated in FIG. 4 . In an embodiment employing a torsion spring sufficiently strong enough to retract the shutter fully, to unroll the shutter 30 to the deployed position, the strap 44 is pulled outwardly away from the shutter track 40 and the opening and downwardly toward the strap recoiler 46 , in the general direction of the arrow F′. As the strap 44 is pulled outwardly and downwardly, the upward force exerted on the tip 62 of the brake tab 56 decreases and the brake tab 56 pivots toward the unlocked position. The strap 44 is released and the force of the torsion spring within the take-up roll 52 winds the excess strap 44 onto the take-up roll 52 . At the same time, the strap 44 is unrolled from the roller tube 22 , thereby unrolling the shutter 30 from the shutter support member 20 . When the strap 44 is released, the tension of the torsion spring 27 rotates the roller tube 22 and pulls the strap 44 tight between the roller tube 22 and the strap recoiler 46 , thereby pivoting the brake tab 56 to the locked position of FIG. 3 and securing the strap 44 to prevent the shutter 30 from rolling or unrolling.
To roll the shutter 30 onto the shutter support member 20 , the strap 44 is pulled outwardly away from the shutter track 40 and the opening and upwardly away from the strap recoiler 46 , in the general direction of the arrow F″. As the strap 44 is pulled outwardly and upwardly, the upward force exerted on the tip 62 of the brake tab 56 decreases and the brake tab 56 pivots toward the unlocked position shown in FIG. 4 . The strap 44 is released and the tension of the torsion spring 27 rotates the shutter support member 20 and the excess strap 44 winds onto the roller tube 22 . At the same time, the strap 44 is unrolled from the take-up roll 52 . When the strap 44 is released, the tension in the torsion spring pulls the strap 44 tight between the roller tube 22 and the strap recoiler 46 , thereby pivoting the brake tab 56 to the locked position of FIG. 3 and securing the strap 44 to prevent the shutter 30 from rolling or unrolling. It is understood that the direction the strap is moved to effect rolling and unrolling is opposite that of a configuration where the shutter is deployed due to gravity, and the torsion spring (if any) merely assists with retraction.
In certain circumstances, it would be desirable to have a quick release mechanism to release brake tab 56 from bearing pin 58 and permit torsion spring 27 to roll shutter 30 , without the need to pull the strap 44 outwardly during the entire rolling process. In various embodiments, the quick release mechanism alters the angle the brake tab 56 and the strap 44 , to release the strap 44 . In other embodiments, the quick release mechanism moves the brake tab 56 from contact with the bearing pin 58 , thereby releasing strap 44 .
One such embodiment is illustrated in FIGS. 3-7 . As shown in FIGS. 3-5 , the housing 48 is mounted to a top mounting bracket 54 and a bottom mounting bracket 55 . Optionally, the housing 48 is pivotally connected to brackets 54 and 55 , which permits the strap recoiler 46 to rotate from side-to-side if the strap 44 is pulled outwardly at an acute angle with respect to the opening and the wall. A mounting track 76 is also provided. The mounting track 76 may be mounted on shutter track 40 , as shown in FIG. 1 , or may be mounted on a nearby portion of wall or any other nearby surface. Illustratively, top mounting bracket 54 is pivotally connected to mounting track 76 at pivot point 70 . As shown, a pin 73 extends through mounting track 76 at opening 71 and through top mounting bracket 54 . However, it is understood that other hinges and devices for pivotally connecting the housing 48 to the mounting track 76 are within the scope of this invention.
As illustrated in FIGS. 3-5 , bottom mounting bracket 55 is removably attached to mounting track 76 by way of a removable pin 74 that extends through pin hole 72 in mounting track 76 and pin hole 72 A (as shown in FIG. 5 ) in bottom of mounting bracket 55 . Removal of removable pin 74 , illustratively by pulling pull ring 78 , allows the housing 48 to rotate on pivot point 70 upward, as shown in FIG. 5 . Once the housing 48 rotates upward, as shown in FIG. 5 , the strap is released from the locked position, and the torsion spring assembly 26 attached to roller tube 22 and the torsion spring 27 in the housing 48 can then work together to roll the strap 44 into the housing 48 and roll the rolling shutter 30 into shutter housing 8 . Such a configuration provides for rapid retraction of the shutter with only the removal of a single pin. Conversely, in certain situations where it may be desirous to seal off a portion of the building, the rolling shutter assembly 10 may be provided with weaker torsion springs or without a torsion spring connected to roller tube 22 . In this alternative embodiment, removal of the pin 74 would allow rolling shutter 30 to open, thereby closing off the opening in which the rolling shutter 30 is mounted.
It is understood, however, that other means of releasably restraining bottom mounting bracket 55 to mounting track 76 are possible and are within the scope of this invention. Various clips, pins, and other quick release mechanisms may be employed, as are known in the art, such that the quick release mechanism may be easily activated illustratively by pulling a ring or ribbon, or by pressing a button or twisting a handle. It is further understood that while brackets 54 and 55 are shown as separate parts that are connected to housing 48 , brackets 54 and 55 may be formed integrally with housing 48 . Alternatively, an opening 71 A for pivot point 70 may be provided through an upper section of housing 48 and pin hole 72 A may be provided in a lower section of housing 48 .
FIGS. 6 and 7 illustrate more detail of the mounting track 76 and the connection between the mounting track 76 and the strap recoiler 48 . As best seen in FIG. 7 , mounting track 76 is U-shaped, with a first side 80 , a second side 81 , and a bottom 82 . Top mounting bracket 54 sits within the U-shaped mounting track 76 , and is retained by pin 73 . Pin 73 extends through hole 72 in the first side 80 of mounting track 76 , through hole 72 A in top mounting bracket 54 , and through hole 72 ′ in the second side 81 of mounting track 76 . It is understood that bottom mounting bracket 55 is similarly retained in mounting track 76 , except that pull ring 78 allows easy removal of removable pin 74 .
As previously discussed, the take-up roll 52 in the strap recoiler 46 includes a torsion spring 27 that provides torque to roll up the excess strap 44 when the shutter 30 is opened. FIG. 8 illustrates the take-up roll 52 , removed from housing 48 . The strap 44 is omitted from the figure for the sake of clarity, but it is understood that the strap is wound around take-up roll 52 , and the take-up roll 52 is shown with a portion of the wall removed to expose a torsion spring 90 . The take-up roll 52 includes a central shaft 92 that is rotatable with respect to the take-up roll 52 . One end of the torsion spring 90 is connected to the take-up roll 52 and the other end is connected to the shaft 92 such that the tension in the torsion spring 90 increases as the strap 44 is unrolled (clockwise rotation of the roll 52 ) and decreases as the strap 44 is rolled up (counter-clockwise rotation of the roll 52 ). When the take-up roll 52 is disposed within the housing 48 , the shaft 92 is held in a fixed position within the housing 48 and is not permitted to rotate within housing 48 . The tension in the torsion spring 90 may be adjusted either by rotating the take-up roll 52 or by varying the amount of the strap 44 that is unrolled from the roll 52 .
The quick release mechanism of FIGS. 3-7 includes a pivoting connection between mounting track 76 and strap recoiler 48 , wherein the strap recoiler housing pivots to release the locking mechanism. However, other configurations that release the locking mechanism to provide a quick release mechanism are within the scope of the present invention. Illustratively, any mechanism that changes the angle between the brake tab 56 and the strap 44 or otherwise disengages brake tab 56 from bearing pin 58 , to release the strap 44 , is within the scope of this invention.
Illustrative embodiments of alternative configurations for a quick release mechanism are shown in FIGS. 9-11 . In these embodiments, rather than moving the strap recoiler 46 to change the angle between the brake tab 56 and strap 44 , these embodiments change the angle by moving the brake tab 56 . In FIG. 9 a lever 96 is provided and is connected to brake tab 56 . Lever 96 and brake tab 56 may be formed integrally, or lever 96 may be connected to brake tab 56 . Movement of lever 96 in the direction shown by arrow G moves brake tab 56 away from bearing pin 58 and into the unlocked position. As shown in FIG. 10 , lever 96 may extend through a slot 97 or other opening in housing 48 , to provide a user with easy access to lever 96 to move lever 96 in the direction shown by arrow G. A notch 98 , provided in slot 97 allows the user to secure lever 96 in position, thereby securing brake tab 56 in the unlocked position. Other mechanisms for retaining lever 96 in the locked or unlocked position are possible.
In FIG. 10 , lever 96 extends through curved slot 97 a and is attached to a knob 99 . Rotation of knob 99 in the direction shown by arrow H moves lever 96 in curved slot 97 a and moves brake tab 56 to the unlocked position. A notch 98 a may be provided to secure lever 96 in position, thereby securing brake tab 56 in the unlocked position. Another notch 98 b at the opposite end of slot 97 a may be provided to secure lever 96 in position such that brake tab 56 is secured in the locked position. Other configurations for securing knob 99 or lever 96 are within the scope of this invention.
Additionally, it is understood that lever 96 could be placed near tip 62 of brake tab 56 , with movement of lever 96 in a direction opposite to that shown by G in FIG. 9 , to move brake tab 56 to the unlocked position. Alternatively, a magnet may be placed on the outside of housing 48 to move brake tab 56 . In yet another alternative embodiment, engagement surface 63 may be moved to change the angle between brake tab 56 and strap 44 . In yet another embodiment, the quick release mechanism is a lever, magnet, or other device that moves bearing pin 58 away from brake tab 56 to release strap 44 . Other configurations are possible that move the brake tab 56 to an unlocked position to provide a quick release mechanism.
Other modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. This description is to be construed as illustrative only, and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and method may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved.
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The present invention is directed to a roll-up partition comprising a rolling shutter, a shutter assembly, a flexible strap and a tensioner. The tensioner includes a locking mechanism that is configured to lock and unlock the flexible strap and a quick release mechanism configured to release the locking mechansim, thus allowing the rolling shutter to change positions. The invention also includes a strap recoiler with a locking mechanism and a quick release mechanism, wherein activation of the quick release mechanism causes the release of the locking mechanism, thus allowing the roll-up partition to change positions. The invention also includes a method of exiting an enclosed space partially bounded by a portal protected by a roller shutter. The method includes operating the quick release mechanism, waiting for the shutter to retract and exiting the space through the portal.
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BACKGROUND
[0001] The following disclosure relates to a tool operated channel latch used to secure a panel against a structure. The latch includes a bracket which mounts to the movable panel and includes an actuating mechanism to open and close the latch. A bolt is pivotably retained relative to the bracket for engaging against the structure closed by the panel. A lock assembly is carried on the actuator to engage a link which is movably coupled with both the bolt and the actuator. The lock assembly includes extending portions to engage at least one corresponding opening of the link. The link provides an over center toggle condition to retain the latch in a locked position until intentionally actuated by an operator.
[0002] One of the issues with some channel latch systems is that the latch may require a tool and two hands to operate the latch. In this regard, some prior art latches require the use of a tool to unlock the latch and then a second tool to pry the latch into an open condition. Other latches include the use of a tool to unlock the latch and then a second hand to manipulate a trigger or an extending portion of the latch to actuate the latching mechanism.
[0003] Other prior art latch systems may have provided for conditions which might not be preferred under some circumstances. For example, a false positive latch condition could be produced by some prior art latch systems. This would be undesirable in some circumstances since it might be preferred to maintain the latch in only one of two states at a given time. Namely, state one fully locked without any question about the locked condition and state two fully unblocked without any question about the condition of the latch being unblocked. As such, it could be desirable to provide a latching system that provides an indication when the latch is fully locked and an indication when the latch is unlocked. These condition indicators will allow the operator of the latch to detect the condition to make sure that there is no false positive latching condition. In this regard, it may be desirable or necessary to have the fully locked position before the device or vehicle with the panel is moved so that the operator of the device knows the panel is in the closed condition. Similarly, when the panel is to be unblocked and opened, for example for purposes of maintenance, it could be desirable to know that the panel is in the unlocked condition.
[0004] It might also be desirable to provide a latching system which can be operated with a single hand and single tool. This would require the elimination of a second prying tool as might be found in some prior art latching systems. Additionally this might require the elimination of a trigger or using a tool in one hand and prying with a second hand which might also be found in some prior art latching systems.
[0005] This background information is provided to identify some information believed by the applicant to be of possible relevance to the present disclosure. No admission is intended, nor should such admission be inferred or construed, that any of the preceding information constitutes prior art against the present disclosure. Other aims, objects, advantages and features of the disclosure will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present disclosure will be described hereafter with reference to the attached drawings which are given as a non-limiting example only, in which:
[0007] FIG. 1 is a perspective view of a channel latch assembly of the present disclosure showing a bracket for mounting to a panel, a bolt pivotably retained on the bracket and extending from the channel latch assembly in a locking condition, an actuator pivotably retained on the bracket, and a link operatively connecting a portion of the actuator to the bolt;
[0008] FIG. 2 is a top plan view of the latch assembly shown in FIG. 1 showing the bracket, a portion of the bolt extending from the bracket of the latch assembly, and an actuator positioned in the central channel of the latch assembly;
[0009] FIG. 3 is a cross sectional side elevational view taken along line 3 - 3 in FIG. 2 showing the relative relationships and connections of the described components of the latch assembly in a locked condition;
[0010] FIG. 4 is a cross sectional side elevational view taken along line 4 - 4 extending through a lock mechanism of the latch assembly showing the locked condition of an extending portion of the lock engaged with a corresponding opening in the link to facilitate an engagement of the lock with the link to prevent unintended opening of the latch assembly;
[0011] FIG. 5 is an exploded perspective view of the latch assembly showing the various components and relationships of the components for further relative description thereof;
[0012] FIG. 6 is a side elevational view of the latch assembly in a closed condition; and
[0013] FIG. 7 is a side elevational view of the latch assembly in an unlocked and fully extended open condition.
[0014] The exemplification set out herein illustrates embodiments of the disclosure that are not to be construed as limiting the scope of the disclosure in any manner. Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
DETAILED DESCRIPTION
[0015] While the present disclosure may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, embodiments with the understanding that the present description is to be considered an exemplification of the principles of the disclosure. The disclosure is not limited in its application to the details of structure, function, construction, or the arrangement of components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of various phrases and terms is meant to encompass the items or functions identified and equivalents thereof as well as additional items or functions. Unless limited otherwise, various phrases, terms, and variations thereof herein are used broadly and encompass all variations of such phrases and terms. Furthermore, and as described in subsequent paragraphs, the specific configurations illustrated in the drawings are intended to exemplify embodiments of the disclosure. However, other alternative structures, functions, and configurations are possible which are considered to be within the teachings of the present disclosure. Furthermore, unless otherwise indicated, the term “or” is to be considered inclusive.
[0016] FIG. 1 shows a perspective view of the latch assembly 20 including a bracket 22 which carries an actuator 24 and a bolt 26 , both pivotably carried on the bracket 22 as described in greater detail below. At least one link 28 , and the case of the illustrated embodiment two links 28 , are pivotably connected at a first end 32 to a portion of the actuator 24 and at a second end 34 to a portion of the bolt 26 . As will be described in greater detail below, the connection of the actuator 24 and bolt 26 with a link 28 provides an over center toggle condition when the four-bar linkage system is in the closed condition. In the closed condition a higher force on the bolt 26 pushes the latch 20 closed with a higher force. The over-center toggle of the link 28 and the connected actuator 24 redirects the forces acting on the bolt 26 to push it closed instead of open.
[0017] FIG. 2 provides a plan view of the latch assembly 20 as described showing a tool receiving recess 36 on a face portion 38 of the actuator 24 . The recess 36 receives a complementary tool head to facilitate rotation about an axis to position a lock assembly 200 , described in greater detail below, in a “lock” or “unlock” position. The face of the actuator 38 also includes indicia 37 to indicate which direction the tool, while engaged in the recess, should be, rotated, leveraged, or moved to unlock or lock the lock assembly to “open” or “close” the latch assembly. The closed latch assembly is shown in FIG. 6 and the open latch assembly is shown in FIG. 7 .
[0018] Turning now to FIG. 3 , a cross sectional side elevational view is shown as taken along line 3 - 3 in FIG. 2 . Also, FIG. 4 is a cross sectional side elevational view taken along line 4 - 4 in FIG. 2 . Description of these Figures is provided with additional reference to FIG. 5 . The combination of these views helps to understand the configuration, orientation, structure, relationships, and function of the various components of the latch assembly 20 . With reference to FIGS. 3-5 , the bracket 22 includes a first passage 40 which receives a first rivet 42 extending there through. The first rivet 42 extending through the first passage 40 engages a corresponding head passage 44 of a head 45 on the actuator 24 and a bushing 46 retained therein. The assembly of the first passage 40 provides a pivot point of the actuator 24 relative to the bracket 22 . Additionally, while a “passage” is mentioned it is recognized that the preferred embodiment of these passages is actually comprised of two holes in two spaced apart flanges 126 , 128 . However, the term “passage” is used generally to refer to the path or other alignment structure to retain the corresponding pivot components 42 , 44 , 46 in engagement with the bracket 22 . Other engaging, retaining, and/or pivoting assemblies are similarly described with the understanding that the specific structures and functions as shown and described are intended to be broadly interpreted by way of illustration and not limitation.
[0019] In a similar manner, a second passage 50 is provided at an end of the bracket 22 spaced apart from the first passage 40 . A second rivet 52 extends through the second passage 50 and engages a corresponding bolt passage 53 in spaced apart knuckles 54 , 55 on the bolt 26 . A corresponding bushing 56 extends through the knuckle passage 53 for engagement by the second rivet 52 . Additionally, a torsion spring 58 is positioned coaxially on the outside of the bushing 56 and rivet 52 combination in a recess 60 positioned generally between the spaced apart knuckles 54 , 55 . A bolt end 62 of the spring 58 abuts a corresponding surface of the bolt 26 . A bracket end 64 of the spring 58 abuts a corresponding surface 66 on a bracket 22 portion 124 . The torsion spring 58 engaged in this manner maintains the bolt 26 in a spring-loaded normally open condition with the spring 58 being compressed when the latch is closed.
[0020] The first end 32 of the link 28 includes a third passage 70 . The third passage 70 receives the third rivet 72 extending there through to engage the corresponding arm passage 74 and bushing 76 retained on an arm portion 75 of the actuator 24 . Spaced apart portions 80 , 82 of the link 28 are positioned on each side of the arm 75 of the actuator 24 .
[0021] The second end 34 of the link 28 includes a fourth passage 100 . The fourth passage 100 includes a fourth rivet 102 which extends through a knee passage 104 spaced apart from the knuckle passage 54 on the bolt 26 . A corresponding bushing 106 is carried in the knee passage 104 with the rivet 102 extending there through. Opposing portions 110 , 112 of the second end 34 are positioned on opposite sides of the knee 105 . This assembly including the fourth rivet 102 provides movement of the second end 34 of the link relative to the knee 105 .
[0022] The face 38 of the actuator 24 extends through a channel opening 120 positioned generally centrally of the bracket 22 . Extending flanges 122 provided along lateral sides of the bracket structure 22 provide mounting positions to attach the bracket 22 to the corresponding door panel in a manner well known in the art. Perpendicular supports 124 , 127 extend between these flange portions to provide structure to the bracket 22 . The first passage 40 and the second passage 50 are each provided in corresponding inwardly extending (relative to the panel to which the latch assembly is attached) flanges 126 , 128 of the bracket 22 .
[0023] The bolt 26 includes threaded adjustment screw 130 and a self-locking threaded insert 132 which are retained in a corresponding adjustment passage 134 on a tip 136 of the bolt 26 . The adjustable screw 130 is retained in the threaded passage 134 to facilitate customized adjustment of the engaging surface 140 against an inside surface of the corresponding structure which is sealed by the panel to which the latching assembly 20 is attached. A jam nut 141 is provided on an opposite end of the passage 134 to receive the threaded shank of the screw 130 to retain the adjusted position of the screw and engaging surface 140 .
[0024] A locking assembly 200 is provided and retained in cooperative relationship with the actuator 24 . The locking assembly 200 includes protruding portions 202 , a rotary surface 204 , a torsion spring 206 and a retaining rivet 208 . The locking assembly extends through the lock passage 210 formed in a body portion 212 of the actuator 24 . The previously described tool receiving recess 36 is formed in a portion of the lock assembly body 214 which positions the recess 36 for receipt of a tool head through the passage 210 .
[0025] The rivet 208 extends through a retaining passage 220 in the body portion 212 and engages a corresponding recess 222 which is defined at least along a partially annular portion 252 of the lock body 214 . In this regard, the rivet 208 retention of the lock body 214 in the passage 210 while facilitating rotary motion of the lock body 214 within the passage 210 .
[0026] A portion of the torsion spring 206 is engaged with the lock body 214 with an opposite end of the torsion spring engaged with an inside surface of the passage 210 . This engagement of the spring 206 with these structures facilitates rotary spring motion of the lock body 214 in the passage 210 . This spring-loaded lock body 214 returns the lock to the normally locked position when the latch is opened or closed. In the closed condition with the latch assembly in a latching configuration as in FIG. 6 , this spring loaded arrangement retains the protruding portions 202 in corresponding openings 230 , 232 in the link 28 . As such, either in the locked condition or the open condition the protruding portions 202 of the lock body 214 are positioned for orientation in the locked position. This is useful in the closed position so that the protruding portions 202 are engaged in the corresponding openings 230 , 232 in the link 28 . The openings 230 , 232 in the link 28 are positioned, on the link, and sized and dimensioned for engagement by a corresponding protruding portion 202 . When the latch is unlocked and disengaged with the actuator 24 operated to disengage the bolt 26 from the structure the protruding portions 202 will abut the corresponding surfaces 240 , 242 of the link 28 preventing inadvertent or incomplete locking and closing of the latch. This condition is shown in FIG. 7 with the protruding portions 202 rotated into the normally locked position by the torsion spring 206 . As such, this blocking condition requires a tool to be inserted into the recess 36 , rotation of the lock body 214 against the spring loaded torsion spring 206 at which point the actuator 24 may be positioned in the closed position with the bolt 26 engaging the structure. Once the tool is removed in this closed arrangement with the protruding portions 202 engaging the corresponding openings 230 , 232 .
[0027] As can be seen by the description and drawings as provided herein, the latch assembly 20 includes a lock assembly 200 which in an opened condition interacts with the link 28 to provide a “blocking” position described above preventing inadvertent partial closure or unlocked closure of the latch. This same locking assembly 200 also provides a positive locking condition to positively lock the latch in a closed position since the locking assembly requires positive operation to return the actuator to the closed position. If the locking assembly is not operated to position the sides 250 and the extensions 202 in between the inner opposing surfaces of the link 28 the face 38 of the actuator 24 will not close flush with the mounting bracket support potions 124 , 127 and indicate an unlocked condition.
[0028] These discrete conditions prevent accidental false positive closures of the latch. Additionally, use of the tool in the recess 36 also may provide a lever or prying device for applying a prying force to disengage the actuator 24 from the closed condition once the latch is unlocked using the same tool. This eliminates the need for providing an additional larger pry opening in the latch assembly or an additional trigger element on the latch assembly. This facilitates a one hand operation, if necessary, to facilitate opening of the latch. This also facilitates a one hand operation of the latch, if necessary, to close the latch. Once the tool is inserted into the recess 36 it is used to rotate the body 214 to disengage or unlock the extensions 202 from the openings 232 , 230 in the link 32 . As the actuator is rotated upwardly away from the bracket to the open position, the opening force on the actuator 24 draws the link 28 along with it. As the link is displaced it draws the connected potion of the bolt 25 which pivots about the rivet 52 in the bracket 22 . This drawing and pivoting motion rotates the bolt out of engagement with the structure to disengage the panel to which the latch is attached form the structure.
[0029] With reference to FIGS. 6 and 7 , the described structures and functions can be seen in the closed position ( FIG. 6 ) and the open position ( FIG. 7 ). In the closed position the link 28 provides an over center toggle assembly at the pivot points of the third rivet 72 and fourth rivet 102 relative to the corresponding pivot points 74 and 104 of the actuator 24 and bolt 26 , respectively. As also shown in FIG. 6 , the protruding portion 202 is illustrated extending through the corresponding passage 232 of the link.
[0030] In the open position of FIG. 7 , it can be seen that the bolt 26 pivots downwardly to disengage the surface 140 from the corresponding structure. This generally provides free and clear movement of the panel to which the latch assembly 20 is attached. As also shown in FIG. 7 , the protruding portions 202 are rotated into the locked position after disengagement from the corresponding openings 232 in the link 28 . It can be seen that the protruding portions 202 will abut the corresponding top surfaces 240 , 242 of the link 28 to prevent accidental or unintended false positive closure of the latch in an unlocked condition. In other words, the latch balks since the protrusions 202 abut the surfaces 240 , 242 and are prohibited from engaging the opening 232 unless a tool is actually used to rotate the lock to engage the protrusions 202 in the opening 232 . With further reference to FIG. 5 , it can be seen that flat portions 250 , 252 are positioned on faces in between the protruding portions 202 to facilitate passage of the lock body 214 between the spaced apart portions 251 , 253 of the link 28 prior to rotating the protrusions 202 into engagement with eh openings 230 , 232 during the locking process.
[0031] The foregoing terms as well as other terms should be broadly interpreted throughout this application to include all known as well as all hereafter discovered versions, equivalents, variations and other forms of the abovementioned terms as well as other terms. The present disclosure is intended to be broadly interpreted and not limited.
[0032] While the present disclosure describes various exemplary embodiments, the disclosure is not so limited. To the contrary, the disclosure is intended to cover various modifications, uses, adaptations, and equivalent arrangements based on the principles disclosed. Further, this application is intended to cover such departures from the present disclosure as come within at least the known or customary practice within the art to which it pertains. It is envisioned that those skilled in the art may devise various modifications and equivalent structures and functions without departing from the spirit and scope of the disclosure as recited in the following claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
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The present disclosure includes a tool operated channel latch used to secure a panel against a structure. The latch includes a bracket which mounts to a movable panel and includes an actuating mechanism to open and close the latch. A bolt is pivotably retained relative to the bracket for engaging against the structure closed by the panel. A lock assembly is carried on the actuator to engage a link which is movably coupled with both the bolt and the actuator. The lock assembly includes extending portions to engage at least one corresponding opening of the link. The link provides an over center toggle condition to retain the latch in a locked position until intentionally actuated by an operator.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
The invention described herein may be manufactured, used and licensed by or for the Government for governmental purposes without payment to me of any royalty thereon.
This is a continuation of application Ser. No. 375,071, filed May 5, 1982., now abandoned.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to method and apparatus for lifting tainter gates and, more specifically to an hydraulically powered pin lift mechanism for raising very large tainter gates in waterways, and the like.
2. Description of the Prior Art
Controlling flow through artifical and natural watercourses is a problem that is as old as civilization itself. Usually, this flow control has been imposed through different types of gates. These gates serve as temporary dams or valves that, when closed, impound water in one portion of the watercourse system or, when open, release accumulated water to permit it to flow into other parts of the system.
Tainter (or taintor) gates, which also are often referred to as "radial" gates, are frequently used for this purpose. Basically, a tainter gate has an upstream face that is curved in the form of an arc, the center of which is at the center of the gate hinge. Raising and lowering the curved face of the gate relative to the hinge opens and closes the watercourse to enable water to flow past the gate or to accumulate upstream of the gate, respectively, depending on the particular needs of the watercourse system.
As watercourse dimensions have increased from the small, primitive irrigation ditches that are still found in many parts of the world to the massive channels of more than seventy feet in depth and sixty feet in width encountered in modern civil engineering practice, the apparatus required to control this flow necessarily must change from simple, manually operated gate valves to large, powerful devices capable of manipulating tainter gates weighing tons against hydraulic forces that are, perhaps, equally great or greater.
A number of techniques have gradually developed through the years for coping with the greater forces that characterize these large watercourses. Illustratively, it has been the practice to couple wireropes to the tainter gates. These wireropes are controlled by means of electrical motor-driven, ribbon-wound cable type hoists to open or close the tainter gates, as desired. Reliance on cable control, however, can lead to a number of difficulties. Typical of these problems is the potential for an uneven load distribution among the wireropes that are secured to both sides of the tainter gates. On occasion, moreover, some of the wireropes wound on which drums have been crushed. This crushing occurs because of the high loads that are applied to the wireropes and the large number of wraps or turns of the cable that are wound onto the drums in order to raise a tainter gate more than 100 feet. These wireropes also create large and undesirable torsional moments in the vertical support beam end frame of the tainter gate, as well as creating undesirable circumferential stresses in the tainter gate skin plate. The large number of wireropes required to control more massive tainter gates introduce still further difficulties in properly tensioning the wireropes and synchronizing their action.
Clearly, as tainter gate sizes increase, it appears that a law of diminishing returns may be overtaking the further application of wirerope technology to watercourse control. More cables, greater lift distances, heavier tainter gates and deeper watercourses all seem to combine to produce the further problems considered above. Accordingly, there is a need for an entirely new approach to tainter gate control.
U.S. Pat. No. 2,125,311 granted Aug. 2, 1938 to B. L. Peterson for "Water Supply and Drainage System for Fishlocks" describes a system in which a tainter valve is directly linked to a rack-and-pinion mechanism. Although this approach overcomes many of the difficulties that have beset wirerope apparatus, the force required for direct gate drive may be excessive for more massive tainter gates, or the mechanical advantage is of such a nature that too much time is required to open these larger gates.
U.S. Pat. No. 2,125,090 granted July 26, 1938 to H. E. Smyser for "Rotatable Water Gate" also discloses a direct mechanical connection between the tainter gate and a worm gear that controls the movement of the gate. Although a worm gear is capable of developing suitable forces, once more the mechanical advantage of this particular mechanism is not acceptable for very large tainter gate installations.
U.S. Pat. No. 2,080,063 granted May 11, 1937 to J. J. Ring for "Roller Gate Construction" also fails to suggest a system that is capable of lifting large tainter gates. Thus, as shown in this patent, a rack, secured to a tainter gate pier meshes with a large pinion gear that is formed on the circumference of the gate structure to enable a chain attached to the gate to draw, or roll the gate up along the rack. The chain in this circumstance must sustain the full load of the gate as it is being lifted, thereby imposing unsatisfactorily inordinate power requirements for large gate application.
Consequently, a need continues to exist for a more efficient and reliable means for lifting or otherwise moving large tainter gates.
SUMMARY OF INVENTION
This need is overcome, to a great extent, through the practice of the invention. Illustratively, a number of equidistantly spaced lifting brackets are attached to the upstream side of the curved face of a tainter gate. Each of these brackets has a generally centrally and horizontally disposed bore and, on the underside of the bracket, an horizontally disposed semicircular recess.
A lifting mechanism is mounted in the pier for the tainter gate in alignment with the brackets. A typical lifting mechanism has a pair of spaced, parallel guide rails that each support respective, oppositely disposed ratchets in which the teeth are oriented to sustain respective pawls in a vertically elevated position. The guide rails are joined at the top by means of a pair of transverse braces that also support an hydraulic cylinder in a manner that permits the piston rod to protrude down into the space between the opposing ratchets. The piston rod, in turn, is connected to a cart that travels between the guide rails through a distance that is about equal to the length of the two ratchets.
The cart not only houses the pawls that engage respective arrays of ratchet teeth but also houses an horizontally disposed movable pin. This movable pin has a diameter that is slightly smaller than the individual diameter of the bracket bores and is hydraulically driven to translate, in an horizontal direction, through a distance that is at least equal to the width of each of the lifting brackets on the curved face of the tainter gate with which it is aligned.
The guide rails are joined at the bottom by means of a pivot pad assembly that also supports a stationary pin. The stationary pin is equal to, or smaller in diameter than the indivdual diameters of the semicircular recesses formed in the underside of the lifting brackets. The stationary pin, too, is hydraulically driven to translate horizontally through a distance that is at least equal to the width of each of the lifting brackets.
To raise the tainter gate, the movable pin is inserted into a lifting bracket bore and the hydraulic cylinder is activated to draw the cart vertically through a distance that is slightly greater than the separation between two adjacent lifting brackets. The stationary pin then is extended under the semicircular recess of the bracket immediately below the bracket in which the movable pin is engaged. The pawls in the cart are retracted and the hydraulic cylinder lowers the tainter gate through a short distance to enable the stationary pin to be received within the bracket recess.
In this way, the tainter gate load is transferred from the movable pin to the stationary pin to enable the hydraulic system to extract the movable pin from the bracket bore and return the cart to the bottom of the guide rails. With the cart abutting the pivot pad, the movable pin is aligned with the bore in the bracket that is resting upon the stationary pin. The hydraulic system inserts the movable pin into this new bracket bore and the stationary pin is retracted to transfer the load once more to the movable bracket. This process is repeated in order to raise the gate in a step-by-step manner to a desired height.
To lower the gate, the procedure is reversed, the movable pin lowering each successive bracket on to the extended stationary pin, the stationary pin in this instance being retracted to enable the bracket with which it just had been engaged to pass downwardly and being once more extended to lodge within the recess in the bracket that has received the movable pin.
There are a number of hydraulic systems that can be used to control the operation of this mechanism. For example, the individual hydraulic units for each of two tainter gates can be coupled together by means of a cross over valve. Alternatively, a number of tainter gates can share in common two hydraulic units through suitable cross over connections.
Synchronizing gate operation is accomplished through gate position indicators that regulate fluid flow to the hydraulic cylinders.
Thus, there is provided an entirely new technique for operating tainter gates and, especially, tainter gates of very large size in a manner that completely avoids wirerope and attendant wirerope problems. The mechanical advantage that characterizes this invention, moreover, is a substantial improvement over prior art rack-and-pinion and chain driven devices. Further, because support for apparatus that characterizes the invention is considerably less than that which would be required in a wirerope system for a tainter gate of the same size, there is a considerable saving in structural steel and concrete through the practice of this invention. Additional cost savings also are now possible not only because large, expensive gears and couplings are eliminated, but also, extensive field installation and alignment procedures are significantly reduced.
The novel features of this invention, as well as the invention itself, both as to its organization and operation will best be understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation, in full section of a typical embodiment of the invention;
FIG. 2 is a front elevation of a typical lifting mechanism for use with the apparatus shown in FIG. 1;
FIG. 3 is a side elevation of the lifting mechanism shown in FIG. 2;
FIG. 4 is a schematic diagram of an hydraulic system for use in connection with the invention;
FIG. 5 is a schematic diagram of another hydraulic system for use in connection with the invention;
FIG. 6 is a portion of a tainter gate showing a different arrangement of bores for controlling gate movement;
FIG. 7 is a portion of the lifting mechanism showing a different way of supporting the mechanism on the pier; and
FIG. 8 is a portion of a tainter gate showing a different bottom bore hole for controlling gate movement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a concrete pier 10 in a watercourse supports a pintle 11 upon which a tainter gate 12 is hinged. Radially extending members 13, 14 and 15 join the hinge to structural support 16 for an arcuate skin plate 17 on the gate.
In accordance with the invention an array of circumferentially aligned lifting brackets, of which bracket 20 is typical, are secured to the upstream side of the skin plate 17. As shown in the drawing, a flange 18 on the bracket 20 is curved to match the profile of the skin plate 17. In this way, the flange provides a suitable means for attaching the bracket 20 to the tainter gate 12 through welds, bolts, and the like to sustain imposed gate loads. Thus, the bracket 20 is sufficiently sturdy to sustain at least half of the applied load that is involved in raising and lowering the tainter gate 12. The other portion of this gate load is borne by a companion mechanism that is not shown in the plane of FIG. 1 of the drawing.
Returning now to the bracket 20, a semicircular, horizontally disposed recess 21, or aperture, is formed in the undersurface of the bracket. An horizontal aperture or bore 22 also is formed in the central portion of the web of the bracket 20. Particular note should be taken of the transverse shape of the bore 22, the lower semicircular half of the bore having a substantially larger diameter than the upper semicircular half of the same bore. The functional importance of this unique and distinctive cross section for the bore 22 will be described subsequently.
The pier 10 also supports a lifting mechanism 23 which is shown in more detail in FIGS. 2 and 3. As illustrated in FIGS. 2 and 3, the lifting mechanism 23 has a pair of spaced, parallel guide rails 24,25. Ratchets 26,27 are mounted on opposing respective faces of the guide rails 24,25. The ratchet and guide rail combinations are joined toward the top ends by means of bracing 30.
The upper end of the guide rails supports a semi-disk-like pivot pad 31, the arcuate parts of the outer surfaces of the pivot pad being journalled, within a mating pillow block 32. An hydraulic cylinder 33 is supported by the bracing 30. For the purpose of this invention, the cylinder 33 responds to an application of hydraulic fluid under pressure to move a piston rod 34 in the direction of arrow 35. The cylinder, however, acts in the manner of an "oleo strut" by permitting the piston rod 34 to move in the direction of arrow 36 in a controlled manner under the weight of the tainter gate (now shown in FIGS. 2 and 3) to slowly and gently lower the gate as described subsquently in more complete detail.
The piston rod 34 is attached to a cart 37. As shown in FIGS. 1 and 3, sets of idler wheels are mounted on the cart 37. The wheels roll on surfaces that are provided by the guide rails 24,25 and the ratchets 26,27, respectively, in order to align the cart 37 for the movement in the directions of the arrows 35,36 between the guide rails.
Two horizontally translatable pawls 43,44 are mounted within the cart 37 in order to engage and to disengage teeth on the respective ratchets 26,27. The pawls 43,44 mesh with corresponding sets of ratchet teeth in a manner that locks the cart 37 in with the teeth on the ratchets 26,27 and prevent movement principally in the direction of the arrow 36.
To engage the pawls 43,44 with the respective ratchets and to release them from these ratchets, a latching device 45 is attached to the cart 37. The latching device is linked to the pawls 43,44 and, upon activation, moves the pawl 43 in the direction of the arrow 46 and pawl 44 in the direction of the arrow 47 to press them into engagement with adjacent sets of ratchet teeth. The disengage the pawls 43,44 from these teeth the latching device 45 is energized to move pawl 44 in the direction of arrow 46 and pawl 43 in the direction of arrow 47 thereby draws the pawls in an horizontal direction further within the cart 37.
In accordance with another aspect of the invention, an horizontally movable pin 50 is mounted in the cart 37. As shown, the motion of the pin 50 is controlled by means of a movable pin hydraulic operating cylinder 51 which drives the pin in an horizontal direction that is perpendicular to the plane of the ratchets 26,27. The pin 50, moreover, is considered a movable pin because it is mounted integrally with the cart 37 in order to move with that cart in the direction of the arrows 35,36. The movable pin 50 also must have sufficient strength to support about half the weight applied in raising and lowering the tainter gate 12, the other portion of this load being carried by a corresponding mechanism that is not projected in the plane of FIG. 1 of the drawing. Further with respect to the pin 50 (FIGS. 2 and 3), the diameter of this pin is equal to or slightly smaller than the corresponding diameter of the semicircular upper half of the bore 22 (FIG. 1) of the lifting bracket 20. The pin diameter, however, is substantially smaller than the diameter of the lower semicircular half of the bore 22. In this manner, and as described more thoroughly in a subsequent portion of this specification, the unique transverse cross section of the bore 22 provides an automatic self-centering feature for the pin 50. As the pin 50 is inserted into the bore 22, any misalignment within a structurally acceptable range between the pin and the bore is absorbed by the lower, larger diameter semicircular part of the bore which guides and seats the pin in a snug fit within the upper semicircular half of the bore.
The length of the pin 50 (FIGS. 2 and 3), or at least the length of its stroke in response to operation of the movable pin cylinder is at least equal to the corresponding depth of the bore 22 (FIG. 1).
Returning once more to FIGS. 2 and 3, the lower ends of the guide rails 24,25 are joined together by means of a pivot pad assembly 52. The lowermost end of the pivot pad assembly 52 terminates in an arcuate pivot pad 53 that provides a degree of flexibility and resiliency in mounting the lifting mechanism 23 with respect to the pier 10. The small degree of freedom of motion that the pivot pads 31 and 53 impart to the lifting mechanism 23 enable this mechanism to adjust itself to the changing angular relationship that it must undergo relative to the curvature of the skin plate 17 (not shown in FIGS. 2 and 3) on the tainter gate 12 as the lifting mechanism draws the gate upward or lowers it downward, as subsequently described.
A stationary pin 54 also is mounted in the pivot pad assembly 52 for movement in an horizontal direction that is perpendicular to the plane of the ratchets 26,27. This horizontal movement of the stationary pin 54 is regulated by means of an hydraulic stationary pin cylinder 55 (FIG. 3) that drives the pin in the direction of arrow 56 to position the pin 54 under the recess 21 (FIG. 1) of the bracket 20 or to move the pin in the direction of arrow 57 in order to withdraw the pin from the recess.
Attention now is invited to FIG. 4, which shows a specific example of an hydraulic fluid distribution system for an array of six tainter gates that embody principles of the invention. An hydraulic unit 60 produces a sufficient volume of hydraulic fluid under pressure to operate lifting mechanisms 61,62 for a tainter gate 63 in the manner subsequently described. the pressurized hydraulic fluid is coupled to the lifting mechanisms, moreover, through a conduit 64. Companion tainter gate 65, operated by means of paired lifting mechanisms 66,67, is powered through an hydraulic unit 70 that is coupled to the lifting mechanisms via a conduit 71. Cross feed between the lifting mechanisms for the two tainter gates 63,65 and their respective hydraulic units 60,70 is provided by way of a cross feed conduit 72 and a cross over valve 73 that permits or interrupts hydraulic fluid transfer between the two gate control systems. Parallel sets of cross feed hydraulic power systems are provided for the remaining two pairs of tainter gates 74,75.
In FIG. 1, a typical hydraulic unit 76 is shown in a machinery room 77 in the pier 10.
A further hydraulic power system for an array of six tainter gates is shown in FIG. 5. Two hydraulic units 80,81 are installed on the reservation adjacent to the tainter gate array. The hydraulic units 80,81 are of substantially larger capacity than those which were described in connection with FIG. 4 in order to each individually provide sufficient hydraulic fluid volume and pressure to power all six of the tainter gates. As shown, the hydraulic unit 80 is connected to lifting mechanisms for tainter gates 82,83,84 through a conduit system 85. In turn, the hydraulic unit 81 is directly coupled to lifting mechanisms for tainter gates 86,87 and 90 via a conduit system 91. Cross feed between the two conduit systems 85,91 is achieved through a cross feed conduit 92 that is interrupted by a cross over valve 93.
A further embodiment of another salient aspect of the invention is shown in FIG. 6. A portion of a tainter gate 94 is illustrated in which skin plate 95 is provided with structural support 96. Lifting mechanism bore 97 is formed in the structural support 96. In this manner the requirement for the brackets that are shown in FIG. 1 is avoided while nevertheless achieving the purposes of the invention.
A further embodiment of another salient aspect of the invention is shown in FIG. 7. The lower portion of the lifting mechanism 102 is illustrated in which the pivot pad 53 (FIG. 2) is replaced with rollers 103 incorporating journals or antifriction bearing. In this manner, friction between the lifting mechanism 23 and the pier is reduced, while nevertheless achieving the purpose of the invention.
A still further embodiment of another salient aspect of the invention is shown in FIG. 8. The lower bore hole 104 of the pier of bore holes 105 has a flat top section of length greater than the flat top section of the stationary pin 106. In this manner, the lifting mechanism 23 (FIG. 2) is allowed to shift when the movable pin 50 is being seated into bore hole 107, while nevertheless achieving the purpose of the invention.
In operation, attention now is invited to FIG. 1 which shows the movable pin 50 and the lifting mechanism 23 extended to protrude into a bore in lifting bracket 98. The movable pin 50 in its extended position is best shown in FIG. 3. To raise the tainter gate 12 (FIG. 1), hydraulic fluid under pressure is supplied from the hydraulic unit 76 to the hydraulic cylinder 33 to draw the piston rod 34 and the attached cart 37 in the direction of the arrow 35. In this condition, the stationary pin 54 is retracted into the pivot pad assembly 52, again as illustrated in FIG. 3, to enable lifting bracket 99 (FIG. 1) to clear the pin 54 and pass upwardly as the piston rod 34 and the attached cart 37 with the bracket 98 on the skin plate 17 coupled to the pin 50 all are drawn in the direction of the arrow 35.
Because of the curved nature of the skin plate 17, the angular relation with the longitudinal axis of the lifting mechanism is constantly changing while the piston rod 34 draws the tainter gate 12 in an upward direction. As hereinbefore mentioned, the pivot pads 31 and 53 provide a sufficient degree of freedom of motion for the lifting mechanism 23 to adjust to these slight angular changes.
Should it be desired to arrest the upward motion of the gate 12 at some intermediate point, the hydraulic pressure is stabilized and the pawls 43,44 (FIG. 2) are extended from the cart 37 (FIG. 1) to engage the adjacent teeth in the ratchets 26,27. To resume the upward movement of the tainter gate 12, hydraulic pressure is once more applied to the cylinder 33, and the pawls without pressure of the gate acting on them are retracted into the cart 37. The cart and the gate is then propelled upward by the applied hydraulic pressured.
The stationary pin 54 is extended when the piston rod 34 has reached a point in its upward travel such that the stationary pin is oriented slightly below the semicircular recess 100 in the lifting bracket 99. Hydraulic pressure in the cylinder 33 is slowly relieved to allow the lifting bracket 99 to settle downwardly onto the extended stationary pin 54. As the pin 54 is seated in the recess 100 and absorbs the load from the gate 12, the movable pin 50 is no longer sustaining this load and can be extracted from the aperture in the bracket 98 with relatively little force. Upon withdrawing the movable pin 50 from the bore in the bracket 98, the hydraulic cylinder 33 runs the cart 37 in the direction of the arrow 36 until the movable pin 50 is in general alignment with bore 101 in the lifting bracket 99. At this point, the self aligning feature of unique transverse cross section that characterizes the brackets herein before described accommodates minor misalignments between the movable pin 50 and the bore 101.
The gate load then is once more transferred to the movable pin 50 as the hydraulic cylinder 33 is activated to draw the cart 37, the movable pin 50 and the attached bracket upward in the direction of the arrow 35, whereupon the stationary pin 54 is retracted to permit the next lower adjacent bracket to pass upwardly in the direction of the arrow 35. And thus, the process described above is repeated until the tainter gate 12 has been lifted to the desired height.
To close or to lower the gate 12, the movable pin 50 is seated in a raised bracket bore and the hydraulic pressure is relieved in a controller manner in order to enable the recessed undersurface of the bracket that is being lowered to settle onto the extended stationary pin 54. Upon seating the lowered bracket on the stationary pin 54 and transferring the gate load to that pin, the movable pin 50 is extracted from the bore in that bracket. The hydraulic cylinder 33 is once more energized to move the cart 37 and the movable pin 50 upwardly in the direction of the arrow 35. At the end of this increment of upward travel, the movable pin is inserted into the bore of the next bracket and the gate load now is transferred to the movable pin 50 by drawing the cart slightly upward in the direction of the arrow 35. The stationary pin 54 is retracted and, as the hydraulic cylinder 33 lowers the tainter gate through one more step, the bracket that just had been supported on the stationary pin 54 passes that pin by moving downwardly in the direction of the arrow 36. After the downwardly moving bracket has cleared the stationary pin 54, the stationary pin is once more extended in order to engage the recessed undersurface of the bracket that is next above and which is moving downwardly in the direction of the arrow 36 under the control of the movable pin 50 and the hydraulic cylinder 33. Naturally, the pawls 43,44 (FIG. 2) in the cart 37 can be activated to arrest the downward motion of the tainter gate 12 (FIG. 1) at an intermediate point between adjacent brackets by meshing the teeth on the pawls with the adjacent ratchet teeth.
Operation of a tainter gate in which the bore 97 (FIG. 6) is formed in the structural support 96 of the skin plate 95 is accomplished in the same manner as that which was described above in connection with the FIG. 1 embodiment of the invention.
As illustrated in FIG. 4, the hydraulic unit 60 can service the lifting mechanisms for both of the tainter gates 63,65 if the cross over valve is open. Further in this regard, hydraulic fluid pressure equalization between all of the four lifting mechanisms 61,62 and 66,67 also is attained if the valve 73 is open. This pressure equalization produces a generally uniform opening and closing operation for both of the gates 63,65 in which the movements of the gates 63,65 are equal. Fine synchronization between the gates is accomplished through position indicators (not shown) on the machinery. These position indicators control fluid flow to the hydraulic cylinders through flow modulating valves. Further in this respect, the position of the movable and stationary pins is identified through an electrical control system (also not shown) that presents a reflection of current equipment position status at a control stand 102. The actual operation of the movable pin 50 (FIG. 3), the stationary pin 54, and the latching device 45 as illustrated in this embodiment of the invention are hydraulically activated and electrically controlled. Naturally, other techniques for operating these pins and pawls are within the scope of the invention.
Attention now is invited to FIG. 5 which shows an entire array of tainter gates 82 through 87 and 90 that are operated through hydraulic fluid supplied from the units 80,81 in which flow can be transferred and system pressure can be controlled by means of the cross over valve 93.
Thus, there has been provided a novel tainter gate lifting system that eliminates wirerope control and the problems associated with the application of wirerope to very large gates. It is estimated, for example, that the techniques characterizing the instant invention are capable of raising a 75 feet high by 62 feet wide tainter gate at a rate of at least one foot per minute. In this projected gate, the adjacent brackets are spaced a distance of 7 feet from each other and the distance travelled by the gate to settle onto a stationary pin in transferring a gate load from a movable pin to a stationary pin is 1/4 inch. The tooth spacing on the ratchets 26,27, moreover, will provide fine position control for the gate in 4 inch increments.
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Illustrative embodiments of the invention are directed to a technique for raising and lowering large tainter gates. Typically, two groups of lifting apertures are formed in the gate. A lifting mechanism, resiliently mounted on the tainter gate pier, inserts a movable pin into an aperture in one of the two groups and draws the gate upwardly. A stationary pin on the lifting mechanism then is inserted into an aperture in the other of the two groups to absorb the gate load while the movable pin is withdrawn and moved to a new aperture in order to continue the step-wise lifting process.
To lower a gate, an essentially reverse procedure is followed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
FIELD OF THE INVENTION
[0004] The present invention relates to wellbore straddle-packer assemblies and methods of wellbore servicing with a pressurized fluid. More particularly, the present invention relates to a wellbore straddle-packer comprising a fluid saver assembly which, upon completion of the service operation, can be moved without venting pressurized fluid to the surface or waiting for the pressurized formation to bleed down.
BACKGROUND
[0005] As conventional sources of natural gas in North America decline while demand for this energy resource continues to grow, coal bed methane (CBM) has been identified as a viable alternative energy source. CBM is aggressively being extracted from multi-zone wellbore formations, and during production of these formations, downhole tools are used to deliver pressurized fluid to stimulate CBM production. In particular, the tool is set within the wellbore to isolate a formation zone, and pressurized nitrogen, or another type of fracturing fluid, is pumped through the tool into the isolated formation zone. The pressurized fluid acts to open or expand “cleats” within the coal seam, thus forming a communication channel through which the CBM can flow into the cased wellbore and then up to the surface.
[0006] Fracturing multi-zone CBM wellbore formations is often performed using downhole cup-style straddle-packers. Typically, pressurized nitrogen is pumped through a work string, such as coiled tubing, once these cup-style straddle-packers are set at a particular location within the wellbore. After fracturing a zone, it may be necessary to allow the pressurized formation to bleed down from the applied treatment pressure in order to unseat the cups and allow movement of the straddle-packer to the next zone to be fractured. The time required for this bleed down to occur may be 20 minutes, for example. Because many CBM wellbores have multiple zones to fracture, such as 15 to 20 zones, the total time waiting for formation bleed down to occur can be significant and increases the cost of fracturing the wellbore. As an alternative to waiting for the formation to bleed down, the pressurized fluid contained in the work string may be vented to the surface. This, however, wastes volumes of pressurized fluid that could otherwise be usefully injected into the CBM formations, thereby also increasing the cost of fracturing.
[0007] Besides the costs associated with venting pressurized fluid, and the time delays associated with waiting to move conventional straddle-packers, the cup-style sealing elements also have operational limits. As the demand for natural gas continues to rise, it has become necessary to drill deeper wellbores, and therefore, fracture formation zones at greater depths. As wellbore depths increase, cup-style sealing elements reach their operational pressure limits and no longer work reliably. Furthermore, the rubber material of the cups is incompatible with acids and other chemicals that may be contained in some wellbore servicing fluids. Even assuming the rubber cups are suitable for use operationally, venting of a pressurized fluid containing acids or chemicals to the surface may be prohibited due to environmental regulations. Where no such prohibition exists, repeated venting of a pressurized fluid containing acid or chemicals is still undesirable, as such venting can be expensive.
[0008] Therefore, due to the time and the increased operational cost associated with moving and re-seating typical cup-style straddle-packers during fracturing of multi-zone CBM well formations, the costs associated with venting pressurized fluid to the surface, the inability of cup-style sealing elements to function reliably at greater wellbore depths, and the incompatibility of rubber cups with acids and other chemicals, a need exists for a downhole tool designed for such operations. Specifically, a need exists for a straddle-packer assembly that reduces the time between fracturing multiple zones, does not require venting of pressurized fluid to the surface, is operational at greater wellbore depths, and is compatible with fluids containing acids and other chemicals.
SUMMARY OF THE INVENTION
[0009] In one aspect, the present disclosure relates to a method for performing a service operation within a wellbore extending into a formation comprising: sealing a first length of the wellbore to define a first isolated formation zone, flowing a pressurized fluid through a tubular string into the first isolated formation zone, and unsealing the first length of the wellbore without venting the pressurized fluid from the tubular string or awaiting depressurization of the first isolated formation zone. The method may further comprise: containing the pressurized fluid within the tubular string, moving the tubular string within the wellbore, sealing a second length of the wellbore to define a second isolated formation zone, flowing a pressurized fluid through the tubular string into the second isolated formation zone, and/or equalizing pressure between the sealed first length and an unsealed portion of the wellbore. In an embodiment, the method is performed in a single trip into the wellbore. The service operation may comprise fracturing a coal bed methane formation, and the pressurized fluid may comprise nitrogen, water, acid, chemicals, or a combination thereof.
[0010] In another aspect, the present disclosure relates to a method for performing a service operation within a wellbore extending into a formation comprising: running an assembly comprising a valve into the wellbore on a tubular string, fixing the assembly within the wellbore to define a first isolated formation zone, flowing a pressurized fluid through the valve into the first isolated formation zone, and closing the valve to contain the pressurized fluid within the tubular string. The method may further comprise: moving the assembly without venting the pressurized fluid from the tubular string or awaiting depressurization of the first isolated formation zone, equalizing pressure across the assembly before moving the assembly, re-fixing the assembly within the wellbore to define a second isolated formation zone, opening the valve, and/or flowing the pressurized fluid through the valve into the second isolated formation zone. In an embodiment, fixing the assembly comprises activating an upper seal and a lower seal within the wellbore to straddle the first isolated formation zone. In another embodiment, fixing the assembly further comprises activating an upper anchor and a lower anchor within the wellbore to straddle the first isolated formation zone. The method may further comprise bypassing pressure around the upper anchor when running the assembly into the wellbore.
[0011] In yet another aspect, the present disclosure relates to a method for performing a service operation within a wellbore extending into a formation comprising: running an assembly into the wellbore on a tubular string, engaging a wellbore wall with the assembly, setting down on the tubular string to activate upper and lower seals of the assembly against the wellbore wall to define an isolated formation zone, additional setting down on the tubular string to open a valve of the assembly, flowing a pressurized fluid through the valve into the isolated formation zone, and picking up on the tubular string to close the valve and contain the pressurized fluid within the tubular string. The method may further comprise additional picking up on the tubular string to move the assembly without venting the pressurized fluid from the tubular string or awaiting depressurization of the isolated formation zone. In various embodiments, the additional picking up opens a bypass flow path, the setting down on the tubular string activates a lower anchor of the assembly against the wellbore wall, and/or the additional setting down on the tubular string activates an upper anchor of the assembly against the wellbore wall.
[0012] In still another aspect, the present disclosure relates to an assembly connected to a tubular string for performing a service operation in a wellbore, the assembly comprising: a mandrel with a flowbore in fluid communication with the tubular string, an upper sealing device, a lower sealing device, a selectively operable valve that enables or prevents fluid communication between the flowbore and the wellbore, and a selectively closeable bypass flow path. The tubular string may comprise coiled tubing, and at least one of the sealing devices may comprise a plurality of sealing elements. The assembly may further comprise a continuous J-slot, drag blocks, an upper anchor, and/or a lower anchor. The upper anchor may comprise a plurality of spring-loaded buttons activated by pressure when the bypass flow path is closed, and the lower anchor may comprise a slip and cone system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more detailed description of the present invention, reference will now be made to the accompanying drawings, wherein:
[0014] FIG. 1 provides a schematic side view, partially in cross-section, of a representative operational environment depicting a coiled tubing work string lowering one embodiment of a wellbore fluid saver assembly into a cased wellbore;
[0015] FIG. 2 provides a schematic side view of a wellbore fluid saver assembly located at a desired depth within the cased wellbore, with its upper and lower sealing elements set above and below a production zone, respectively;
[0016] FIGS. 3A through 3H , when viewed sequentially from end-to-end, provide a cross-sectional side view from top to bottom of one embodiment of a wellbore fluid saver assembly;
[0017] FIGS. 4A through 4F , when viewed sequentially from end-to-end, provide a cross-sectional side view of the wellbore fluid saver assembly of FIG. 3 in a run-in configuration;
[0018] FIGS. 5A through 5F , when viewed sequentially from end-to-end, provide a cross-sectional side view of the wellbore fluid saver assembly positioned at a desired depth in the wellbore and ready to set;
[0019] FIGS. 6A through 6F , when viewed sequentially from end-to-end, provide a cross-sectional side view of the wellbore fluid saver assembly anchored within the wellbore, a bypass flow path open, upper and lower sealing elements set, and a valve partially open;
[0020] FIGS. 7A through 7F , when viewed sequentially from end-to-end, provide a cross-sectional side view of the wellbore fluid saver assembly with the valve fully opened during fracturing;
[0021] FIGS. 8A through 8F , when viewed sequentially from end-to-end, provide a cross-sectional side view of the wellbore fluid saver assembly after fracturing is complete and the assembly has been picked up to be moved to the next formation zone; and
[0022] FIG. 9 provides a schematic cross-sectional side view of a J-slot and an interacting lug that form part of the wellbore fluid saver assembly.
NOTATION AND NOMENCLATURE
[0023] Certain terms are used throughout the following description and claims to refer to particular assembly components. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”.
[0024] As used herein, the term “tool” refers to the entire wellbore fluid saver assembly.
[0025] Reference to up or down will be made for purposes of description with “up”, “upper”, or “upstream” meaning toward the earth's surface or toward the entrance of a wellbore; and “down”, “lower”, or “downstream” meaning toward the bottom or terminal end of a wellbore.
[0026] In the drawings, the cross-sectional side views of the wellbore fluid saver assembly should be viewed from top to bottom, with the upstream end toward the top and the downstream end toward the bottom of the drawing.
DETAILED DESCRIPTION
[0027] A single embodiment of a wellbore fluid saver assembly, also referred to herein as “tool”, and its method of operation will now be described with reference to the accompanying drawings, wherein like reference numerals are used for like features throughout the several views. There is shown in the drawings, and herein will be described in detail, a specific embodiment of the tool that connects to a coiled tubing work string to inject high pressure fluid, such as nitrogen, into a formation for fracturing. It should be understood that this disclosure is representative only and is not intended to limit the wellbore fluid saver assembly to use with a coiled tubing work string, to nitrogen as the pressurized fluid, or to fracturing as the only wellbore service operation, as illustrated and described herein. One skilled in the art will readily appreciate that the wellbore fluid saver assembly disclosed herein may be connected to any type of work string for wellbore servicing in general, and not only for fracturing. Furthermore, one skilled in the art will understand that other wellbore servicing liquids and gases could be used instead of nitrogen, such as, for example, water, acid, chemicals, or a combination thereof.
[0028] FIG. 1 and FIG. 2 depict one representative wellbore servicing environment for the wellbore fluid saver assembly 200 . FIG. 1 depicts a coiled tubing system 100 on the surface 170 and one embodiment of a wellbore fluid saver assembly 200 being lowered on coiled tubing 150 into a wellbore 160 extending into a surrounding formation F. The coiled tubing system 100 may include a power supply 110 , a surface processor 120 , and a coiled tubing spool 130 . An injector head unit 140 feeds and directs the coiled tubing 150 from the spool 130 into the wellbore 160 .
[0029] FIG. 2 depicts the wellbore fluid saver assembly 200 of FIG. 1 after it has been lowered to a desired depth and positioned in the wellbore 160 . Specifically, upper sealing elements 17 and lower sealing elements 61 , as well as anchoring upper buttons 9 and anchoring lower slips 45 , are shown set against a casing 165 lining the wellbore 160 . As set in this position, the tool 200 straddles a production zone “A” of interest, which has previously been perforated 300 through the casing 165 and cement 167 into the surrounding formation F. The upper sealing elements 17 and the lower sealing elements 61 of the tool 200 seal against the casing 165 to isolate the production zone A prior to fracturing.
[0030] Referring now to FIGS. 3A through 3H , these cross-sectional side views depict the individual components of one embodiment of a wellbore fluid saver assembly 200 . In particular, when viewed from end to end, FIGS. 3A through 3H represent a cross-sectional side view of the tool 200 from top to bottom. The assembly 200 comprises three partially concentric tubular systems 210 , 220 , 230 that reciprocate axially with respect to one another, and a lug assembly 68 at its lower end. An inner tubular system 210 comprises a threaded coupling 1 , a top mandrel 2 , a ported mandrel 30 , and a lower collet 36 as depicted in FIGS. 3A through 3F . The threaded coupling 1 includes a box end 11 for connecting to the coiled tubing 150 and threads into the upper end of the top mandrel 2 , which in turn threads into a lock ring 25 and the upper end of the ported mandrel 30 as shown in FIG. 3D . An upper collet ring 26 surrounds the lower end of the top mandrel 2 and axially resides between the lock ring 25 and the ported mandrel 30 , which threads at its lower end into the lower collet 36 as shown in FIG. 3E . The ported mandrel 30 comprises valving ports 60 , bypass ports 66 and a flow blocking section 31 that terminates an inner flowbore 15 extending through the threaded coupling 1 , the top mandrel 2 , and the ported mandrel 30 .
[0031] A middle tubular system 220 surrounds the inner tubular system 210 and comprises a top sleeve cap 3 , a top sleeve 4 , a hold down body 8 , a seal element mandrel 23 , and an upper collet 28 as shown in FIGS. 3A through 3D . The top sleeve cap 3 threads into the top sleeve 4 , which in turn threads onto the hold down body 8 . The lower end of the hold down body 8 threads into a first gauge ring 16 and onto the seal element mandrel 23 . The hold down body 8 includes a plurality of recesses within which are disposed piston buttons 9 biased to a retracted position by piston springs 10 . The opposite end of the seal element mandrel 23 is threaded into the upper collet 28 as shown in FIG. 3D . The seal element mandrel 23 supports an upper set of sealing elements 17 , with each individual sealing element 17 separated by spacers 18 . The set of sealing elements 17 and spacers 18 reside axially between first and second gauge rings 16 , 14 as shown in FIGS. 3B and 3C .
[0032] Referring now to FIGS. 3C through 3H , an outer tubular system 230 surrounds a portion of the middle tubular system 220 and a portion of the inner tubular system 210 . The outer tubular system 230 comprises a spring housing 20 , a sleeve cap 22 , a connecting sleeve 29 , a valve body 33 , a ported sub 34 , a lower collet housing 35 , a bottom nipple 41 , a lower packer top sub 42 , a lower packer mandrel 55 and a bottom sub 56 . The spring housing 20 threads into the second gauge ring 14 , and a Belleville spring 21 is positioned axially between the spring housing 20 and the upper end of the sleeve cap 22 as shown in FIG. 3C . The lower end of the sleeve cap 22 threads into the connecting sleeve 29 , which in turn threads onto the upper end of the valve body 33 as shown in FIGS. 3C and 3D . The lower end of the valve body 33 threads to the ported sub 34 , which in turn threads into the lower collet housing 35 as shown in FIG. 3E . The lower end of the lower collet housing 35 threads onto the bottom nipple 41 , and a lower collet ring 37 is shown axially positioned between the bottom nipple 41 and a shoulder 32 on the inner surface of the lower collet housing 35 as shown in FIG. 3F . A shear ring 38 receives a shear screw 39 , which extends through the bottom nipple 41 to lock the outer tubular system 230 with respect to the inner tubular system 210 .
[0033] As depicted in FIGS. 3F and 3G , the bottom nipple 41 is provided with lower threads 46 to connect into a box end 48 of the lower packer top sub 42 . A third gauge ring 43 threads between the lower packer top sub 42 and the lower packer mandrel 55 . A fourth gauge ring 51 threads onto a cone 44 that is used to activate one or more slips 45 . A lower set of sealing elements 61 resides between the third gauge ring 43 and the fourth gauge ring 51 with element spacers 18 provided between each of the individual sealing elements 61 . A continuous J-slot 62 is formed into the outer surface of the lower packer mandrel 55 as shown in FIG. 3G . The lower end of the lower packer mandrel 55 threads into the bottom sub 56 as shown in FIG. 3H . The wellbore fluid saver assembly 200 also comprises a plurality of O-rings 6 for sealing between components of the tubular systems 210 , 220 , 230 , as well as a plurality of set screws 7 for locking the various components of the tubular systems 210 , 220 , 230 together as depicted in FIG. 3A through 3H .
[0034] Referring again to FIG. 3H , the lug assembly 68 comprises a slip cage 47 , a lug ring 49 and a drag block body 54 containing a drag block 52 and a spring 53 . The lug assembly 68 is disposed about the lower packer mandrel 55 and connects to the J-slot 62 by a lug 50 extending from the lug ring 49 . The drag block body 54 threads into the slip cage 47 , and the slips 45 extend upwardly from the slip cage 47 for interaction with the cone 44 . The drag block 52 is attached to the drag block body 54 and biased radially outwardly by a drag block leaf spring 53 that is located in a cavity between the drag block body 54 and the drag block 52 . The lug ring 49 and the lug 50 reside in recesses along the inner surface of the drag block body 54 , with the lug 50 extending to engage the continuous J-slot 62 . The interaction between the lug 50 and the continuous J-slot in various configurations of the tool 200 is also depicted in FIG. 9 and will be discussed in more detail herein.
[0035] Referring again to FIGS. 3B through 3E , the wellbore fluid saver assembly 200 also comprises a number of ports that provide various flow paths through the assembly 200 . As shown in FIG. 3E , the ported mandrel 30 comprises inner valving ports 60 and the ported sub 34 comprises outer valving ports 63 . As such, the ported mandrel 30 and ported sub 35 comprise a valve 67 that is open when the inner valving ports 60 and the outer valving ports 63 are at least partially aligned, and that is closed when these ports 60 , 63 are totally out of alignment. Accordingly, when the valving ports 60 , 63 are aligned, they allow communication of pressurized nitrogen 180 from the flowbore 15 to the surrounding wellbore 160 .
[0036] The ported mandrel 30 also includes bypass ports 66 that interact with the outer valving port 63 when the valve 67 is closed to allow fluid communication along a lower bypass flow path 12 between a lower flowbore 24 and the wellbore 160 . Referring to FIGS. 3B through 3D , an upper bypass flow path 69 is provided in a gap between the inner tubular system 210 and the middle tubular system 220 , and this upper bypass flow path 69 is defined by bypass ports 70 , 71 , and 72 that are located in the top sleeve 4 , the upper collet 28 , and the connecting sleeve 29 , respectively. Like the lower bypass flow path 12 , the upper bypass flow path 69 is also open when the valve 67 is closed.
[0037] As shown in FIGS. 3B and 3E , in addition to the components introduced above, there are also three molded seals 5 , 64 , 65 that are important for directing the flow of pressurized nitrogen 180 through the bypass flow paths 12 , 69 , or through the valve 67 , or both. The upper molded seal 5 is located near the interface between the top sleeve 4 and the hold down body 8 as shown in FIG. 3B . When the upper bypass flow path 69 is open, namely, when flow is permitted through ports 72 , 71 and 70 , the upper molded seal 5 prevents such flow from actuating the piston buttons 9 . The central molded seal 64 is located between the valve body 33 and the ported sub 34 , and the lower molded seal 65 is located near the interface between the ported sub 34 and the lower collet housing 35 as shown in FIG. 3E . Both of these molded seals 64 , 65 prevent the loss of pressurized nitrogen 180 from the valve 67 when the valve 67 is open and the bypass flow paths 12 , 69 are closed.
[0038] The wellbore fluid saver assembly 200 assumes various operational configurations during fracturing of the formation F surrounding the wellbore 160 , which include not only the actual fracturing process, but also run-in and movement of the tool 200 from one production zone to the next. The remaining figures illustrate the sequential operational configurations of the wellbore fluid saver assembly 200 during wellbore fracturing. In general, as will be described in more detail herein, FIGS. 4A through 4F depict the wellbore fluid saver assembly 200 as configured during run-in; FIGS. 5A through 5F depict the assembly 200 located adjacent to the production zone of interest and ready to set; FIGS. 6A through 6F show the tool 200 anchored, the upper and lower sets of sealing elements 17 , 61 set, and the valve 67 partially open to allow communication of the pressurized fluid 180 between the flowbore 15 and the surrounding wellbore 160 ; FIGS. 7A through 7F depict the valve 67 fully open, as it will be during the fracturing operation; and FIGS. 8A through 8F depict the valve 67 closed after completion of the fracturing operation with the tool 200 being moved by the coiled tubing 150 to the next production zone or being removed from the wellbore 160 .
[0039] Referring now to FIGS. 4A through 4F , the tool 200 is shown in its run-in configuration, i.e. the configuration of the tool 200 as it is lowered or “run-in” to the wellbore 160 to a desired depth adjacent to a production zone A shown in FIG. 4D . During run-in, the operator may elect to begin pumping pressurized nitrogen 180 to fill the coiled tubing 150 . Valve 67 is closed, because the inner valving ports 60 and outer valving ports 63 are totally out of alignment, and the flow blocking section 31 is blocking flow of the nitrogen 180 through outer valving ports 63 as shown in FIG. 4D . Thus, the pressurized nitrogen 180 being pumped into the coiled tubing 150 at the surface 170 is contained within the coiled tubing 150 and prevented from communicating with the surrounding formation F. As the assembly 200 is run-in, the drag blocks 52 shown in FIG. 4F are in continuous contact with the casing 165 , providing a centralizing effect as the tool 200 is lowered into the wellbore 160 .
[0040] As shown in FIGS. 4B through 4D , during run-in the bypass flow paths 12 , 69 are open, as indicated by the position of bypass ports 66 , 70 , 71 and 72 relative to the upper, middle, and lower molded seals 5 , 64 and 65 . As the wellbore fluid saver assembly 200 is run-in, a differential pressure distribution develops along the length of the tool 200 . The faster the speed of run-in, the higher the differential pressure along the tool 200 . If this pressure differential is high enough, the fluid pressure can compress or set the upper set of sealing elements 17 and the lower set of sealing elements 61 . Therefore, to equalize the pressure distribution along the tool 200 , and thereby prevent compression of the upper set of sealing elements 17 and the lower set of sealing elements 61 , wellbore fluid bypasses both sets of elements 17 , 61 . Specifically, as shown in FIGS. 4C and 4D , the wellbore fluid flows upwardly through a lower flowbore 24 in the tool 200 that is blocked at its upper end by the flow blocking section 31 in the ported mandrel 30 , and then through the bypass ports 66 into the lower bypass flow path 12 and out into the wellbore 160 through outer valving ports 63 . Simultaneously, as shown in FIGS. 4A through 4C , the wellbore fluid is routed along the upper bypass flow path 69 by flowing into ports 72 , through ports 71 , and out of ports 70 into the wellbore 160 . This bypass flow does not actuate the piston buttons 9 due to the position of the upper molded seal 5 , which prevents the piston buttons 9 from being exposed to internal pressure. The piston buttons 9 are pressure-actuated to extend outwardly and act as a locking device near the upper set of sealing elements 17 . During run-in, it is desirable to avoid locking the tool 200 in this manner.
[0041] Referring to FIGS. 4D through 4F , also during run-in, it is desirable to avoid inadvertent anchoring of the tool 200 near the lower set of sealing elements 61 . The cone 44 and the slips 45 , when engaged, anchor the tool 200 against the casing 165 . Therefore, to prevent the cone 44 from inadvertently engaging the slips 45 , a shear ring 38 and shear screw 39 shown in FIG. 4D are provided to lock the lower collet 36 to the bottom nipple 41 such that these components do not move relative to each other during run-in. The force exerted on the coiled tubing 150 during run-in is insufficient to sever the shear screw 39 . As long as the shear screw 39 engages the shear ring 38 , the cone 44 is prevented from moving relative to and sliding under the slips 45 . The shear ring 38 and shear screw 39 also prevent excessive wear on the lower collet 36 , which would otherwise bear the load carried by the shear ring 38 . Referring to FIG. 4F , the interaction between the continuous J-slot 62 and the lug 50 similarly prevents the lug assembly 68 from pushing the slips 45 upward relative to the cone 44 and engaging the cone 44 . As shown in FIG. 9 , lug 50 is located in slot 80 during run-in. This slot 80 is a shorter slot designed to prevent the lug assembly 68 from pushing the slips 45 upward relative to the cone 44 and engaging the cone 44 . Due to the position of the lug 50 within slot 80 , the lug assembly 68 is dragged along the casing 165 as the coiled tubing 150 lowers the wellbore fluid saver assembly 200 downhole.
[0042] After run-in is complete and the tool 200 has reached a desired depth adjacent to a production zone A, the operator prepares the tool 200 to set. FIGS. 5A through 5F show the tool 200 in its ready to set configuration. To move the tool 200 from the run-in configuration of FIGS. 4A through 4F to the ready to set configuration, the operator simply picks up the coiled tubing 150 , and therefore the attached tool 200 . During this lifting process, the shear screw 39 and shear ring 38 remain intact as shown in FIG. 5D , the valve 67 remains closed as shown in FIG. 5C , thus keeping nitrogen 180 contained within the coiled tubing 150 , and the bypass flow paths 12 , 69 remain open. As shown in FIG. 5F , when the tool 200 is picked up, the resistance provided by the drag blocks 52 at the casing 165 allow the coiled tubing 150 , the inner tubular system 210 , the middle tubular system 220 , and the outer tubular system 230 to travel upwards relative to the stationary lug assembly 68 until the bottom sub 56 contacts the lower end of the drag block body 54 . Simultaneously, as represented in FIG. 9 , the continuous J-slot 62 slides from an initial position at the top of slot 80 downwardly along lug 50 until the lug 50 contacts angled channel 84 of the continuous J-slot 62 , thereby causing the lug ring 49 to rotate. The rotation of the lug ring 49 shifts lug 50 downwardly into the adjacent slot 81 along the continuous J-slot 62 to prepare for the next operational step of the tool 200 , which is to set and anchor.
[0043] FIGS. 6A through 6F show the tool 200 in its set and anchored position. To move the tool 200 from the ready to set configuration of FIGS. 5A through 5F to the set and anchored position, the operator slacks off weight, meaning a downward force is applied to the coiled tubing 150 . Referring again to FIG. 9 , with the lug 50 in slot 81 at the onset of slack off, the downward force on the tool 200 causes slot 81 of the continuous J-slot 62 to slide along lug 50 until the lug 50 contacts angled channel 85 of the J-slot 62 , thereby causing the lug ring 49 to rotate and the lug 50 to shift from slot 81 to adjacent slot 82 . Referring again to FIGS. 6A through 6F , as slack off continues, the cone 44 engages the slips 45 to extend the slips 45 outwardly into engagement with the casing 165 as shown in FIG. 6F , thus anchoring the tool 200 near the lower set of sealing elements 61 .
[0044] Further slack off compresses the upper set of sealing elements 17 as shown in FIG. 6B and the lower set of sealing elements 61 as shown in FIG. 6E , severs the shear screw 39 so that it no longer engages the shear ring 38 as shown in FIGS. 6D and 6E , and causes the lower collet 36 to overcome the lower collet ring 37 as shown in FIG. 6D . Referring to FIG. 6D , the lower molded seal 65 is positioned to block the lower bypass flow path 12 such that flow is no longer permitted to bypass the lower set of sealing elements 61 by flowing through the bypass ports 66 outwardly through the outer valving ports 63 into the wellbore 160 . Also, as shown in FIG. 6B , due to the position of the upper molded seal 5 relative to bypass ports 70 in the top sleeve 4 , flow is no longer permitted to travel along the upper bypass flow path 69 to bypass the upper set of sealing elements 17 and the piston buttons 9 . As shown in FIG. 6D , the valve 67 is partially open because the inner valving ports 60 and outer valving ports 63 are partially aligned, so high pressure nitrogen 180 therefore flows from the coiled tubing 150 through the flowbore 15 and outwardly through the valve 67 . This pressure activates the piston buttons 9 , which “grip” the casing 165 , thus locking the tool 200 against the casing 165 near the upper set of sealing elements 17 as shown in FIG. 6B . Thus, in summary, FIGS. 6A through 6F show the tool 200 anchored by slips 45 and piston buttons 9 and sealed against the casing 165 by the upper set of sealing elements 17 and the lower set of sealing elements 61 , with the bypass flow paths 12 , 69 closed, and the valve 67 partially open. In this configuration, the tool 200 has isolated production zone A. An extension 90 may be required in the assembly 200 to provide the proper spacing between the upper set of sealing elements 17 and the lower set of sealing elements 61 , depending upon the length of the production zone A to be isolated.
[0045] Next, valve 67 will be fully opened and the fracturing operation performed. FIGS. 7A through 7F show the tool 200 with the valve 67 fully open as depicted in FIG. 7D , as the valve 67 would be during fracturing. To fully open the valve 67 by completely aligning the inner valving ports 60 and the outer valving ports 63 , additional set down weight is applied. The approximate amount of weight equals the amount of force required to cause the upper collet ring 26 to overcome the upper collet 28 as shown in FIG. 7C . This amount of force is applied to the coiled tubing 150 . Once the upper collet ring 26 overcomes the upper collet 28 , valve 67 is near its fully open position. Slack off continues as the operator monitors the nitrogen pressure within the coiled tubing 150 for a pressure spike that indicates valve 67 is fully open. Once that pressure spike is observed, the operator ceases to slack off. During this slacking off process, the lug assembly 68 , the middle tubular system 220 and the outer tubular system 230 of the tool 200 remain stationary while the inner tubular system 210 moves downwardly until extensions 75 on the ported mandrel 30 engage a shoulder 76 on the top sleeve 4 as shown in FIG. 7B .
[0046] With the valve 67 fully open, fracturing can take place. During fracturing, the upper set of sealing elements 17 may tend to slip downwardly, causing some loss of sealing capacity and nitrogen pressure. To prevent such slippage from occurring, the Belleville springs 21 are provided to exert an additional force on the upper set of sealing elements 17 , thereby holding them in place against the casing 165 as shown in FIG. 7B .
[0047] Once fracturing is complete, the tool 200 can be moved to the next production zone or removed from the wellbore 160 . Before moving the tool 200 , it must be unlocked. Unlike existing downhole cup-style straddle-packers where the nitrogen pressure must be vented or the formation pressure must be bled down until the cups relax, there is no such requirement to unlock the wellbore fluid saver assembly 200 . Instead, an open lower bypass flow path 12 via bypass ports 66 in the ported mandrel 30 communicating with outer valving ports 63 , and an open upper bypass flow path 69 via the bypass ports 70 , 71 , 72 , provide pressure equalization across the tool 200 while the valve 67 is closed to contain the nitrogen 180 within the tool 200 and coiled tubing 150 .
[0048] FIGS. 8A through 8F depict the tool 200 when it has been unlocked and it is being moved. To achieve this unlocked configuration, the operator simply picks up on the coiled tubing 150 and the attached tool 200 . By picking up the tool 200 , the inner tubular system 210 moves up until the extensions 75 on ported mandrel 30 engage a shoulder 77 on the top sleeve cap 3 as shown in FIG. 8A to pull the middle tubular system 220 upwardly. Thus, the load on the upper set of sealing elements 17 is removed, allowing these sealing elements 17 to relax or un-set. Continued tension on the coiled tubing 150 causes the upper collet ring 26 to travel upwards until it passes over the upper collet 28 as shown in FIG. 8B . Due to this relative movement, the inner valving ports 60 and the outer valving ports 63 are no longer aligned, thereby closing valve 67 as shown in FIG. 8C . At the same time, the lower bypass flow path 12 is opened due to the position of the bypass ports 66 in the ported mandrel 30 relative to the lower molded seal 65 . Because valve 67 is now closed, high pressure nitrogen 180 is contained within the coiled tubing 150 and the tool 200 and no longer applies a pressure load to the piston buttons 9 . Hence, the piston buttons 9 are retracted by the biasing piston spring 10 as shown in FIG. 8A . Continued tension to the coiled tubing 150 causes the lower collet 36 to pass over the lower collet ring 37 as shown in FIG. 8C , similar to what has already transpired with the upper collet 28 . The lower set of sealing elements 61 then relax or un-set as shown in FIG. 8E . Referring now to FIG. 9 , the continuous J-slot 62 slides along lug 50 as lug 50 shifts from slot 82 to slot 83 . J-slot 62 continues to travel upwards relative to lug 50 until lug 50 reaches the end of slot 83 and no further movement of J-slot 62 relative to the lug assembly 68 is permitted. Finally, as shown in FIGS. 8E and 8F , the cone 44 disengages from the slips 45 . This relative movement is possible, again, because the drag block 52 continuously engages the casing 165 to provide resistance to the tension load on the coiled tubing 150 .
[0049] The tool 200 is now ready to be moved. Valve 67 is closed, the upper set of sealing elements 17 and the lower set of sealing elements 61 are unset, the tool 200 is unanchored at both ends, and the bypass flow paths 12 , 69 are open. After the tool 200 is moved to the next frac zone, such as production zone “B” shown in FIG. 2 , for example, the entire operational sequence is repeated. Specifically, the tool 200 is moved to the ready to set configuration, if not already in this configuration, as shown in FIGS. 5A through 5F . Then the tool 200 is anchored, the upper set of sealing elements 17 and lower set of sealing elements 61 are set, and the valve 67 is partially opened, as depicted in FIGS. 6A through 6F , and so on. In this manner, multiple production zones may be fractured during a single trip downhole. Furthermore, fracturing of the wellbore 160 is completed in a minimal amount of time and with minimal waste of pressurized nitrogen 180 .
[0050] The foregoing description of the wellbore fluid saver assembly 200 which, upon completion of a wellbore service operation can be moved without venting nitrogen 180 to the surface 170 or waiting for the formation F to bleed down, has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously many other modifications and variations of the wellbore fluid saver assembly 200 are possible. In particular, another frac fluid could be used, instead of nitrogen. For example, frac fluids used in acidizing are compatible with this tool. Also, the sealing elements 17 , 61 may be replaced with other types of sealing devices. A different number or combination of components may be employed, and other variations are possible.
[0051] While a single embodiment of the wellbore fluid saver assembly 200 has been shown and described herein, modifications may be made by one skilled in the art without departing from the spirit and the teachings of the invention. The embodiment described is representative only, and are not intended to be limiting. Many variations, combinations, and modifications of the application disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims.
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A method for performing a service operation within a wellbore extending into a formation comprises sealing a first length of the wellbore to define a first isolated formation zone, flowing a pressurized fluid through a tubular string into the first isolated formation zone, and unsealing the first length of the wellbore without venting the pressurized fluid from the tubular string or awaiting depressurization of the first isolated formation zone. An assembly connected to a tubular string for performing a service operation in a wellbore comprises a mandrel with a flowbore in fluid communication with the tubular string, an upper sealing device, a lower sealing device, a selectively operable valve that enables or prevents fluid communication between the flowbore and the wellbore, and a selectively closeable bypass flow path.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
The United States Government has rights in this invention pursuant to Contract No. DE-AC04-76DP00789 between the Department of Energy and AT&T Technologies, Inc.
BACKGROUND OF THE INVENTION
The present invention relates to an empirical electrical method for remote sensing of steam quality utilizing flow-through grids which allow measurement of the electrical properties of a flowing two-phase mixture.
The measurement of steam quality in the oil field is important to the efficient application of steam assisted recovery of oil. Because of the increased energy content in higher quality steam it is important to maintain the highest possible steam quality at the injection sandface. The effectiveness of a steaming operation without a measure of steam quality downhole close to the point of injection would be difficult to determine. Therefore, a need exists for the remote sensing of steam quality.
A number of methods currently exist for the measurement of steam quality. For example, a December 1981 publication by Sandia National Laboratories, SAND80-7134, contains an article by A. R. Shouman entitled "Steam Quality Measurement: A State of the Art Review". Shouman reviewed existing methods and identified two techniques which could be useful for remote sensing of pure steam, one based on acoustic propagation characteristics of two-phase flow and a second on venturimeters.
Another method is disclosed by H. A. Wong, D.S. Scott, and E. Rhodes in an article "Flow Metering in Horizontal Adiabatic Two-Phase Flows" found in Flow/81: Its Measurement and Control in Science and Industry, Vol. 2, 1981, pp. 505-516. Wong et al. have developed a twisted tape venturimeter for two-phase quality measurements. Although this method has been used for steam quality measurements in the field, no detailed calibration measurements on wet, high pressure steam have been reported.
A venturimeter/orifice plate system has been used successfully (although not downhole) for wet steam quality measurements at up to 980 pounds per square inch (psi) by D. B. Collins and M. Gacesa as described in the March 1971 publication of J. Basic Engineering on pp. 11-21.
Other more recent techniques of steam quality measurement include gamma and x-ray attenuation. In order to be useful however, they require extensive calibration against known standards over the complete range of conditions which may be encountered downhole.
Therefore it is desired to provide an empirical electrical method for the remote sensing of steam quality that can be adapted to downhole steam quality measurement.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an empirical method for the remote sensing of steam quality.
It is another object of the present invention to provide an empirical method for the remote sensing of steam quality that can be easily adapted to downhole steam quality measurements.
It is a further object of the present invention to provide a device for allowing measurement of the electrical properties of two-phase flow in the method of steam quality measurement.
It is a still further object of the present invention to provide a device for allowing measurement of the electrical properties of two-phase flow in the method of steam quality measurement which will not alter the flow characteristics and at the same time be able to withstand an adverse environment.
Briefly described, in accordance with the present invention, an empirical electrical method for the remote sensing of steam quality has been developed. A device is made from special flow-through grids which allow measurement of the electrical properties of a flowing two-phase mixture without interfering with the flow. The effect on the capacitance of the flowing mixture at low frequencies yield a straight line relationship. The device must be calibrated for each specific application, and clearly can be adapted to other applications.
More specifically, the present invention is directed to a method for measuring the quality of steam flowing through a conduit in a downhole oil well system at the injection sandface, the improvement comprising the steps of: calibrating the system by filling a conduit containing two spaced electrodes with steam samples of known qualities; applying an AC signal across the terminals; measuring the capacitance between the electrodes as a function of frequency of the applied signal for each steam sample; and determining a frequency range where measured capacitance is a linear function of steam quality. The calibrated system is then used by injecting an unknown sample of steam into the conduit; applying an AC signal at a selected frequency within the frequency range to the electrodes; measuring the capacitance between the electrodes at the selected frequency; and determining steam quality from the capacitance measurement.
The electrodes may be spaced either longitudinally of the conduit in which case planar electrodes are used or transversely of the conduit in which case cylindrical electrodes are used.
In either case the electrodes are disposed downhole adjacent to the oil well sandface and all capacitance measurements are made remotely above the steam injection zone.
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 hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a plan view of a single planar flow-through electrode a pair of which are utilized to measure the steam quality in accordance with the present invention;
FIG. 2 is a side elevational view partially in section illustrating three flow-through electrodes of the type illustrated in FIG. 1 mounted in a pipe for measurement of electrical and thermal properties of steam flowing therethrough;
FIG. 3 is a diagrammatic view of a portion of a flow system including a cooler bath, a conventional enthalpy tank for measuring steam quality, and an input to an analyzer and signal source;
FIG. 4 is a diagrammatic view of the laboratory apparatus utilized for measuring steam quality with the standard calorimeter techniques of the enthalpy tank of FIG. 3 and the electrical properties using the electrodes of FIG. 2 for developing the empirical data to be utilized in the downhole steam quality measurement method of the present invention;
FIG. 5 is a diagrammatic view of a data analyzing and recording system for the steam quality and electrical parameters measured by the system of FIG. 4;
FIG. 6 is a graph showing a correlation of steam quality with the measured capacitance between a pair of electrodes of FIG. 2 having capacitance at a low frequency voltage signal (20 Hz) applied therebetween;
FIG. 7 is a graph showing a correlation of steam quality with the measured capacitance between a pair of electrodes of FIG. 2 with a high frequency voltage signal (2000 Hz) applied therebetween;
FIG. 8 is a graph illustrating the substantially linear relationship between capacitance and steam quality between a voltage signal frequency range of about 20 to 200 Hz, as determined by the empirical data generated by the system of FIG. 4; and
FIG. 9 is an alternative embodiment of cylindrical electrodes spaced transversely of a conduit through which steam is flowing at a downhole location.
DETAILED DESCRIPTION OF THE INVENTION
Referring in detail to FIG. 1 there is illustrated a single flow-through electrode 10 for measurement of electrical and thermal properties of steam flowing therethrough. As will become more readily apparent hereinafter a spaced pair of such electrodes will be utilized in accordance with the present invention to measure steam quality downhole near the sandface of an oil well.
Each electrode 10 is made using a computer-generated rectangular grid pattern 12 of 0.51 mm wires 14 on a 6 mm grid space 16 surrounded by a 25 mm outer annulus 18 of a 3 mm width. A tab 20 extends from the outer annulus 18. This computer-generated pattern is photo etched onto 0.13 mm 304 stainless steel resulting in a physical electrode having parts corresponding to those computer-generated parts described hereinabove.
Electrodes 10 are plated with Wood's nickel strike to a thickness of about 0.0025 to 0.005 mm and then with about 0.0025 to 0.0037 mm of gold on top of the nickel by the Englehart technique. Electrical connection to the electrode 10 is made with 2.18 mm chromel/alumel, stainless steel sheath thermocouple wires 22 with the ball spot welded to the electrode 10 at a point 24. The sheath 22 is sealed with RE-X glass ceramic 26 at one end of a bidirectional sleeve 28 mounted in a perpendicular arrangement on tab 20.
The RE-X glass ceramic 26 was developed by General Electric for high voltage insulators and has a coefficient of expansion closely matched to chromel/alumel resulting in a good glass to metal seal. RE-X glass ceramic 26 is workable at 950° C. but will withstand a continuous temperature of 830° C. without degradation rendering it highly suitable for application in downhole steam measurement. This glass ceramic 26 has a weathering resistance better than glass and as good as glazed porcelain.
At the sleeve 28 end opposite that of the ceramic seal 26 are electrode leads 30 to be coupled to an impedance analyzer and thermocouple readout provided in the data recording system of FIG. 5 to be described hereinafter.
Referring to FIG. 2 there is illustrated a side elevational view partially in section of an electrical grid system of a plurality of spaced flow-through electrodes 10 for measurement of electrical and thermal properties of steam flowing through a conduit or tube 32. The tube 32 is disposed in the laboratory system of FIG. 4 to be described hereinafter.
Three electrodes 10 are mounted in a 50 mm ID pyrex T-tube 32 having flanged ends 34a, b and c with gaskets 36a, b and c mounted to each respective flanged end 34a, b and c by any suitable attachment means such as bolts 38(a-f). The three electrodes 10 are held in place by phenolic (laminated sheet cloth fabric base) spacers 40 with a 50 mm outer diameter and a 25 mm inner diameter. These spacers 40 are arranged such that the distance between each adjacent electrode 10 is 12 mm.
Leads 30 from the electrodes 10 and thermocouples 22 are fed out through the right angle section of the pyrex T-tube 32 to a junction box 42 (see FIG. 4). The junction box 42 serves as the branching off area whereby it is possible to measure either temperature through the thermocouples 22 of each electrode 10 or electrical parameters through just one lead 30 of each thermocouple 22. Use of this junction box 42 is useful to prevent interference between temperature measurements and measurements of electrical parameters.
FIG. 3 illustrates a portion of a flow system including conventional enthalpy tank 50 utilized in the laboratory system of FIG. 4 to be described hereinafter for measuring steam quality using standard condensing calorimeter techniques.
An enthalpy tank 50 is made by forming a coil 52 of 10 mm copper inside a container 54. Steam is passed through the coil 52 and allowed to exit through a perforated cylinder 56 at the end of the coil 52 and into water 58. The initial column of water 58 should be chosen to cover both the coil 52 and exit cylinder 56. A stirring magnet 60 located on the bottom of the enthalpy tank 50 is activated by a stirrer motor 62 and subsequently keeps the water 58 well mixed.
A small change in temperature (ΔT) of the water is used to measure the initial and final mass and temperature of the water over a range of 30° C. in order to reduce evaporative losses as much as possible. The container 54 is insulated by insulation blanket 64 to minimize heat loss and thermal variations.
The actual calculation of steam quality X is a result of the equation: ##EQU1## where h f is the enthalpy of saturated liquid, h fg is the change in enthalpy between a saturated liquid and a saturated vapor, and h is the measured enthalpy. Values for h f and h fg are taken from standard tables for the measured values of the steam temperature and/or pressure.
All measured quantities are for the appropriate systems in equilibrium. For instance, after the steam is turned off to the enthalpy tank 50, the copper coil 52 is disconnected from the rest of the system and the water bath 58 is stirred until the enthalpy tank has come to thermal equilibrium.
FIG. 4 illustrates a laboratory apparatus and method for developing the empirical data required for measuring downhole steam quality utilizing standard calorimeter techniques with enthalpy tank 50 of FIG. 3 and the flow-through electrode grid structures 10 of FIGS. 1 and 2.
In utilizing this laboratory procedure, the steam quality is measured first with enthalpy tank 50 followed by electrical parameter measurements with electrodes 10 in tube 32.
Plant steam is generated by suitable means, dispensed through a cooler bath having cooling coils 68 used to vary steam quality, then the steam quality is measured first in the enthalpy tank 50 as previously described. Measurements from this enthalpy tank 50 may be fed through lead lines 66 a and b to data logger 44 shown in FIG. 5. After steam quality has been measured in this manner, the steam is then diverted to an experimental vessel 70 containing the pyrex T-tube 32, having flow through electrodes 10 therein. Electrode leads 1, 2 and 3 are fed to the junction box 42.
In every case, the electrode grid system enclosed in the pyrex T-tube 32 is kept at steam temperature by temperature controlled heat tape wrapped around the tube chamber after which the whole chamber is wrapped in insulation. This combination is generally indicated as a heater 72 and is kept at steam temperature by a heater control 74. Various valves V, gauges G and drains D complement the system described. After the electrode chamber in T-tube 32 reaches equilibrium, electrical measurements may be made between each adjacent pair of electrodes, with the data being averaged.
FIG. 5 illustrates a view of a detecting and recording system for the data generated in the laboratory system of FIG. 4.
Temperature measurements are obtained through the thermocouples 22 using a data-logger 44, and electrical parameters are measured through one lead 30 of each thermocouple 22 using an impedance analyzer 46. In measuring the impedance, an operator switches the junction box 42 to scan successive pairs of electrode leads 30 which are input into the junction box 42. Automated data recording is done at 5, 10, 20, 50, 100, 200, 500, 1000, 2000 and 5000 Hertz (Hz) of the parallel capacitance and conductance between each set of electrodes 10 being scanned. At each frequency, a series of measurements is made and averaged, then these data are fed into a computer 48. All data is analyzed by the computer 48 to determine whether computer transfer errors have occurred and corrective measurements are made as needed. Intermediate results may be printed for each frequency, and when measurements have been made over the entire range of frequencies, all accumulated data is stored on magnetic tape for later analysis.
Lead lines 66 a and b entering into data logger 44 serve to transfer data obtained from standard condensing calorimeter techniques as described with respect to FIG. 3. Results from the standard condensing calorimeter technique are used as a basis of comparison to validate the accuracy of the steam quality measurements using the electrical parameters (capacitance) of the flow through electrode grids.
FIG. 6 is a graph showing actual test results correlating steam quality with capacitance between electrodes 1 and 2 at low frequencies (20 Hz) of voltage signals applied therebetween. This proves to be a straight line (linear) relationship, indicating that capacitance measurements using the flow through grid process at low frequencies will yield accurate and easily interpretable steam quality information.
FIG. 7 is a graph showing actual test results correlating steam quality with capacitance between electrodes 1 and 2 at high frequencies (2000 Hz) of voltage signals applied therebetween. The non-linear relationship illustrated makes measurements using the flow-through grid system at high frequencies difficult to predict and may result in erroneous projections of steam quality at the sandface.
FIG. 8 is a graph illustrating the test results of the laboratory system of FIG. 4 over a wide frequency range of voltage signals applied between electrodes 1 and 2. the results show a substantially linear relationship of steam quality curves between frequency and capacitance in the frequency range from about 20Hz to 200Hz. Thus, the test results show that steam quality can be accurately measured as a function of the capacitance between spaced flow-through electrodes over a frequency range of 20 Hz to 200 Hz.
A variation in the geometry of the flow through electrodes previously described could be two concentric cylinders E1,E2 made of a similar wire mesh as in the electrodes 10 illustrated in FIG. 9. Electrodes E1,E2 are mounted such that their center lines are also on the center line of the steam injection string pipe P. Additional information may be obtained from this arrangement such as if any steam has condensed and is on the outer walls of the tubing. This could be measured by obtaining the capacitance M between the outer electrode E1 and the pipe P. The capacitance C between E1 and E2 is measured to determine steam quality.
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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An empirical method for the remote sensing of steam quality that can be easily adapted to downhole steam quality measurements by measuring the electrical properties of two-phase flow across electrode grids at low frequencies.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of the Invention
My invention relates to the field of ladder work trays and more particularly relates to a ladder work tray designed for use with hollow rung ladders. The principle of the invention is a support shaft attached to the tray which passes through a hollow rung of the ladder. The shaft is kept from rotating by a block on the end of the shaft which engages one of the ladder side rails. Provision is made to hold the tray nearly level regardless of the angle of the ladder. The tray is designed to hold tools and painting equipment for workers on ladders.
2. The Prior Art
The prior art includes U.S. Pat. No. 3,822,846, to Jesionowski. This invention places a stud inside of the hollow ladder rung and uses a cam to lock the device in position. A similar invention is U.S. Pat. No. 4,318,523 to Weatherly. This invention uses two rungs for mounting the tray. Another invention, U.S. Pat. No. 4,445,659 to LaChance also requires the use of two hollow ladder rungs. Still another invention, U.S. Pat. No. 4,489,911 to Riley also uses two rungs of the ladder to hold the tray in place. These inventions have drawbacks that include overly complex manufacture, high cost and difficulty of erecting.
SUMMARY OF THE INVENTION
My invention is a solution to the problem of how to provide a ladder tray that is simple and inexpensive in construction. My invention also provides a ladder tray that may be mounted using one rung of the ladder and that may be adjusted and held to a nearly level position regardless of the angle of the ladder. I provide a tray on one end of a longitudinally fluted shaft. The shaft is small enough in diameter to produce a sliding fit when passed through the hole in one of the rungs of a conventional metal ladder. On the other end of the shaft I place a stabilizer block which engages the rail of the ladder on that side. Locking means are provided to keep the block engaged with the ladder rail and the shaft from rotating and thus to hold the tray rigid. In addition, provision is made to lock the tray in the desired angle relative to the ladder rails so as to be in a nearly horizontal position to keep tools and paints from sliding off the tray.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the invention on a ladder.
FIG. 2 is a side view of safety chain attachments.
FIG. 3 is a front view of the cinch nut of FIG. 1.
FIG. 4 is a side view of the cinch nut of FIG. 1.
FIG. 5 is a top view of the stabilizer block of FIG. 1.
FIG. 6 is a front view of the stabilizer block of FIG. 1.
FIG. 7 is a side view of the shaft of FIG. 1.
FIG. 8 is an end view of the threads of FIG. 7 taken along the plane 8--8.
FIG. 9 is a section of the flutes of FIG. 7 taken along the plane 9--9.
FIG. 10 is a section of the shaft of FIG. 7 taken along the plane 10--10.
FIG. 11 is a front view of the spacer of FIG. 1.
FIG. 12 is a side view of the spacer of FIG. 1.
FIG. 13 is a top plan view of the tray of FIG. 1.
FIG. 14 is a sectional view of the tray of FIG. 1 taken along the plane 14--14.
FIG. 15 is a sectional view of the tray of FIG. 1 taken along the plane 15--15.
DESCRIPTION OF PREFERRED EMBODIMENT
As shown in in the drawings, where like numerals refer to like parts throughout, I provide a tray 10 having a low raised edge 12 around the top surface. The tray 10 is attached to a shaft 14 that has a male longitudinally fluted portion 44 and a threaded end portion 42 as best seen in FIG. 7. On the other end of the shaft from the tray 10, I provide a stabilizer block 24 which has a centrally located female fluted hole 38. The block 24 is provided with shoulders 25. The block 24 is shaped to engaged the side rail 36 of a conventional commercially available aluminum, wood or fiber glass ladder 32 of the variety having a plurality of hollow rungs such as hollow rung 34. The stabilizer block 24 prevents rotation of the shaft 14 and the attached tray 10. The nut 26 is a non-essential safety feature which prevents separation of the block 24 and the tray 10. As shown in FIGS. 2, and 5, chains 16 may be fastened to the block 24 by means of a rivet eye bolt 18 and a female rivet 20. A hole 21 is provided in one of the shoulders 25 of block 24 for this purpose. Chain rings 22 may be used to attach the chains 16 to the rivet eye bolt 18. In the center of the block 24, as best seen in FIG. 6, is provided a female fluted hole 38. The fluting 38 is sized to slidably engage the male fluting 44 of the shaft 14 as seen in FIG. 7. The cinch nut 26, as seen in FIGS. 3 and 4, is provided to engage the threaded end 42 of the shaft 14. A spacer 28, as best seen in FIGS. 11 and 12, is provided to fit between the cinch nut 26 and the block 24. The spacer 28 is provided with a central hole 29. The function of the spacer 28 will be detailed hereinafter in reference to the operation of the invention. The construction of the tray 10 may be best understood with reference FIGS. 13 thru 15. The tray 10 may be made of metal, plastic, nylon, wood or other materials and may be provided with stiffening members 46 on the under side. A central hole 48 is provided in the tray 10 to receive the shaft 14. The invention is made so that the shaft 14 is rigidly attached to the tray 10. The shaft 14 is not allowed to use to rotate in the hole 48 of the tray 10. However, the shaft 14 and the tray 10 may be demountable, thus allowing for easy transport and storage.
OPERATION
In operation, the shaft 14 with its attached tray 10 is pushed through the center of the desired rung 34 of the ladder 32, as best illustrated in FIG. 1. The stabilizer block 24 is then placed over the shaft 14 so that the shoulders 25 of the block 24 engage the left side rail 36 of the ladder 32. The block 24 is followed by spacer 28 and finally the cinch nut 26 which is placed over the threaded end 42 of the shaft 14. The female flutes 38 of the block 24 engage the male flutes 44 of the shaft 14. The cinch nut 26 is then tightened to hold the desired angular position of the tray 10. The tray 10 is thus prevented from rotating and stays in the level position in which it was first inserted through the rung 34. The safety chains 16 may be then attached to the side of the building or other object to which the ladder 32 is applied. The flute arrangement illustrated in FIGS. 6, 7 and 9 allows the tray 10 to be adjusted to a nearly level position no matter what the angle of the ladder rail 36. Once the cinch nut 26 is tightened flutes 38 and 44 prevent any rotation of the tray 10 from the selected flute alignment. The present invention can be installed at any height by one person and is easily and safely moved. The tray 10 can support sufficient weight of the usual tools of a handyman. The raised portion 12 around the edge of the tray 10 keeps any materials from rolling off the tray 10 due to the normal minor motions of the ladder. The block 24 is sized to fit most available ladders and the spacer block 28 allows adjustment when the invention is applied to the upper half of an extension ladder in which the width of the side rail of the extension portion of the ladder is of slightly less than the side rail of the base portion of the extension ladder. Although illustrated with the tray on the right of the ladder, the invention can be reversed to put the tray on the left of the ladder for a left-handed user.
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes such as the number of flutes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to falling within the scope of the invention as claimed.
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A work tray for mounting on hollow rung ladders. The tray has a single shaft which goes through one rung of the ladder. Lock means are provided to keep the tray from rotating or from pulling out of the rung. Angular adjustment means are provided so that the tray may be kept level when the ladder is used at different angles.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 616,680, filed June 14, 1984, which is now U.S. Pat. No. 4,568,219.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to road grading equipment and in particular to a drag-type road grader.
2. Description of the Prior Art.
Nonpaved roads comprising dirt, gravel and the like generally require periodic maintenance to repair the damage done thereto by vehicular traffic. A common maintenance procedure is to regrade and relevel the roads with equipment especially designed for this purpose. For example, self-propelled road graders are well known and may be provided with blades for scraping, leveling and reshaping a road surface. The blades are generally adjustably mounted with respect to height, pitch and angle relative to the direction of travel. For road grading purposes, the blades are usually oriented at an oblique angle with respect to the direction of travel so that excess road material flows transversely.
However, such self-propelled, conventional road graders have several drawbacks for the maintenance of roads comprising dirt, gravel and the like. First of all, generally only a single blade is mounted thereon. The single blade performs both cutting and filling operations wherein material is respectively removed from the high spots and deposited in the low spots. The only packing and compression of such redistributed material which occurs is by the rear wheels of the vehicle. Therefore, only the fractional portion of the blade's swath directly in the path of the vehicle rear wheels is compacted.
Secondly, self-propelled road graders operate best on relatively dry roads because their blades tend to stick in damp road materials. However, dry, loose material is susceptible to being blown out of level before being compacted by vehicular traffic. For example, pot holes filled under dry conditions with a single-blade road grader may be emptied and reopened by a high wind.
Yet another disadvantage of conventional, self-propelled road graders is their slow operating speeds. Excessive blade vibration or "chatter" typically occurs at speeds of approximately four miles per hour. The relatively slow operating speeds of such equipment tend to increase the cost of road maintenance therewith through such factors as labor, equipment usage, fuel consumption, maintenance and the amount of equipment required to maintain a given road network.
Drag-type road graders are also well known and are pulled along roads by tractors and the like. In fact, such drag-type road graders may be successfully employed in combination with self-propelled, single-blade road graders since the addition of the former can help compensate for the deficiencies of the latter. An exemplary drag-type road grader is shown in the Hall U.S. Pat. No. 1,185,090 and comprises a rectangular frame with a pair of blades extending thereacross at oblique angles. The Thurston U.S. Pat. No. 1,303,415 shows a frame with transverse blades. The frame members of the Thurston device are pivotally connected whereby the frame may be skewed to form a parallelogram to adjust the angles of the blades with respect to the direction of travel.
SUMMARY OF THE INVENTION
In the practice of the present invention, a road grader is provided which includes a frame having a pair of parallel, longitudinal trusses interconnected by rectangular subframes. Each subframe is pivotally connected to the trusses and includes a blade assembly. A tongue assembly extends along the direction of travel and the longitudinal axis of the grader and includes power cylinders for skewing the frame to parallelogram-shaped configurations by longitudinally shifting the trusses relative to each other and by rotating the subframes with respect to the trusses. The subframes are pivotally connected to the frame trusses by a plurality of hinge mechanisms with vertical, pivotal axes. A pair of wheel assemblies are retractably mounted on the frame for transporting the grader in a non-working mode.
A hydraulic blade lift mechanism for the road grader includes T-shaped rocker members pivoted on inner members of the frame hinge assemblies associated with one of the grader blades. The rockers on each side are connected by scissor arms, and a hydraulic ram connects with the scissor arms such that extension and retraction of the ram levers the blade vertically. Ball sockets are provided in the linkage between the rocker members and the outer members of the hinge assemblies to allow skewing of the frame.
Road material deflector plates are mounted on stringers pivotally connected to the blade assemblies. The deflector plates control the lateral dispersal of road surface material scraped up by the blades to better fill in depressions on the road surface.
OBJECTS OF THE INVENTION
The objects of the present invention are: to provide a drag-type road grader; to provide such a grader for roads comprising dirt, gravel and the like; to provide such a grader which is well adapted for working relatively damp roads; to provide such a grader with a plurality of transverse blades; to provide such a grader with a frame which may be skewed to angle the blades a desired amount relative to the direction of travel; to provide such a grader which includes a blade for compacting redistributed material; to provide such a grader which includes a hydraulic system for skewing its frame; to provide such a grader which includes retractable wheels for towing in a non-working mode; to provide such a grader wherein the blades are independently and vertically adjustable; to provide a mechanism for hydraulically adjusting the height of one of the blades; to provide such a grader which is efficient in operation, economical to manufacture, capable of a long operating life, and generally well adapted for the proposed usage thereof.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan of a road grader according to the present invention.
FIG. 2 is a top plan of the road grader in a first skewed configuration.
FIG. 3 is a top plan of the road grader in a second skewed configuration.
FIG. 4 is a side elevation of the road grader.
FIG. 5 is a vertical cross section of the road grader taken generally along line 5--5 in FIG. 1.
FIG. 6 is a vertical cross section of the road grader taken generally along line 6--6 in FIG. 4.
FIG. 7 is a vertical cross section of the road grader taken generally along line 7--7 in FIG. 1.
FIG. 8 is a fragmentary perspective of the road grader particularly showing a hinge assembly.
FIG. 9 is a fragmentary side elevation of the road grader particularly showing a transport wheel assembly.
FIG. 10 is a vertical cross section of the road grader taken generally along line 10--10 in FIG. 4.
FIG. 11 is a fragmentary, vertical cross section of the road grader particularly showing a compacting blade.
FIG. 12 is a fragmentary horizontal sectional view taken on line 12--12 of FIG. 5 and illustrates details of a hinge assembly.
FIG. 13 is a transverse sectional view of a modified road grader frame incorporating a hydraulic scissor lift mechanism for one of the grader blades.
FIG. 14 is a view similar to FIG. 13 at a reduced scale and illustrates the grader blade in a fully lowered position.
FIG. 15 is a view similar to FIG. 14 and illustrates the grader blade in a fully raised position.
FIG. 16 is a plan view taken on line 16--16 of FIG. 13 and illustrates details of the lift mechanism.
FIG. 17 is a fragmentary plan view of a grader frame and illustrates a mounting structure for road material deflector plates associated with the grader blades.
FIG. 18 is a fragmentary side elevational view of the deflector plates and mounting structure.
FIG. 19 is an enlarged side elevational view of one the deflector plates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Referring to the drawings in more detail, the reference numeral 1 generally designates a road grader embodying the present invention. The road grader 1 generally comprises a distortable frame 2, a pair of retractable transport wheel assemblies 3 and a tongue assembly 4. First, second, third and fourth blade assemblies 11, 12, 13 and 14 respectively extend transversely across the frame 2. The frame 2 includes a pair of longitudinal trusses 16 each having upper, lower and outer rails 17, 18 and 19 rigidly interconnected by chords 20. The outer rails 19 are spaced equidistantly from the upper and lower rails 17 and 18 and form triangular configurations therewith when viewed from the end.
A plurality of hinge and blade depth adjustment assemblies 25 are mounted on each truss above respective ends of the blade assemblies 11, 12, 13 and 14. Each hinge assembly 25 includes inner and outer angle members 26, 27 (FIG. 8). The outer angle members 27 are welded to respective upper and lower rails 17, 18 and chords 20 at the intersections thereof and include four receivers for blade assembly mounting bolts 28.
The inner angle member 26 of each hinge assembly 25 is welded to a respective upright hinge tube 29 with upper and lower ends 30, 31 protruding above and below respective upper and lower rails 17, 18. The inner angle member 26 includes a plurality of elongated slots 32 for receiving the bolts 28 whereby the angle members 26, 27 are vertically adjustably connected. A hinge pin 37 (FIG. 12) comprising, for example, a length of hollow pipe having an outside diameter slightly less than the inside diameter of the hinge tube 29 is inserted in the latter and rotatable with respect thereto about a vertical axis. Upper and lower collars 38, 39 are mounted on the hinge pin 37 at the upper and lower ends 30, and 31 respectively. The upper collars 38 of the four transversely aligned pairs of hinge assemblies 25 are interconnected by four tie rods 40.
Each blade assembly 11, 12, 13 and 14 includes a respective transverse torque tube 46 (FIG. 8) having a rectangular cross-sectional configuration. Each torque tube 46 is welded to a respective pair of lower collars 39. Blade mounting bars 47 (FIG. 11) are welded to the torque tubes 46 and include longitudinally spaced receivers for blade mounting bolts 49.
First, second, third and fourth blades 51, 52, 53 and 54 (FIG. 4) are bolted on the blade mounting bars 47 of respective blade assemblies 11-14. Each blade 51-54 includes a proximate leg 55 with longitudinally spaced receivers for the bolts 49 and a distal leg 56 forming an obtuse angle with respect to the proximate leg 55. Although the blade mounting bars 47 and the blades 51-54 are substantially identical, they are mounted on the blade assemblies 11-14 in different orientations for performing different functions. The first and second blades 51, 52 are oriented as shown in FIG. 1 for scraping with their distal legs 56 extending downwardly and rearwardly. The blade mounting bars 47 of the blade assemblies 11, 12 are welded on rear faces of respective torque tubes 46.
The blade mounting bar 47 of the third blade assembly 13 is welded on the front of the torque tube 46. The third blade 53 functions as a cutter and is bolted to the blade mounting bar 47 with its distal leg 56 extending forwardly, that is, in the direction of travel. The blade mounting bar 47 of the fourth blade assembly 14 is welded to a respective torque tube 46 along the bottom edge of its front face and slopes upwardly and forwardly therefrom forming an upwardly open acute angle with the front face of the torque tube 46. Spacers 57 (FIG. 11) are welded to the upper edge of the torque tube front face and to the blade mounting bar 47 of the fourth blade assembly 14. The fourth blade 54 is bolted to the blade mounting bar 47 with its proximate leg 55 sloping downwardly from front to back and its distal leg 56 substantially horizontal and positioned beneath the torque tube 46. The fourth blade 54 functions to compact and smooth the material scraped and cut by the preceeding blades 51, 52 and 53.
Associated tie rods 40 and torque tubes 46 are rigidly connected at their ends to respective hinge pins 37 by the collars 38, 39 whereby they are maintained in parallel, vertically spaced relationship. Associated tie rods 40, torque tubes 46, collars 38 and 39, and hinge pin pairs 37 thus interconnected form rectangular first, second, third and fourth subframes 61, 62, 63 and 64. The third subframe 63 includes diagonal braces 65 (FIG. 10) connected to the tie rod 40 and the torque tube 46 at locations spaced slightly inwardly from the hinge pins 37. The diagonal braces 65 function to maintain the subframes 61-64, and particularly the third subframe 63, in rectangular configurations and to resist racking and twisting forces acting on the frame 2 about its longitudinal axis.
The tongue assembly 4 includes a tongue 73 extending generally along the longitudinal axis of the grader 1 with front and back ends 74, 75. The tongue 73 comprises a rectangular tube 76 with a hitch clevis 77 on the tongue front end 74 for connection to a tractor or tow vehicle (not shown) and a tongue mounting clevis 78 mounted on the tube 76 at the tongue back end 75.
The tongue 73 is pivotally attached to a cross-bar 81 (FIG. 5) extending between the trusses 16 in front of the second subframe 62 by a tongue mounting bolt 82. The cross-bar 81 includes clevis ends 83 pivotally bolted to cross-bar mounting ears 84 extending forwardly from the hinge assemblies 25 at the second subframe 62. The cross-bar 81, in conjunction with the rectangular subframes 61-64, helps to maintain the trusses 16 in parallel, spaced relation.
A pivot bar 87 (FIG. 7) is attached to a hinge assembly 25 at the first subframe 61 and to the tongue tube 76 by ball and socket connections 88 at its opposite ends. The pivot bar 87 centers the tongue 73 within the first subframe 61 and aligns it with the grader longitudinal axis and direction of travel. The ball and socket connections 88 allow for limited movement of the pivot bar 87 from the horizontal so that the tongue 73 can float to a limited extent in a vertical plane. Such vertical tongue movement might result, for example, from relative dislocation between the grader 1 and a tow vehicle caused by changing road surface elevations. A tongue stop 89 extends upwardly from the torque tube 46 of the first blade assembly 11 and provides a lower limit to the vertical travel of the tongue 73.
A pair of linear motors comprising double-acting hydraulic power cylinders 91 are provided for skewing the frame 2. Each hydraulic cylinder 91 is pivotally connected to a cylinder mounting ear 92 on a respective side of the tongue tube 76 and to a cylinder mounting bar 93 extending forwardly from the cross-bar 81. Hydraulic lines 94 communicate the cylinders 91 with a source (not shown) of pressurized hydraulic fluid which may be located, for 14 example, on the tow vehicle.
Each transport wheel assembly 3 includes a pair of wheels 101 with tires 102 and wheel carriages 103 for extending and retracting the wheel carriages 103 between lowered and raised positions. Each wheel carriage 103 includes a pair of triangular wheel carriage subframes 104 comprising base, vertical and hypotenuse members 105, 106 and 107 (FIG. 9). A wheel carriage tube 111 (FIG. 1) interconnects the subframes 104 at the intersections of their base and vertical members and is rotatably received within a wheel carriage bushing 112 welded to a respective lower rail 18 and a chord 20. The wheel carriage bushing 112 connections with the truss 16 are reinforced with triangular gussets 113. The subframes 104 are interconnected at the intersections of their vertical and hypotenuse members 106, 107 by a cylinder mounting beam 114. At the intersections of their base and hypotenuse members 105 and 107, axles 115 are attached to the subframes 104 for mounting the wheels 101.
A pair of linear motors comprising double-acting hydraulic power cylinders 121 are provided for extending and retracting the wheel assemblies 3. Each cylinder 121 is pivotally connected at one end to a cylinder mounting ear 122 welded to a respective lower rail 18 and a chord 20. A cylinder rod 123 includes clevis end 126 which is pivotally connected to a tab 124 positioned in the cylinder mounting beam 114. Hydraulic lines 125 communicate the hydraulic cylinders 121 with the source of pressurized hydraulic fluid.
In operation, the road grader 1 may be transported to a work location by extending (lowering) the transport wheel assemblies 3. As shown in FIG. 4, the axles 115 of the transport wheels 101 are positioned forwardly of the transverse center line of the frame 2 so that the road grader 1 is tail-heavy in its transport position. The tongue 73 is attached to a tow vehicle and because the grader 1 is tail-heavy, the tongue 73 rests on the tongue stop 89.
The transport wheel assemblies 3 are retracted by extending the hydraulic cylinders 121 so that the wheels 101 are positioned above the level of the blades 51-54. The grader 1 is then skewed with the frame skewing cylinders 91. The hydraulic system causes one of the cylinders 91 to extend as the other retracts and vice versa so that the frame 2 is skewed to either of the configurations shown in FIGS. 2 and 3 whereby excess road material is strewn laterally to the left or right. Thus, the operator can selectively determine which side of the grader 1 is to receive the excess material therefrom.
The functions of the blades 51-54 may be altered by reversing their orientations. For example, the second blade 52 is shown in a scraper orientation. However, by reversing it so that its distal leg 56 extends in the direction of travel it will function as a cutter. The elongated slots 32 allow for adjusting the working depths of the blades 51-54. Vertical adjustments are accomplished by loosening the depth adjustment bolts 28, shifting the angle members 26, 27 vertically with respect to each other and retightening the bolts 28 with the blade properly repositioned. Such working depth adjustments may be required to compensate, for example, for differential wear in respective blades 51-54.
Referring to FIGS. 13-16, a hydraulic lift mechanism 200 for varying the vertical position of one of the blades of the grader 1 is illustrated. The lift mechanism 200 is particularly applicable to a cutter blade assembly 201 including a cutter blade 202, corresponding to the cutter blade assembly 13 and cutter blade 53 of the embodiment illustrated in FIGS. 1-12. The cutter blade assembly 201 includes a cross member or torque tube 203 which pivotally connects between the side trusses 204 and 205 of the grader frame 206. The cross member 203 has a pair of upstanding members or standards 207 which are sleeved within support tubes 208. The standards 207 are intended to be rotatable and slidable within the tubes 208 and include an upper collar 209 and a lower collar 210 to limit respectively the downward and upward movement of the standards 207 within the support tubes 208. The tubes 208 are attached to the trusses 204 and 205 as by welding to an inner angle 211 which is slidably attached to an outer angle 212 affixed to the side trusses.
The upper collars 209 have outwardly extending rocker mounting ears 215 on which rocker members 216 are pivotally mounted. Each rocker member 216 is formed of spaced apart parallel rocker components which act in unison The rocker members are "T" shaped and each includes an upper leg 217, a lower leg 218, and a side leg 219. A pair of anchor ears 222 extends outwardly from each of the support tubes 208. An anchor link 223 is pivotally connected between each set of side legs 219 and anchor ears 222. Because it is desired that the grader frame 206 be skewable to orient the grader blades diagonally, the joints between the anchor links 223 and the anchor ears 222 and side legs 219 are ball socket joints 224 (FIG. 16). This allows pivoting about horizontal axes for the lifting motion and about vertical axes for the skewing motion.
A pair of scissor arms 227 and 228 are pivotally connected between the left and right rocker members 216 in crossed fashion. That is, each scissor arm extends between the upper leg 217 of one rocker member and the lower leg 218 of the other rocker member. The pivot pins 229 which connect one of the scissor arms, for example, arm 227 to the rocker members 216 are longer than for the other arm 228 to provide sufficient clearance between the arms. A blade lift hydraulic ram 230 is pivotally connected between the scissor arms 227 and 228. When the ram 230 is extended (FIG. 14), the upper legs 217 are pivoted inwardly, thereby pivoting the side legs 219 upwardly. Because of the anchoring effect of the links 223 and the ears 222, this causes the blade assembly 201 to be lowered. When the ram 230 is retracted (FIG. 15), the blade assembly 201 is raised. The blade assembly 201 may also assume positions between the upper and lower extremes. Preferably, the supply and return of hydraulic fluid to the ram 230 is controlled by solenoid valves (not shown) to minimize the routing of hydraulic hoses (not shown). Depending on the dimensions of the angles 211 and 212, it might be necessary to form cutouts 231 therein to clear the scissor arms 227 and 228.
Referring to FIGS. 17-19, a deflector plate mounting structure 300 is illustrated. The structure 300 includes a plurality of stringers or plate mounting bars 301 pivotally connected to cross members or torque tubes 302 of a road grader frame 303 and a pair of deflector plates 304 associated with each blade 305 mounted on the cross members 302. The deflector plates 304 are provided to control the lateral dispersal of road material removed from a road surface. Each cross member 302 includes a pair of pivot posts 306 positioned outboard of the frame hinge posts 307 which correspond to the hinge assemblies 25 of the road grader 1. The stringers 301 are connected to the pivot posts by U-bolts 308.
In cases where it is desirable to provide a lift mechanism for varying the height of a blade 305, the stringers 301 may be separated for pivoting about the legs of the U-bolts 308, as is shown at the middle cross member 302 in FIGS. 17 and 18. The pivot posts 306 and U-bolts 308 allow the deflector plates 304 to maintain their relative positions with respect to the associated blades 305 when the
grader frame 303 is skewed to orient the blades 305 diagonally. The deflector plates 304 are preferably provided with slots 309 for adjustably attaching the plates to the stringers 301 by bolts 310.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
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A drag-type road grader including a skewable frame and a plurality of blade assemblies extending transversely across the frame. A tongue assembly is mounted on the frame and includes hydraulic cylinders for skewing the frame to alternative parallelogram-shaped configurations whereby the blade assemblies are angled with respect to the direction of travel. Retractible wheel assemblies are provided for transporting the grader in a non-working mode.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
a) Field of the Invention
This invention relates to a new or improved counterbalance system for use in overhead doors, to a drum for use therein, and to a door installation employing such system.
b) Description of the Prior Art
Over the years, numerous designs of counterbalance systems for upwardly opening or overhead doors have been devised, and examples are shown in various prior patents, such as U.S. Pat. No. 1,469,542 Storms, U.S. Pat. No. 1,603,379 Dautrick and U.S. Pat. No. 3,094,163 Herber, and more recently, an earlier design of my own shown in U.S. Pat. No. 4,887,658. The door opening arrangements disclosed in the foregoing patents make use of weights to provide the counterbalance force required during door opening. Door opening systems employing springs to provide the counterbalance force are well known, and are widely used, particularly in domestic garage doors.
Various forms of torsion or tension springs may be employed utilizing systems of cables and pulleys to transmit the spring force to the door. Spring operated counterbalance systems for doors tend to be troublesome to install, and while such systems are often not unduly expensive, they can be troublesome from the point of view of maintenance, and are subject to failure, for example through fracture of a spring or the like. Furthermore, with spring counterbalance systems it is difficult if not impossible to ensure that the spring force is accurately matched to the door load throughout the range of door opening movement.
SUMMARY OF THE INVENTION
The present invention provides a counterbalance system for an overhead door, such door being movable from a closed position wherein it is arranged in a generally vertical orientation closing a doorway and an open position wherein it is disposed above said doorway and at least partially horizontally oriented, guide means acting between the lateral edges of the door and the sides of the doorway to guide the door in its movement between open and closed positions, said counterbalance system comprising: a spool adapted to be rotatably mounted on a horizontal axis on the structure surrounding the doorway and cable means connected to said spool and said door such that rotation of said spool in a direction to wind the cable onto the spool applied through the cable a force urging the door to move in the opening direction, the weight of the door as it moves away from the closed position being supported initially by said cable and subsequently to an increasing extent by said guide means as the door moves towards the fully open position; a winding drum fixed to rotate with said spool; an elongate flexible load transmitting element connected to said drum to unwind therefrom as said spool rotates to wind the cable thereon, and vice versa; said force-transmitting element freely suspending a counterweight such that the mass thereof provides a torque acting on said drum said spool and said cable to urge said door in the opening direction; and means for varying said torque in accordance with the rotational position of said drum and said spool, such that the opening force applied to said door diminishes in relation to the proportion of the weight of the door that is supported by said cable means.
The torque varying means preferably comprises a U-shaped channel of conico-spiral configuration to receive a force transmitting element in the form of a second cable which supports a counterweight that is raised or lowered as the drum is rotated in one direction or the other. In an alternative configuration the force transmitting element is in the form of a thick cable or belt that is wound on the drum in a single coil such that the radius at which the cable or belt winds onto the drum varies continuously as the drum rotates, and the torque applied to the drum therefore varies as a function of the thickness of the cable or belt and the length of it that is coiled onto the drum.
The spool and the drum may be separate elements each attached to a shaft that is mounted to rotate at the top of the doorway, a drum and a spool being positioned in proximity to each edge of the doorway. The force transmitting element may be a second cable that either supports the counterweight directly, or which is formed in a loop having one end anchored to the door frame, the counterweight being carried by a pulley that is supported in the loop.
Preferred embodiments of the invention as disclosed herein provide a door counterbalance system that is particularly easy to install, and that also affords a ready means of adjustment upon installation to achieve accurate counterbalancing. The disclosed counterbalance system is relatively cheap, and is safe and highly reliable in operation. The basic counterbalance system is readily adaptable to accommodate various types of overhead doors whether they be standard lift, high lift, or even vertical lift.
From another aspect the invention provides for use in a counterbalance system for a vertically movable door, a drum comprising a hub defining therein an axle bore extending from end-to-end of the drum, said drum having an outer periphery configured with a continuous groove extending generally helically thereon and progressing from one end of the drum to the other, the drum defining in the axial direction a first region wherein said groove defines a plurality of turns about the axis at a constant radius; a second region wherein the radius of said groove from said axis increases progressively from said constant radius to a maximum radius that is of the order of at least twice said constant radius, said groove continuing at said maximum radius through a plurality of turns about said axis.
Preferably there are three turns of the groove at said minimum (constant) diameter, and five or six turns at said maximum diameter. The drum is suitable for use with standard lift doors using the groove essentially only up to the end of the intermediate section. For high lift doors, a length of the groove at said maximum diameter is used, this length corresponding to the vertical lift section of the door opening movement. For purely vertical lift doors, only the maximum diameter region of the groove is used.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will further be described, by way of example only, with reference to the accompanying drawings wherein:
FIG. 1 is an overall perspective view from the inside of a building showing a preferred embodiment of an overhead door counterbalance system in accordance with the invention;
FIG. 2 is an elevational view of the door and counterbalance system with parts omitted for reasons of clarity, the door being shown in different positions in the left and right hand side of the figure;
FIG. 3 is an elevational view to a larger scale showing an important part of the counterbalance system;
FIG. 4 is a fragmentary view taken in the direction indicated by the arrows IV--IV in FIG. 3; and
FIG. 5 is a side elevational view of the door counterbalance system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, an overhead garage door 11 is formed by a series of horizontally divided sections 12 pivotally interconnected by hinges 13. At each edge of the door the hinges carry a laterally projecting hinge pin 13a which in known manner supports a roller or the like (not shown) received within a track structure 14 mounted in the door frame 15 at each side of the doorway and adapted to guide movement of the door sections during opening and closing. As shown, the tracks 14 are vertically arranged and extend at their upper ends through a curved intermediate section 14a into a generally horizontal top section 14b that projects away from the doorway, the top sections being supported by any suitable means, e.g. hangers attached to a ceiling (not shown). The upper edge of the top door section and the lower edge of the bottom door section likewise carry laterally projecting pins 13b carrying guide means such as rollers 8 (see FIG. 3) which cooperate with the track 14.
Extending horizontally above the doorway is a shaft 16 rotatably carried in a central bearing 17 and in two lateral bearings 18 (see FIG. 3) adjacent opposite side edges of the door.
Close to each end of the shaft 16 and fixed to rotate with it is a flanged cylindrical spool 19 positioned substantially in alignment with the lateral edge of the door. A cable 20 is wound on this spool and extends vertically downwards being attached at its end to a bracket 21 at the lower corner of the bottom door section. On the opposite side of the bearing 18 the shaft 16 carries a drum assembly 22 which is best seen in FIGS. 3 and 4. The drum 22 has an axial bore 23 extending therethrough between a flange 24 at one end and a collar 25 at the other. A clamping screw 26 is threaded in a radial through bore 27 in the collar 26 and can be tightened to engage its tip 28 against the surface of the shaft thereby fixing the drum 22 to rotate with the shaft. Between the flange 24 and the collar 25, the drum is of generally frusto-conical outline defined by a continuous groove 29 that extends in a spiral/helical manner from a small diameter end adjacent the flange 24 to a larger diameter end adjacent the collar 25. The radius of the groove 29 from the axis of the shaft 26 is at a maximum adjacent the collar 25, and remains constant for about 5 or 6 turns as indicated by the region 30. Adjacent the flange 24 there is a region of minimum diameter 31 extending for about 3 turns, and between these two regions is an intermediate region 32 wherein the radius of the groove changes in a continuous manner.
A cable 35 is wound onto the drum in the groove 29, one end of the cable being attached to the flange 24 by means of a grub screw 36, the cable then being laid into the groove 29 to an extent corresponding to the rotational position of the drum 22. From the drum the cable 35 descends in a loop 37 and has its opposite end 38 attached to a bracket 39 mounted on the door frame 15. An elongate counterweight 40 has a clevis 41 attached to its upper end and providing a bearing for a grooved pulley wheel 42 which runs on the cable loop 37.
Four radially extending cylindrical sockets 33 are provided spaced at 90° intervals around the periphery of the collar 25.
As shown particularly in FIGS. 1 and 4, a tubular guide housing 44 is vertically arranged adjacent each edge of the door frame 15 and is attached thereto e.g. by wood screws 45. The housings 44 guide the counterweights 40 for vertical movement therein. In addition, the housings 44 provide protection for the counterweights to ensure that their movement is unimpeded, and protect the users from inadvertent contact with the counterweights.
As will be appreciated from the foregoing description, as the door 11 is moved from its closed position shown in FIG. 1 shown in the left hand side of FIG. 2, to its opened position as shown in the right hand side of FIG. 2, the door sections 12 guided by their pin mounted rollers 8 in the tracks 14, moves successively from the vertical position, around the curved track sections 14, into a substantially horizontal position wherein they are supported by the top portions 14b of the guides. During this movement the weight of the door 11 is substantially counterbalanced by the counterweights 40 so that the effort required to move the door from its closed to its opened position is minimal. Furthermore, this effort does not vary substantially throughout the range of opening movement of the door. This effect is achieved by careful selection of the configuration of the drums 22 and the mass of the counterweights 40 in relation to the weight of the door and the diameter of the spools 19. Thus, for example, 10 for a door 11 having a weight of say 200 pounds, each counterweight system must provide a counterbalance force of up to 100 pounds, and this force must diminish in proportion to the increasing proportion of the weight of the door that is supported by the horizontal top sections 14b of the track.
When the door is in the closed position as shown in the left hand side of FIG. 2, the cable 35 is wound onto the drum 22 as far as the maximum diameter region 30 of the groove 29. At this location, the lifting force applied to the cable 20 as a result of the mass of the counterweight 40 will be a function of the ratio of the spool diameter 19 to the diameter of the region 30 of the drum groove. As shown, this ratio is approximately 2:1, and therefore two counterweights 40 of mass 100 pounds each will provide sufficient force to counterbalance the full weight of the door.
As the door is opened, the cable 35 unwinds from the drum groove 29 at a progressively decreasing radius, and therefore the torque applied to the shaft 16 also progressively decreases until the minimum-radius groove region 31 is reached, at which location the cable leaves the drum at a radius very much less than the radius of the spool 19, so that the torque applied to the shaft 16 is correspondingly reduced as the door approaches its fully opened position and substantially its entire weight is supported by the top track portions 14b.
Adjustment of the counterbalance force can be effected quite easily if it is necessary to make slight changes to more closely match this force to the manner in which the effective weight of the door is reduced during opening. To do so, when the door is in the fully closed position, a torque bar or the like implement (not shown) can be inserted into one of the sockets 33 in the drum collar 25 and used as a torque arm to support the drum 22 against rotation under the force of the counterweight, whereupon the screw 26 can be slackened, freeing the drum relative to the shaft. The drum can therefore be rotated under control of the torque bar to vary the extent to which the cable 35 is unwound from the drum, and thus vary the torque applied to the shaft 16 through the counterweight, with the door 11 in its fully closed position. When the desired position of angular adjustment of the drum 22 has been reached, the screw 26 is re-tightened to once again clamp the drum to the shaft.
Likewise, upon installation of the counterbalance system, the counterweight 40 may simply be placed in position as shown at the right hand side of FIG. 2 and supported on a block or the like. With the shaft 16 and its spools 19 and drums 22 mounted as shown, the cable 35 can be attached to the flange 24 and wound around one or two turns of the drum, thereafter being passed downwardly around the pulley 42 and looped back to the mounting bracket 39. With the clamping screw 26 slackened, the torque bar can thus be used to rotate the drum 22 winding the cable onto it and thereby raising the counterweight 40. When the counterweight has been raised to the desired position, the screw 26 is tightened to clamp the drum to the shaft.
The counterbalance system can readily be adapted for use with what are referred to as "high lift" doors, i.e. doors which upon opening initially travel vertically for a substantial distance before the door sections start to turn into the horizontal position. In such applications a track such as that shown in broken lines at 14' (FIG. 5) is utilized. It will be seen that as compared with the earlier described embodiment, in this configuration the door must be raised vertically by a distance D before the door sections start to swing out of the vertical position. This is readily accommodated by the counterbalance system shown since all that is necessary is to wind the cable 35 around the maximum diameter region of the groove 29 over a length corresponding to D. When the system is thus configured, it will be appreciated that, moving from the closed position, over the initial opening distance D. the torque applied to the drum 23 to the cable 35 will be constant, as also will be the counterbalance force applied to the door through the cables 22. This is necessary since during the initial distance D from the closed position, the entire weight of the door is supported by the cables 20.
It will be seen that with the cable 35 forming a loop 37 as shown in FIG. 4, the vertical movement of the counterweight 40 will equal approximately 1/2 of the length of cable unwound from the drum. It would be possible to dispense with the loop 37 and suspend the counterweight 40 directly on the cable 35. In this arrangement the full mass of the counterweight would be applied to the cable 35, but of course the vertical movement of the counterweight would correspond exactly in length to the length of cable unwound, and during unwinding, the counterweight would be subjected to greater lateral movement. The effect of lateral movement would however be rather minimal and could easily be absorbed by the guide housing 44. The guide housing could conveniently be made of a plastic tubing, e.g. of PDC, so that minimal frictional forces would be encountered.
As compared to the arrangement shown, the arrangement discussed whereby the counterweight 40 is attached directly to the cable 35 would enable one to use a counterweight that is half the mass of the counterweight 40, or alternatively would enable one to use a drum having a maximum diameter of the groove 29 approximately 1/2 of the diameter shown in FIG. 3.
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An overhead door system employs counterweights which operate through cables connected to a drum which tapers from one end to the other so that the effective force acting on the door in the opening direction is reduced as the proportion of the weight of the door to be supported reduces. The system is adjustable readily to accommodate different types of doors having different opening characteristics in terms of the proportion of the doors weight that must be counterbalanced at different stages of the door opening movement.
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BACKGROUND OF THE INVENTION
1) Field of the Invention
The field of this invention relates generally to resurfacing methods and more particularly to a new and improved method of recycling an asphalt surface such as a roadway or pavement.
2) Description of the Prior Art
Asphalt is widely used in the construction of highways and parking areas where large areas need to be covered with a relatively hard, flat, weather-resistant surface suitable for vehicular travel. With prolonged usage these asphalt surfaces develop cracks which permit the seepage of water therethrough to undermine the sand and rock subbase. Asphalt pavement includes a light oil that functions as a binder with the aggregate contained within the asphalt. The sun, as well as the amount of vehicular travel, causes this light oil to vaporize thereby causing the asphalt roadway to deteriorate. This deterioration of the asphalt surface necessitates reconditioning of that surface.
In the past it has been a common practice to recondition a worn asphalt surface by a hot application of a new mat of asphaltic material over the existing surface to form a new flat surface. This application of new material raises the general level of the asphalt surface by 1 inch to 11/2 inches. The problem with such an application of new material is that after a few years, and the surface has been reconditioned four or five times, the new surface is 5 inches to 9 inches higher than the old original surface. This raised surface level can be an especially serious problem, especially now where the roadway is at a higher level than the adjoining gutters or sidewalks. Each time a roadway is resurfaced by using overlay procedures reduces overhead room of underpasses. Where overlaying is done across bridges, each overlay applied to the bridge adds to the dead weight that the bridges must carry thereby diminishing the amount of vehicular weight that the bridge is able to carry with safety.
A more recent practice has been to recondition old asphalt surfaces by breaking up of the existing asphalt aggregate material, picking up the material for reconditioning, heating and then reapplying the heated reconditioned material as a new surface. The pavement is heated, scarified to a certain depth by a scarifying tool producing loose aggregate material. This loose aggregate material is then picked up, placed within a mixing vat where it is pulverized, combined with a light oil and then reapplied to the asphalt material.
This past method of recycling of the old asphalt has a disadvantage that it requires picking up of the old asphalt, moving it to a mixing location and then bringing it back and reapplying it to the roadway. It would substantially diminish the cost of resurfacing an asphalt roadway or pavement if this recycling procedure did not require the physical picking up of the loose aggregate material and transporting such to a mixer and then retransporting it back to be applied to the asphalt surface.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to resurface a deteriorated asphalt surface (roadway or pavement) by utilizing the existing material of the surface and accomplishing the resurfacing directly on the surface, eliminating the need for transporting of the material of the surface during the regeneration process.
Another objective of the present invention is to utilize an asphaltic pavement resurfacing process which can be accomplished at a substantially lower cost than previously known for resurfacing processes.
Another objective of the present invention is to provide a surface asphalt recycling process which maintains the established surface configuration such as the common slightly domed configuration for water drainage.
The method of resurfacing an asphalt surface of the present invention utilizes applying sufficient heat to a section of asphalt surface to raise the temperature of the surface to between 220° F. and 375° F. This section of the surface is then scarified to an depth of about 1 inch to 11/2 inches producing a layer of loose aggregate material. A small amount, generally within the range of 10% to 30% by weight of the loose aggregate material, of additional virgin asphalt is applied. To this section of the surface there is now applied a quantity of light oil which has been heated to about 240° F. The amount of light oil that is applied is to be within the range of 0.09 gallons per square yard of surface to 0.12 gallons per square yard. The loose aggregate material, oil and virgin asphalt are thoroughly and evenly mixed, screeded and then rolled achieving compaction and cementing.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 to 9 generally depict the sequence of operations of the method of the present invention that are required to resurface a section of asphalt surface with little or no consideration being given to the actual apparatus that would be employed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIG. 1 there is shown a deteriorated section of asphalt surface 10 which includes a plurality of cracks 12. A heater 14 is placed over the section of the pavement 10 with generally the size of the heater 14 being fourteen feet by eighteen feet. Propane gas is to be emitted and ignited within the heater 14 producing an exceedingly high heat environment. This heater 14 is slowly moved across the surface 10 and, after the heater has passed, the section of the surface directly behind the heater 14 will be within the range of 240° F. to 375° F. The now heated surface 10 has a scarifier 16 conducted thereover. The scarifier 16 includes a plurality of sharp rakes 18 each of which is independently mounted on the scarifier 16. This independent mounting will permit the rakes 18 to pass over any kind of solid object such as a manhole. The rakes 18 will dig into the surface 10 to the depth of about 1 to 11/2 inches with this depth being selectable. The result is the upper surface of the surface 10 is formed into a layer of loose aggregate 20.
Referring now to FIG. 3, a hopper 22 is passed over the surface 10 with a quantity of virgin asphalt 24 being contained within the hopper 22. This virgin asphalt 24 is dispensed from the hopper 22 by means of an auger producing a windrow 26 of new virgin asphalt on the surface 10. The virgin asphalt 24 will be heated generally in the range of 220° F. to 240° F.
Referring particularly to FIG. 4 the section of surface 10 which has the loose aggregate 20 and the windrow 26 has conducted thereover a pipe 28 from which extends a plurality of spray nozzles 30. The pipe 28 connects to reservoir 32. Contained within the reservoir 32 is a quantity of an oil 31. This oil 31 is petroleum based and it is what is frequently termed a "light oil". The specification for this light oil 31 is referred to as a RA-5, light grade. This oil 31 is made up of alphaltenes and malthenes. In such an oil the greater the alphaltenes the more viscous the oil and logically the less the alphaltenes, the less viscous or lighter the oil. The oil 31 that is used in conjunction with this invention contains about 1% to 4% of alphaltenes with malthenes being in the range of 96% to 99%. During service of a roadway or pavement, the alphaltenes increase in proportion because the malthenes eventually vaporize. This results in the asphalt pavement becoming progressively harder and more brittle producing the cracks which are referred to as deterioration of the surface. Putting back into the loose aggregate material 20 this light oil causes the asphalt loose aggregate material 20 to be as good as new.
Referring particularly to FIG. 5, a roller 34 is conducted over the surface section 10 of the surface. This roller 34 includes a mass of cutting blades 35. These cutting blades 35 more finely pulverize the loose aggregate material 20 and windrow 26 that contains oil 31 and distribute the virgin material of windrow 26 across the width of the pavement section 10.
Referring particularly to FIG. 6, conducted across the section 10 are a pair of curved blades 36 which pick up the loose aggregate material 20/31/26, mixing such and dispensing of the loose aggregate material 20/31/26 onto a V-shaped section of another pair of curved blades 38. The loose aggregate material 20/31/26 is continuing to be mixed when conducting past the blades 38 and then is deposited in conjunction with a split auger 40. It is the function of the auger 40 to evenly distribute the loose aggregate material 20 that has now been combined with the virgin asphalt material 26 and the oil 31.
Referring now to FIG. 7 a screed 42 is passed over the section 10 producing a smooth level surface of the loose aggregate material 20/31/26. Conducted across this smooth level surface of the section 10 is a compacting roller 44 which is shown in FIG. 8. Actual compaction will occur by generally at least two different types of compaction roller vehicles that are driven across the section 10. After compaction by the roller 44, there is produced the resurfaced asphalt surface within the section 10 shown in FIG. 9.
The equipment used for the heater 14 is designed to comply with the requirements of the local Bureau of Air Pollution Control where the heater 14 is being used. The heater 14 shall have a minimum rating of 15 million BTUs output per hour. The heater 14, although designed to use propane, is also capable of using butane. The combustion chambers shall be insulated and totally enclosed to provide sufficient heat to the pavement 10 in order to sufficiently raise the temperature of the section 10 of the surface. Scarifier 16 may also include a mechanically driven milling drum utilizing carbide cutting bits similar to the roller 34. The width of the scarified pavement shall not be greater than the width of the heater 14. The milling drums that are used, such as roller 34, are normally hydraulically controlled to vary the depth of cut within section 10.
The section 10 shall have a laboratory analysis performed to determine the amount of oil 31 that is to be applied. If the section 10 has only slightly deteriorated, then generally an amount of about 0.09 gallons per square yard of oil will be applied. If the pavement 10 is exceedingly brittle and well deteriorated, approximately 0.12 gallons per square yard of oil will be applied. This is assuming the preselected depth for scarifying of the surface is about one inch. If the preselected depth is increased to about 11/2 inches, an appropriate proportional increase in the amount of oil is to be applied.
Generally for the roller 44 there will be utilized two different roller devices with one being a double drummed steel roller and the other being a pneumatic tire roller. Each of these rollers should be at least twelve tons in weight. The compaction temperature with the rollers 44 shall be at least 220° F.
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The method of resurfacing an asphalt surface which comprisies heating of the surface, scarifying the surface creating a layer of loose aggregate material, adding an amount of additional virgin asphalt in the amount of 10% to 30% by weight of the loose aggregate material, evenly applying a quantity of heated light oil to the loose aggregate material, thoroughly mixing of the loose aggregate material and the oil, screeding the loose aggregate material forming a level surface and then rolling the level surface achieving compaction plus cementing of the loose aggregate material.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation in-part of U.S. patent application Ser. No. 06/712,158, entitled MINE TRUSS STRUCTURES AND METHOD, filed Mar. 15, 1985, now abandoned without prejudice.
FIELD OF INVENTION
This invention pertains to mines, tunnels, and the like, more particularly, relates to (1) the general concept and method of trussing mine floors and (2) the advantageous utilitarian design of truss structures that are useful both in floor and ceiling truss systems.
DESCRIPTION OF PRIOR ART
No prior art is currently known which addresses the problem of eliminating, by use of an active tensile system, tendencies of floor heave in mines, tunnels, and allied constructions; however, there do exist prior art passive support structures that drastically reduce the opening size of the tunnel or mine portion involved. These latter structures take the form of timber cribs, jacks, and so forth.
As to structures to facilitate maintenance of mine floor integrity, the present invention provides uniquely designed brackets, channels, and composite structures for maintaining the same. As to both channels and brackets utilized in connection with anchoring bolts, each will include an angulated bearing surface employed as a reaction surface for the nuts threaded onto anchoring bolts such as roof bolts. Accommodating apertures are provided for appropriate passage of roof- or anchor-bolts and tie rods where utilized. Certain of the structures used for compression stressing floors can also be employed in connection with mine roofs, as between adjacent pillars, for example.
There has been prior art addressed as to mine roofs. Essentially different problems are encountered as to the roofs relative to the floors as is hereinafter pointed out. In any event, the prior art as to the truss structures for roofs include the so-called Birmingham truss as is illustrated in an initial patent to White, U.S. Pat. No. 3,505,824, which was a continuation of U.S. Pat. No. 3,427,811. Another popular design for ceiling truss structures only is manufactured by the Jennmar Corporation known as the "Bethlehem" design for trusses, U.S. Pat. No. 4,395,161.
A further discussion and evaluation of various types of roof trusses is found in a document entitled "The Evaluation of Roof Trusses--Phase I" prepared for the U.S. Dept. of the Interior, Bureau of Mines, by the Dept. of Civil Engineering, University of Pittsburgh, Summary Report dated Feb. 28, 1979. The above patents and article are fully incorporated therein by way of reference.
In connection with the structures shown in U.S. Pat. No. 4,395,161, there is a basic problem of critical spacing of the primary devices and that the structures will not accommodate situations where the roof bolts may be closely spaced or disposed rather far apart. In the applicant's invention, in contrast, the use of the threaded tie rods and the access areas of the brackets permit an indefinite extension of the tie rods, depending upon their length, through the brackets where the brackets are rather closely spaced together. Also, there is no interference as between the tie rods and the roof bolts or other structure in the applicant's invention, as contrasted with U.S. Pat. No. 4,395,161.
As to the Birmingham truss structure, the rods utilized have to be bent during the process of installation, that is, going from the angulated position of the roof anchor hole to the horizontal position intended for the truss. Furthermore, turnbuckles, and complicated block arrangements are needed to complete the installation in U.S. Pat. No. 3,505,824. The structure has proven quite time-consuming for mine installations; likewise, frequently there is complaint by mine personnel as to the requirement of in situ bending during the installation process. Similar objections can be raised in connection with other types of trusses as currently known.
BRIEF DESCRIPTION OF INVENTION
It is imperative to note that the present invention deals with an active system for, e.g., pre-stressing the mine floor to prevent floor heave. This is to be contrasted with passive systems where the cribs or other supports are installed, where the earth is not pre-stressed thereby, but rather that should a cave-in or a heave commence, the cribbing system, for example, will tend to prevent this. The present invention in contrast is not passive but active, imposing the state of pre-stressing at the outset. This likewise applies to roof truss installations.
While the present invention may not in all context totally eliminate all cribbing in all mines, yet crib structures can be reduced to a bare minimum and thus will maintain the integrity of the cross-sectional open area of the mine and its components for desired usage.
According to the present invention, the concept of trussing a mine floor is considered unique; in one form of the invention horizontal tie rods or equivalent and/or advantageous brackets for the purpose of trussing is central and is believed unknown in the prior art. Accordingly, multi-timber cribs, jacks, and so forth, can be substantially eliminated, thus reducing frictional forces as to air passage and also utilizing a maximum opening for the use of personnel, expulsion of ore, and so forth.
A particularly useful object in practice of the invention, and which can be used for floor and roof truss structures, is a unique bracket that simply requires threaded nuts used for the tensioning of bolts and tie rods utilized. Accommodation apertures are provided in the bearing plate structure of each truss bracket. Appropriate reaction surfaces are provided for the nuts required and utilized to tension the tie rods and also the anchor bolts. A preferred type of truss bracket is designed to substantially reduce, if not eliminate, force couples and also, by the design thereof, to insure maximum stability and integrity through anticipated loadings of the truss bracket by tension-type tie rods to be connected thereto.
In other preferred forms of the invention, relative to the mine floor, there are provided composite rod and wire mesh structures that complement the truss structures to give further strength in maintaining floor integrity, preserving mine opening, and precluding tendencies of floor heave.
OBJECTS
Accordingly, a principal object of the present invention is to provide a method and also an active system or apparatus for trussing mine floors to preserve floor integrity and deter floor heave.
A further object is to provide suitable structure integral with and also operationally associated with trusses suitable for trussing mine and tunnel floors.
A further object is to provide a new and improved bracket and channel structures for use in trusses for both floors and roofs of mines, tunnels, and the like.
An additional object is to provide structure that can be easily and quickly handled, in a most convenient manner, to erect active system trusses in mines, tunnels, and the like.
An additional object is to provide a new and improved truss bracket capable of withstanding substantial loadings as are or may be present at installation.
BRIEF DESCRIPTION OF DRAWINGS
The present invention may best be understood by reference to the following description, taken in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of a mine truss forming a part of the present invention.
FIG. 2 is a fragmentary, enlarged, side-elevation of a representative side, in this instance the right-hand side of the mine truss of FIG. 1.
FIG. 3 is a top plan of the structure of FIG. 2, the tie rod means shown in FIG. 2 being deleted for purposes of clarity.
FIG. 4 is a bottom plan of the truss bracket of FIGS. 2 and 3.
FIG. 5 is an end view section of a mine showing the representative mine trusses of FIGS. 1-4 as being installed as a roof truss, and also when elongated, as a floor truss.
FIG. 5A is an end view in section of a mine opening, without any mine truss structures, but illustrating the essentially parabolic tensile stressed area above the mine roof line and also a compression zone in the strata immediately beneath the floor line of the mine.
FIG. 6 is an enlarged fragmentary detail, shown principally in section and taken along the line 6--6, illustrating the configurement wherein a wire mesh and also abutment plates for additional rock anchors are included to further deter or eliminate tendencies of the floor of the mine to heave.
FIG. 7 is a top plan in fragmentary view of the structure of FIG. 6.
FIG. 8 is similar to FIG. 5 but illustrates as to the reinforcing structure for the mine floor an optional embodiment of the invention wherein cross channels are used, each of the channels being provided with suitable means for facilitating bolt anchor attachment; this figure also illustrates additional vertical structure for anchoring the channels, and any mesh or rods disposed underneath, directly against the floor of the mine, as for example, between its pillars.
FIG. 9 is an enlarged fragmentary detail, princiapply in section and taken along the line 9--9 in FIG. 8, illustrating the method of attachment of the anchor shanks or bolts used to secure the structure to the rock formation below, the reaction structure primarily being indicated in section.
FIG. 10 is a plan view illustrating a succession of trusses being installed, whether of channel form as in FIG. 8 or as in the tie rod form of FIG. 5; in either event, the wire mesh if used may include rods that can be mounted to the individual channels as the case may be and fasten the entire structure together so that the same will bear directly against the mine floor.
FIG. 11 is a side elevation of a preferred form of one type of truss bracket, the same being shown as installed and accommodating rod means to be disposed intention.
FIG. 12 is a bottom plan of a structure seen in FIG. 11 and is partially cut away in section for convenience of illustration.
FIG. 13 is a front elevation of the structure in FIG. 12, being taken along the line 13--13 in FIG. 12, and also illustrates that the central triangular portion may be solid when so desired.
FIG. 14 is an end elevation taken along the line 14--14 in FIG. 12, and is partially broken away to indicate the solid nature, in one form of the invention, of the triangular portion of the truss bracket; a similar structural condition is also seen in FIG. 13.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 1-4 truss assembly 10 is shown to include a pair of oppositely-facing truss brackets 11 which are secured in place by anchor bolts, i.e., roof bolts or floor bolts 12, and between which are disposed the spanning tie rods 13. Each of the truss brackets 11 includes a truss bearing plate 14 which is essentially horizontal in disposition, enlarged for support beyond plates 15, 16, and which is thus provided with a vertical, depending tie rod reaction plate 15 and an angulated anchor bolt bearing plate or member 16 having an exterior hypotenuse surface. The bearing plate 16 forms the hypotenuse of the triangular form of the truss, the smaller included angles approximately 45°. The permissible range of the orientation of plate 16 relative to the other plates, for 45°-installed anchor bolts, will be between 40° and 50°. This is for the purpose of effecting a correct truss relationship for proper retentive holding of the anchor bolt 12, at 90° with respect to plate 16, when tightened by its respective nut 17. The plates will be spec-welded together for maximum strength; similarly, the material size or gauge of the plate will be chosen to provide the strength necessary, depending upon the installation in which the trusses are employed. The two trusses 11 are identical in construction, one being simply rotated 180° about its vertical axis so as to provide for the assembly 10 as indicated.
The rods 31, oppositely offset relative to anchor bolt orientation, may be any number but in the construction shown are two in number, and these simply comprise wholly or partially threaded rods such as the DYWIDAG thread bars as manufactured, by way of example, by the DWIDAG Systems International, USA, Inc. It must be understood, however, that other types of rods can be employed, so long as partial or whole threads are utilized for coaction with tightening nuts 19 that are threaded onto the rod ends.
Rather than welding, the wedge-shaped truss brackets can be manufactured as castings or forgings. However, it is believed that, for purposes of desired strength, a welded construction for the truss brackets hereinabove described will be preferable.
In installation and operation, the anchor bolts 12 will be installed with suitable resin or other types of anchorage into the pre-drilled roof or floor bolt bores or holes 11A. There are various ways of anchoring anchor bolts such as roof bolts, as is well known in the art. For example, quick setting resin constructions, multi-time resin constructions, wedge-joints or expansion joints can be employed such that, in any event, at least the outer extremities of the anchor bolts are firmly secured in the pre-drilled strata. Subsequent to this, the truss is made up by the truss brackets being installed over the roof bolts in the manner shown and the roof bolt nuts 17 being tightened to bear against the respective nut bearing surfaces 16A. Appropriate tension is thus supplied to the respective, e.g., roof bolts.
In mine roof installations, for example, it should be mentioned at this juncture that in standard practice in the installation of roof bolts in mines, the essential 45° criterion is used. However, in those instances where one needs a greater vertical-force component relative to roof bolt tension such as, for example, where the angulation for the e.g. roof bolt relative to the horizontal is or approaches 60°, then the plate 16 can be reoriented such that the bearing surface thereof relative to the roof bolt nut will be at a 90° relationship relative to the axis of the new orientation of the roof bolt. In this event, angle A will be approximately 30°. Again, however, this is an unusual practice since for the 60° roof bolt orientation, the bolt would have to be of sufficient length such that its anchorage will appear over the compression zone immediately above the pillar area of the mine being trussed. Such then elongation of the roof bolt is not necessary where the 45° orientation is used.
To accommodate the placement of the tie rods and anchor bolts various oversized apertures will be employed such as apertures 20 and 21 relative to the tie rods and elongated aperture 22 relative to plate 14. As to a respective anchor bolt 12 itself, aperture 23 is provided as a passageway and serves in combination with aperture 22 to accommodate roof or anchor bolt placement, the surface 23A being a bearing surface for the nut 17 that tightens the anchor bolt in place.
Finally, securement apertures 24 and 25 accommodate the tie rods utilized. It should be noted that, depending upon anticipated mine conditions, the various apertures may be designed to accommodate any anticipated offset relative to adjacent portions of the roof of the mine along a horizontal roof plane. Accordingly, if there is any angulation present because of essential displacement of the roof surface at the opposite bracket locations and, considering the thickness of bracket material, then the apertures at 23, 24 and 25 may be made oversized to accommodate ease of assembly. It should be observed that the tightening function of the nuts relative to the roof bolts and the tie rods can be made in accordance with the particular roof orientation encountered.
At this juncture, it is important to observe that the naturally occuring stress distribution pattern of a mine roof is different from that experienced as to a mine floor. See FIG. 5A.
Without the installation of a truss, and considering a roof area between two adjacent mine pillars, it will be noted that there is a tensile area or tension force distribution pattern which resembles somewhat a parabola PA with the covex area thereof pointing upwardly. That is to say, there are forces of tension in the rock strata which progressively increase as the center of the roof between the mine pillars is approached. What is needed, and what has been pointed out extensively in the literature, is the fact that, to avoid other types of constructions such as the wood crib construction, the prior literature has concentrated on other types of trusses so as, by the use of mine bolts and a horizontal truss structure underneath the roof, to place the strata above the roof line at the tensile stress zone in compression. Additionally, the roof bolts will be anchored in areas in compressed areas above the rib-line R1 of ribs R of the mine pillars. The rock in compression immediately above the roof line and interior of the truss span, in being in compression, is held so that there will be precluded any roof drop-out at trussed areas.
The situation as to the mine floor is quite different. The mine floor strata condition, as contrasted with the roof and its naturally occurring tensile zone, is different in that floor does not have a natural tensile zone. Rather, the floor is basically all in minor compression, owing largely to downward pillar thrust. The action of a truss structure, now newly proposed, on the floor of a mine entry, for example, would be to pre-load the floor zone and increase the compressive forces, particularly horizontal compressive forces, if present, which may already exist in the floor zone thus to tend to deter upward floor heave. These adjacent pillar zones cause naturally occurring compressive forces to act downwardly and, because of the horizontal nature of the floor strata, these forces thrust elemental floor volumes inwardly in compression and toward the central portion of the mine entry floor. Such a condition is particularly aggravated when a weak clay stone or other rock type occurs within approximately 5 to 10 feet of the floor line. In such cases the vertical compressive forces from the pillars are translated to horizontal forces along these weak strata, causing floor rupture and heave.
Where a truss structure is to be employed for precluding floor heave, then the truss brackets will be made of appreciably heavier material; likewise, the tie rods and anchor bolts used will be of substantially heavier material.
FIG. 5 illustrates employment of the present invention's truss assembly in a floor installation as well as in roof installation, but with the brackets spread apart a greater distance so as to place as much of the floor in increased compression as possible. Thus, truss assembly 10 includes depending anchor bolts which are each angulated outwardly, generally in 45° relationship relative to the vertical and are being tensioned by respective nuts 17 bearing upon bracket plate 16 of respective truss bracket 11. The anchor ends of the bolts are secured in place in the rock formation beyond the rib line of the pillars, this so that the compressive forces set up by the pillars can be utilized in the retention of the bolts in the rock strata. The horizontal tie rods 13 are placed under tension by the tightening down of nuts 20 and 21, this so as to increase substantially the compression forces in the rock strata below the floor line, and this to an extent such that floor heave upwardly is avoided. Accordingly, there is resisted the tendency of materials proximate the center area of the floor to proceed upwardly under the compressive forces beneath this floor area as contributed by the downward pressure of the pillars on opposite sides of the mine opening. For floor installations, 3 there will be substantial increases in the material thicknesses making up the brackets, as well as in the horizontal tie rods so that the tremendous pressures as might be experienced through the weight of the overburden over the pillars, and the pillar weights themselves, can be offset by the tension of the tie rods and the compressive forces produced thereby in the rock strata immediately beneath the floor level.
In connection with the tremendous pressures that are experienced as to floors and potential floor heave, it is strongly urged that the trussed area be at least 80 percent of the distance between the pillars; also, that the securement bolts be substantially well under the mine pillars and elongated and allowed for a substantially increased anchorage area. This situation in connection with mine floors is to be contrasted with the force distribution pattern experienced at the roof wherein, as a rule of thumb, the parabolic tensile zone approximates sixty percent of the roof area, twenty percent being on either side of such area and being essentially in compression. As to the roof, the brackets should be placed inwardly about 1/5th of the distance from the pillar rib line, or slightly less so as to insure that the entire tensile zone is encompassed. With the floor, however, a substantially greater extent of the floor must be trussed and additional anchorage utilized.
FIGS. 6, 7 illustrate a further elaboration that can optionally be used in trussing mine floors, where the particular strata encountered dictates such a construction. In FIGS. 6, 7 it is noted that there is disposed beneath bracket 11 and the rods 13 a wire mesh W or material similar to chain link fences. This can proceed across underneath the bases of the truss brackets to aid in the prevention of floor heave. Additionally, and once the wire mesh and the basic trusses, in single or multiple units, are installed, additional holes may be drilled as at 26 and anchor bolts 27' with nuts 27A installed, with the anchor bolt nuts, bolt heads or reaction portions thrusting against a respective plate 28 that overlays the mesh. A series of holes and bolts can be installed to accomplish these purposes. Finally, see FIG. 10, adjacent pairs of tie rods 31, or channels 13A substituted therefor, may be conveniently joined together by longitudinally disposed rods 27 which are secured to the aforementioned tie rods by suitable juncture brackets 28 of any convenient form. The precise structure employed here are optional and may vary in accordance with particular installations desired. The essential point is that the tie rods or tie rod pairs can be coupled together in any convenient manner, and, additionally, mesh can be employed for further insuring against floor heave. Additional structural reliability is achieved through the employment of the additional bolts 27' hereinabove described.
While believed less satisfactory, there are other types of trussing structures that can be employed for use in mine floors. These will include the so-called Bethlehem design of trusses as fully disclosed in U.S. Pat. No. 4,395,161 which is fully incorporated herein by way of reference. Also employable with the floor structure is the so-called Birmingham truss structure as is shown in U.S. Pat. No. 3,505,824 issued to White, which also is fully incorporated by way of reference.
In FIGS. 8 and 10 an optional construction is shown in connection with the trussing of mine floors. A series of truss assemblies 10 are provided each of which include a respective channel 13A and also depending bolts 32 which are installed similarly to roof bolts. Disposed between the upwardly oriented legs 33 and 34 of the channel is an inverted angle iron bracket 35 that is welded in place and which includes aperture 36 together with corresponding aperture 37 of the base 38 of the channel for receiving the bolt and the tightening of the same through its associated nut to the channel. This construction will exist at opposite end portions of the channel for each channel employed. Additionally, the channels can be disposed under and/or over horizontal tie rods or bars at 41, and the latter implaced over mesh 42.
In installation the mesh would be disposed over the floor first. Subsequently, the essentially parallel horizontal tie rods will be implaced and can be secured together between themselves or to the later installed channels by any conventional means as desired, as the case may be. Subsequently, the angulated holes at 32A and 32B are drilled, accompanied by the optional drilling of representative holes 32C and 32D, the latter has as many holes as may be desired. Subsequent to the drilling operation the bolts 32 are anchored down and the channels tightened by the appropriate nuts 40 and 41 against the angle iron 35 as previously described. After this operation has been completed, additional bolts as at 42 and 43 may be installed through reinforcing plates 44, etc. of the channels, and appropriate nuts or other attachments used to secure the channels down with the vertical bolts being under tension. The spacing of the channels along the drift is optional depending upon the conditions that are encountered and the trussing desired.
The above trussing concept relative to floors is believed to be completely new and is applicable to coal mines, metal mines, that also in connection with even highway tunnels, by way of example, where civil engineers simply drill through a hill or mountain area and need to preclude a floor heave going through such tunnel. In such event, any one of the several structures described can be utilized and installed at the floor and thereafter, concrete and appropriate road material deposited so that the roadway can be completed. In such event, however, the materials used will need to be anodized or otherwise treated to prevent rusting and/or other deterioriation.
The above techniques and structures described will be suitable as well for phosphate mines, trona mines, anywhere long-wall or short-wall techniques are employed, etc.
In FIG. 11 the truss bracket 44 is shown to include a horizontal bearing plate 45 and a tie rod nut reaction plate 46 depending therefrom and integral therewith. The bearing plate 45 and reaction plate 46 will assume a mutual, 90° orientation. Interposed in the structure to the left of reaction plate 46 is a gusset member 47 which, in the embodiments shown in FIGS. 11 and 12, includes an angulated or hypotenuse anchor-bolt bearing plate 48 and a pair of gusset plates 49 and 50 which are welded to bearing plate 48 and also to the bearing plate 45 and reaction plate 46. The gusset plates are in right-triangular form and are welded in place both to bearing plate 48 and also to bearing plate 45 and reaction plate 46. Accordingly, in the embodiments shown in FIGS. 11 and 12, the interior of the triangular gusset member 47 is hollow at 51. An enlarged aperture at 52 will be supplied in bearing plate 45 to accommodate passage of anchor bolt 53. The outer bearing surface 54 of bearing plate 38 will serve as a reaction-surface contact for the forward engagement end 55 of anchor bolt nut 56. Aperture 57 thus will be provided for anchor bolt 53 passage in the angulated bearing plate 48. Apertures 53 and 54 will be provided in the vertical reaction plate 46 and are seen in FIG. 12.
There are a number of features and advantages in connection with the preferred truss bracket 44 in FIGS. 11 and 12. In a preferred form of this truss bracket the intersection of surface 54 with axis A1 of the anchor bolt 53 should lie along the horizontal plane joining the axes A2 of parallel tie rods 59. These latter, of course, will be provided with tie rod tension producing nuts 60 which are threaded on such tie rods. Accordingly, where the intersection between surface 54 and axis A1 is aligned with axis A2 of the tie rods, then there will be a maximum of stability in the truss bracket when the nuts 56 and 60 are tightened down. This is because the horizontal force component of tension produced in anchor bolt 53 will likewise lie in the same plane as joins axes A2 of the two tie rods 59; hence, no force-couple will appear as between the tension force vector lying along the axis of the tie rods and the horizontal force component of the tension produced in anchor bolt 53. An outer limit for the desired position of the intersection between surface 54 and axis A1 will be at extremity E as seen in FIG. 11. The distance D between surface 61 and extremity E is a permissible range within which the horizontal component of such force vector may appear; thus, extremity E defines the maximum or lowest permissible orientation of the intersection between surface 54 and axis A1. To remove the force couple altogether, and as before mentioned, the intersection of the plan defined by surface 54 and axis A1 should appear in line with axis A2 of tie rods 59 so that these are coincident.
A further effort in reducing the possible appearance of force couples is in the provision of a pair of tie rods 59 equally spaced from and on opposite sides of the axis A1 of anchor bolt 53, also as shown relative to bracket 11 in FIG. 3. Accordingly, as the nuts 60 are torqued down so as to place the tie rods in tension, there will be no turning moment generated relative to the centrally placed anchor bolt 53. Again, oversized aperture 52 is provided as a passageway for anchor bolt 53 in the bearing plate 45.
Owing to extreme loadings of in-situ installation of the truss bracket 44, there should be a substantial "beafing up" of the structure of the gusset member--hence, the provision of gusset plates 49 and 50 which are welded in place both to the angulated bearing plate 48 and also to bearing plate 45 and reaction plate 46. This likewise provides ease of machining, especially as to bearing plate 48 where the same is initially produced, chamfered at its ends in angulated form as seen in FIG. 11, and then simply welded in place at W at its several junctures with the remaining structure. Likewise, the gussets will be completely welded in place about their peripheries at W1.
FIGS. 13 and 14 illustrate end views of a structure shown in FIGS. 11 and 12, and, additionally, illustrates that the gusset member may be solid rather than hollow. This is seen in connection with gusset member 47A. In such event, of course, an aperture 51A will be provided for anchor bolt 53 which will provide the access of the hollow area at 51 where the gusset member is fabricated from the two gusset plates and bearing plate 48 in connection with the embodiments shown in 11 and 12. However, in connection with the provision of a solid triangular gusset member as seen in FIGS. 13 and 14, there will be necessitated the addition of machine time required to drill aperture 51A.
An initial impression that the structure of FIGS. 13, 14 could be simply cast. However, to produce the material strengths clearly approaching that necessitated in truss installation and suitable tightening down of the anchor bolt 53 and tie rods 59, the pre-cast structure would have to be extremely bulky and very heavy. It is much preferred that suitable bar stock be enclosed to fabricate the bracket and suitable high-spec welding be employed to accomplish the fabrication of such truss bracket. In such event a high-strength structure can be achieved without the massive bulk required should one take a casting approach.
The truss brackets illustrated in FIGS. 11 through 14 may be substituted for or used in conjunction with the installations of any of the prior figures, and this advantageously.
A final note: the bearing plate 45 should be extended at 45' to the right in FIG. 11 so as to provide an increased surface area for surface 62, this to retain the abutting rock formation in place substantially at opposite sides of the upward extension of anchor bolt 53 in FIG. 11. Surface 62 needs to contact the rock formation surface for substantial distances on opposite sides of anchor bolt 53; especially as this is a case where the anchor bolt assumes an orientation constituting a pronounced deviation from the vertical.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention.
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A method of essentially maintaining the integrity of mine floors and precluding floor heave, this without the necessity of incorporating timber cribs, jacks and so forth, as utilized in the prior art. Floor integrity is maintained with a minimum of obstruction of the mine opening. Truss structures herein are designed to deter floor heave and, optionally, also may be adjusted in certain instances for employment as roof trusses even though stress patterns of the strata will differ. Truss-bracket, channel, and allied constructions are incorporated and are of advantageous design as hereinafter pointed out. Of special import is the bracket, of nominal triangular cross-section which facilitate through-placement of tie rods and anchor bolts in tension and in a manner deterring the generation of force couples. The truss structures will be installed between mine pillars, broadly defined as any side structure, rock or otherwise, spanned by a mine- or tunnel-roof.
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[0001] This application is a divisional application of my co-pending patent application bearing Ser. No. 10/371,373 filed 19 Feb. 2003.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a device and a method for delivering an impact or a force to a device. More particularly, but not by way of limitation, this invention relates to a percussion apparatus used with tubular members.
[0003] Rotary bits are used to drill oil and gas well bores, as is very well understood by those of ordinary skill in the art. The monetary expenditures of drilling these wells, particularly in remote areas, can be a very significant investment. The daily rental rates for drilling rigs can range from a few thousands dollars to several hundreds of thousands of dollars. Therefore, operators have requested that the well bores be drilled quickly and efficiently.
[0004] Prior art drill bits include, for instance, the tri-cone rotary bit. The tri-cone bit has been used successfully for many years. The rock will be crashed by the impact of the tri-cone buttons. Also, the PDC bit (polycrystalline diamond compact bit) has been used with favorable success. The PDC cutters do not crash, but will shear off the rock. Both bit types have their advantages, nevertheless tri-cone bits, utilizing the crashing action, are more universally useable. Therefore, attempts have been made to enhance the impact and hence the crashing action utilizing separate impact and/or jarring tools in order to drill wells or as an aid in drilling wells. However, those attempts have been largely case limited, non-economical, or unsuccessful.
[0005] Therefore, there is a need for a device that can deliver an impact and a force to a drilling tool, like a bit. There is a further need for a percussion-impacting tool that can be placed within a work string that will aid in the drilling and remedial work of wells. Further an impacting tool is needed that will aid to move a work string. There is also a need for a percussion-impacting tool that can be placed inside a tubular, for cleaning out the tubular. There is an additional need for percussion-impacting tools that can support compacting actions for cementing casing and tubing in well bores and others. These, and many other needs, will be met by the following invention.
SUMMARY OF THE INVENTION
[0006] A tool for delivering an impact and a force is disclosed. The tool comprises a cylindrical member having an internal bore, with the internal bore containing an anvil shoulder and a first guide profile. The tool further includes a first rotor disposed within the internal bore, and wherein the first rotor comprises a body having an outer circumference with a second guide profile thereon and an internal portion, and wherein the first rotor contains a radial hammer face. In a first position, the second external guide profile of the first rotor will engage with the first helical guide profile of the cylindrical member so that the radial hammer face can contact the anvil shoulder. In a second position, the second guide profile of the first rotor will engage with the first guide profile of the cylindrical member so that the radial hammer face is separated from the anvil shoulder.
[0007] In one embodiment, the internal bore of the cylindrical member contains a third guide profile and a second anvil shoulder. The tool further comprises a second rotor disposed within the internal bore, and wherein the second rotor comprises a body having an outer circumference with a fourth guide profile thereon, and wherein the second rotor member contains a second radial hammer face.
[0008] The fourth guide profile of the second rotor will engage with the third thread profile of the internal bore so that the second radial hammer face contacts the second anvil shoulder. The fourth guide profile of the second rotor will engage with the third guide profile of the internal bore so that the second radial hammer face is separated from the second anvil shoulder.
[0009] In the preferred embodiment, the first rotor further comprises a plurality of blades. The blades are arranged so that a flow stream therethrough will cause a rotation of the rotor. The flow stream may be either in a liquid, or gaseous state, or a combination of both.
[0010] The tool may further comprise a stator positioned within the internal bore, with the stator positioned to direct the flow stream to the first rotor. In the preferred embodiment, the stator comprises a cylindrical member having a plurality of blades disposed about a central core, and wherein the plurality of blades of the stator directs the flow stream to the first rotor so that the first rotor rotates.
[0011] A method of delivering an impact and a force to a tool is also disclosed. The method includes providing a device for delivering an impact or force to the tool, the device comprising a member having an internal bore with a first guide profile; a rotor disposed within the internal bore, and wherein the rotor comprises a body having an outer circumference with a second guide profile thereon, and wherein the rotor contains a radial hammer face. The method further includes flowing a flow stream down the internal bore and then flowing the flow stream through the internal portion of the rotor. The flow stream may be in a liquidized or gaseous state, or a combination of both. The rotor is rotated by the flow stream flowing therethrough.
[0012] Next, the first guide profile is engaged with the second guide profile so that the rotor travels in a direction opposite the flow of the flow stream. The rotor continues to rotate via the flow stream flowing therethrough. The first guide profile and the second guide profile engage so that the rotor travels in the same direction as the flow of the flow stream. When traveling in the same direction as the flow stream, the radial hammer face impacts against an anvil of the member having the internal bore. The radial hammer face of the rotor can also hit an anvil that is connected to any kind of tool like a bit when traveling in the same direction as the flow stream. Put another way, the rotor travels in an oscillating mode along the central axis of the member having the internal bore caused by the engagement between the first guide profile with the second guide profile.
[0013] The method further comprises continuing to flow the flow stream down the internal bore and through the rotor which in turn rotates the rotor by flowing the flow stream therethrough. The first guide profile and the second guide profile are engaged so that the rotor travels in a direction opposite the flow of the flow stream. As the flow stream continues to be flown, the rotor continues to rotate which in turn continues to engage the first guide profile with the second guide profile so that the rotor travels in the same direction as the flow of the flow stream, and the radial hammer face will, in turn, impact against the anvil.
[0014] In one of the preferred embodiments, the tubular member is connected to a drill bit member and the method further comprises drilling the well bore by percussion impacting of the radial hammer face against the anvil. In another of the preferred embodiments, the percussion sub is axially connected to a drill bit member. Alternatively, for example, the tubular member may be connected to an object stuck in a well, and the method further comprises jarring the object by percussion impacting of the radial hammer face against the anvil.
[0015] In yet another embodiment, a tool for delivering an alternating force is disclosed. The tool in this embodiment comprises a first member having an opening and first profile, with the first member having a first area thereon. A second member is disposed within the opening of the first member, with the second member containing a second profile, and a second area. The second member has a first position relative to the first member wherein the first profile cooperates with the second profile so that the second area contacts the first area. The second member has a second position relative to the first member wherein the first profile cooperates with the second profile so that the second area is separated from the first area. In one embodiment, the second member is a rotor, and wherein the rotor contains a plurality of blades disposed about a center core and wherein the plurality of blades turn in response to a flow stream flowing there through. Also, the first area may be an anvil shoulder, and the second area may be a hammer. In a preferred embodiment, the first member is a cylindrical member.
[0016] In yet another preferred embodiment, a tool for vibrating a cement slurry within a well bore is disclosed. The well bore will have a concentric casing string therein. The tool includes a first member attached to a cementing shoe, the cementing shoe being disposed at an end of the casing string. The first member has an anvil and a first profile thereon. The tool further contains a rotor disposed within the first member, with the rotor having a second profile and a hammer, and wherein the rotor is disposed to receive the cement slurry pumped down an inner portion of the casing string. The first profile will cooperate with the second profile, in a first position, so that the hammer contacts the anvil. The first profile further cooperates with the second profile, in a second position, so that the hammer is separated from the anvil. This oscillating movement of the rotor vibrates the cement slurry. In one embodiment, the rotor contains a plurality of blades disposed about a center core and wherein the blades turn in responsive to the cement slurry flowing there through. A stator may be included in order to direct the cement slurry into the blades of the rotor. In the preferred embodiment, the first member is a cylindrical member attached to the casing string within the well bore. A shock module member may be included, with the shock module member being operatively associated with the rotor.
[0017] The described percussion tool can be described more particularly, but not by way of limitation, as a percussion sub. An advantage of the presented percussion subs in drill strings will result in increase rates of drilling penetration. Another advantage is that the percussion sub may be used to free work strings that become stuck in a well. Still yet another advantage is that the percussion sub of the present invention can obtain very high vibration frequencies. For instance, frequencies of 20 Hz are possible.
[0018] Another advantage is that numerous configurations of the percussion sub are possible within a work string. For example, the percussion sub can be used in a drill string as an addition to existing drilling equipment; or the percussion sub used as a stand alone tool; or the percussion sub can be placed in more than one position in the drill string; or the percussion sub can be combined in series with more than one percussion subs. The percussion sub can also be an integral member of any other apparatus connected to a work string in order to function as a percussion tool.
[0019] Another advantage is that the percussion sub can also be used in a drill string with a rotary steerable assembly. Yet another advantage is that the percussion sub can be placed in a drill string having a motor or a turbine assembly. Still another advantage is that the percussion tool can be used to cement casing within a well bore.
[0020] A feature of the present invention includes use of a turbine type of design that utilizes a plurality of rotator blades. The flow stream flows through the internal portion of the rotor, through the blades so that the rotor rotates. Another feature is the rotor will have disposed thereon a guide profile that cooperates with a reciprocal guide profile that allows for a raised and lowered position. In one embodiment, the guide profile is on the outer circumference of the rotor, while in another embodiment, the guide profile is contained on an internal portion.
[0021] Another feature is that the flow through the internal bore of the percussion sub activates the percussion sub. The flow stream can be a liquid, a gas, a liquid stream with solids, a gas stream with solids, or a mixture of liquids, gas and solids. Still yet another feature is that the operator can control the frequency of the hammer striking the anvil by varying the pumping rate, by varying the guide profiles, by varying the number of rotors, or by varying the rotor arrangement. Yet another feature is that the operator can control the amount of impact of the hammer striking the anvil by varying the mud weight, by varying the guide profiles, by varying the blade design, or by varying the rotor weight. Still yet another feature is that the percussion sub will continue vibrating despite flow streams containing high solids contents.
[0022] Yet another feature is that the only moving part is the rotor with blades therein. Another feature is the novel guide profiles. The cooperating guide profiles are highly dependable and results in a minimum of moving components. Still another feature is the percussion tool can be placed in a casing string with a cementing shoe and the percussion tool is used to cement the casing string within the well bore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1A is a top view of the rotor of the present invention.
[0024] FIG. 1B is a cross-sectional view of the rotor from FIG. 1A taken along line I-I.
[0025] FIG. 1C is a circumference view of the rotor seen in FIG. 1A .
[0026] FIG. 2A is a top view of the sleeve of the present invention.
[0027] FIG. 2B is a cross-sectional view of the sleeve from FIG. 2A taken along line II-II. FIG. 2C is a circumference view of the sleeve seen in FIG. 2A .
[0028] FIG. 3A is a top view of the stator of the present invention.
[0029] FIG. 3B is a cross-sectional view of the stator from FIG. 3A taken along line III-III.
[0030] FIG. 4A is a cross-sectional view of the percussion bottom sub of the present invention.
[0031] FIG. 4B is a top view of the percussion bottom sub.
[0032] FIG. 5 is a cross-sectional view of the percussion top sub of the present invention.
[0033] FIG. 6A is a partial cross-sectional view of the preferred assembled percussion sub shown in the raised position.
[0034] FIG. 6B is a partial cross-sectional view of the preferred assembled percussion sub of FIG. 6A shown in the lowered position.
[0035] FIG. 7A is a schematic illustration of a percussion sub embodiment having a rotor with external guide and an anvil.
[0036] FIG. 7B is a schematic illustration of a laid out helical profile.
[0037] FIG. 8 is a schematic illustration of another percussion sub embodiment having a rotor with internal guide and an anvil.
[0038] FIG. 9 is a schematic illustration of another percussion sub embodiment having a rotor with external guide, a stator and an anvil.
[0039] FIG. 10 is a schematic illustration of another percussion sub embodiment having multiple rotors with external guides, stators and anvils.
[0040] FIG. 11 is a schematic illustration of another percussion sub embodiment having multiple rotors, stators, and anvils, whereby some stator function as anvils.
[0041] FIG. 12 is a schematic illustration of another percussion sub embodiment having multiple rotors with more than one external guide and multiple stators functioning as anvils, whereby all the rotors are interconnected.
[0042] FIG. 13 is a schematic illustration of another percussion sub embodiment having multiple rotors with one external guide and multiple stators functioning as anvils, whereby all the rotors are connected to each other.
[0043] FIG. 14 is a schematic illustration of another percussion sub embodiment having multiple rotors, multiple stators, with an axial moveable bit attached thereto.
[0044] FIG. 15A depicts a schematic illustration of the circumference view of the rotor engaging the sleeve in a raised position.
[0045] FIG. 15B depicts the rotor and sleeve of FIG. 14A in a lowered position.
[0046] FIG. 16 is a schematic illustration of the percussion sub positioned within a drill sting.
[0047] FIG. 17A is schematic illustration of a prior art cementing technique.
[0048] FIG. 17B is a schematic illustration of another preferred percussion sub embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] Referring to FIG. 1A , a top view of the rotor 2 of the present invention will now be described. The rotor 2 comprises a generally cylindrical member having an outer wall 4 that extends radially inward to the internal portion 5 ; the rotor 2 contains a plurality of blades within the internal portion 5 (seen in FIG. 1B ). Returning to FIG. 1A , the blades 6 , 8 , 10 , 12 , 14 , 16 , 18 , 20 emanate from a center core 22 . The blades 6 - 20 are disposed with a certain angle or pitch, as will be fully set out later in the application.
[0050] In FIG. 1B , a cross-sectional view of the rotor 2 from FIG. 1A taken along line I-I will now be described. It should be noted that like numbers appearing in the various figures refer to like components. As illustrated in FIG. 1B , the internal portion 5 has the center core 22 , with the center core 22 having extending therefrom the blade 14 extending to the outer wall 4 . The blade 14 is attached at one end to the center core 22 and at the other end to the outer wall 4 . The center core 22 extends to the hammer radial face 23 . The rotor 2 has a first radial surface 24 that is essentially flat and a second radial surface 26 . The blade 14 has an angle of inclination of 45 degrees in the embodiment shown. It should be noted that the number of blades and the actual angle of inclination may vary. In other words, it may be that a greater number of blades in some applications are required, while in some instances, a lesser number of blades is required. Additionally, while an angle of inclination of 45 degrees is shown (denoted by the numeral 21 ), it should be understood that the angle may vary from zero (o) degrees to ninety (90) degrees. The rotor 2 is of similar construction to rotors of a turbine design that is commercially available from Smith International Inc. and Neyrfor Inc. under the trademark of Turbo Drill.
[0051] Referring now to FIG. 1C , a circumference view of the rotor 2 seen in FIG. 1A will now be described. In particular, FIG. 1C depicts the circumference view of the outer wall 4 . The outer wall 4 has the first flat radial surface 24 and the second surface 26 . FIG. 1C depicts that the second radial surface 26 is a jagged saw tooth profile 27 , which begins at the surface 28 which then slopes generally downward, as denoted by the numeral 30 which in turn concludes at curved surface 32 , with the curved surface 32 having a radius of 0.125 inches in the preferred embodiment. The curved surface 32 extends to the vertically extending surface 34 which in turn extends to the second surface 36 . The second surface 36 will again extend to the generally downward sloped surface 38 and wherein the sloped surface 38 concludes at the curved surface 40 , with the curved surface 40 having a radius of 0.125 inches in the preferred embodiment.
[0052] Reference is now made to FIG. 2A which is a top view of the sleeve 44 of the present invention. The sleeve 44 is a generally cylindrical member that contains an outer wall 46 and an inner surface 48 . FIG. 2B is a cross-sectional view of the sleeve 44 from FIG. 2A taken along line I-I. The sleeve 44 has a top surface profile, seen generally at 50 , and a bottom surface, seen generally at 52 . The top surface 50 is an essentially matching jagged saw-tooth profile 50 with the second surface 26 of the rotor 2 . Referring now to FIG. 2C , the circumference view of the sleeve 44 , and in particular the outer wall 46 , seen in FIGS. 2A and 2B will now be described. The second surface 50 is a jagged saw-tooth profile 50 which begins at the surface 54 which then slopes generally downward, as denoted by the numeral 56 which in turn concludes at curved surface 58 , with the curved surface 58 having a radius of 0.125 inches in the preferred embodiment. The curved surface 58 extends to the vertically extending surface 60 which in turn extends to the second surface 62 . The second surface 62 will again extend to the generally downward sloped surface 64 and wherein the sloped surface 64 concludes at the curved surface 66 , with the curved surface 66 having a radius of 0.125 inches in the preferred embodiment.
[0053] A stator 70 is seen in a top view in FIG. 3A . The stator 70 is generally cylindrical and contains an outer wall 72 that in turn extends to an inner diameter surface 74 . The stator 70 has disposed therein a plurality of blades, namely blades 76 , 78 , 80 , 82 , 84 , 86 , 88 , 90 . The stator blades will be attached at one end to the inner diameter surface 74 and at the other end to the center core 92 . The stator blades will be disposed at an angle of inclination that will be more fully explained with reference to FIG. 3B .
[0054] Referring now to FIG. 3B is a cross-sectional view of the stator 70 from FIG. 3A taken along line A-A. Stator 70 has a first end 91 a and second end 91 b . The blade 84 as an example is shown sloping downward at an angle of inclination of 45 degrees. The other blades ( 76 , 78 , 80 , 82 , 86 , 88 , 90 ) will slope downward in a similar fashion at an angle of inclination of 45 degrees. As noted earlier, the actual angle of inclination can be varied. The stator is designed to direct the flow stream to the rotor as will be more fully explained later in the application. As noted earlier, the flow stream may be a liquid or a gas, or a mixture of both. The flow stream may also contain solids.
[0055] Referring now to FIG. 4A , a cross-sectional view of the percussion bottom sub 100 of the present invention will now be described. The bottom sub 100 comprises a generally cylindrical body having a first thread surface 102 that extends to a second outer surface 104 which in turn extends to the second thread surface 105 . Extending radially inward, the bottom sub 100 contains a first inner surface 106 that leads to center passage means 108 . The center passage means 108 contains a plurality of openings, including the opening 110 , which will have placed therein a nut and bolt which will serve as an anvil for an embodiment, as will be more fully explained later in the application. The center passage means 108 also contains openings spaced about the opening 110 , with these openings being generally aligned with the rotor 2 thereby providing an output path for the flow stream; in FIG. 4A , openings 112 and 114 are shown disposed through the center passage means 108 .
[0056] In FIG. 4B , a top view of the percussion bottom sub 100 will now be described. The opening 112 and the opening 114 is shown, along with the other openings 116 , 118 , 120 . The center 110 will have placed therein a nut and bolt for the anvil, which is not shown in this view.
[0057] Referring now to FIG. 5 , a cross-sectional view of the percussion top sub 124 of the present invention will now be described. The percussion top sub 124 is a generally cylindrical member that includes an outer surface 126 which extends to an internal bore 128 . The internal bore 128 contains an internal thread 130 that in turn extends to a shoulder 132 . The shoulder 132 extends to the internal thread means 134 . The percussion top sub 124 and percussion bottom sub 100 are threadedly connected.
[0058] FIG. 6A is the preferred embodiment of the assembled percussion sub 136 seen in a partial cross-section in the raised position. The internal thread means 134 will threadedly engage with the thread surface 102 thereby connecting the percussion top sub 124 and the percussion bottom sub 100 . Thus, the stator 70 has its first end 91 a abutting the shoulder 132 . It should be noted that in some of the embodiments herein disclosed, the stator 70 itself is an optional component, as will be more fully explained later in the application. The stator 70 in turn is adjacent the rotor 2 . The stator 70 will direct the flow stream into the rotor 2 . The rotor 2 is positioned so that the jagged saw-tooth guide profile 27 (as seen in FIG. 1B ) will be adjacent the sleeve 44 , and in particular, the jagged saw-tooth guide profile 50 (as seen in FIG. 2C ) wherein the cooperation of the profiles will result in the percussion effect of the present invention. The bolt 138 is seen disposed within the opening 110 . The bolt 138 will serve as the anvil. Since the rotor 2 will be rotating during a flow down the bore 128 of the sub 136 and the internal portion 5 of the rotor 2 , the jagged saw-tooth guide profile 27 (as seen in FIG. 1B ) of the rotor with the complementary jagged saw-tooth profile 50 (as seen in FIG. 2C ) of the sleeve will cause the rotor to raise then lower and strike with the hammer radial face the bolt 138 , serving as anvil, which in turn transmits the impact to the percussion sub 136 . The direction of flow of the fluid stream is denoted by the arrow 11 in FIG. 6A .
[0059] The frequency of the impact can be affected by several factors including the rate of pumping through the percussion sub 136 . Other factors include the specific design of the profile, like the number of jagged saw-teeth. It should be understood that the percussion sub may be mounted in conjunction with a bit, or in work strings that contain other types of bottom hole assemblies. For instance, the percussion sub could be included on a fishing work string to aid in providing a jarring action when so desired by the operator. In the case wherein the percussion sub 136 is connected to a bit, the bit will be subjected to the impact.
[0060] The sleeve 44 is fixedly connected to the percussion bottom sub 100 by conventional means such as welding or thread means or can be formed integrally thereon.
[0061] FIG. 6A depicts the assembly while the rotor 2 has been raised due to the interaction of the jagged profile of the rotor 2 against the jagged guide profile of the sleeve 44 . The rotor 2 moves reverse to the direction of the flow of the flow stream when moving in the rotary motion. FIG. 6B depicts the assembly in FIG. 6A while the rotor 2 has been lowered in order to strike the sleeve, with the lowering being due to the interaction of the jagged guide profile of the rotor 2 against the jagged profile of the sleeve 44 . In particular, the hammer radial face 23 of the rotor 2 contacts the bolt 138 . As seen in FIG. 6B , the rotor 2 moves in the same direction of the flow of the flow stream when moving in a linear motion.
[0062] Referring now to FIG. 7A , a schematic illustration of a percussion sub 170 embodiment having a rotor 172 with external guide profile 174 and an anvil 176 will now be described. In this embodiment, the rotor 172 will be rotated by the flow of a flow stream down the inner bore 178 . The sub 170 will be situated within a work string, as previously discussed. Thus, as the rotor 172 is rotated, the external guide profile 174 will cooperate with an inner guide profile 180 located on the inner body of the sub 170 . In accordance with the teachings of the present invention, as the rotor 172 turns, the cooperation of the external profile 174 and the internal profile 176 will cause a raising of the rotor 172 and in turn a lowering of rotor 172 which results in a striking of the hammer (rotor 172 ) against the anvil 176 . It should be noted that the external guide profile and internal guide profiles herein described will be similar to the jagged saw-tooth guide profile previously discussed in that the profiles provide a guide for cooperative engagement of the rotor to rotate as well as to raise and lower. The profiles for FIGS. 7A through 13 have a helical type of profile. The helical profile may take the form of a thread profile due to the curved nature of the profile about a cylindrical surface. FIG. 7B depicts a laid out the helical profile.
[0063] In FIG. 8 , a schematic illustration of another percussion sub 182 embodiment having a rotor 184 with internal guide profile 186 and an anvil 188 will now be described. The anvil 188 is either formed on the sub 182 or affixed to the sub by conventional means such as threads, welding, press fitting and other means. The anvil has a center section 190 that extends therefrom, with the center section 190 containing a guide profile 192 . In this embodiment, the rotor 184 will be rotated by the flow of the flow stream down the inner bore 194 . The sub 182 will be situated within a work string, as previously discussed. Thus, as the rotor 184 is rotated, the internal guide profile 186 will cooperate with the guide profile 192 located on the center section 190 of the anvil 188 . In accordance with the teachings of the present invention, as the rotor 184 turns, the cooperation of the guide profile 192 and the guide profile 186 will cause a raising of the rotor 184 and in turn a lowering of rotor 184 which results in a striking of the hammer (i.e. rotor 184 ) against the anvil 188 .
[0064] In FIG. 9 , a schematic illustration of another percussion sub 196 embodiment having a rotor 198 with external guide 200 , a stator 202 and an anvil 204 is shown. In the embodiment of FIG. 9 , the stator 202 will direct the flow of the flow stream through the inner bore 206 . The flow will cause the rotor 198 to rotate wherein the external guide 200 , which is formed on the rotor 198 , will cooperate with the external guide 200 , which is formed on the wall of the percussion sub 196 . Hence, the rotor 198 will raise then lower thereby causing the hammer effect as previously described.
[0065] In FIG. 10 , a schematic illustration of another percussion sub 208 embodiment having multiple rotors with external guides, stators and anvils will now be described. More particularly, the stator 210 a directs flow of the flow stream to the rotor 212 a . The anvil 214 a is connected to the percussion sub 208 . The rotor 212 a has an external guide profile 216 a that will cooperate with the internal guide profile 218 a which in turn will raise the rotor 212 a , then lower the rotor 212 a thereby striking the anvil 214 a.
[0066] Mounted in tandem is stator 210 b which receives the flow and then directs flow to the rotor 212 b . The anvil 214 b is connected to the percussion sub 208 . The rotor 212 b has an external guide profile 216 b that will cooperate with the internal guide profile 218 b which in turn will raise the rotor 212 b , then lower the rotor 212 b thereby striking the anvil 214 b.
[0067] FIG. 11 is a schematic illustration of another percussion sub 220 embodiment having multiple rotors and stators and wherein the stators function as anvils. As seen in FIG. 11 , a stator 222 a directs flow of the flow stream to the rotor 224 a and wherein the rotor 224 a has an external guide profile 226 a that will cooperate with an internal guide profile 228 a formed on the internal portion of the percussion sub 220 . Thus, the rotor 224 a will be rotated which in turn causes the raising and then lowering of the rotor 224 a thereby striking the stator 222 b . Note that the stator 222 b acts as an anvil for the rotor 224 a.
[0068] In the embodiment of FIG. 11 , the second stator 222 b directs flow to the second rotor 224 b and wherein the rotor 224 b has an external guide profile 226 b that will cooperate with an internal guide profile 228 b formed on the internal portion of the percussion sub 220 . Thus, the rotor 224 b will be rotated which in turn causes the raising and then lowering of the rotor 224 b thereby striking the stator 222 c , wherein the stator 222 c serves as an anvil. Additionally, stator 222 c directs flow to the rotor 224 c and wherein the rotor 224 c has an external guide profile 226 c that will cooperate with an internal guide profile 228 c formed on the internal portion of the percussion sub 220 . Thus, the rotor 224 c will be rotated which in turn causes the raising and then lowering of the rotor 224 c thereby striking the anvil.
[0069] Referring now to FIG. 12 , a schematic illustration of another percussion sub 231 embodiment having multiple rotors and stators and anvils wherein the rotors are contacting each other, therefore, allowing for all rotors to oscillate in the same direction and frequency. The percussion sub 231 contains an anvil 232 that is connected to the sub 231 and has a center section 233 extending through the inner bore 234 of the sub 231 . The anvil 232 has ports 236 for the passage of the flow through the inner bore 234 and through the rotors and stators. The percussion sub 231 includes a rotor 238 a that is disposed about the center section 233 . The rotor 238 a has an external guide profile 240 a that will engage within an internal guide profile 242 a for cooperation as previously described. A stator 244 a will direct flow of the flow stream to the rotor 238 a which in turn will cause rotor 238 a to rotate.
[0070] The rotor 238 a is fixedly attached, such as by thread means, splines or couplings, via a shaft 246 a to the rotor 238 b . The shafts 246 a consist of interconnecting pieces, with the interconnection being protruding teeth that cooperate with reciprocal grooves. The shafts 246 a and 246 b can also be interconnected via other means such as thread means.
[0071] The stator 244 b directs the flow to the rotor 238 b . The rotor 238 b has an external guide profile 240 b that cooperates with the internal guide profile 242 b . In this embodiment, the raising and lowering of the rotor 238 b will strike the stator 244 a ; hence, stator 244 a acts as an anvil. The rotor 238 b is fixedly attached, such as by thread means, via a shaft 246 b to the rotor 238 c . The stator 244 c directs the flow to the rotor 238 c . The rotor 238 c has an external guide profile 240 c that cooperates with the internal guide profile 242 c . In this embodiment, the raising and lowering of the rotor 238 c will strike the stator 244 b . In operation, the rotors 238 a , 238 b , 238 c will rotate in phase and rise and lower in phase, since they are connected.
[0072] FIG. 13 is a schematic illustration of another percussion sub 250 embodiment having multiple rotors, and stators. The percussion sub 250 is similar to the percussion sub 231 of FIG. 12 except that there is only a single external guide profile 252 that cooperates with and engages into the internal guide profile 254 . The other components found in FIG. 13 are similar to those found in FIG. 12 , and similar numerals refer to like components. Thus, as flow of the flow stream is directed down the bore 234 , external guide profiles 252 engagement with the internal guide profile 254 will cause all of the rotors to rise, then fall striking the corresponding stators.
[0073] With reference to FIG. 14 , a schematic illustration of another percussion sub 260 embodiment having multiple rotors, stators, with a bit attached thereto will now be described. The embodiment of FIG. 14 also illustrates an interconnection means for interconnecting the rotors. Additionally, in the embodiment of FIG. 14 , the bit that is connected to the tubular string is axial moveable relative to the tubular string. More specifically, the bit 264 is axially attached by conventional spline means with the top of the bit serving as an anvil 266 . The splines, schematically illustrated at 268 , are provided for allowing axial movement of the bit 264 relative to the tubular member 269 of sub 260 in oscillating movement, thereby allowing the incremental axial extension of the bit into the formation face. Please note that the tubular member 269 will be connected to a work string such as a drill string. The spline means consist of a series of projections on a bit shaft that fit into slots on the corresponding tubular 269 , enabling both to rotate together while allowing axial lateral movement, as is well understood by those of ordinary skill in the art.
[0074] At the top portion of the rotor 270 is the projection 272 . A first stator 274 is provided so that the flow stream is directed to the rotor 270 , as previously described. The stator 274 has a bore 276 disposed there through. The second rotor 278 is disposed within the sub 260 , and wherein the rotor 278 contains a stem 280 disposed through bore 276 . The stem 280 contains a groove 282 , and wherein the groove 282 will cooperate with the projection 272 . The groove 282 and projection 272 are the interconnection means for interconnecting the rotors for rotational movement and are similar to a tongue in groove arrangement.
[0075] At the top portion of the rotor 278 is the projection 284 . A second stator 286 is provided so that the flow stream is directed to the rotor 278 , as previously described. The stator 286 has a bore 288 disposed there through.
[0076] The third rotor 290 is disposed within the sub 260 , and wherein the rotor 290 contains a stem 292 disposed through bore 288 . The stem 292 contains a groove 294 , and wherein the groove 294 will cooperate with the projection 284 . The groove 294 and projection 284 are the interconnection means. At the top portion of the rotor 290 is the projection 296 . A third stator 298 is provided so that the flow stream is directed to the rotor 290 , as previously described. The stator 298 has a bore 300 disposed there through.
[0077] The fourth rotor 302 is disposed within the sub 260 , and wherein the rotor 302 contains a stem 304 disposed through the bore 300 . The stem 304 contains a groove 306 , and wherein the groove 306 will cooperate with the projection 296 . The groove 306 and projection 296 are the interconnection means. A fourth stator 308 is provided, and wherein the stator 308 directs the flow stream to the fourth rotor 302 . Due to the interconnection of the rotors 270 , 278 , 290 , 302 , the rotors will rotate together as flow is directed therethrough. Thus, the rotors 270 , 278 , 290 , 302 rise and fall (oscillate) in unison thereby providing the impact to the bit. In the embodiment shown in FIG. 14 , the bit is actually impacted twice in a single cycle: first, by the rotors hitting the bit; second, by the falling work string, with the increment of downward movement of the work string being dependent upon the amount of hole created by the bit due to the first impact. The first rotor 270 has a guide profile 380 that is placed at the low side of the rotor 270 . The tubular member 269 of the sub 260 has an opposing guide profile 382 located on the inner body of the sub 170 . Hence, all interconnected rotors 270 , 278 , 290 , 302 need only one pair of guide profiles ( 380 , 382 ) to guide all rotors.
[0078] Referring to FIG. 15A , the schematic illustration depicts the circumference view of the rotor 2 engaging the sleeve 44 in a raised position since the jagged saw-tooth guide profiles are not engaged. The surface 36 of the rotor 4 is contacting the surface 62 of the sleeve 44 . Notice the gap between the slope surface 30 of the rotor 4 and the slope surface 64 of the sleeve 44 . Flow will occur through the internal portion 5 of the rotor 2 , as previously described. The rotor 2 moves reverse to the direction of the flow of the flow stream when moving in rotary motion. FIG. 15B depicts the rotor 2 and sleeve 44 of FIG. 15A in a lowered position since the jagged saw-tooth guide profiles are engaged. Hence, the surface 36 of the rotor 2 has been allowed to clear surface 62 of the sleeve 44 thereby lowering rotor 4 . The slope surface 30 of the rotor 2 is now next to the sloped surface 64 of the sleeve 44 . The rotor 2 moves in the same direction of the flow of the flow stream when moving in linear motion.
[0079] FIG. 16 is a schematic illustration of the percussion sub positioned within a drill sting 332 having a bit 334 . As can be seen, the percussion subs 136 a , 136 b , 136 c can be placed in more than one position in the drill string 332 . Additionally, the percussion subs 136 a,b,c can be used with a motor turbine tool 336 in the drilling of a well bore 338 . The percussion sub of the present invention can also be used with other tools, such as rotary steerable tools. In fact, the present apparatus may be added to most work strings any time a percussion effect is needed. It should be noted that the percussion sub of the present invention can be utilized as a component of different systems wherein a percussion and/or hammer effect is required. The percussion sub can be used in any surface or subsurface tool string, to clean out tubulars, as an impact hammer, as a vibration tool, as a cementing tool, as a compacting tool, etc.
[0080] In yet another embodiment disclosed with the teachings of this invention, FIG. 17A depicts a schematic representation of the prior art technique used for cementing a casing string within a well bore. As those of ordinary skill in the art will appreciate, a well bore 400 is drilled. A casing string 402 is placed within the well bore 400 . The bore hole wall of the well bore 400 has an exposed formation face. A cementing shoe 404 is contained on the end of casing 402 . A cementing shoe 404 is commercially available from Halliburton Energy Services under the name Cementing Shoe or Casing Shoe, and is usually constructed of a drillable material such as aluminum.
[0081] Cement is generally pumped down the inner portion of the casing 402 . The cement slurry in the casing is designated by the number 406 , and is schematically shown. The cement is pumped down casing 402 in the direction of flow arrow 408 , through the cement shoe 404 , and out into the annulus area 410 .
[0082] As those of ordinary skill in the art will recognize, the drilling fluid, denoted by the number 412 , was already in place within the inner diameter of the casing 402 and the annulus area 410 before placement of the cement. The cement within the annulus area 410 is denoted by the numeral 420 . Therefore, as the cement is pumped down the inner portion of the casing 402 , and up annulus 410 , the drilling fluid 412 will be displaced, as is readily understood by those of ordinary skill in the art. The pumping of the cement continues until all of the cement has been pumped down the inner portion of casing 402 , and the annulus area 410 is completely filled with cement. The cement then is allowed to harden, thereby fixing the casing string 402 within the well bore 400 .
[0083] Referring now to FIG. 17B , the cementing technique shown in FIG. 17A now contains a percussion tool, such as seen in FIGS. 6A and 6B and denoted as 136 . The percussion tool 136 is placed above the cementing shoe 404 in casing 402 . A shock module 440 is positioned between the percussion tool 136 and the casing 402 . The shock module 440 has build-in compression and tension systems like spring means 442 a or arrangements of similar means. The spring means 442 a can be a tension type of coil spring having a first end abutting shoulder 442 b and a second end abutting shoulder 442 c . In one embodiment, the shock module 440 is threadedly connected to the percussion tool 136 at one end, and at the other end, the shock module 440 is connected to casing 402 via splined means.
[0084] The shock module 440 lets the percussion tool 136 and the cementing shoe 404 concurrently move in an axial direction up and an axial direction down the well bore 400 relative to the casing 402 , hence, ensuring the axial vibration (shown by arrow 444 ) of the percussion tool 136 . In an embodiment not shown, the shock module 440 can be an integrated member of the percussion tool 136 itself. As seen in FIG. 17B , the disclosed shock module 440 enhances the effect and the efficiency of the desired invention; however, the inclusion of the shock module 440 is not necessary to practice the invention herein disclosed.
[0085] As cement is pumped in the flow direction of 408 down the inner diameter of casing 402 , the cement will be flowed through the percussion tool 136 . The pumping of the cement slurry will cause the percussion tool 136 to vibrate in an oscillating manner 444 , as previously described. The cement slurry will be subjected to the rotor blades of percussion tool 136 . Additionally, the rotor of the percussion tool 136 will travel in a first longitudinal direction, followed by a second longitudinal direction, all as previously described. The cement slurry exiting the percussion tool 136 will enter the cement shoe 404 . The slurry will then exit the cement shoe 404 and will travel into the annulus area 410 , displacing the drilling fluid 412 .
[0086] In the prior art pumping of cement (such as seen in FIG. 17A ), as the cement is pumped downhole, it is subjected to a static movement (pure static pressure). As those of ordinary skill in the art will recognize, problems occur due to imperfectly sealed formation-casing interfaces. Thus, remedial works, such as squeeze jobs, must be performed in order to insure a proper placement of cement in the annulus area, as well as to insure proper bonding of the cement to the outer diameter of the casing.
[0087] As per the teachings of this new invention, the percussion tool 136 is placed above the cementing shoe 404 and the cement slurry can be pumped through the rotor and stator blades as other drilling slurries. Part of the hydraulic horsepower of the cement flow, which is being pumped, will be transformed into mechanical horsepower in the sense that the cement slurry becomes a vibrating mass column in the well bore. This vibration of the slurry reduces the friction between the cement particles itself, between the cement particles and the formation, and between the cement particles and the casing. This is a dynamic phase which is accomplished because of the percussion tool 136 , and differs from the prior art static movement of the cement slurry. This dynamic phase allows the cement slurry to flow more easily into formation voids, pore cracks, fissures, etc.
[0088] Additionally, because the percussion tool 136 is vibrating the cement column, the cement particles have better settling. This will trigger fewer voids (porosity) in the annulus, therefore providing a much better sealing effect between cement particles, which in turn allows for better sealing effect between casing and formation, and casing and cement. Another advantage is that, since there is less porosity, there is higher density, which amounts to a better seal in the porous space of a formation. Additionally, with the teachings of the embodiment of FIG. 17B , there is reduced friction, hence less pressure column, therefore allowing for a higher cement column behind the casing with an equal amount of applied static pressure. For instance, see the cement column in FIG. 17A denoted by the numeral 414 , and the cement column denoted by the numeral 416 in FIG. 17B . Hence, because of the reduced friction, the same amount of pumping pressure will allow for a higher displacement shown as the difference between the distance of line 446 b of FIG. 17B and line 446 a of FIG. 17A into the annular area 410 . To put it another way, single line static pressure (cement pumps from the surface) will push the cement higher into the annulus behind the casing due to less pressure resistance when use of the percussion tool 136 is included. The difference of cement column height in the annulus 410 can also be explained with an enhanced efficiency of dynamic pressurized fluid in comparison with static pressurized fluids.
[0089] Actually, twice the percussion tool 136 and the shock module 440 will actuate the cement column. First, the rotor of the percussion tool 136 will vibrate the cement column itself. The cement column starts to pulsate. Second, the percussion tool 136 and cementing shoe 404 oscillate due to the axial movement enabled by the shock module 440 , thus they by themselves as a whole will activate the cement slurry once more.
[0090] Although the present invention has been described in terms of specific embodiments, it is anticipated that alterations and modifications thereof will no doubt become apparent to those skilled in the art. It is therefore intended that the following claims be interpreted as covering all such alterations and modifications as fall within the true spirit and scope of the invention.
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A percussion apparatus and method of using the percussion apparatus. The apparatus may be used for delivering an impact to a tubular string. The apparatus comprises a cylindrical member having an internal bore containing an anvil and a first guide profile. The apparatus further includes a rotor disposed within the internal bore, and wherein the rotor member comprises a body having an outer circumference with a second guide profile thereon, and wherein the rotor contains a radial hammer face. In a first position, the second external guide profile of the rotor will engage with the first guide profile of the cylindrical member so that the radial hammer face can contact the anvil. In a second position, the second guide profile of the rotor will engage with the first guide profile of the cylindrical member so that the radial hammer face is separated from the anvil shoulder. Multiple rotors and multiple stators may be employed. The rotor may be operatively associated with a stator that directs flow into the rotor. The rotor may be comprised of a plurality of inclined blades. The percussion apparatus may be incorporated into a tubular string and used for multiple purposes within a well bore. For instance, a method of cementing a well with the percussion apparatus is disclosed.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 61/494,266, filed Jun. 7, 2011, which is incorporated herein by reference in its entirety.
FIELD
This disclosure generally relates to building products. More particularly, this disclosure relates to a system, components, and method for managing loads and conditions, such as airflow, thermal loads, and environmental conditions, in buildings.
BACKGROUND
Traditionally, pitched roofs include a protective covering, such as tiles or shingles, presented on a roof board or “deck” that covers an unconditioned space or “attic.” The attic can serve as a buffer to a conditioned, living space below the attic. It can desirable to attempt to maintain the temperature of the attic, through the use of ventilation, so that the temperature of the attic is at or near the outside environmental air temperature.
Such ventilation can be done using soffit vents and roof or ridge vents. Even if such vents are included, however, they can be inadequate and/or deteriorate with the age of the home. As a result, roofs can develop unwanted thermal heat loads (heat gains) in the conditioned, living space in the summer season and the removal of thermal heat (heat loss) in the conditioned, living space during the winter period.
Furthermore, many heat loads can be caused by “radiant” heat, which can cause high cooling energy costs in buildings, particularly in warm southern climates that receive a high incidence of solar radiation. It is not uncommon for the air temperature within a space adjacent to or under a roof to exceed the ambient outside air temperature by 40° F. (about 22° C.) or more, due to absorption of solar energy by the roof. This can lead to a significant energy cost for cooling the living spaces of a building to a comfortable living temperature. Most homes do not have solutions for managing or reducing radiant heat.
Also, in colder climates, traditional roofs can have inadequate air flow from the soffit to the peak exit can lead to ice build-up or “ice dams” at the lower eaves area. Ice dams form when there is snow on the roof and removal of thermal heat (heat loss) of the conditioned space, or heat from solar gain absorbed by the portions of the roof that are not snow covered, melts snow on the roof. The resulting water travels down the roof to lower portions of the roof that are below 32° F. (usually at the eves) and the water refreezes. The ice then forms a small dam that slowly builds up and, eventually, the water can back up behind the dam. This backed-up water can then work its way under the shingles and leak into the space below. Poor unconditioned space ventilation in colder climates can also lead to build up of frost and condensation that form on the underside of the roof.
BRIEF SUMMARY
This disclosure provides a system, components, and method for managing airflow by or within the roof system, the thermal heat loads and heat loss of the roof system, the temperature of conditioned and/or unconditioned spaces in a building, and the ventilation of the conditioned and/or unconditioned spaces in a building. The subject matter of this disclosure, in its various combinations, either in apparatus or method form, may include the following list of embodiments:
1. A system for management of thermal loads relative to a roof having first and second decks covering an unconditioned space in a building and a peak, said system comprising:
a first channel extending from proximate a lower end of the first deck towards the peak and a second channel extending from proximate a lower end of the second deck towards the peak; and
a router positioned proximate the peak, said router enabling air flowing to the peak from said first channel to be selectively routed to one of a plurality of directions.
2. The system of embodiment 1, wherein said plurality of directions are selected from the group consisting of:
out of a peak vent included at the peak and into the atmosphere,
to said second channel,
back to said first channel,
into the unconditioned space,
into an heat recovery unit,
into an air make-up unit, and
any combinations thereof.
3. A roofing article for use in the system of any one of the preceding embodiments, said roofing article comprising a body and a roofing article channel defined therein, such that when said roofing article is arranged on said first deck, said roofing article channel forms at least a portion of said first channel.
4. A roof covering for use in the system of any one of embodiments 1 to 2, said roofing covering comprising a plurality of roofing articles, each roofing article comprising a body and a roofing article channel defined in said body, such that when said plurality of roofing articles are arranged on said first deck, said roofing article channels of said plurality of roofing articles arranged on said first deck collectively form at least a portion of said first channel and when said plurality of roofing articles are arranged on said second deck, said roofing article channels of said plurality of roofing articles arranged on said second deck collectively form at least a portion of said second channel.
5. The system of any one of embodiments 1 to 2, further comprising a covering presented on said first and second decks, said first channel being defined within said covering presented on the first deck and said second channel being defined within said covering presented on the second deck.
6. The system of embodiment 1, further comprising a covering presented on said first and second decks, said first channel being defined intermediate said first deck and said covering presented on the first deck and said second channel being defined intermediate said second deck and said covering presented on the second deck.
7. The system of any one of embodiments 4 to 6, further comprising one or more vents included in covering, said vents operably extending from said first channel to a top surface of covering.
8. The system of any one of embodiments 1 to 2, wherein said first channel and said second channel are positioned above the first deck and second deck, respectively.
9. The system of any one of embodiments 1 to 2, wherein said first channel and said second channel are positioned below the first deck and second deck, respectively.
10. The system of any one of the preceding embodiments, wherein said router is a linear actuator.
11. The system of any one of the preceding embodiments, further comprising a selectively openable and closeable vent proximate a lower end of the first deck, such that said vent, when opened, enables air to enter into or exit out of said first channel.
12. The system of any one of the preceding embodiments, further comprising a selectively openable and closeable vent proximate a lower end of the second deck, such that said vent, when opened, enables air to enter into or exit out of said second channel.
13. The system of any one of the preceding embodiments, further comprising an air movement component to effect movement of air in at least one of said first and second channels.
14. The system of embodiment 13, wherein said air movement component is a fan.
15. The system of any one of embodiments 13 to 14, wherein said air movement component is configured to push and pull air.
16. The system of any one of the preceding embodiments, further comprising one or more sensors presented with at least one of said first deck or said second deck.
17. The system of embodiment 16, wherein said one or more sensors comprise a sensor selected from the group consisting of: a temperature sensor, a moisture sensor, a heat flow sensor, an impact sensor, a fire sensor, and a carbon monoxide sensor, or combinations thereof.
18. The system of any one of embodiments 2 to 17, wherein said heat recovery unit comprises a dryer.
19. A method for releasing thermal loads using the system of any one of the preceding embodiments, wherein said air flowing to the peak from said first channel is selectively routed out of the peak vent into the atmosphere.
20. A method for collecting thermal loads using the system of any one of the preceding embodiments, wherein said air flowing to the peak from said first channel is selectively routed into the unconditioned space.
21. A method for using thermal loads from the first deck to heat the second deck using the system of any one of the preceding embodiments, wherein said air flowing to the peak from said first channel is selectively routed to said second channel.
22. A method for blowing off a roof covering using the system of embodiment 7, wherein said air flowing to the peak from said first channel is selectively routed to back to said first channel and out of said one or more vents included in said covering.
23. A method for using thermal loads from the first deck to heat a conditioned space using the system of any one of the preceding embodiments, wherein said air flowing to the peak from said first channel is selectively routed to an heat recovery unit.
24. A system for management of thermal loads relative to a building panel, said system comprising:
a first channel extending from proximate a lower end of the panel towards an upper end of the panel; and
a router positioned proximate the upper end of the panel, said router enabling air flowing to the upper end of the panel from said first channel to be selectively routed to one of a plurality of directions.
25. The system of embodiment 24, wherein the panel comprises a roof deck.
26. The system of embodiment 24, wherein the panel comprises a wall.
27. A system for management of thermal loads relative to a roof having first and second decks covering an unconditioned space in a building and a peak, said system comprising:
a first channel extending from proximate a lower end of the first deck towards the peak and a second channel extending from proximate a lower end of the second deck towards the peak; and
a router positioned proximate the lower end of the first deck, said router enabling air flowing to the lower end of the first deck from said first channel to be selectively routed to one of a plurality of directions selected from the group consisting of:
out of a vent included proximate the lower end of the first deck and into the atmosphere,
back to said first channel,
into the unconditioned space,
into an heat recovery unit,
into an air make-up unit and
any combinations thereof.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The disclosure can be more completely understood in consideration of the following detailed description in connection with the accompanying drawings, in which:
FIG. 1 is a schematic side view of a traditional roof system;
FIG. 2 is a schematic side view of a roof system of this disclosure;
FIG. 3A is a schematic perspective view of a roof system of an embodiment of this disclosure;
FIG. 3B is schematic side view of the roof system of FIG. 3A ;
FIG. 4A is a schematic perspective view of a roof system of a further embodiment of this disclosure;
FIG. 4B is schematic side view of the roof system of FIG. 4A ;
FIG. 5A is a schematic perspective view of a roof system of a further embodiment of this disclosure;
FIG. 5B is schematic side view of the roof system of FIG. 5A ;
FIG. 6A is a schematic perspective view of a roof system of a further embodiment of this disclosure;
FIG. 6B is schematic side view of the roof system of FIG. 6A ;
FIG. 7A is a schematic perspective view of a roof system of a further embodiment of this disclosure;
FIG. 7B is schematic side view of the roof system of FIG. 7A ;
FIG. 8A is a schematic perspective view of a roof system of a further embodiment of this disclosure;
FIG. 8B is a schematic side view of the roof system of FIG. 8A ;
FIG. 9A is a schematic perspective view of a roof system of a further embodiment of this disclosure;
FIG. 9B is a schematic side view of the roof system of FIG. 9A ;
FIGS. 10A-10F are schematic side views of a roof peak air router of this disclosure in various configurations;
FIG. 11A is a schematic perspective view of a roof system of a further embodiment of this disclosure;
FIG. 11B is a close-up schematic view of a soffit vent (air router) of embodiments of this disclosure; and
FIG. 12 is a schematic perspective view of a roof system of a further embodiment of this disclosure.
While the above-identified figures depict an embodiment of the disclosed subject matter, other embodiments are also contemplated, such as those noted in the disclosure. In all cases, this disclosure presents the disclosed subject matter by way of representation only and not by limitation. The figures are schematic representations, for which reason the configuration of the different structures, as well as their relative dimensions, is for illustrative purposes only. Numerous modifications and embodiments can be recognized by those skilled in the art, which modifications and embodiments are within the scope and spirit of this disclosure.
DETAILED DESCRIPTION
This disclosure broadly relates to roof systems and methods of using such roof systems. Various exemplary embodiments of the disclosure will now be described with particular reference to the drawings. Embodiments of this disclosure may take on various modifications and alterations without departing from the spirit and scope of the disclosure. Accordingly, it is to be understood that the embodiments of this disclosure are not to be limited to the following described exemplary embodiments, but is to be controlled by the limitations set forth in the claims and any equivalents thereof. An appreciation of various aspects of the invention will be gained through a discussion of the examples provided below.
The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected illustrative embodiments and are not intended to limit the scope of the disclosure. Although examples of construction, dimensions, and materials are illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized.
Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.
The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range.
As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise. For example, reference to “a layer” encompasses embodiments having one, two or more layers. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
The term “polymer” will be understood to include polymers, copolymers (e.g., polymers formed using two or more different monomers), oligomers and combinations thereof, as well as polymers, oligomers, or copolymers that can be formed in a miscible blend. Additionally, the terms “attic” and “unconditioned space” are used interchangeably herein.
Referring to FIG. 1 , a traditional roof 10 generally includes one or more roof portions 12 extending between a soffit 14 and a roof peak or ridge 16 . Roof 10 includes a protective covering 18 , such as concrete or clay tiles or asphalt shingles, on a roof board or deck 20 that covers an unconditioned space or attic 22 . Attic 22 can serve as a buffer to a living space 24 below the attic. Roof 10 can include vents 26 on the soffit and also vents on the roof (not depicted) and/or a ridge vent 28 .
Referring to FIG. 2 , the roof system 110 according embodiments of this disclosure can include one or more roof portions 112 , each having a roof board or deck 120 , a soffit 114 having a soffit duct or vent 126 (which vent 126 can include an air router), a roof peak or ridge 116 , and a protective covering 118 , such as concrete or clay tiles or asphalt shingles, on deck 120 . Roof system 110 further includes one or more passive or active roof management components. Such components can include, for example, vent open/close components 130 on the top and/or bottom of the soffit vent 126 , one or more blowers or fans 132 (such as, for example, variable speed/high pressure fans and can be used to effect movement of air, such as the pushing and/or pulling of various air movements), one or more ridge air routing members or air routers 134 for routing air flow in the roof system 110 (see FIGS. 10A-10F ), sensors or sensing members 136 , such as, for example, moisture, temperature, heat flow, impact, fire, and carbon monoxide sensors.
In embodiments, sensors 136 can be moisture, temperature, heat flow, impact, fire, and carbon monoxide sensors. Those skilled in the art will recognize that other sensors can be used without departing from the spirit and scope of this disclosure.
In embodiments of roof system 110 , protective covering 118 can include roof system including one or more channels 119 running partially or fully from the soffit region to or near the ridge or peak of the roof, such as that described in PCT International Publication No. WO 2012/033816 A1, entitled “ABOVE-DECK ROOF VENTING ARTICLE” and U.S. Patent Application No. 61/579,297, entitled “ABOVE-DECK ROOF VENTING ARTICLE,” both of which are incorporated herein by reference in their entirety. Roof system 110 can further include one or more solar cells 138 and each of the roof system management components can, optionally, be solar-powered. Air routers 134 can be or include one or more air ducts that run along, such as parallel, ridge 116 of roof system 110 . The cross section and/or shape of the ducts can vary with size and shape. The materials of air router 134 can be any of a number of materials, including, for example, lightweight, non-rusting metals and or various low-high temperature polymers, although those skilled in the art would recognize that other materials can be used. Electric-actuated linear actuators can be included to create various valve ports of air router 134 . Other methods of mechanical gating can be used in air router 134 are contemplated. Output from software can close or open the respective gates to enable natural and or forced air flow through air router 134 . Depending on climate zone location and secondary operations tied to roof system 110 , air router 134 can have multiple ports. The examples have been shown for four-way and six-way ports, although other air router 134 configurations, including more than six ports or less than four ports are contemplated.
The roof system 110 of embodiments can include controls (including, for example, hardware and/or software, not depicted) to enable further optimization of the thermal energy management of a building and for controlling the roof system management components. For example, the temperature and relative humidity/dew point temperature of an unconditioned attic space can automatically effect air flow movement using roof system. Likewise, structure ventilation could trigger air flow movements to mechanical devices or buffering heat/cold air.
Referring to FIGS. 3A and 3B , in a first embodiment, radiant energy is depicted as impinging upon the right roof portion 112 of roof system 110 . Positions 1, 2, 5 and 6 of air router 134 can be open (see FIG. 10A ), which routes warmer air from both roof portions 112 of roof system 110 up to ridge 116 , such as through a channel or channels 119 included in at which point the warmer air exits. Air router 134 generally extends along substantially the entire length of ridge 116 .
Referring to FIGS. 4A and 4B , in a second embodiment, radiant energy is depicted as impinging upon the right roof portion 112 of roof system 110 . Blower 132 on right roof portion 112 can be set to push soffit air and the blower 132 on left roof portion 112 can be set to pull warmer air. Positions 2 and 5 of air router 134 can be open (see FIG. 10B ). The warmer air is then routed from the warmer right roof portion to cooler left roof portion.
Referring to FIGS. 5A and 5B , in a third embodiment, to transfer air to a cooler side of a roof using a below-deck solution, blower 132 on right roof portion 112 can be set to push soffit air and blower 132 on left roof portion 112 can be set to pull air. Positions 2 and 4 of air router 134 can be open (see FIG. 10C ). The air is then routed from the right roof portion 112 to the left roof portion 112 . The air is then pushed through channels 119 provided in or with protective covering 118 .
Referring to FIGS. 6A and 6B , in a fourth embodiment, all positions of air router 134 can be closed (see FIG. 10D ) and the right and left blowers 132 can be set to pull outside air using, for example, variable blower speed. This will cause air to be blown onto the roof system 110 through vents (not depicted) included in protective covering 118 . This configuration can be useful, for example, when it is desired to blow water, snow, or other debris (such as leaves) off of roof system 110 .
Referring to FIGS. 7A and 7B , in a fifth embodiment, radiant energy is depicted as impinging upon the right roof portion 112 of roof system 110 . In this embodiment, positions 2 and 3 of air router 134 can be open (see FIG. 10E ) the soffit ducts (air routers) and blowers/fans are controlled through the software for force air convection direction (pushing or pulling), natural convention in the soffit and attic areas, and balance system ventilation. The left and right blowers 132 can be set to re-circulate warmer air through the channel 119 included in or with the protective covering. The unconditioned space can be used as a buffer to store warm air or cool air depending on the season.
Referring to FIGS. 8A and 8B , in a sixth embodiment, in a cold climate case, radiant energy is depicted as impinging upon the right roof portion 112 of roof system 110 . In this embodiment, positions 2, 3, 4 and 5 of air router 134 can be open (see FIG. 10F ) and the soffit ducts (air routers) and blowers/fans are controlled through the software for force air convection direction (pushing or pulling), natural convention in the soffit and attic areas, and balance system ventilation. The left blower 132 can, optionally, be set to push soffit air and the right blower 132 can be set to push soffit air. New air is routed to flow into a home air make-up unit 140 and old air flows out of unit 140 .
Referring to FIGS. 9A and 9B , in a seventh embodiment, in a warm climate case, radiant energy is depicted as impinging upon the right roof portion of roof. In this embodiment, positions 2, 3, 4 and 5 of air router 134 can be open (see FIG. 10F ) and the soffit ducts (air routers) and blowers/fans are controlled through the software for force air convection direction (pushing or pulling), natural convention in the soffit and attic areas, and balance system ventilation. The left blower 132 can, optionally, be set to push soffit air and the right blower 132 can be set to push soffit air. New air is routed to flow into unit 140 and old air flows out of unit 140 .
Referring to FIGS. 10A-10F , the various air router 134 configurations are depicted schematically for each of the embodiments depicted and described with respect to FIGS. 3-9 .
Referring to FIGS. 11A and 11B , a soffit duct (air router) is depicted. In a first configuration, the soffit duct can be open, by opening a first gate 140 , such as an electric-actuated “air gate or linear actuator,” to the channel 119 for air flow. It is depicted with open gates for natural convection in the bottom or closed gates for force convection through the respective blowers. In another embodiment, a second gate 142 , such as an electric-actuated “side gate,” can be open for below deck air flow management.
Referring to FIG. 12 , in embodiments, a blower 144 can be located or positioned in attic 122 and in fluid (air) communication, such as through ductwork 146 , with air routers 134 and air gates 140 and, optionally, second air gates 142 to manage airflow by or within the roof system 10 , the environmental thermal loads of the roof system 10 , the temperature of conditioned and/or unconditioned spaces in a building, and the ventilation of the conditioned and/or unconditioned spaces in a building, such as, for example, as described above with respect to FIGS. 3-9 . To do so, blower 144 can be controlled to selectively push and/or pull air to or from air routers 134 and air gates 140 and, optionally, second air gates 142 —depending upon what result is desired.
In embodiments, such as those depicted in FIGS. 3-9 and 11 , channels 119 , such as those included in above-deck protective covering, that extend up the slope of the deck mate or align with dedicated ports on air router 134 , such as the #2 port (right) or #5 port (left) of the air router 134 , as depicted in FIGS. 10A-F .
The embodiments of this invention should not be considered limited to the particular examples described herein, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the embodiments of this invention can be applicable will be readily apparent to those of skill in the art to which the embodiments of this invention are directed upon review of the instant specification.
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A system for management of a roof having first and second decks covering an unconditioned space in a building and a peak, the system having a first channel extending from proximate a lower end of the first deck towards the peak and a second channel extending from proximate a lower end of the second deck towards the peak. The system further includes a router positioned proximate the peak, the router enabling air flowing to the peak from the first channel to be selectively routed to one of a plurality of directions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALL SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to protective and decorative coverings for windows, doors, and the like, and more particularly to storm shutters, awnings, and louvers to provide security and protection against large magnitude storms such as hurricanes.
2. Description of Related Art
Window and door coverings, such as awnings and shutters, are known in the art, and are used for decoration, security, weather protection, and the like.
Conventional awnings, such as "Bahama" style awnings, typically have a perimeter framework with a plurality of horizontal louvers or slats. The louvers include openings between individual louver slats to allow air and sunlight to enter the structure to which the awning is attached, and to permit persons within the structure to see out. The frame can be attached at the top by a hinge to the top of a window or other opening. The awning is presized in length and width to cover the entire window or other opening. The awning can be rotated about the hinge, with the lower portion of the awning moving in an arc relative to the hinge, and away from the lower portion of the window. The awning can thus be positioned at some desired angle relative to the window. The lower portion of the awning can be held away from the window by support arms. The arms can be removable and/or include a release mechanism to permit the lower portion of the awning to be moved toward the window to a closed position substantially parallel to the window to provide security or storm protection.
However, because the awning louvers have openings between the louver slats to allow air and sunlight to enter the structure, the protection provided is limited by the strength of the individual horizontal louver slats. Individual louver slats having an opening between adjacent slats cannot provide sufficient protection against large magnitude storms such as hurricanes.
Subsequent to hurricane Andrew hitting South Florida in August of 1992, several Florida counties have begun to require minimum building code standards for storm shutters. For example, in the Miami Florida area, Dade County standards require the shutter to withstand certain tests including a large missile impact test consisting of a length of 2"×4" wood weighing 9 pounds shot from an air cannon at approximately 34 miles per hour directly into the shutter. Conventional Bahama awnings having openings between adjacent slats fail to pass these tests.
There is a need for a Bahama style awning that provides the desirable features of the awning, can protect against major storms, and can pass strict building code standards testing.
Conventional shutters; such as Colonial style shutters typically include at least one shutter panel made of a perimeter framework and a plurality of horizontal louver slats. The shutter is typically attached at one edge by hinges to the edge of an opening such as a window or door of a structure. The shutter can be presized to cover the entire window. The shutter is normally kept in the open position adjacent to the window. The shutter can be rotated about the hinges to the closed position covering the window.
More typically, a pair of shutters can be mounted adjacent the window, one on either side. The pair of shutters can be presized such that together, when closed, they cover the entire window or other opening. When closed, the pair of shutters meet near the vertical center of the window and are connected together to form a protective cover over the entire window.
The Colonial style shutters are normally kept in the open position, and only cover the window area when closed for protection. Therefore, the horizontal louvers do not require openings between adjacent louver slats to allow air and sunlight to enter the structure. The conventional Colonial style shutter can thus have a sturdy backing plate permanently attached to the back side of the shutter, to provide sufficient support for protection against significant storms such as hurricanes. The sturdy backing plate can be attached to the perimeter framework and can cover the entire louvered area. A sturdy backing plate so attached permits a conventional shutter to pass building code standards testing, such as the Dade county large missile impact test.
However, the addition of a permanent backing plate to the shutter adds additional weight to the shutter, adds additional costs in raw material, and adds additional labor costs and time for assembly. There is a need for a Colonial style shutter that is inexpensive, easy and quick to manufacture, that can provide protection against major storms, and that can pass strict building code standards testing.
BRIEF SUMMARY OF THE INVENTION
The present invention provides, in one embodiment, a "Bahama" style awning that attaches to a structure in a conventional manner that permits light and air to enter the structure, that can be utilized to protect against major storms, and that can pass strict building code standards testing, as described herein. In an alternate embodiment, the invention provides a "Colonial" style shutter that is inexpensive, easy and quick to manufacture, that can provide protection against major storms, and that can pass strict building code standards testing, as described herein.
The awning embodiment can include a perimeter framework to retain a plurality of horizontal louver slats that include openings between adjacent louvers to allow air and light to enter the structure to which the awning is attached, and to permit persons within the structure to see out. The perimeter framework is adapted to receive a substantially planar, removable rigid plate that, when in place, can extend from the perimeter framework to cover the entire louvered area. The rigid plate can provide security and protection against major storms, and need only be inserted into the awning when additional security and protection is required.
The awning can be made nearly any size or shape, with substantially rectangular being the preferred shape. The perimeter framework can include a pair of substantially vertical members, or jams, forming a left and a right edge of the awning. A pair of substantially horizontal members form an upper edge and a lower edge of the framework. The rigid plate can be removably disposed in a pair of fitted vertical slots, one slot in either vertical jam. The lower horizontal member includes matching slots, that align with the slots in the jams, for receiving the rigid plate. Once fully inserted into the slots, the plate can be attached to the perimeter framework by conventional removable fasteners, such as stainless steel screws.
The awning can attach at the upper edge by a hinge mechanism to the upper edge of the window, doorway, or other opening. The awning can rotate about the hinge from an open position to a closed position covering the opening in the structure to which the awning is attached. One or more support arms can be used to retain the lower edge of the awning at a preselected distance from the lower edge of the opening.
The awning with the rigid plate in place provides protection against major storms and can pass strict building code standards testing such as Dade County Florida's large missile impact test consisting of a length of 2"×4" wood weighing 9 pounds shot from an air cannon at approximately 34 miles per hour directly into the shutter. The awning can further withstand cyclic air testing consisting of cyclic air pressures with a peak equivalent to 48 pounds per square foot in the inward direction and 80 pound per square foot in the outward direction. In addition, the awning can withstand other building code standards, such as the Southern Building Code Congress International (SBCCI).
In an alternate embodiment, a shutter includes a perimeter framework that retains a plurality of horizontal louvers that provide a solid protective covering. Like the awning embodiment discussed above, the shutter embodiment can be made nearly any size or shape, with substantially rectangular being the preferred shape. The framework can include a pair of substantially vertical members, or jams, forming a left and a right edge, and a pair of substantially horizontal members forming an upper edge and a lower edge of the framework. The shutters can attach along one vertical edge by a hinge mechanism to an edge of the window, doorway, or other opening of the structure to which the shutter is attached. The shutter can be rotated about the hinge to cover the window or doorway, and can be sized to cover the entire opening into the structure.
Two shutters can be utilized, one attached to each vertical edge of the window or door and sized to cover the opening when each are closed. The shutter edges opposite the hinge mechanisms can meet together in between the vertical edges of the window or door preferably near the vertical center, and can be connected together to provide additional security.
A plurality of shutter panels can be connected together at adjacent edges to form extra wide shutter assemblies, for extra wide openings. The connection of the shutter panels at adjacent edges can be rigid or foldable.
The shutter embodiment remains in the open position as a decorative accessory to a window or doorway, and, when desired, covers the window or doorway in the closed position to provide security or storm protection. Therefore, the louvers utilized in the shutter embodiment do not require openings between adjacent louvers to allow air and light to pass, such as in the louvers in the awning embodiment. The louver sections for the shutters can thus be solid sections suitable for protection against major storms, and that can pass strict building code standards, such as discussed herein above.
The louvers for each shutter panel can be made of at least one unitary section of preselected size, that can be made of extruded aluminum. A plurality of louvered sections of preselected width can be made that interlock together in length to form modular louvered sections of nearly any size.
Accordingly, it is an object of the present invention to provide an awning that lets in light and air, that can protect against storms, and that can pass strict building code standards testing.
It is another objective of the present invention to provide a shutter that can include modular enclosed louvered sections, can be closable to provide protection against storms, and that can pass strict building code standards testing.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a front perspective view of a first embodiment of the present invention in use.
FIG. 2 is a exploded front perspective view of the awning of FIG. 1.
FIG. 3a is an exploded, inverted, bottom plan view of the awning of FIG. 2.
FIG. 3b is an inverted bottom plan view of the awning of FIG. 2.
FIG. 4 is a perspective view of the rigid support plate of the first embodiment of the present invention.
FIG. 5 is a front perspective view of a second embodiment of the present invention in use.
FIG. 6 is an exploded front perspective view of the shutter of FIG. 5.
FIG. 7a is an exploded side elevational view of an alternate embodiment of louvers.
FIG. 7b is a side elevational view of the louvers FIG. 7a.
FIG. 8a is an exploded side elevational view of an alternate embodiment of the louvers shown in FIG. 7a.
FIG. 8b is a side elevational view of an alternate embodiment of the louvers shown in FIG. 7b.
FIG. 9 is a side elevational view of an alternate embodiment of an upper portion of the louvers shown in FIGS. 7a, 7b, 8a, and 8b.
FIG. 10 is a front perspective view of that shown in FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a first embodiment of the present invention, a "Bahama" style awning shown generally as 1, is illustrated attached by hinge mechanism 2 to a structure 4 over window 6. Awning 1 can rotate about hinge mechanism 2, from an open position as shown to a closed position against structure 4 and covering window 6. Support arms 8 can be used to retain awning 1 in the open position a at a preselected angle relative to window 6. Structure 4 can be a dwelling, store, warehouse, or other structure. Window 6 can include nearly any opening in structure 4 of nearly any shape. Awning 1 can be shaped to correspond to the shape of window 6, with rectangular being the preferred shape, and as illustrated in FIG. 1.
Awning 1 includes perimeter framework 10, to retain a plurality of louver slats 12. Substantially planar, rigid support plate 14 is removable from awning 1, as fully described herein below.
Referring to FIG. 2, awning 1 is illustrated in a front exploded view. Perimeter framework 10 includes substantially vertical members, or jams 16 and 18 which form the vertical edges of framework 10. Substantially horizontal members 20 and 22 form the upper member and lower member, respectively of framework 10. A plurality of louvers 12 are held together at each end by identical support members 24. Louvers 12 are retained in support members 24 in conventional manner, as known in the art. Louver support members 24 retain louvers 12 such that apertures 26 are maintained between adjacent louvers 12. Apertures 26 allow light and air to pass through awning 1, and allow persons within structure 4 to see out of window 6 with awning 1 in place, as shown in FIG. 1.
Louver support members 24 are inserted into identical slots 28 in jams 16 and 18. Upper member 20 is inserted into recessed areas 30 and 31 in jams 16 and 18 respectively, and lower member 22 is inserted into recessed areas 32 and 33 in jams 16 and 18, respectively. Jams 16 and 18, upper member 20, lower member 22 and louvers 12 are assembled as described above, and secured together by stainless steel rivets or stainless steel screws, or other conventional fasteners, to form awning 1.
Referring to FIGS. 3a and 3b, lower member 22 includes slots 34 and 36, which align with recessed areas 38 and 40 in jams 16 and 18, respectively. Rigid plate 14 includes protruding portions 42 and 44, as shown in FIG. 4. Rigid plate 14 within protruding portions 42 and 44 can thus be slid into slots 34 and 36 and into recessed areas 38 and 40, as shown in FIGS. 1 and 3a-3b. Rigid plate 14 can include one or more apertures 46 for attachment by conventional removable fasteners to perimeter framework 10.
Thus for storm protection, rigid plate 14 can be inserted and secured to awning 1 while awning 1 is attached to structure 4. Support arms 8 can be lowered to close awning 1 against window 6. Once in place, awning 1 can provide storm protection even against major storms such as hurricanes, and can pass strict building code standards testing, as described herein above.
It is preferable in the first embodiment, as illustrated in FIGS. 1 and 2, that rigid plate 14 be disposed in front of louvers 12 to protect louvers 12 from storm damage. In the embodiment where rigid plate 14 is disposed in front of louvers 12, FIGS. 3a and 3b are illustrated in an inverted or upside-down orientation. Alternately in the first embodiment, rigid plate 14 can be placed behind louvers 12. As can be seen from FIGS. 1, 2, 3a, and 3b, shutter 1 can be assembled and attached to structure 4 such that rigid plate 14 can be disposed in front of or behind louvers 12. In the embodiment where rigid plate 14 is disposed behind louvers 12, FIGS. 3a and 3b are not inverted.
Referring to FIG. 5, a second embodiment of the present invention, a pair of "Colonial" style shutters shown generally as 50 and 52, are illustrated attached by conventional hinge mechanisms 51 adjacent window 7 of structure 4. Shutter 50 is shown in the open position, and shutter 52 is shown in the closed position covering a portion of window 7. When shutters 50 and 52 are both closed, window 7 is fully covered.
Window 7 can be any size or shape opening into structure 4. Shutters 50 and 52 could be made nearly any size or shape to correspond to window 7. Alternately, a single large shutter could be made to cover window 7, or a plurality of shutters could be made, and rigidly or foldably connected at adjacent edges, as known in the art, to cover window 7.
In the preferred embodiment, shutters 50 and 52 are rectangular, and are sized in width approximately one half the width of window 7, and when closed meet near the vertical center of window 7. Shutters 50 and 52 are identical and only one of which will be described herein to avoid repetition.
Shutter 50 includes a perimeter framework 54 and a plurality of louvers 56. Louvers 56, as fully described herein below, include a substantially planar rigid solid back portion 57. "Solid" referring to the substantial lack of openings or apertures between adjacent louver slats 56.
Referring to FIG. 6, shutter 50 includes substantially vertical members or jams 58 and 60, and substantially horizontal upper member 62 and substantially horizontal lower member 64. Upper member 62 inserts into recessed areas 66 and 67 in jams 58 and 60, respectively. Lower member 64 inserts into recessed areas 68 and 69 in jams 58 and 60, respectively. Louvers 56, with rigid back portion 57, insert into identical slots 70 in jams 58 and 60. Once assembled, jams 58 and 60, upper member 62 and lower member 64, and louvers 56 are connected together using stainless steel rivets, stainless steel screws, or other conventional fasteners, to form shutter 50.
Referring to FIGS. 7a and 7b, louvers 56 include a substantially planar rigid back portion 57. Louvers 56 can be made in modular louver sections comprised of upper section 72, lower section 74, and any number of inner louver sections 73. Each louver section 72-74 can include at least one louver 56, and are illustrated in FIGS. 7a and 7b with three louvers 56 each. Louvers sections 72-74 can be combined together, as described below, to fit any length shutter 50.
Upper louver section 72 can include upper stepped portion 76 on back portion 57, which connects to upper member 62 during assembly by suitable fasteners, such as stainless steel rivets, screws, and the like. Lower louver section 74 can include lower stepped portion 78 on back portion 57, which connects to lower member 64 during assembly also by suitable fasteners, such as stainless steel rivets, screws, and the like.
Opposite upper stepped portion 76, upper louver section 72 includes a first connector 80. Opposite lower stepped portion 78, lower louver section 74 includes a second connector 81. Connectors 80 and 81 are meting connectors, sized and shaped to removably interconnect together to form a rigid connection between adjacent louvers. Inner louver sections 73 include a first connector 80 on an upper edge and a second connector 81 on a lower edge. Thus, upper louver section 72 can be connected directly to lower louver section 74, or one or more inner louver sections 73 can be connected between upper louver section 72 and lower louver section 74, as illustrated in FIGS. 7a and 7b.
First connector 80 is illustrated as a "female" connector, and second connector 81 is illustrated as a "male" connector. Alternately, first connector 80 can be a male connector and second connector 81 can be a female connector. It is only critical that connectors 80 and 81 mate together to rigidly connect adjacent modular louvered sections, not which is the "male" or which is the "female" connector.
FIGS. 8a and 8b illustrate an alternate embodiment that utilizes lower section 75 in-place of lower section 74. Section 75 continues back portion 57, but does not have any louvers 56.
Thus, the louvered sections 72-74 and 75, forming rigid back portion 57, can have nearly any number of louvers 56, or none. The louver sections 72-74 and 75 can be made of extruded aluminum of nearly any size, and can be modularly assembled to form nearly any size and length shutter 50. Alternately, one louvered section can be made, which can have back portion 57 with upper stepped feature 76 and lower stepped feature 78, to be used as a single louver section that when attached to perimeter framework 54 forms shutter 50.
When shutter 50 and shutter 52, with louvers 56 having solid rigid back 57, are closed and secured over window 7, security and protection against major storms is provided to structure 4. In addition, the shutters can pass strict building code standards testing as described herein above.
Referring to FIGS. 9 and 10, the louvered sections illustrated in FIGS. 7a, 7b, 8a, and 8b can include one or more apertures 90 for viewing out and allowing light in while the shutters are in place over a window. Six apertures 90 are shown in upper louver section 72, however, more or fewer apertures 90 can be utilized. In addition, while apertures in the upper louvered section are preferable, apertures can also be disposed in other louvered sections. The louvered sections illustrated in FIGS. 7a-10 can be utilized with any shutter type, including the "Bahama" or "Colonial" type shutter.
The "Bahama" and "Colonial" shutter types described herein above are not intended to be limiting to only two attachment styles or mechanisms. The features described herein above for the "Bahama" style shutters can be utilized in a "Colonial" style shutter, and the features described herein above for the "Colonial" style shutters can be utilized in a "Bahama" style shutter. The features of the invention described as "Bahama" and "Colonial" type shutters can be utilized in alternate shutter types not specifically listed herein, and are considered within the scope of the present invention.
The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.
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The present invention provides, in one embodiment, an awning that permits light and air to enter the structure to which the awning is attached, that can be utilized to protect against major storms, and that can pass strict building code standards testing. The awning includes a perimeter framework that is adapted to receive a removable rigid support plate. In an alternate embodiment, the invention provides a shutter that is inexpensive, easy and quick to manufacture, that can provide protection against major storms, and that can pass strict building code standards testing. The shutter includes modular louver sections that have an integral rigid backing plate.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to earth-boring bits of the rolling cutter variety. Specifically, the present invention relates to the cutting structure and cutting elements of earth-boring bits of the rolling cutter variety.
2. Background Information
The success of rotary drilling enabled the discovery of deep oil and gas reserves. The rotary rock bit was an important invention that made that success possible. Only soft formations could be commercially penetrated with the earlier drag bit, but the original rolling-cone rock bit invented by Howard R. Hughes, U.S. Pat. No. 939,759, drilled the hard caprock at the Spindletop field, near Beaumont Texas, with relative ease.
That venerable invention, within the first decade of this century, could drill a scant fraction of the depth and speed of the modern rotary rock bit. If the original Hughes bit drilled for hours, the modern bit drills for days. Bits today often drill for miles. Many individual improvements have contributed to the impressive overall improvement in the performance of rock bits.
Rolling-cutter earth-boring bits generally employ cutting elements to induce high contact stresses in the formation being drilled as the cutters roll over the bottom of the borehole during drilling operation. These stresses cause the rock to fail, resulting in disintegration through near-vertical penetration of the formation material being drilled. When cutters are offset, their axes do not coincide with the geometric or rotational axis of the bit and a small component of horizontal or sliding motion is imparted to the cutters as they roll over the borehole bottom. While this drilling mode prevails on the borehole bottom, it is entirely different in the corner and on the sidewall. The corner is generated by a combined crushing and scraping or shearing action, while the borehole wall is produced in a pure sliding and scraping (shearing) mode. In the corner and on the sidewall of the borehole, the cutting elements have to do the most work and are subjected to extreme stresses, which makes them prone to break down prematurely, and/or wear rapidly.
Recently, there has been a general effort to introduce the improved material properties of natural and synthetic diamond or super-hard materials into earth-boring bits of the rolling-cutter variety. Super-hard materials have been used in fixed-cutter or drag bits to good effect for many years. Fixed-cutter bits employ the shearing mode of disintegration discussed above almost exclusively. Although diamond and other super-hard materials possess excellent hardness and other material properties, they generally are considered too brittle for most cutting element applications in rolling-cutter bits, an exception being the shear-cutting gage inserts discussed above.
Recent attempts to introduce diamond and similar materials into rolling cutter bits have relied on a diamond layer or table secured to a substrate or backing material of fracture-tough hard metal, usually cemented tungsten carbide. The substrate is thought to supplement the diamond or super-hard material with its increased toughness, resulting in a cutting element with satisfactory hardness and toughness, which diamond alone is not thought to provide.
One problem with the diamond/substrate inserts is the tendency of the diamond or super-hard material to delaminate from the substrate. The cause of this delamination is thought to be forces acting parallel to the interface between the diamond layer or table and the substrate superimposed on the high residual stresses at this interface. These stresses shear the diamond table off of its substrate.
Several attempts have been made to increase the strength of the interface. U.S. Pat. No. 4,604,106, to Hall et al. discloses a transition layer interface that gradually transitions between the properties of the super-hard material and the substrate material at the interface between them to resist delamination. Although this method appears to yield satisfactory results, it requires expensive and time-consuming fabrication techniques. Other patents, such as commonly assigned U.S. Pat. No. 5,351,772, Oct. 4, 1994 to Smith, provide a non-planar interface between the diamond table and substrate. U.S. Pat. No. 5,355,969 to Hardy et al. is another example of the non-planar interface between the super-hard and substrate.
At any rate, most attempts to incorporate diamond or other super-hard materials into the cutting structures of earth-boring bits of the rolling-cutter variety employ a non-diamond substrate material in addition to the super-hard material.
A need exists, therefore, for earth-boring bits of the rolling-cutter variety having super-hard cutting elements that are relatively easily manufactured with a satisfactory combination of material properties.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide an earth-boring bit having super-hard cutting elements with satisfactory material properties.
These and other objects of the present invention are achieved by providing an earth-boring bit having a bit body and at least one bearing shaft depending inwardly and downwardly from the bit body. A cutter is mounted for rotation on each bearing shaft and includes a plurality of cutting elements arranged in circumferential rows. The circumferential rows include a gage row on the outermost surface of each cutter and several inner rows on each cutter inward of the gage row. At least one of the cutting elements in one circumferential row is formed fully or predominantly of super-hard material. The cutting element comprises a cutting end projecting from the surface of the cutter and generally cylindrical base secured in a socket in the cutter. The cutting end of the cutting element is formed entirely or predominantly of super-hard material and the base may be formed entirely or predominantly of super-hard material. According to the preferred embodiment of the present invention, the super-hard cutting element may be a heel or inner-row element secured to the cutter end and inner circumferential row.
According to the preferred embodiment of the present invention, the super-hard cutting element may be a gage-row element secured to the cutter in the gage row.
According to the preferred embodiment of the present invention, the super-hard trimmer cutting element has a chisel-shaped cutting end.
According to the preferred embodiment of the present invention, the super-hard gage-row, cutting element has a frusto-conical cutting end.
According to the preferred embodiment of the present invention, the super-hard material is selected from the group consisting of polycrystalline diamond, thermally stable polycrystalline diamond, natural diamond, and cubic boron nitride.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an earth-boring bit according to the present invention.
FIG. 2 is an elevation view of a super-hard cutting element for the heel or inner rows of an earth-boring bit according to the present invention.
FIG. 3 is an elevation view of a super-hard cutting element for the gage rows of an earth-boring bit according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the figures, and particularly to FIG. 1, an earth-boring bit 11 according to the present invention is illustrated. Bit 11 includes a bit body 13, which is threaded at its upper extent 15 for connection into a drillstring. Each leg or section of bit 11 is provided with a lubricant compensator 17 to adjust or compensate for changes in the pressure or volume of lubricant provided for the bit. At least one nozzle 19 is provided in bit body 13 to spray drilling fluid from within the drillstring to cool and lubricate bit 11 during drilling operation. Three cutters, 21, 23, 25 are rotatably secured to a bearing shaft associated with each leg of bit body 13. Each cutter 21, 23, 25 has a cutter shell surface including an outermost or gage surface 31 and a heel surface 41 immediately inward and adjacent gage surface 31.
A plurality of cutting elements, in the form of hard metal or super-hard inserts, are arranged in generally circumferential rows on each cutter. Each cutter 21, 23, 25 has a gage surface 31 with a row of gage elements 33 thereon. A heel surface 41 intersects each gage surface 31 and has at least one row of heel inserts 43 thereon. At least one scraper element 51 is secured to the cutter shell surface generally at the intersection of gage and heel surfaces 31, 41 and generally intermediate a pair of heel inserts 43.
The outer cutting structure, comprising heel cutting elements 43, gage cutting elements 33, and a secondary cutting structure in the form of chisel-shaped trimmer or scraper elements 51, combine and cooperate to crush and scrape formation material at the corner and sidewall of the borehole as cutters 21, 23, 25 roll and slide over the formation material during drilling operation. According to the preferred embodiment of the present invention, at least one, and preferably several, of the cutting elements in one or more of the rows is formed predominantly of super-hard material.
FIG. 2 is an elevation view, partially in section, of a super-hard cutting element 51 according to the present invention. Cutting element 51 comprises a generally cylindrical base 53, which is secured in an aperture or socket in the cutter by interference fit or brazing. Cutting element 51 is a chisel-shaped cutting element that includes a pair of flanks 55 that converge to define a crest 57. Chisel-shaped cutting element is particularly adapted for use as a trimmer element (51 in FIG. 1), a heel element (41 in FIG. 1) or other inner-row cutting element. A chisel-shaped element is illustrated as an exemplary trimmer, heel, or inner-row cutting element. Other conventional shapes, such as ovoids, cones, or rounds are contemplated by the present invention.
FIG. 3 is an elevation view, partially in section, of a super-hard gage-row insert 33 according to the present invention. Gage-row insert 33 comprises a generally cylindrical body 35, which is provided at the cutting end with a chamfer 37 that defines a generally frusto-conical cutting surface. The intersection between cutting surface 37 and flat top 39 defines a cutting edge for shearing engagement with the sidewall of the borehole.
Both chisel-shaped element 51 and gage insert 33 are formed predominantly of super-hard material. The term "super-hard material," as used herein, includes natural diamond, polycrystalline diamond, thermally stable polycrystalline diamond, cubic boron nitride, the material resulting from chemical vapor deposition (CVD) processes known as "thin-film diamond," or "amorphic diamond," and other materials approaching diamond in hardness and having material properties generally similar to diamond. All super-hard materials have measured hardness in excess of 3500-5000 on the Knoop scale and are to be distinguished from merely hard ceramics, such as silicon carbide, tungsten carbide, and the like.
The predominantly super-hard material insert is usually formed at high pressure and temperature conditions under which the super-hard material is thermodynamically stable. This technique is conventional and known by those skilled in the art. For example, a insert may be made by forming a refractory metal container or can to the desired shape, and then filling the can with super-hard material powder to which a small amount of metal material (commonly cobalt, nickel, or iron) has been added. The container then is sealed to prevent any contamination. Next, the sealed can is surrounded by a pressure transmitting material which is generally salt, boron nitride, graphite or similar material. This assembly is then loaded into a high-pressure and temperature cell. The design of the cell is dependent upon the type of high-pressure apparatus being used. The cell is compressed until the desired pressure is reached and then heat is supplied via a graphite-tube electric resistance heater. Temperatures in excess of 1350° C. and pressures in excess of 50 kilobars are common. At these conditions, the added metal is molten and acts as a reactive liquid phase to enhance sintering of the super-hard material. After a few minutes, the conditions are reduced to room temperature and pressure. The insert is then broken out of the cell and can be finished to final dimensions through grinding or shaping.
According to the preferred embodiment of the present invention, at least the cutting ends of elements 51, 31 are formed entirely of super-hard material. All super-hard materials contain at least traces of other materials. For instance, polycrystalline diamond employs cobalt as a binder during its formation process and cobalt remains in the material. As used herein, the term "entirely of" super-hard material is intended to include these traces of material other than super-hard material. The term "predominantly of" super-hard material is intended to exclude layers of super-hard material over substrates that comprise most of the volume of the element.
It may be desirable to provide a cutting element formed entirely of super-hard material with a portion of the element formed of a less wear-resistant and more easily formed material. For example, a 0.063 inch layer of conventional cemented tungsten carbide may be provided on the base of the cylindrical body of the element (opposite the cutting end) to protect the super-hard material while the element is press or interference fit into its aperture or socket in the cutter. Such a layer of hard metal may also be provided where a portion of the element requires tumbling, grinding, or other finishing operations. Such a layer of non-super-hard material is encompassed within the meaning of "predominantly super-hard material." Such a layer of non-super-hard material should constitute not more than about 10-20% by volume of the cutting element.
The earth-boring bit according to the present invention possesses a number of advantages. A primary advantage is that the earth-boring bit is provided with more efficient and durable cutting elements.
The invention has been described with reference to preferred embodiments thereof. It is thus not limited, but is susceptible to variation and modification without departing from the scope and spirit of the invention.
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An earth-boring bit has a bit body. At least one cantilevered bearing shaft depends inwardly and downwardly from the bit body and a cutter is mounted for rotation on the bearing shaft. The cutter includes a plurality of cutting elements, at least one of which has a generally cylindrical element body of hard metal. A pair of flanks extend from the body and converge to define a crest. The crest defines at least one sharp cutting edge at its intersection with one of the flanks.
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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 Application Ser. No. 60/742,235 filed Dec. 5, 2005, the entire disclosure of which is herein incorporated by reference.
FIELD OF INVENTION
The present invention relates to a method for estimating minimum miscibility enrichment for an injectant in an enhanced oil recovery candidate reservoir.
BACKGROUND
Producing hydrocarbons from an underground reservoir requires those fluids to be driven to the producing wells, and then lifted several hundred meters against the force of gravity. The large-scale behavior of a reservoir can be described by considering the drive energy of the reservoir and its surroundings. The producing lifetime of a reservoir may generally be categorized as follows:
Primary recovery: where the natural drive energy locked up in the reservoir and its surroundings is used to produce hydrocarbons Secondary recovery: where the natural drive energy of the reservoir is supplemented by injection of a fluid, normally water or gas Tertiary recovery: where residual hydrocarbons trapped after conventional secondary recovery techniques are mobilized by the injection of fluids that are not normally found in the reservoir (e.g. surfactants, steam, and polymers)
Enhanced oil recovery (EOR) involves methods of recovering more oil from a reservoir than can be obtained from the naturally occurring drive mechanisms such as solution gas drive (fluid expansion) or water influx. EOR involves the introduction of artificial/supplemental forces or energy into the reservoir for the purpose of aiding the natural drive mechanisms. EOR can occur at any stage in the production life, although it is usually relegated to secondary or tertiary aspects. Some types of EOR include water flooding, gas flooding, steam injection, and carbon dioxide injection.
Planning an EOR project demands meticulous attention to the various factors that influence the selection of an EOR candidate. Although EOR is a powerful technique for recovering more hydrocarbons from a producing reservoir, it is not always a commercially viable option. Traditionally the EOR potential of candidate reservoirs is evaluated using classical reservoir engineering techniques. Engineers quantify EOR potential one field at a time using numerical methods and field specific data. This process can be very time-consuming and often yields inaccurate or incomplete results. For purposes of this application, “gas flooding” refers to gas injected to access oil not accessible to a waterflood. In a gas flooding operation, “injected gas” refers to the gas injected. “Injectant” refers to an enriching agent such as propane, butane, hydrogen sulfide, or other substances added to the gas injected to improve recovery.
SUMMARY OF THE INVENTION
The present inventions include method for estimating minimum miscibility enrichment (MME) for an injectant used in gas flooding of a reservoir at a given operating pressure comprising performing a plurality of slim tube simulations for the reservoir, determining minimum miscibility pressure (MMP) for a plurality of injected gases, creating a plot of recovery factor (RF) vs. 1−(MMP−P)/MMP wherein P is the operating pressure of the reservoir having at least one of the plurality of injected gases, wherein 1−(MMP−P)/MMP is a dimensionless pressure, wherein the plot has having a y-intercept and slope, obtaining a recovery factor equation RF=i+s(1−(MMP−P)/MMP) wherein i is the y-intercept and s is the slope, determining a value for i, determining a value for s and calculating the recovery factor.
BRIEF DESCRIPTON OF FIGURES
FIG. 1 shows a linear correlation of MMP versus API gravity for the five injectants.
FIG. 2 shows an example set of slim tube simulation results for an enrichment experiment.
FIG. 3 shows recovery factor versus dimensionless pressure for West Lutong K/L oil and all injectant gases.
FIG. 4 shows recovery factor versus dimensionless pressure and enrichment (0%, 20% and 50% propane enrichment) for all oils.
FIG. 5 shows the slope of slim tube recovery factor versus dimensionless pressure plot, plotted versus propane mole fraction of the enriched gas.
FIG. 6 shows the intercept of the slim tube recovery factor versus dimensionless pressure plot, plotted versus propane mole fraction of enriched gas.
FIG. 7 shows an example of Level 1 screening options.
FIG. 8 shows an example of Level 2 screening options.
FIG. 9 shows an example of Level 3 screening options.
DETAILED DESCRIPTION
For purposes of this application, “gas flooding” refers to gas injected to access oil not accessible to a waterflood. In a gas flooding operation, “injected gas” refers to the gas injected. “Injectant” refers to an enriching agent such as propane, butane, hydrogen sulfide, and others added to the gas injected to improve recovery. “Target oil” is defined as the remaining oil in the reservoir, which is accessible by a gas flood. Target oil represents the EOR potential for a reservoir based on the volumetric sweep efficiency, the remaining oil saturation at a given watercut and a discount factor applied to account for the decrease in slim tube recovery at pressures lower than MMP. “Volumetric sweep” is defined as the volume of the swept zone divided by the total reservoir volume. Minimum miscibility pressure (“MMP”) is defined as the minimum pressure required for achieving miscibility. Minimum miscibility enrichment (“MME”) is defined as the mole fraction of propane (or other enriching agent such as butane, hydrogen sulfide, or others required to reach miscibility at a given pressure. “Recovery factor” refers to the slim tube recovery factor discussed that discounts recovery for cases with operating pressure below MMP. “STOIIP” stands for stock tank oil initially in place, and is defined as the stock barrels of oil initially in place.
Some basic concepts underpin the process of screening for an EOR candidate reservoir.
Oil and gas reservoirs contain both water and hydrocarbon, with the distribution of these fluids being controlled initially by a balance between gravity and capillary forces. Oil and water are immiscible which gives rise to a capillary force and thus a tension exists at the fluid interface. The forces required to move interfaces prevents oil from completely displacing water, leaving connate water saturation. These same forces also do not allow water imbibing back into the pore throat, either through water flooding or aquifer influx, to completely displace oil, leaving residual oil saturation.
Ideal recovery would then be the difference between initial and residual oil saturation, however in practice, recoveries are then controlled by two factors: (1) mobility ratio and (2) economic limit. Oil/water mobility ratio compares oil and water viscosities and relative permeability at a given saturation. Favorable mobility occurs when the viscosities of the oil and water are similar and unfavorable mobility occurs when there are large differences in viscosities, resulting in lower recovery factors for a similar pore volume injected. Economic limit, such as producing watercut or minimum oil production rate, affect the ultimate recovery of a reservoir, leaving behind remaining oil saturation—typically higher than the residual.
Understanding volumetric sweep efficiency is key to understanding how much of the reservoir oil has been contacted by a flood mechanism. Volumetric sweep efficiency is a combination of vertical and areal sweeps. Very discontinuous reservoirs have low areal sweep efficiency as they tend to be compartmentalized and require dense well spacing. Well-connected, laterally continuous reservoirs exhibit good communication between wells and typically require fewer wells, therefore high areal sweep efficiency. Reservoirs with large permeability variations or high Dysktra-Parsons coefficient (Vdp), a statistical quantification of how permeability varies in a given sample, flood out layers preferentially. Whereas reservoirs with low permeability variation tend to flood layers more uniformly. Permeability contrast controls vertical sweep efficiency. For purposes of screening, neither quantity can be calculated independently for each reservoir.
Unlike water and oil, gas and oil are mutually soluble at certain conditions. When gas and oil are soluble, the interfacial tension is significantly reduced allowing for ideal displacement. Few gases are instantly soluble in oil or first contact miscible. Most commercial gas injection projects undergo a more complex process of mixing either through vaporizing or condensing oil components into a gas rich phase continually over multiple contacts creating a transitional phase that has little to no interfacial tension with oil and the capillary forces that trap oil in the oil/water system cease to exist. The degree of solubility is a function of the oil and gas compositions and reservoir pressure and temperature. The minimum pressure required achieving miscibility is typically determined using laboratory slim tube experiments.
For many reservoirs, miscibility cannot be realistically achieved without fracturing the reservoir or injecting at unreasonably high surface pressures. To improve the miscible behavior at current reservoir conditions for a given solvent, oil components, such as propane, butane, hydrogen sulfide, or other substances can be added to “enrich” the gas. Propane and other intermediate components are known to improve, in this case lower, the required miscibility pressure.
Gravity segregation will impact vertical sweep efficiency and is captured in the overall sweep efficiency estimate. However, gas injected is typically less dense and less viscous than oil or water and therefore will have a tendency to flow vertically. In horizontal floods, gas migration to the uppermost reservoirs could reduce the vertical sweep efficiency. The effects are more pronounced in high permeability and or vertically continuous reservoirs. If known to be an issue, two options exist: (1) reduce pattern spacing or (2) increase injection rate.
In viscous dominated reservoirs, target oil is a function of remaining oil saturation water swept zones because a tendency is for a gas flood to follow the flow paths created by a preceding waterdrive. Target oil is by far the most critical parameter to understand when considering a gas flood. Based upon experience, attractive oil targets exceed 25% remaining oil saturation in swept zones. A less than expected target oil will undoubtedly worsen the efficiency, defined as the volume of gas required per incremental barrel recovered.
Sweep and gravity segregation calculations provide a good first step; however to better understand a gas flood, areal full field static and dynamic models are more suitable. Furthermore, to better understand the effects of vertical heterogeneity, smaller, more detailed models are useful for understanding processes in some embodiments of the invention.
Full implementation of gas flooding will often require new investment in facilities and wells. This investment decision will be supported by the results of a gas injection pilot.
One embodiment of the invention using four levels of screening to synthesize field data into a manageable number of opportunities is described below:
Level 1: Limit the target reservoirs to those with significant long range EOR potential Level 2: Limit the pilot targets to those most likely to achieve miscibility Level 3: Limit pilot choices to locations with suitable gas sources and well availability, and where production or monitored response is within the available time frame Level 4: Select the highest-ranking options in level 3 and build prototype models to estimate gas flood performance
In some embodiments of the invention, a method for selecting a candidate reservoir for enhanced oil recovery from a plurality of reservoirs comprises selecting a reservoir, calculating a normalized raw score based on target oil for the reservoir (S Target Oil ) and calculating a normalized raw score based on recovery factor for the reservoir (S Recovery Factor ). The method may further include calculating a normalized raw score based on time frame for injection (S Timing ), calculating a normalized raw score based on Lake Gravity number for the reservoir (S Gravity ), calculating a normalized raw score based on spacing for wells in the reservoir (S Wells ), and/or calculating a normalized raw score based on facilities (S Facilities ). These scores are then each multiplied by a respective weighting factor and added together to obtain a total score for the reservoir. The total scores of each reservoir are then compared to total scores for other reservoirs and a ranked list of the candidate reservoirs is produced.
Advantages of some embodiments of the invention may include one or more of the following:
Quick screening of a large number of candidates Ability to calculate the recovery factor under immiscible conditions Emphasis on the use of actual performance data to predict EOR potential Flexible enough to allow for review of basin-wide potential as well as generation of a candidate list for pilot consideration Includes notional pilot costs Screening tool allows user to define screening criteria
Those of skill in the art will appreciate that many modifications and variations are possible in terms of the disclosed embodiments, configurations, materials, and methods without departing from their spirit and scope. Accordingly, the scope of the claims appended hereafter and their functional equivalents should not be limited by particular embodiments described and illustrated herein, as these are merely exemplary in nature.
EXAMPLE
A screening approach was presented that estimates EOR potential under gas flooding under various reservoir conditions using different solvents for Baram Delta (BDO) reservoirs. The customized screening tool allowed for rapid screening of over 1,000 candidates.
The nine offshore Baram Delta fields were discovered in 1969, and contain an estimated 4,000+ MM stock tank barrels in place ranging in gravity between 20 and 40 API. The productive reservoirs range in depth from 2,000 to 9,000 ftss. Historical production rates have been relatively flat at 80-100,000 barrels of oil per day maintained primarily through infill drilling and new infield development and/or expansion. Most reservoirs are supported by strong aquifer drives with two notable exceptions at Baronia (RV2 reservoir)—currently under waterflood, and several Baram reservoirs currently under depletion.
After 30 years of production, several of the large producing reservoirs have achieved high recovery efficiencies (>45%) and have begun producing at high watercuts. Reviewing published data, by the Journal of Petroleum Technology on EOR, suggests that gas flooding is appropriate for commercial EOR projects in the depth and API range of most BDO fields.
Due to the large number of reservoirs to be considered, a systematic approach was developed to provide a hierarchical screening, which includes the following objectives:
1. Assess the full EOR potential for both miscible and immiscible gas flooding 2. List reservoirs in order of attractiveness for eventual full scale gas injection 3. Identify a suitable location for a gas EOR pilot & identify a suitable injectant to use for the pilot
1. Assess the Full EOR Ptential for Both Miscible and Immiscible Gas Flooding
Estimating Miscibility Pressure
No actual MMP data for BDO oils was available for this screening exercise. Twelve old, in some cases 30 years old, PVT datasets spanning a wide range of API (20-40 API) were available and modeled with an equation-of-state PVT modeling package. Regression on the parameters of the equation of state model was used to obtain matches to the experimental data.
Fourteen component models were then converted into input for a simulator for which a slim tube model was available. Slim tube experiments were performed for each oil at various pressures and injectants.
Linear correlations between API gravity and simulated MMP, shown in FIG. 1 , were developed to estimate MMP for reservoirs with only API and no PVT data.
MMP=A+B*API (1)
The values for A and B are given below in Table 1.
TABLE 1 A and B fitting parameters Injectant A B CO2 8503.4 −154.9 70% CO2, 30% C1 7204.1 −93.4 Wet HC Gas 7886.5 −112.4 Mid HC Gas 7871.6 −76.5 Dry HC Gas 13398.0 −197.8
Recovery Factor and MME
To develop correlations for all injectants, a more useful quantity to plot against is a dimensionless scaled pressure, P dim , which is written as the following expression:, 1 −(MMP−P)/MMP, wherein P is the operating pressure.
All recovery curves tend to collapse into one curve, as shown in FIG. 3 , from which the following correlation was developed:
RF=i+s (1−( MMP−P )/ MMP ) (3)
Similarly, plotting the scaled pressure, P dim , versus recovery factor for the enrichment cases shows a similar behavior as shown in FIG. 4 .
For screening purposes, one function was derived based on all data, both enriched and non-enriched gas. Any given slim tube simulation can then be characterized by its MMP, slope and intercept of recovery factor versus dimensionless pressure as shown in FIG. 5 and FIG. 6 , and maximum recovery factor. The following equations for i and s are as follows where X C3 is the mole fraction of propane in the injected gas:
i= 0.1828−0.42617 X C3 (4)
s= 0.8172+1.5956 X C3 +7.1929 X C3 2 (5)
Recovery factor for any pressure and propane enrichment can now be calculated. To calculate MME level, the equations were rearranged first calculating MMP ne for the non-enriched gas at the operating pressure, P op :
P
d
=
1
-
(
MMP
ne
-
P
op
)
MMP
ne
(
6
)
Expanding equation (3) yields the following equation, where RF ne is the estimated recovery at P op and X C3,ne is the mole fraction of propane in the non-enriched gas:
RF ne =0.1828−0.4262 X C3,ne +(0.8172+1.5956 X C3,ne +7.1929 X C3,ne 2 ) P d (7)
By definition, MME is the mole fraction of propane required to reach miscibility or when P=P op . Setting the RF ne =RF max yields the following equation for which X MME can be solved:
7.1929 P d X MME 2 +(1.5956 P d −0.4262) X MME +(0.1828+0.8172 P d −RF max )=0 (8)
Volumetric Sweep
Assuming no recovery from unswept zones, the sweep is the estimated ultimate recovery (EUR) divided by the recovery factor in the swept zone at a given watercut.
E
s
=
EUR
1
-
S
_
0
S
oi
(
9
)
EUR can be estimated from water drive performance and S oi can be derived from saturation height function modeling. In this example, permeability, porosity and capillary pressure data is not available for every reservoir, therefore for screening, S oi is taken to be 82% based on saturation-height modeling of typical BDO sandstone, 300-600 md permeability.
Classic Buckley-Leverett (1942) and Welge (1952) techniques were used to estimate remaining oil saturation or S o in the swept zone. For fractional flow calculations, it is more convenient to work in terms of S w or the average water saturation in the swept zone using the following equation:
S o =1 − S w (10)
Based on fractional flow theory, average water saturation can be represented by:
S w _ = S w 2 + ( 1 - f w ) ⅆ f w ⅆ S w ( 11 )
where S w2 is the water saturation at the producing well, f w is the fractional flow at given watercut and df w /dS w calculated at saturation S w2 . Fractional flow and the derivative of fractional flow can be calculated using the following equations and Corey model for relative permeability:
f
w
=
1
(
1
+
k
ro
2
k
rw
2
μ
w
μ
o
)
(
12
)
k
ro
2
=
k
ro
,
i
(
1
-
S
w
2
-
S
orw
S
oi
-
S
orw
)
N
o
(
13
)
k
rw
2
=
k
rw
,
Sor
(
S
w
2
-
S
wc
)
1
-
S
orw
-
S
wc
)
N
w
(
14
)
Limited acid and asphaltene data was available, which along with oil and rock properties control wettability—which then influences Corey exponents and residual oil saturation. Because oil character is a major influence, three sets of relative permeability parameters were derived as a function of API and are shown in the table 2 below:
TABLE 2
Input SCAL parameters
API Gravity
<25
25-35
>35
Swc
0.18
0.18
0.18
Sorw
0.19
0.19
0.19
Soi
0.82
0.82
0.82
krw, sorw
0.41
0.44
0.48
kro, cw
1.00
1.00
1.00
Nw
2.53
2.29
2.14
No
2.97
3.28
3.59
In this example, relative permeability parameters were assigned to each reservoir based on API and used to calculate remaining oil saturation at a given watercut.
Target Oil
Target oil represents the EOR potential for the reservoir and can be calculated as follows:
TgtOil= E s * S o *RF *STOIIP (15)
where E s represents volumetric sweep efficiency, S o is remaining oil saturation at a given watercut and RF is the discount factor applied to account for the decrease in slim tube recovery at pressures lower than MMP.
RF =Recovery P op /Recovery MMP (16)
Sweep under gas flood is expected to be similar to sweep under water drive, which in viscous dominated cases is a good first approximation. Errors in STOIIP or sweep do not affect target oil calculations, as they are inversely proportional, so estimates using this method are valid for estimating target oil.
Project Timing
In this example, the screening tool requires user input of pilot injection rate and time frame to estimate total to be injected:
V=365.25TQB g (17)
where T is the injection time in years, Q is the gas injection rate in mscf/d and B g is the gas formation volume factor. Assuming one pore injected into the reservoir, the distance from injector to an observation well is calculated as follows:
L
=
5.615
V
π
S
oi
ϕ
h
(
18
)
This distance is compared to known well to well distances for each reservoir and requires a newly drilled well if the minimum spacing to inject one pore volume is exceeded. Well to well distances affects the gravity calculation and if a new well is required, this impacts cost of the pilot.
Gravity Override
The tendency of injected gas to gravity segregate can be estimated from the Lake Gravity Number, which is a ratio of particle movement laterally versus vertically and is given by:
G = t flowbetweenwells t segregatevertically = k v k rw Δρ g μ w A cross - section q L h ( 19 )
where Δpg is the density difference between gas and water (gas density is calculated from the NIST14 database for the different solvents for a given reservoir pressure and temperature), k v is the vertical permeability, μ w is water viscosity (the reservoir at the start of gas flooding is mostly water), and q is injection rate. Low gravity number is more favorable in BDO reservoirs to achieve high vertical sweep efficiency. For each reservoir, a gravity number was calculated using the assumed well spacing for the pilot.
Capital Costs and Well Inventory
Location specific capital costs were developed for each field location. If the minimum required well spacing for the pilot was less than the current well spacing, the cost of one additional well was added to the facilities cost. For screening, a minimum of two wells is required for piloting, but may not reflect ultimate pilot design.
The cost of injectants is assumed to be the same for all cases and therefore was not included in the screening exercise. Areas with a large number of wells available have a high likelihood of finding suitable wells for a pilot and thus will be considered in the ranking.
Ranking Factors
In this example, a total score for each reservoir is calculated which is combination of normalized raw score for each category multiplied by a weighting factor.
S tot =w TargetOil S TargetOil +w RecoveryFactor S RecoveryFactor +w Timing S Timing +w Gravity S Gravity +w Wells S Wells (20)
The results presented assume the following weighting factors:
w Targetoil =4 w RecoveyFactor =2 w Timing =1 w Gravity =1 w Wells =1
In this example target oil receives the highest ranking to focus on those reservoirs with the highest EOR potential. Recovery factor refers to the slim tube recovery factor discussed that discounts recovery for cases with operating pressure below MMP. Achieving miscibility in the reservoir is critical to ensure ideal displacement and therefore is weighted higher. Timing, gravity and wells all receive low weighting, as they are, to some extent, controllable either through drilling more wells or increasing injection rate.
A spreadsheet based screening tool was created to perform rapid screening under various criteria. The most recent reserves database was used as input data, which includes the following data items:
Field, Block and Reservoir Name STOIIP Estimated Ultimate Recovery from current operations Current Cumulative Oil Production Current Reservoir Pressure Initial Reservoir Pressure Reservoir Temperature Oil API gravity Gas-Oil ratio Reservoir Depth
The data was validated to the extent possible and not all reservoirs had a complete set of data above. For large fields, most data was present, although some reservoirs lacked critical data such as reservoir depth and initial pressure, which prevents the full range of screening.
The tool follows the four levels described earlier with the options outlined below and shown in FIGS. 7 through 9 . The choices made in each level control which reservoirs “pass” and continue on to the next level. For overall BDO wide EOR potential, all reservoirs pass Level 1.
Level 1; (a) field/block/sand to include, (b) specify min/max EUR, (c) max remaining reserves, (d) include/not include reservoirs never produced and (e) apply minimum STOIIP Level 2; (a) specify injectant composition, (b) specify whether gas is to be enriched; if enrich, then specify enrichment level or MME, (c) specify if immiscible candidates screen through, and (d) specify MMP error bound on MMP calculation that defines whether a reservoir is miscible or not Level 3; (a) specify abandonment watercut—used to estimate remaining oil saturation, (b) specify pilot duration, (c) specify gas injection rate, (d) source gas carried over from Level 2, and (e) weighting factors to be used in scoring Level 4; In this example, this was not employed. If this level were to be used, one would create a database of recovery curves, both modeled and actual, to compare calculated estimates to numerical simulation results
2. List Reservoirs in Order of Attractiveness for Eventual Full Scale Gas Injection
The screening spreadsheet was first used to estimate total EOR for six BDO fields. All restrictions were removed allowing for all reservoirs to pass through. Of the 1,000+ reservoirs, only 123 reservoirs had sufficient data to do calculations; these reservoirs represent 52% of the total STOIIP. The values have been normalized against the total potential and shown in Table 3. The four highest EOR potential areas are highlighted below and include a mixture of both miscible and immiscible targets. West Lutong interestingly has both miscible and immiscible targets.
TABLE 3
Individual Field EOR Potential
Normalized EOR Potential
Field
Miscible
Immiscible
Bakau
0.01
0.00
Baram
0.38
0.01
Fairley
0.04
0.00
Siwa
0.00
0.01
Tukau
0.00
0.18
West Lutong
0.19
0.17
When considering different injectants, pure CO2 is the clear standout in terms of the largest EOR potential. All values are normalized against the highest reserves potential value (from CO2) in Table 4. Injecting dry gas or 90% methane reduces the overall potential by 35%.
TABLE 4
EOR Potential for Various Injectants
Normalized EOR Potential
Injected Gas
Miscible
Immiscible
Total
CO2
0.63
0.37
1.00
70% CO2, 30% C1
0.17
0.71
0.88
83% C1
0.00
0.74
0.74
90% C1
0.00
0.65
0.65
However, it is worth noting that similar potential as CO2 injection was obtained by enriching 83% methane gas with propane up to 30%.
A list of the top ranking candidates is shown in Table 5 below with those chosen for further static and dynamic modeling or Level 4 evaluation highlighted.
TABLE 5 Top EOR Potential Candidate List Field Block Tops West Lutong Block 1-MAIN M/N West Lutong Block 1-MAIN K/L Tukau Block 1 J1/J9 Baram Block 4 S8.1/S14.5 Tukau Block 2 J2/J9 Baram Block 3 S11.1/13.6 Baram Block 3 S8.1/S9.2 Baram Block 2 N1.0/O3.0 Baram Block 5 S13.4/S14.1 West Lutong Block 1A-DEEP U1/W Tukau Block 1 E9/G3
3. Identify a Suitable Location for a Gas EOR Pilot & Identify a Suitable Injectant to Use for the Pilot
The purpose of prototype modeling was to refine recovery estimates for the top ranking candidates in Level 3. No static or dynamic models exist for any of the fields considered. However, a recent completed field study of the nearby Bokor field was deposited in the same delta as the candidate fields and thus considered an adequate analogue to derive static model properties.
The process followed this approach:
Identify zones within the Bokor model of analogous depositional environment, e.g. shoreface, tidal channel, etc. Import property grids into a proprietary model building software, and cookie cut out the model area and grid porosity sized specifically to the well spacing of interest; for instance the well spacing at West Lutong. Dozens of layer porosity grids were then exported for the different depositional environments. Each field's layers assigned a depositional environment Using the deckbuilder, customized prototype models were built as follows:
Grid layers added representing actual producing intervals Layer porosity grids randomly selected from grids generated above—depositional environment dependent. Porosity distribution used to assign values, again by depositional and rock type Permeability assigned using field specific phi-k relationships derived from core Capillary pressure and relative permeability curves assigned to each grid cell—a function of permeability Well constraints applied from actual rates and pressures Field specific FWL applied Aquifer model applied where appropriate
TABLE 6
Comparison of recovery, CO2 injection-80% HCPV Injected
Level 3
Simulation
Incremental
Incremental
Recovery
Recovery
Field
Block
Tops
Factor (%)
Factor (%)
West Lutong
Block 1
KL
24%
8%
West Lutong
Block 1
MN
20%
10%
Tukau
Block 1
E9/G3
10%
6%
Tukau
Block 1
J1/J9
12%
17%
Baram
Block 4
S8.1/S14.5
15%
14%
TABLE 7
Comparison of recovery, 35% Propane enriched HC Gas-80%
HCPV Injected
Level 3
Simulation
Incremental
Incremental
Recovery
Recovery
Field
Block
Tops
Factor (%)
Factor (%)
West Lutong
Block 1
KL
29%
11%
West Lutong
Block 1
MN
21%
14.1%
Tukau
Block 1
E9/G3
11%
12.8%
Tukau
Block 1
J1/J9
16%
19.6%
Baram
Block 4
S8.1/S14.5
15%
16.1%
The cases that correlated best with Level 3 estimates were fully miscible or operating at a pressure well above MMP. Cases such as West Lutong K/L operating ˜400 psi below MMP, considered immiscible, shows a significantly lower recovery factor reflecting impaired sweep efficiency similar to the dry gas floods. West Lutong M/N operated at near miscible conditions, within 100 psi of MMP.
The choice of pilot location narrowed to two candidates, Baram S8 and West Lutong M/N. Tukau J1/J9, although showed promising incremental recovery, applies only to a small portion of the Tukau STOIIP, which is largely comprised of heavier oil. Baram and West Lutong miscible/near miscible candidates represent almost ⅔ of all EOR potential of the six fields considered.
In an attempt to further differentiate the two final candidates, five key criteria were reviewed and are shown in Table 8.
TABLE 8
Comparison of top candidates for pilot selection
West
Ranking Parameters
Baram
Lutong
1. EOR potential
3
2
2. Structural simplicity
1
3
3. Cost
2
2
4. Producer pilot well spacing
1
1
5. Pilot economics
3
2
Total
10
10
Legend
1 = Poor
2 = Fair
3 = Good
4 = Excellent
Although the data indicates that both opportunities could be pursued, the screening tool and method provides the operator with enough information to make a reasonable decision. The same screening tool and method have been used with success to select EOR candidates in various other reservoirs.
|
A method for estimating minimum miscibility enrichment (MME) for an injectant used in gas flooding of a reservoir at a given operating pressure comprising performing a plurality of slim tube simulations for the reservoir, determining minimum miscibility pressure (MMP) for a plurality of injected gases, creating a plot of recovery factor (RF) vs. 1−(MMP−P)/MMP wherein P is the operating pressure of the reservoir having at least one of the plurality of injected gases, wherein 1−(MMP−P)/MMP is a dimensionless pressure, wherein the plot has a y-intercept and slope, obtaining a recovery factor equation RF=i+s(1−(MMP−P)/MMP) wherein i is the y-intercept and s is the slope, determining a value for i, determining a value for s and calculating the recovery factor.
|
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF INVENTION
This invention relates generally to tractor front loader equipment, and more particularly to quick disconnect apparatus which is operable by a single operator for attaching front loader tools such as buckets, spikes, bag lifters, grabs, pallet forks and the like.
BACKGROUND OF THE INVENTION
Dedicated tractors are known which incorporate a fixed tool for performing a particular function. For example, a snow plow tractor incorporates a plow which is attached to a loader assembly and is movable for plowing and lifting snow into a pile. Other examples include farm tractors for lifting hay or spreading manure. An obvious disadvantage to these dedicated tractors is the duplication of the motorized cab.
DESCRIPTION OF THE PRIOR ART
General purpose tractors include an extendable loader assembly for accommodating removable tools so that only one motorized cab is necessary for performing a variety of functions. Removable tools for some tractors require at least two persons for installation. Such tractors are first positioned so that the loader assembly is near the tool. The operator of the tractor in conjunction with a second person then manually aligns the tool to the tractor loader assembly. Next, coupling pins or bolts are inserted through the tool and the loader assembly. This alignment procedure usually requires the coupling pins or bolts to be forced into place and requires tools such as a hammer or wrench to be carried with the tractor.
Another limitation of conventional coupling apparatus is that the coupling pins or bolts may be dropped or lost. The tractor operator must carry additional pins or bolts as replacements.
It will be appreciated that an improved coupling apparatus for tractor front loaders is needed which may be connected and disconnected by a single person, is safe to operate, and requires no external tools to engage.
SUMMARY OF THE INVENTION
The coupling apparatus of the present invention provides quick and simple change of front loader tools on a tractor. The present invention increases tractor utility and efficiency by providing safe, single operator connection and disconnection of tractor front loader tools.
One advantage of the present invention is that no external tools are required for a single operator to safely engage and disengage tractor front loader tools. Another advantage of the invention is that no detachable parts are necessary to secure the tools to the tractor. Yet another advantage is that the coupling apparatus incorporates a self leveling feature making alignment of the tool with the quick disconnect apparatus easy.
These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings and to the accompanying specification.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numerals and letters indicate corresponding elements throughout the several views:
FIG. 1 depicts a partial side view of a tractor with its front loader incorporating the present invention which is further detailed in FIGS. 2, 3 and 4;
FIG. 2 depicts a partial perspective view of the front loader with the present invention engaged between the loader and a bucket;
FIG. 3A and 3B depict detailed first and second cutaway views of the present invention in an engaged and a disengaged position respectively; and
FIG. 4 depicts a detailed view of a rotary to linear translator mechanism employed with the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description of the preferred embodiment, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration a specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
Reference is now made to FIG. 1 which depicts a partial side view of a tractor with its front loader incorporating a quick disconnect apparatus in accordance with the principles of the present invention. A tractor 10 having a hydraulically activated front loader 12 has attached to it a bucket tool 14 with the aid of the present invention. The front loader 12 includes at least two anchors 16A and 16B symmetrically disposed on either of its ends and at least two alignment sleeves 26A and 26B also symmetrically disposed on either of its ends, further detailed in FIGS. 2, 3 and 4. Symmetry of elements in the present invention is denoted throughout the drawings and disclosure by the notation A and B.
It will be apparent to those skilled in the art upon a reading of the present specification that the present invention is applicable to a front loader 12 activated by means other than hydraulics. It should also be understood that the present invention is applicable to other machines which benefit from a quick disconnect apparatus for releasing detachable tools.
Reference is now made to FIG. 2 which depicts a partial perspective view of the front loader 12 engaged with a bucket 14. The bucket 14 as well as other detachable tools such as, but not limited to, a manure fork, a hay spike, a pallet fork, and a grab, include at least two hook members 20A and 20B which are operatively engageable with the two anchors 16A and 16B forming a part of front loader 12. Anchors 16A and 16B extend substantially coaxial to the arc of hook members 20A and 20B. In the preferred embodiment, the portion of the front loader 12 which attaches to the bucket 14 comprises first and second member pairs (21A, 22A) and (21B, 22B) coupled together by orthogonal beams 24A and 24B and transverse members 25 and 27 thereby defining a rectangular coupling frame. Beams 24A and 24B include anchors 16A and 16B coupled to members 21A and 21B and sleeves 26A and 26B respectively. Sleeves 26A and 26B are disposed below and substantially parallel to anchors 16A and 16B. Securing pins 28A and 28B travel through sleeves 26A and 26B into securing receptacles 38A and 38B defined in sidewalls of adjacent bucket 14 for securing to front loader 12. Securing pins 28A and 28B travel coaxially with sleeves 26A and 26B and are pivotally coupled to linear translator arms 30A and 30B with hinge pins 32A and 32B respectively. A second end of arms 30A and 30B are pivotally coupled to engagement arm 36 through plate member 46 with coupling pins 40A and 40B respectively, best seen in FIG. 4 and described in more detail hereinbelow.
A coil spring 37 has its first end movably attached to engagement arm 36 and its second end rigidly attached to the front loader 12 provides biasing in the engaged or disengaged position. That is, spring 37 urges securing pins 28A and 28B through sleeves 26A and 26B into securing receptacles in bucket 14 when engagement arm 26 is rotated clockwise as viewed in FIG. 2. Likewise, spring 37 urges retraction of securing pins 28A and 28B out of the securing receptacles 38A and 38B into sleeves 26A and 26B when engagement arm 36 is rotated counterclockwise as viewed in FIG. 2. The front loader 12 may be engaged with bucket 14 so that anchors 16A and 16B couple with hook members 20A and 20B and lifted so that bucket 14 pivots about hook members 20A and 20B on anchors 16A and 16B. The operator may then easily rock bucket 14 on hook members 20A and 20B about anchors 16A and 16B to align securing receptacles 38A and 38B in bucket 14 with sleeves 26A and 26B. Securing pins 28A and 28B are then easily fitted therethrough.
Reference is now made to FIGS. 3A and 3B which depict partial cutaway views of the present invention in an engaged and a disengaged position. As can be seen from FIG. 3A, pins 28a and 28b extend through sleeves 26a and 26b respectively, on front loader 12 and through securing receptacles 38a and 38b on bucket 14 thus operatively engaging bucket 14 to the front loader 12. As engagement arm 36 is rotated counterclockwise as seen in FIG. 3B, securing pins 28a and 28b retract from securing receptacles 38a and 38b in bucket 14 into sleeves 26a and 26b of the front loader 12 thus disengaging bucket 14 from front loader 12. Arms 30a and 30b are pivotally attached on a first end by hinge pins 32a and 32b to securing pins 28a and 28b. Pins 40a and 40b pivotally attach a second end of arms 30a and 30b to plate member 46 for engagement with engagement arm 36. Spring 37 imparts a force normal to the top surface of engagement arm 36 thus urging a torque in the clockwise or counterclockwise direction on arm 26.
FIG. 3A depicts securing pins 28a and 28b urged in the engaged position. As engagement arm 36 is rotated counterclockwise as best seen in FIG. 3B, the normal force imparted on by spring 37 lessens until engagement arm 36 reaches a twelve o'clock position with respect to the rotational axis of pin 34. As the arm travels further in a counterclockwise direction, the normal force exerted by spring 37 on engagement arm 36 reverses surfaces. The engagement bar 36 thus urges pins 28a and 28b to retract completely from securing receptacles 38a and 38b in bucket 14 and into sleeves 26a and 26b in front loader 12.
Reference is now made to FIG. 4 which depicts a more detailed view of a rotary to linear translator practiced in accordance with the principles of the present invention. The translator is activated by rotating engagement arm 36 in a clockwise or counterclockwise direction. Plate member 46 is rotatably attached to arm 36 through pin 34. Pins 40A and 40B couple linear translator arms 30A and 30B to plate member 46. Pins 40A and 40B are fixed to plate member 46 off the rotational axis of pin 34. Engagement arm 36 being rigidly attached to pin 34, imparts a torque on pin 34 and the attached plate member 46. As engagement arm 36 is rotated about the axis of pin 34, plate member 46 imparts a tangential force on coupling pins 40A and 40B causing arms 30A and 30B to linearly translate. The linkage between arms 30A and 30B and plate member 46 is such that rotational movement is translated into linear movement in a direction substantially coaxially with pins 28A and 28B. Bushings 42 and 44 provide a bearing surface for pin 34 and engagement arm 36 to rotate thereon. Spring 37 is rigidly attached at point 48 which is stationary with respect to the rotation of pin 34 and may be a part of the front loader 12.
The pivot pin 34 is supported for rotational movement relative to the coupling frame of the front loader by a support plate 49. The support plate 49 is attached to the front loader coupling frame, and has an open pocket 51 in which the pivot pin 34 is received. The bushings 42, 44 are mounted on the pivot pin 34 intermediate the plate member 46 and the engagement arm 36, with the bushing 42 and bushing 44 straddling the support plate 49.
As best seen from FIGS. 3A and 3B, clockwise rotation of engagement arm 36 linearly extends pins 28A and 28B through sleeve 26A and 26B into securing receptacles 38A and 38B respectively. Likewise, counterclockwise rotation of engagement arm 36 linearly retracts pins 28a and 28b from securing receptacles 38A and 38B into sleeves 26A and 26B respectively. It is to be understood that other rotational to linear translator mechanisms may be used without departing from the scope of the present invention. It is to be also understood that a linear to linear translator may also be used without departing from the scope of the present invention. Those skilled in the art will recognize other expedients for translation mechanisms which may be practiced with the securing pins 28A and 28B without departing from the scope of the present invention.
While the preferred embodiment example has been discussed herein, the present invention is not so limited, and various aspects may be applied to other applications wherein a quick disconnect securing pin mechanism would be beneficial. The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustible or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
|
A quick disconnect apparatus for attaching tools to a tractor front loader is disclosed which aligns quickly and is easily engageable and disengageable by a single operator.
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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 new and useful improvements in grain bin construction, particularly construction of grain bins adjacent the base and floor area thereof which is normally subject to the ingress of moisture with subsequent damage occurring to grain stored therein.
Normally, a base is provided upon which an outwardly facing angle iron is secured. The lower perimetrical edge of the grain bin engages the outer surface of the vertical flange of the angle iron and is bolted thereto with or without a sealant being provided. However, it will be appreciated that such a construction is difficult to seal both between the wall of the grain bin and the vertical flange of the angle iron and, more importantly, between the horizontal flange of the angle iron and the floor of the bin which is normally made of concrete.
Consequently, moisture often seeps into the grain bin from the exterior thereof and causes the grain to become damp, particularly the grain adjacent the lower perimetrical corners of the grain bin. This not only causes grain spoilage, but also may induce the generation of heat with the subsequent damage and possibility of fire occurring.
SUMMARY OF THE INVENTION
The present invention overcomes these disadvantages by providing a grain bin including in combination a perimetrical wall, a floor including an upper, substantially horizontal surface portion and an outer, substantially vertical perimetrical edge portion, and means to secure said wall of said floor adjacent the lower perimetrical edge portion of said wall and water impervious shield means extending from adjacent said lower edge of said wall over the perimetrical edge portions of said floor and downwardly to cover the vertical edge portion of the floor in moisture shedding relationship, said means to secure said wall to said floor including a member extending around said floor adjacent the perimeter thereof, said member including an upwardly extending flange and a horizontal flange, said member being secured to said floor by said horizontal flange and to said wall by said upwardly extending flange, said shield means being secured to said wall and extending over the perimetrical edge of said floor and downwardly therefrom.
Another advantage of the invention is to provide a device of the character herewithin described which can either be incorporated in existing grain bin constructions or can be incorporated in new grain bin construction.
Another advantage of the invention is to provide a device of the character herewithin described which, in one embodiment may provide a moisture shedding construction formed from the lower perimetrical wall of the grain bin per se.
A still further advantage of the invention is to provide a device of the character herewithin described which is simple in construction, economical in manufacture and otherwise well suited to the purpose for which it is designed.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary cross sectional view of the junction between the lower end of the bin wall and the floor with one embodiment of the invention incorporated therein.
FIG. 2 is a view similar to FIG. 1, but showing an alternative embodiment.
FIG. 3 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 4 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 5 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 6 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 7 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 8 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 9 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 10 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 11 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 12 is a view similar to FIG. 1, but showing a further embodiment.
FIG. 13 is a view similar to FIG. 1, but showing a further embodiment.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Proceeding therefore to describe the invention in detail, reference should first be made to FIG. 1 in which reference character 20 illustrates the lower corner or perimetrical portion of a grain bin which includes a substantially vertical wall 21 formed in this instance of corrugated metal, secured upon a substantially horizontal floor 22 which is normally formed from concrete. However, it will be appreciated that both the floor and the grain bin wall can be manufactured from other materials, if desired.
Means are provided to secure the grain bin wall 21 to the floor and in FIG. 1 consists of a member collectively designated 23. In this embodiment, the member is in the form of an angle iron having a substantially vertical flange 24 and a substantially horizontal flange 25 with the horizontal flange 25 facing inwardly of the bin wall 21.
The perimetrically extending flange 23 is secured to the upper surface 26 of the floor by means of bolt means 27 although other fastening means can be provided.
It is situated spaced slightly inwardly from the outer perimetrical edge 28 of the floor 22 as clearly shown and a shield collectively designated 29 is provided as will hereinafter be described. In this particular embodiment, the shield is preferably made of sheet metal but synthetic plastic or other suitable material can be used. It includes the substantially perimetrically extending vertical portion 30 which then curves downwardly and outwardly over the outer corner 31 of the floor and then extends outwardly and downwardly at an angle indicated by reference character 32 as clearly illustrated. It is secured as by bolt assembly 33 or the equivalent, between the lower perimetrical edge portion 34 of the wall and adjacent the upper perimetrical edge 35 of the vertical flange 24 of the member 23 and it will be appreciated that suitable sealant (not illustrated) may be provided between the wall and the shield and between the shield and the vertical flange as well as between the horizontal flange 25 and the floor 26.
This provides a water or moisture shedding configuration so that there is no possibility of moisture lodging in the area indicated by reference character 36 which is normal and which provides the ingress of moisture under certain conditions.
The other figures of the drawings show variations of this construction and where applicable, corresponding reference characters have been used.
In FIG. 2, the inwardly facing angle iron member 23 is situated quite close to the outer perimetrical edge 28 of the floor so that the shield 29A, in this embodiment, is substantially vertical and extends from between the wall 21 of the bin and the vertical flange 24 of the member 23, substantially vertically over the perimetrical edge 28 of the floor, as clearly illustrated. Once again the necessary sealant materials are preferably provided.
It will, of course, be appreciated that shield 29A could be made integral with and as an extension of the lower side of the wall 21 and the construction illustrated in FIG. 2 and described herein is considered to include this alternative even although it is not illustrated specifically.
In FIG. 3, the member 23 is provided with a vertical flange 24A which is substantially longer than the horizontal flange 25. In this embodiment, the lower perimetrical portion 34 of the wall is extending downwardly and over the perimetrical edge 28 of the floor and acts directly as the shield, as clearly illustrated. Once again, as in all the embodiments, desirable sealing materials may be used and in fact are preferable, but not essential. However, it is desirable if only to seal the bolt assemblies 33 where they pass through various components.
FIG. 4 shows an embodiment in which the member 23 is in the form of a V-shaped angle iron with the substantially vertical portion 24B curving inwardly and upwardly as clearly shown and with the shield 29 including the diagonally directed portion 37 terminating in the downturned flanged portion 32.
FIG. 5 shows a similar configuration to FIG. 4 except that the member 23 may be formed rather than cast or rolled with the angle between the substantially vertical and horizontal portions being curved as indicated by reference character 38.
FIG. 6 shows a construction similar to FIG. 1 with the exception that the member 23 is in the form of an angle iron with vertical flange 24 and a horizontal flange 25A which extends outwardly towards the perimetrical edge of the floor rather than inwardly as shown in previous embodiments.
This construction is often found in existing grain bins so that the shield collectively designated 29 is readily added to existing bins by bolting same between the lower perimetrical edge portion 34 of the wall and the vertical flange 24 in a manner similar to that hereinbefore described. In this embodiment, the shield 29 includes the substantially vertical portion 30, the outwardly and downwardly extending portion 38, and the floor edge overlapping portion 32.
FIG. 7 also shows an outwardly facing angle iron member 23 with a perimetrical connector member 39 bolted to the vertical flange of member 23 and extending upwardly therefrom. The bin wall and the upper portion of the shield 29 are bolted adjacent the upper end of this perimetrical connector 39 as clearly shown.
In FIG. 8, the member 23 is situated inwardly of the perimetrical edge of the floor and the bin wall is secured to the vertical flange 24 thereof in the conventional manner. The member 23 is secured to the floor by means of a horizontal flange 25 as hereinbefore described.
The shield 29, in this embodiment, includes a curved upper portion 40 shaped to fit one of the outwardly curving corrugations 41 of the wall and is bolted thereto by means of bolt connector 43 with sealant or caulking 44 being situated between the curved portion 40 and the wall portion 41. Alternatively, of course, it will be appreciated that the portion 40 can be shaped to fit one of the inwardly curving corrugations but this construction is not illustrated.
This shield then extends outwardly and downwardly in a diagonal direction as indicated by reference character 45 and terminates in a vertically extending portion 46 which extends over the outer perimetrical edge 28 of the floor of the bin, as clearly shown. Once again this embodiment is readily added to existing constructions.
In FIG. 9, which shows conventional construction, the shield collectively designated 29A is situated between the horizontal flange 25 of the member 23 and the upper surface 26 of the floor 22. This shield includes the horizontal portion 47 extending outwardly to the perimetrical edge 28 of the floor and then extends downwardly in a substantially vertical flange 48 as clearly shown.
A rubber seal or similar type seal 49 is situated between the horizontal flange 25 of member 23 and the horizontal portion 47 of the shield 29A, for sealing purposes.
In FIG. 10, the member 23A is in the form of a perimetrically extending T-bar having a horizontal flange 49 engaging the upper surface 26 of the floor and being secured thereto by means of bolt assemblies 27. The vertical flange 50 of the T-bar is situated at the outer edge of the horizontal flange 49 and includes the upwardly extending portion 51 and the downwardly extending portion 52. The upwardly extending portion 51 is bolted to adjacent the lower perimetrical edge portion 34 of the wall and on the inner surface thereof, whereas the lower portion 52 extends over the perimetrical edge 28 of the floor and acts as the aforementioned shield.
FIG. 11 shows a construction similar to FIG. 10 with the exception that the vertical portion 51A is spaced inwardly from the vertical portion 52A, thereby extending upwardly from intermediate the inner and outer edges of the horizontal portion 49A of the member 23B with the bin wall being secured to the vertical portion 51A on the outside thereof and the vertical portion 52A extending downwardly over the perimetrical edge 28 of the floor and acting as the shield.
FIG. 12 shows member 23C in the form of a double angulated member where a horizontal portion 53 engaging the upper surface 26 of the floor 22 and being secured thereto by bolt assemblies 27 as hereinbefore described.
A vertical flange 54 extends upwardly from the inner edge of the horizontal portion 53 and the bin wall portion 34 is bolted thereto as clearly illustrated.
A vertical flange portion 55 extends downwardly from the outer edge of the horizontal portion 53 over the perimetrical edge 28 of the floor and acts as the shield, once again as clearly illustrated.
FIG. 13 shows a construction which is particularly suitable for prime manufacture. In this embodiment, the lower wall portion 34 of the bin wall is angulated outwardly to form a horizontal flange 56 which engages the upper surface 26 of the floor 22 and is bolted thereto by means of nut and bolt assemblies 27. A vertical flange portion 57 is formed on the outer edge of the horizontal portion 56 and extends downwardly over the perimetrical edge 28 of the floor thus acting as the shield.
In all instances, the nut and bolt assemblies 27 are preferred, but other means of fastening can be used.
In all instances, the member 23, etc., is preferably formed in sections and bolted together as it is assembled upon the floor of the grain bin. This is particularly so if the grain bin is cylindrical in configuration.
Although the term "angle iron" has been used, nevertheless it will be appreciated that members 23, etc., can be formed from steel, aluminum, plastic or any other suitable material and the term "angle iron" is inclusive.
Since various modifications can be made in my invention as hereinabove described and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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One embodiment of the present device includes a perimetrical shield or flashing secured between the lower edge of the wall and the conventional outwardly facing angle iron base secured to the floor. Shield is bolted or riveted between the wall and the angle iron and extends over and preferably slightly below the lower perimetrical edge of the floor of the bin. Another embodiment includes the shield situated between the wall and an inwardly facing perimetrical angle iron which is easy to manufacture and is less likely to provide moisture ingress. A further embodiment includes the shield being formed as an extension of the wall and being shaped to extend over and slightly below the perimetrical edge of the floor and to be bolted either to the floor or to the angle iron.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of Invention
The invention relates generally to the field of oil and gas production. More specifically, the present invention relates to a perforating system. Yet more specifically, the present invention relates to a shaped charge having a modified boss for use in a perforating gun system.
2. Description of Prior Art
Perforating systems are used for the purpose, among others, of making hydraulic communication passages, called perforations, in wellbores drilled through earth formations so that predetermined zones of the earth formations can be hydraulically connected to the wellbore. Perforations are needed because wellbores are typically completed by coaxially inserting a pipe or casing into the wellbore. 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.
Perforating systems typically comprise one or more perforating guns strung together, these strings of guns can sometimes surpass a thousand feet of perforating length. In FIG. 1 an example of a perforating system 4 is shown. For the sake of clarity, the system 4 depicted comprises a single perforating gun 6 instead of a multitude of guns. The gun 6 is shown disposed within a wellbore 1 on a wireline 5 . The perforating system 4 as shown also includes a service truck 7 on the surface 9 , where in addition to providing a raising and lowering means, the wireline 5 also provides communication and control connectivity between the truck 7 and the perforating gun 6 . The wireline 5 is threaded through pulleys 3 supported above the wellbore 1 .
Perforating guns typically include a cylindrical gun strip 16 coaxially housed within a gun body 14 . Shaped charges 8 are provided within the gun strip 16 and aimed generally perpendicular to the axis of the wellbore 1 . FIG. 2 provides an example of a shaped charge 8 that includes a housing 18 , a liner 22 , a quantity of high explosive 24 inserted between the liner 22 and the housing 18 , and a booster charge 26 adjacent the base of the high explosive 24 .
The shaped charges 8 are typically connected to a detonating cord 27 which is affixed to the shaped charge 8 by a case slot 25 proximate to the booster charge 26 . Igniting the detonation cord 27 creates a compressive pressure wave along its length that initiates the booster charge 26 that in turn ignites the high explosive 24 . When the high explosive 24 is detonated, the force of the detonation collapses the liner 22 and ejects it from one end of the charge 8 at very high velocity in a pattern called a “jet” 12 . The jet 12 perforates the casing and cement lining the wellbore 1 and creates a perforation 10 that extends into the surrounding formation 2 .
Shaped charges 8 also include a boss 20 protruding outward from the case 18 perpendicular to the axis A SC of the case 18 . The boss 20 fully circumscribes the case 18 outer circumference. A perspective example of the gun strip 16 is provided in FIG. 3 illustrating holes 28 formed through the gun strip 16 for receiving shaped charges 8 therein. The shaped charge 8 is inserted into the hole 28 until the boss 20 , whose outer diameter extends past the hole 28 outer diameter, contacts the outer surface of the gun strip 16 . Thus the boss 20 supports the shaped charge 8 in the gun strip 16 and vertically aligns the shaped charge 8 in the gun strip 16 . However, because the boss 20 is generally planar but the gun strip 16 outer diameter is curvilinear, the entire radius of the boss 20 does not lie above the hole 28 , but instead the hole 28 outer diameter is shaped to accommodate the shaped charge 8 placement. Accordingly although the shaped charge 8 outer diameter is substantially circular, the typical gun tube 16 hole 28 is not. This can be a problem in certain perforating guns employing a “high density” shot pattern. For example, FIG. 3 illustrates an example of a gun tube 16 having high density shot pattern wherein adjacent holes 28 are sufficiently close that a web portion 30 between the holes 28 is too narrow to provide adequate structural support.
SUMMARY OF INVENTION
Disclosed herein is a perforating gun with a first shaped charge having a charge case, a liner, and explosive disposed between the liner and charge case. The perforating gun also includes an annular gun strip, a first boss on the charge case partially circumscribing the charge case outer periphery, a first hole formed through the side of the gun strip, and a landing on the gun strip and adjacent the hole formed to mateingly cooperate with the first boss. A second boss may optionally be provided on the charge case partially circumscribing the charge case outer periphery. The respective ends of the first and second boss may, in one embodiment, be substantially equidistant from one another. The lengths of the first and second boss may range from about 10% to about 30% of the charge case circumference. The length of the first and second boss may be about 20%. A second landing may be included on the gun strip and adjacent the hole formed to mateingly cooperate with the second boss. The charge case has an open end and a closed end, and an axis extending through the open and closed ends, the charge case being substantially symmetric about the axis. The gun strip may include a second hole in the gun strip adjacent to the first hole, a web defined by the portion of the gun strip body between the first hole and the second hole, a landing on the gun strip on the second hole perimeter, the landings being disposed away from the web. The web dimensions comprise structural integrity sufficient for a high density perforating gun. The perforating gun may further comprise a detonation cord coaxially extending through the gun strip, and a cord slot formed on the bottom end of the charge case formed for attachment with the detonation cord, the first boss and landing formed to align the cord slot with the detonation cord when inserted into the hole. The landing may comprise notches configured to mate with the respective ends of the first boss and a planar section between the notches.
Also disclosed herein is a method of forming a wellbore perforating device comprising, (a) providing a shaped charge with a first boss that partially circumscribes the shaped charge outer periphery, (b) providing a gun strip with a first hole and a first landing formed adjacent the hole edge, the landing configured to cooperatively mate with the first boss, (c) inserting the shaped charge into the gun strip hole, and (d) cooperatively mating the first boss with the first landing. The shaped charge in the method may further include a second boss partially circumscribing the shaped charge outer periphery and the gun strip may further include a second landing configured to cooperatively mate with the first boss, the method further comprising cooperatively mating the second boss with the second landing. The perforating device may further comprise a second shaped charge having a boss partially circumscribing its outer periphery, a second hole, a landing formed adjacent the second hole configured to cooperatively mate with the boss of the second shaped charge, and a web portion defined between the first and second hole, wherein the landings are disposed away from the web. The web dimensions are sufficient for use in a high density perforating gun application. The method may further comprise deploying the perforating device within a wellbore and initiating detonation of the shaped charges.
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 partial cutaway side view of a prior art perforating system in a wellbore.
FIG. 2 illustrates a cutaway view of a shaped charge.
FIG. 3 is a perspective view of a gun strip with holes for shaped charges.
FIG. 4 is a side view of an embodiment of shaped charge case.
FIG. 5 is an overhead view of an embodiment of shaped charge case.
FIG. 6 is a perspective view of a gun tube formed to receive a shaped charge case formed in accordance with the present disclosure.
FIGS. 7 and 8 are respectively perspective and axial views of an embodiment of a gun strip with shaped charges.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. For the convenience in referring to the accompanying figures, directional terms are used for reference and illustration only. For example, the directional terms such as “upper”, “lower”, “above”, “below”, and the like are being used to illustrate a relational location.
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments of the invention 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 invention is therefore to be limited only by the scope of the appended claims.
FIG. 4 is a side view of an embodiment of a charge case 32 for use in a shape charge of a perforating system. The case body 34 is a container-like structure having a bottom 33 sloping upward with respect to the axis A x of the charge case 32 . The charge case 32 as shown is substantially symmetric about the axis A x . In the embodiment shown, the case 32 transitions into the upper portion 35 where the case 32 outer surface slope steepens. The upper portion 35 also has a profile oblique to the axis A x . Extending downward from the bottom portion 33 is a cord slot 36 having a pair of tabs 37 . The tabs 37 are configured to receive a detonating cord therebetween and are generally parallel with the axis A x of the charge case 32 .
A crown portion 41 defines the portion of the case body 34 extending from the upper terminal end of the upper portion 35 . The upper most portion of the crown portion 41 defines the opening of the charge case 32 and lies in a plain that is largely perpendicular to the axis A x . In the embodiment shown, the crown portion 41 has an outer surface extending generally parallel with the axis A x . A boss element 38 is provided on the outer surface of the crown portion 41 . The boss element 38 is an elongated member whose elongate section partially circumscribes a portion of the outer peripheral radius of the crown portion 41 , and thus partially circumscribes the outer circumference of the charge case 32 . In the embodiment shown, the boss element 38 cross section is largely rectangular and extends outward from the outer radius of the charge case 32 .
FIG. 5 provides an overhead view looking along the axis A x of the charge case 32 and through its opening. In this embodiment, two boss elements ( 38 , 39 ) extend outward from the outer radius of the charge case 32 and along a portion of its outer radius. The boss elements ( 38 , 39 ) may each extend from about 10% to about 30% of the charge case 32 circumference. In one embodiment, the bosses ( 38 , 39 ) each extend approximately 20% of the charge case 32 circumference.
FIG. 6 illustrates a perspective view of an example of a gun strip 40 combineable with the charge cases 32 of FIGS. 4 and 5 . The gun strip 40 illustrated is an annular member provided with holes 42 configured to receive the charge cases 32 therein. Landings ( 43 , 48 ) are formed in the gun strip 40 on the gun strip 40 body adjacent the outer circumference of the holes 42 . In the embodiment of FIG. 6 , the landings ( 43 , 48 ) comprises notches ( 44 , 45 , 46 , 47 ) configured to cooperatively mate with respective ends of the bosses ( 38 , 39 ). The landings ( 43 , 48 ) may also optionally provide a planar surface (rather than the angular outer surface of the gun strip 40 ) in the region of the gun strip 40 between the notches ( 45 , 45 , and 46 , 47 ). The cooperative mating between the bosses ( 38 , 39 ) and the landings ( 43 , 48 ) orients the shape charge 32 within the gun strip 40 without mechanically affixing the charge case 32 to the gun strip 40 . The cooperative mating restricts charge case 32 radial movement within the holes such that the charge case is maintained in alignment until it is mechanically affixed or otherwise fastened to the gun strip 40 .
Provided in FIG. 7 is a perspective view of the charge cases 32 formed in accordance with the present disclosure and positioned within a gun strip 40 . As shown, the ends of the boss 38 are received within the notches ( 44 , 45 ) of the landing 43 . The cooperative mating between the boss 38 and boss 39 and the landings ( 43 , 48 ) provides a novel manner of seating the charge case 32 within the gun strip 40 .
For the purposes of discussion herein, a high density shot typically has at least 10-12 shaped charges per linear foot of perforating gun. In some instances however high density shots may include guns having as few as 6 shots per linear foot. Referring again to FIG. 6 , the gun strip 40 provides an example of a high density configuration. As is the case in high density guns, first and second holes ( 42 , 49 ) are disposed so that their respective peripheries are proximate to one another thereby leaving a relatively narrow strip of gun strip material between the holes. The placement of these holes ( 42 , 49 ) defines a web 50 which comprises the gun body material between these two adjacent holes ( 42 , 49 ). As noted above, certain high density configurations result in a web lacking sufficient structural integrity to support charges within the particular gun strip. However, another advantage of the charge case disclosed herein is realized by configuring the holes such that the respective landings are disposed on the hole periphery away from the web 50 . In the embodiment of FIG. 6 , the landings of the holes ( 42 , 49 ) are disposed at roughly 90° or more from the midpoint of the web 50 . Since the bosses ( 38 , 39 ) are aligned with the landings ( 43 , 48 ) the bosses ( 38 , 39 ) are therefore also away from the web 50 . Accordingly, use of the embodiments described herein results in a gun tube having web dimensions producing sufficient structural integrity, even in the case of a high density configuration.
FIG. 8 provides a view looking along the axis of the gun strip 40 having multiple charge casings 32 disposed therein. In this view, a detonation cord 52 is shown coupled with the tabs 37 and cord slot 36 of the respective charge casings 32 . The respective cord slots 36 of each charge case 32 are aligned for receiving the detonation cord 52 therethrough. Aligning the cord slots 36 to readily receive the detonation cord greatly increases the ease of attaching the perforating cord 52 to each charge case 32 , thereby significantly reducing the time required to assemble a perforating gun. The alignment of each of the cord slots 36 of the charge casings 32 in the gun strip 40 is accomplished by an appropriate placement of the boss of each charge case, and the landings in which the charge case 32 is cooperatively mated with. The cord slot 36 alignment described above can be accomplished in conjunction with forming a high density perforating gun and can also be accomplished for charge cases used in applications that are not high density. Thus use of the boss and/or landings described herein is useful for forming high density perforating guns and for pre-aligning charge cases so their respective cord slots may readily receive a detonation cord.
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 exist 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 perforating gun having a charge case with a boss element partially circumscribing Optionally the pair of bosses may be included that are substantially symmetric about the axis of the charge case. Forming a shaped charge with such a charge case allows for gun strips to be formed with increased web material between adjacent shape charges in the gun strips. The increased web material provides for a more structurally sound gun tube, especially when dealing with high density charges. Notches may be provided in the gun tube on the outer radius of the holes formed to receive the shape charges, the notches are to be aligned with the bosses on the outer periphery of the shaped charge case. This also may orient the charge cases so they are pre-aligned for ready connection to an associated detonation cord.
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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 has to do with wellhead equipment used in connection with a pumping oil well, preferably one pumped with a rotated rod string. For years, a typical conventional pumping wellhead for a rotary pumping oil well has been constructed as shown in FIG. 1 . The assembly comprises from the bottom up: a flanged casing head attached to the well casing; a flanged tubing head having an internal hanger from which the well tubing string is suspended; a tubing head adapter having a flanged connection at its bottom end and a threaded connection of smaller diameter at its top end; a production blow-out preventer (B.O.P) body having top and bottom threaded connections and including side openings for receiving the B.O.P. ram components; a flow tee body having threaded bottom and top connections and a threaded or flanged side opening for connecting with a flow line; a polished rod stuffing box; and a rotary drive assembly for rotating the well's rod string to power a downhole progressive cavity pump. These components, except for the rotary drive assembly, combine to form a vertical central bore extending therethrough. The polished rod of the rod string extends through this central bore.
The combination of the tubing head adapter, B.O.P. body and flow tee body components is commonly collectively referred to as a ‘pumping tree’.
The assembly of wellhead components above the tubing head is usually referred to collectively as the ‘Christmas tree’.
A recent improvement in the production wellhead art is disclosed in Canadian patent 2,197,584, issued Jul. 7, 1998 and re-issued May 16, 2000. This patent is owned by the present applicant. More particularly, this patent teaches integrating the tubing head adapter, B.O.P. body and flow tee body into a unitary structure, referred to as an ‘integral or composite pumping tree’, by forging, casting or machining a single steel body. The composite pumping tree is illustrated in prior art FIGS. 2 and 2 a and forms the lower end of the Christmas tree.
Another recent improvement in the production wellhead art is disclosed in Canadian patent application 2,280,581, filed by the present applicant. This patent application teaches integrating a tubing head adapter, shut-off valve body, B.O.P. body, and flow tee body into a composite pumping tree. This pumping tree is illustrated in prior art FIG. 3 .
As previously stated, the rotary drive assembly usually has a stuffing box at its bottom end. The primary function of the stuffing box is to prevent upward leaking of fluid around the rotating polished rod. The stuffing box comprises a body or housing containing annular packing, which seals between the housing and the polished rod of the rod string.
Rotation of the polished rod eventually produces wear of the stuffing box packing. Therefore, changing the packing is part of the regular oilfield maintenance program.
Prior art FIGS. 1, 2 and 3 show a rotary drive assembly mounted to the stuffing box by an ‘open’ frame. The frame has side ‘windows’ which enable access to the stuffing box packing gland, so as to change out the packing. However this frame introduces significant vertical separation between the rotary drive assembly and the pumping tree. This is undesirable as the rotary drive assembly vibrates when operating and applies offset forces that can create damage to the wellhead below. It is desirable to minimize the spacing between the rotary drive assembly and the pumping tree.
A modified rotary drive assembly is shown in FIG. 4 . In this unit, the stuffing box housing is now integral with the rotary drive assembly. This variation has had the benefit of shortening the distance between the rotary drive assembly and the pumping tree.
However, it is more difficult to change out the packing of the stuffing box illustrated in FIG. 4 . This process now requires:
shutting off the rotary drive assembly;
closing the production B.O.P by rotating the ram screws to advance the B.O.P rams into engagement with the polished rod;
providing a service rig having a line which is attached to the polished rod to suspend the rod string;
disconnecting the rod clamp normally suspending the rod string from and drivably connecting it with the rotary drive assembly;
disconnecting the rotary drive assembly from the pumping tree;
lifting the rotary drive assembly up using a second line from the service rig;
securing a rod clamp to the polished rod below the rotary drive assembly, to secure the rod string;
then fully removing the rotary drive assembly;
replacing the packing; and
re-assembling the equipment.
This process can also be dangerous. Since the rod string is driven and rotated, it has a built-in torque. This torque can generate a back-spin force, which can cause injury to personnel in various situations.
With this background in mind, it is an objective of the present invention to provide a polished rod locking assembly, forming part of the pumping tree and preferably being an integral component of the tree, which locking assembly can be actuated to clamp onto the polished rod to prevent back-spin and to grip the polished rod with sufficient force so as to suspend the weight of the rod string.
It is another objective to provide a leverage assembly in conjunction with the locking assembly, which is operative to apply high axial torque to the locking means to better secure the rod string.
It is another objective to provide a locking means capable of functioning like a blind ram to seal off the vertical bore of the wellhead, when the polished rod has parted in the stuffing box.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, a polished rod locking assembly (“PRL assembly”) is provided for inclusion as part of the pumping tree of a wellhead. This PRL assembly can be closed to clamp onto and frictionally engage the polished rod, to prevent back-spin, and to grip it with sufficient force so as to be able to suspend the rod string from the wellhead during stuffing box maintenance. These actions and results are hereafter collectively referred to as “securing” the polished rod. More particularly, the PRL assembly comprises:
body means, which may be a separate component in a pumping tree formed of connected components or which preferably is integrated into a one piece integral pumping tree;
the body means forms a central bore (which forms part of the pumping tree vertical bore) and a pair of opposed, preferably horizontal, radial side openings. The side openings are internally threaded along part of their length and extend between the body means' outer peripheral surface and the central bore;
an externally threaded locking member is positioned in each body side opening. These locking members can be radially advanced to frictionally engage the polished rod. Each locking member preferally comprises an inner cylindrical member and an outer, rotatable, threaded shaft. The shaft functions, when rotated or screwed, to advance or retract the inner member. The cylindrical member and shaft are interconnected so that the inner member does not rotate while the rotating shaft pushes or pulls it. The inner member has a vertically grooved inner end face which will embrace the polished rod as it contacts and frictionally engages it. More preferably, the inner member is formed in two parts. The innermost part is horizontally pivotally connected to the outer part and there is a slight clearance between the two parts. The outer part closely fits the internal surface of the side opening and remains stationary. The innermost part can tilt to a limited extent to accommodate misalignment of the polished rod. Each locking member seals against the surface forming the side opening in which it is contained. The outer end of the locking member protrudes from the body means;
the inner end of an external lever arm is connected, preferably at right angle, with the protruding outer end of one of the locking members, for rotation or turning thereof. Movement of the outer end of the arm will cause the locking member to turn to a limited extent about its axis. Threaded means, such as a swing bolt having an annular head, is pivotally connected by means, such as a bolt, with the outer end of the arm. A post is anchored to the body means or tree. The post supports a rotatable sleeve at its outer end. The swing bolt extends through the opening formed by the sleeve. A nut, threaded on the end of the swing bolt, can be turned with relatively low torque to induce a relatively powerful lineal pull by the swing bolt on the arm. This causes relatively high torque to be applied to the locking member which in turn applies high lineal, inwardly directed force on the polished rod.
As a consequence, the locking members can be activated by hand turning their outer ends, to bring their inner end faces into firm contact with the polished rod. The arm and swing bolt assembly can then be introduced and operated to bias the locking member with considerable lineal force against the polished rod to ensure sufficient frictional engagement to secure the heavy rod string.
The specific described assembly provides a lever arm for turning the locking member and a mechanical means for biasing the arm's free end with a powerful lineal force to cause the locking member to secure the polished rod.
In another aspect, the PRL assembly is constructed so that it can operate as a “blind ram” to close the vertical bore of the pumping tree. More particularly, the body means and locking members are modified so that one locking member can retract sufficiently to enable the other locking member to extend across the vertical bore to close it. The other locking member carries seal means suitable for sealing the vertical bore from the radial openings when the locking member is in the closed position.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a prior art wellhead for a rotary pumping well comprising a pumping tree formed of interconnected separate components, the wellhead having a rotary drive assembly at its upper end;
FIG. 2 is a side view of a prior art wellhead for a rotary pumping well, incorporating an integral or composite pumping tree;
FIG. 2 a is a partly broken away perspective view of a prior art composite pumping tree;
FIG. 3 is a side view of a prior art wellhead incorporating an integral pumping tree having an integral shut-off valve;
FIG. 4 is a side view of a wellhead for a rotary pumping well comprising an integral pumping tree and having a PRL assembly constructed as an integral part of the tubing head adapter, the wellhead having a rotary drive assembly incorporating an integral stuffing box;
FIG. 5 is a side view of a wellhead incorporating an integral pumping tree having a shut-off valve and a PRL assembly constructed as an integral part of the tubing head adapter section of the tree;
FIG. 6 is a side view of a wellhead incorporating an integral pumping tree having a PRL assembly located above the production rod B.O.P.;
FIG. 7 is a side view in section of one embodiment of the PRL assembly;
FIG. 8 is a plan view in section of the assembly of FIG. 7;
FIG. 9 is a sectional side view showing part of the PRL assembly of FIG. 7, positioned within a partly shown housing or body and engaging a polished rod;
FIG. 10 is a sectional side view showing a self-aligning locking member positioned within a partly shown housing and engaging a polished rod;
FIG. 11 is a sectional plan view of the assembly of FIG. 10;
FIG. 12 is a sectional plan view showing a locking member connected with a leverage assembly;
FIG. 13 is a sectional side view showing an upper PRL assembly coupled with a leverage assembly, together with a lower production rod B.O.P.;
FIG. 14 is an external side view of part of the assembly of FIG. 13;
FIG. 15 is a sectional plan view of a PRL assembly, adapted to convert to a blind ram assembly covering the vertical bore, in an open position;
FIG. 16 is a sectional plan view of the PRL assembly of FIG. 15, in a closed rod-engaging position; and
FIG. 17 is a sectional plan view of the PRL assembly of FIG. 16, in a closed blind ram position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One embodiment of the PRL assembly 1 is illustrated in FIGS. 4, 5 , 7 , 8 and 9 . This PRL assembly 1 comprises a body means 2 having a vertical central bore 3 extending therethrough. The PRL assembly 1 forms part of the bottom connection 31 of an integral production pumping tree 4 . The bottom connection 31 is adapted to mate and connect with the top connection 5 of a wellhead tubing head 6 . The PRL assembly bore 3 forms part of the vertical internal bore 67 of the wellhead 7 , through which the polished rod 8 extends and through which fluid is produced.
The body means 2 forms a pair of opposed horizontal radial openings 9 extending between its outer peripheral surface means 10 and the bore 3 . Each radial opening 9 has inner and outer sections 11 , 12 . The opening sections 11 , 12 have offset centerlines 14 , 13 . The outer opening section 12 has a larger diameter than the inner opening section 11 , so that a shoulder 15 is formed at their junction.
A pair of cylindrical members 16 are positioned in the radial opening inner sections 11 and are slidable therealong. Each cylindrical member 16 has inner and outer ends 17 , 18 . The inner end 17 of the cylindrical member 16 has an end face 19 forming a vertical groove 100 , for conforming with and engaging the polished rod 8 .
A pair of tubular gland assemblies 20 are threaded into the opening outer sections 12 . The gland assemblies 20 form part of the body means 2 . In the embodiment of FIGS. 8 and 9, each gland assembly 20 comprises an externally threaded tube 21 , an outer ring 22 , packing 23 and an inner ring 24 abutting the shoulder 15 . The threaded tube 21 can be actuated to energize the packing 23 . The tube 21 is also internally threaded.
A pair of screws or shafts 26 , having externally threaded outer ends 27 , extend through the gland assemblies 20 and engage the outer ends 18 of the cylindrical members 16 . The outer end 27 of each shaft 26 protrudes out of its associated gland assembly 20 so that it is accessible for rotation. The shaft 26 and cylindrical member 16 together make up a unit referred to as a locking member 50 .
Each shaft 26 has a T-shaped head 25 at its inner end, which is received in a correspondingly T-shaped slot 28 formed in the outer end 18 of its associated cylindrical member 16 . As a result of this connection and the offset centerlines, the shaft 26 and cylindrical member 16 are connected for axial movement together but the shaft can be turned without rotating the cylindrical member.
As illustrated, the PRL assembly radial openings 9 are positioned between stud holes 30 of the bottom connection 31 of the pumping tree 4 .
It is to be noted that in this previously described embodiment:
the body means 2 forms part of the bottom flanged connection 31 of an integral pumping tree 4 ; and
the axial centerlines 14 , 13 of each associated shaft 26 and cylindrical member 16 are offset and the two elements are connected by a T-shaped head 25 and slot 28 arrangement, whereby the elements are tied together and move as a unit axially, but the threaded shaft 26 (which generates the lineal locking force) can rotate without turning the cylindrical member 16 (which will be locked with the vertical rod 8 ).
In operation, each gland tube 21 can be screwed in, to compress its packing 23 and provide a seal around the unthreaded inner end 29 of the contained shaft 26 . To lock the polished rod 8 , the shafts 26 are advanced inwardly, biasing the locking members 16 into firm contact with the polished rod 8 .
In a variant, the inner end portions of the polished rod locking members 16 can pivot to align with the polished rod 8 , to thereby prevent damage to the rod's surface.
When the B.O.P. rams are closed about the polished rod 8 , the latter can be tilted slightly. If the polished rod cylindrical members 16 are rigidly fixed and perpendicular to the axis of the bore 3 , they can damage the tilted polished rod.
In this alternative assembly, shown in FIGS. 10 and 11, each cylindrical member 16 is formed in two parts, an inner part 16 a and an outer part 16 b . The parts 16 a , 16 b are connected so that they move together axially as a unit, but inner part 16 a can pivot slightly to self-align with the polished rod 8 . More particularly the inner part 16 a has a spherical nose 40 which is received in a spherical cavity 41 formed in the inner end of outer part 16 b . There is a slight clearance 31 between the cylindrical member parts 16 a , 16 b . A horizontal bolt 43 holds the parts 16 a , 16 b together while allowing part 16 a to pivot when it is fully inserted into the vertical bore 3 and has cleared the inner surface 32 of the tree side wall 33 . To prevent the inner part 16 a getting separated should the bolt 43 break, it has a short thread 44 which can be threaded past a short thread 45 formed by the outer part 16 b . The shaft 26 has a centerline 46 and the cylindrical member 16 has a centerline 47 , which centerlines are offset one from the other.
O-rings 101 are mounted around each cylindrical outer part 16 b , for sealing against the adjacent inside surface 65 of the radial opening 9 in which the part is contained. It will be noted that the gland assembly 20 in this embodiment does not contain packing.
The PRL assembly 1 has been described in terms of a body means 2 which is provided by two partial segments of the bottom connection 31 , positioned between pairs of bolt holes 48 as shown in FIGS. 4, 5 and 18 . This design is useful when the radial openings 9 are of relatively small diameter, as are the contained components. When it is desirable to use components of greater diameter, then the body means 2 involves a complete transverse layer of the tree 4 , as shown in FIG. 6 .
The PRL assembly 1 comprises a leverage assembly 51 which is designed with the following concept in mind:
the shafts 26 can be hand turned with a wrench to bring the cylindrical member end faces 19 into firm contact with the polished rod 8 —this is referred to as “hand tightening” the locking members 50 ;
the leverage assembly 51 can then be used to apply a much greater rotational torque to one of the shafts 26 to thereby increase the frictional force with which the end faces 19 secure the polished rod 8 .
The leverage assembly 51 is illustrated in FIGS. 12, 13 and 14 . It comprises a post 52 affixed to the tree 4 . The post 52 extends outwardly in parallel with the adjacent shaft 26 . A sleeve 53 is rotatably mounted on the outer end of the post 52 . The sleeve 53 can turn on the post 52 . The sleeve 53 forms a through-hole 69 . A horizontal, externally threaded swing bolt 54 extends through the through-hole 69 . At its inner end the swing bolt 54 has an annular head 55 . A nut 56 is screwed onto the outer end 57 of the swing bolt 54 . The nut 56 abuts the sleeve 53 . An arm 58 extends between the swing bolt's annular head 55 and the shaft 26 . The arm 58 has a hollow box-like section as shown in FIG. 12 . At its lower end, the arm 58 has a transverse hexagonal opening 59 . A hexagonal nut 60 is fixed on the shaft's outer end 27 . When the arm 58 is added to the leverage assembly 51 , its lower end opening 59 receives the shaft nut 60 and the arm 58 engages the nut 60 , so that they will turn together. At its upper end, the arm 58 has a second transverse opening 61 . A bolt 62 extends through the arm upper opening 61 and through the opening 63 of the swing bolt annular head 55 . A nut 64 locks the bolt 62 in place, to effect a pivoting connection between the upper end of the vertical arm 58 and the inner end of the horizontal swing bolt 54 .
From the foregoing, it will be appreciated:
that the swing bolt nut 56 can be turned to cause the swing bolt 54 to linearly retract to the right (having reference to FIG. 14 ), thereby applying a powerful pull on the bolt 62 linking the arm 58 and swing bolt 54 ; and
this bias or pull applied to the upper end of the arm 58 applies powerful torque to the shaft nut 60 , causing the shaft 26 to advance to linearly bias the cylindrical member 16 into tight frictional engagement with the polished rod 8 .
In another embodiment shown in FIGS. 15-17, the PRL assembly 1 comprises relatively long and short gland members 20 a , 20 b . One cylindrical member 16 c is longer than the other cylindrical member 16 d . One gland assembly 20 a is relatively longer than the other gland assembly 20 b . The gland assembly 20 a forms a longer cavity 70 a for accommodating the cylindrical member 16 c in the retracted or open position shown in FIG. 15 . The gland assembly 20 b forms a cavity 70 b which is adapted to accommodate the cylindrical member 16 d in the ‘blind’ position shown in FIG. 17, thereby enabling the cylindrical member 16 c to cover or extend across the vertical bore 3 . The cylindrical member 16 c carries a suitable seal 68 for sealing the vertical bore 3 and the radial openings 9 .
From the foregoing it will be understood that the body means 2 and the locking members 50 co-operate to enable one cylindrical member 16 c to extend transversely across the vertical bore 3 to close and seal it.
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The assembly functions to clamp onto and frictionally engage the polished rod of a well's rod string, with sufficient force to suspend the string from the wellhead. The assembly comprises an annular body forming opposed, radial, internally threaded side openings extending from its outer circumferential surface to its central vertical bore. An externally threaded locking member is positioned in each side opening and protrudes externally. The locking members can be manually threaded inwardly to engage the polished rod. An external leverage assembly is anchored to the body and engages one of the locking members. This leverage assembly can be manually turned to tighten the locking member against the polished rod with powerful axial force to provide enhanced gripping.
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BACKGROUND OF THE INVENTION
[0001] U.S. Pat. No. 6,253,655 discloses a method of making an armor to resist projectiles, with a foam plastic inner layer that absorbs energy during impacts. The same principle is applied in the present invention, with notable contrasts in the simplicity of the design, methods of construction and configuration of the final product.
[0002] U.S. Pat. No. 6,240,686 teaches that foam plastic blocks can be effectively arranged to support building loads. The invention requires the use of tensioning skins and includes multiple joints that are avoided in the present invention.
[0003] U.S. Pat. No. 6,218,002 discloses a concrete mixture containing a barrel shaped polystyrene bead as the aggregate. The concrete in this formulation contrasts with the present invention. It uses only one size of virgin polystyrene beads while the present invention uses recycled aggregates of varied sizes, allowing small particles to fill voids between larger particles and contribute to the resiliency of the structure.
[0004] U.S. Pat. No. 6,151,841 discloses a pyramid shaped shelter that is erected above ground with Plexiglas(TM) windows. The shelter demonstrates the merits of triangular sides in resisting wind, but it fail to address the problem of joints, which are eliminated in the present invention.
[0005] U.S. Pat. No. 6,131,343 discloses a parabolic-like shaped dome shelter that may be constructed of or covered with corrugated metal. This patent teaches the value of dome shapes in resisting wind, but it does not provide the simplicity, insulation and other attributes of the present invention.
[0006] U.S. Pat. No. 5,953,866 discloses a storm shelter that is partly buried underground with provisions for an emergency jack to forcibly open the sliding door. It is an attribute of the present invention that it is located above ground and is less likely to entrap occupants. In addition, ordinary carpenter tools can be used to cut an emergency escape if the door becomes inoperable. This feature does not diminish the fact that the lightweight concrete in the present invention resists severe impacts, including bullets.
[0007] U.S. Pat. No. 4,879,855 discloses a building method that incorporates polystyrene in structure walls. Walls built with this method perform satisfactorily in extreme wind conditions, but failures have occurred at wall-roof intersections. In addition, the foam plastic produces toxic gasses when exposed in building fires. The concrete in the present invention is remarkably fire proof and the design eliminates joining problems and most of the concrete required in U.S. Pat. No. 4,879,855. In the present invention polystyrene beads are coated with a formulation to create a lightweight material that performs all of the functions of the heavy concrete and steel in the above-cited patent.
[0008] People living in undeveloped and developed countries occupy structures, including emergency shelters, that are vulnerable to collapse and wind-blown missile penetration during extreme wind conditions. Few residential structures are designed to resist the highest velocity winds, and every year injuries and death occur due to intrusion of flying objects and building collapse. Shelters made of steel and concrete are often placed at floor level or below the floors inside residences. These shelters save lives, but they have recognized disadvantages. Their cost exceeds the budget limitations of many families, and occupants may be trapped under collapsed building materials. Underground shelters require expensive excavation and forming, and occupants are sometimes at risk from flooding. Stairways take up shelter space and they are inconvenient and dangerous. Typical engineering techniques used to design shelters ignore such risks and concentrate on overcoming maximum hurricane or tornado wind pressures. Structures are built with a safety factor that proves to be inadequate when the siding and roof assemblies separate and crash into adjacent property and when they collapse under loads of debris carried onto them by high winds.
[0009] In this invention less dense materials create a structure that exceeds the performance of typical shelters. This is accomplished by a smooth exterior design that prevents the wind, regardless of velocity or direction, from achieving a direct hit. Most flying objects glance off the structure in this invention without imposing the shocks felt by conventional shelters. Direct hits by lengths of 2×4 lumber moving at 150 miles per hour do not penetrate this structure. Unlike steel, the lightweight concrete in this invention has a low coefficient of thermal expansion. It does not rust, decay when exposed to below-ground moisture, or react adversely to freeze-thaw cycling. It is a good insulator and withstands exposure to heat and flames in excess of 1700 degrees F.
SUMMARY OF THE INVENTION
[0010] It is thus an object of this invention to provide a low cost structure that is safe during extreme weather, durable and easily transported. This invention, because of its superior shape, material formulation, manufacturing method and door design meets the objectives.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is an elevation view of the shelter.
[0012] [0012]FIG. 2 is a view of the shelter dome showing the radio antenna, ventilation ports, interior diverters and debris collection bags.
[0013] [0013]FIG. 3 is a view of the shelter dome from directly above showing ventilator port openings.
[0014] [0014]FIG. 4 is a view of the preferred tie-down method.
[0015] [0015]FIG. 5 is a view of an alternate tie-down method.
[0016] [0016]FIG. 6 is a view of the molds used to construct the structure.
[0017] [0017]FIG. 7 is a view of the shelter floor with a ramp for handicapped access.
[0018] [0018]FIG. 8 is a view of the sliding door mechanism with the door opened to the inside.
[0019] [0019]FIG. 9 is a view of the sliding door mechanism with the door opening to the outside.
[0020] [0020]FIG. 10 is a view of the door latching mechanism in the open or unlatched position.
[0021] [0021]FIG. 11 is a view of the door latching mechanism in the closed or latched position.
[0022] [0022]FIG. 12 is a view of the door hardware and overhead track mechanism.
[0023] [0023]FIG. 13 is a view of the latching mechanism isolated on the door.
DETAILED DESCRIPTION OF THE INVENTION
[0024] This description provides illustrative information in support of the claims and should not be regarded as defining the language in the claims. Those familiar with the art will recognize that other structure dimensions and variations in shape of the dome and in the concrete mix design are within the scope of this invention.
[0025] [0025]FIG. 1 illustrates a monolithic dome-shaped structure 1 with the general location of the door latches and catches 4 , some of the air vents 2 and viewing ports 3 . The lightweight concrete comprising this structure provides extraordinary resistance to weather and the impacts of wind driven objects. The shape of the structure and the smooth exterior finish 1 minimize wind friction. These features and the large area of contact at the base work together to resist overturning. The viewing ports 3 are made of heavy transparent plastic or glass to allow safe viewing.
[0026] [0026]FIG. 2 displays a cutaway section of the domed roof with ventilation ports 7 . These ports are nominally 2 inch diameter pipes made of plastic or steel. They replace larger window-like vents normally used. The number of vents is determined by the size of the structure and occupant load. Sufficient vents 7 to sustain healthy breathing conditions and equalize interior air pressure with outside atmospheric pressure can be easily installed by boring holes in the shelter. Because of their small diameter multiple vent pipes do not impair the structural integrity or smoothness of the structure's exterior. The pipes 7 are inclined upward from the outside to reduce infiltration by water and to provide drainage. Removable diverters 8 are connected to the vent pipes 7 on the inside. The sharp angles of the diverters 8 and the small diameter of the pipes reduce air velocity and prevent all but the smallest flying objects from entering the structure. Fine debris is caught in removable bags 6 that are permeable to admit required airflow. The bags serve as visual indicators of air movement and pressure conditions. The bags 6 , diverters 8 and pipes 7 can be easily cleaned. A radio antenna 9 allows one-way or two-way communications depending on the type of receiver-transmitter 10 selected. The antenna 9 penetration through the roof is sealed to prevent water intrusion.
[0027] [0027]FIG. 3 is an overhead view illustrating the preferred placement of ventilation ports 12 below the top of the domed roof 11 and the radio antenna 13 . The door 14 is equipped with hinging and latching devices of sufficient strength to develop wind and impact resistance equal to other parts of the structure. In this view the door 14 slides into the structure to open and outward to close. In this configuration the door temporarily occupies interior space. It provides protection against weather during closing.
[0028] [0028]FIG. 4 illustrates the preferred tie-down method with the bent ends 20 of ½ inch diameter anchor bolts 18 embedded in the concrete floor 19 and the threaded ends penetrating the structure near the base. Tamper-proof nuts 17 protect against vandalism and provide the structure with resistance against uplift and overturning during the most severe winds. The anchor bolts 18 are inserted through the holes in the base of the wall prior to pouring the concrete floor 19 . Large washers 16 and tamper-proof nuts 17 are installed after the concrete floor is cured.
[0029] [0029]FIG. 5 illustrates an alternate tie-down method. Holes large enough to permit insertion of ½ inch diameter bolts are provided at a minimum of 8 locations around the perimeter at the base of the structure. After the structure is permanently placed on the ground the inside wall serves as a form for pouring the concrete floor 28 that has nominal compressive strength of 2500 PSI. An L-shaped anchor bolt 27 is placed vertically in the wet concrete adjacent to each hole in the structure base. 3-inch by 3-inch slotted angle plates 26 are placed over the anchor bolts 27 and the horizontal wall bolts 25 . On the exterior large washers 22 are placed over the bolts to distribute the load on the lightweight concrete. Tamper-proof nuts 23 permanently attach the wall to the concrete floor.
[0030] [0030]FIG. 6 illustrates the method of forming and pouring the lightweight concrete to construct the monolithic structure. In the preferred embodiment the dome-shaped lower mold 29 is inverted and coated on the interior surface with form-release material. Cured spacer blocks 31 six inches thick made of the lightweight concrete are secured along the sides of the mold. One block 32 is secured to the bottom of the mold at the center. These blocks are identical in composition to the lightweight concrete comprising the rest of the shelter. They bond to it and become part of the structure. The lower mold 29 is partially filled with the fluid lightweight concrete creating a reservoir. A second upper mold 34 six inches smaller in diameter but identical in shape to the lower mold is forced down into the fluid concrete, descending until it rests on the center spacer block 32 and against the other spacer blocks 3 l. The pressure of the upper mold 34 pressing into the fluid concrete 33 is sufficient to cause it to rise and fill the six inch space between the two molds. Vibrators are applied to the outside of the lower mold and the inside of the upper mold to cause fine particles to accumulate against the molds, creating smooth surfaces. After sufficient curing the upper mold 34 is pulled up and out of the inverted structure. The lower mold 29 and the rigid structure are inverted together so the structure is resting on its base. The lower mold 29 is then removed from the outer surface of the structure, completing the process.
[0031] [0031]FIG. 7 is a side view with a shelter wall segment showing the handicapped access ramp 36 . A ramp is required because the door entrance is nominally 4 inches above ground level 39 . Flexible gaskets 37 attached to grooves in the floor and in the bottom of the door compress against mating gaskets to prevent water intrusion. In a typical environment the concrete floor and handicapped access ramp are poured on solid natural ground 39 . If installed on flood plains the structure must be placed on elevated ground.
[0032] [0032]FIG. 8 is a view of the shelter door 40 and the operating mechanism used to open the door to the inside. The door 40 is a cutaway segment of the structure wall 41 . The top of the door is connected to 2 Unistrut(TM) tracks 44 that are attached by 2 brackets 47 to the roller assemblies 42 . The rollers run inside the track and cannot be derailed. Two flat plate brackets 47 , one on each face of the door are attached with bolts on each upper corner of the door. The roller assemblies 42 are equipped with ball bearings. The rollers 42 align the door 40 for precise fit against the gaskets 43 surrounding the door. The bottom door control assembly consists of notched ball bearing-equipped rollers 45 fitted onto 90 degree steel angle tracks 46 secured to the concrete floor with the v facing upward and the open angle down. Notched rollers 45 fit precisely over the steel angle tracks to control the position of the door and share the weight with the upper track and roller assembly. All door edges and mating structure surfaces are equipped with flexible gaskets 43 that firmly seal the door. The upper track assembly 44 is located above the door opening to provide head clearance to standing shelter occupants. The lower track assembly 46 is configured to allow passage of wheel chairs.
[0033] [0033]FIG. 9 is a view of the door and door operating mechanism with the door configured to be opened by moving it to the outside. This configuration may be selected in low wind areas. This configuration avoids temporary loss of interior space caused by the door opening in, but it causes the door and the upper track assembly 53 to be exposed to wind-driven debris. The lower 58 and upper 53 track mechanisms are identical to the track mechanisms in FIG. 8 except for being extended outside. The tracks holding the door are supported on the inside by two columns 55 made on fiberglass, pvc pipe or other material that is non conductive to avoid risk from lightening strikes. In this configuration the ramp 60 on one side of the shelter provides handicapped access to the structure. When closed, as shown in lighter color, the door 56 is held by 2 heavy latches 52 , one on each side of the door. The latches can be operated from inside or outside of the structure. These latches 52 consist of steel plates mounted on ½ inch diameter bolts fitted through pipes penetrating the door to form bearings. The lower roller assembly 54 consists of notched rollers fitted over angle tracks 58 . The door closes against replaceable gaskets 57 firmly sealing all edges.
[0034] [0034]FIG. 10 is a view of the door 63 and its 2 latch assemblies in the open or unlatched position. These latches 61 consist of ¼ inch thick steel plates nominally 4 inches wide and 8 inches long. 4 identical latches are used, 2 on the inside and 2 on the outside of the door 63 . 2 pipes the same thickness as the door are inserted through a close fitting hole in the door and a ½ inch diameter steel bolt threaded on both ends is fitted through the pipe creating a bearing. The bolt is firmly attached to the latch plates 61 . Catches 62 are installed on the shelter walls 64 adjacent to the door on both sides. This configuration allows easy rotation of the latches which are operable from inside or outside of the structure.
[0035] [0035]FIG. 11 is a view of the door and its latch assembly 65 in the closed position. The latch is easily operated from either the inside or outside by grasping the latch handle 67 and turning the latch to a horizontal position inside the catch plate. Replaceable gaskets where the door closes 68 into the structure wall provide weatherproof seals.
[0036] [0036]FIG. 12 is a view of the door and overhead track assembly 70 with material above the door cut away to show the tracks 70 . Also shown are overhead rollers 71 , door hanging brackets 72 , outside catches, 73 and outside latches 74 . The door 75 is carried on the rollers 71 to a distance of required opening, such as three feet into the shelter. The door is carried out to close against flexible gaskets on all edges 76 .
[0037] [0037]FIG. 13 is a view of the two latch plates 78 showing a door segment 77 , the bearing pipe 79 and latch bolt 80 .
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Disclosed is a monolithic prefabricated structure that is wind and impact resistant. This special pre-cast lightweight concrete structure is a blend of special aggregates and additives combined to resist the impacts of flying debris and extremes of weather. The curved exterior surface minimizes wind friction and deflects debris. The circular structure has a low center of gravity and firm attachment to a floor made of concrete. It has protected ventilation openings, viewing ports and a strong smooth-fitting door.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
At an initial stage of this field, a climbing step constituted by a substantially U-shaped or bent metalic bar was used in such a manner that its free ends are embedded into concrete. In the great majority of cases, however, the step member is exposed to the wind, rains or toxic gases, whereby the step member undergoes corrosion. For the purpose of preventing this kind of corrosion, there has been proposed a U-shaped step which is disclosed in the specification of U.S. Pat. No. 2,064,803, the arrangement being such that its portion exposed from the concrete is coated with synthetic resin.
The device of U.S. Pat. No. 2,064,803 certainly exhibited effectiveness against the corrosion. However, where a plurality of climbing steps are installed on the wall surface of, for instance, a manhole by embedding their proximal portions therein, a person ascending or descending the steps must search for the tread portion of the individual steps with his feet, because such steps are difficult to recognize by eyesight especially when used in poorly lighted areas.
On the other hand, the specification of Japanese Utility Model Laid-Open No. 66746/1985 discloses another type of step wherein a disc-like small reflection plate is embedded in a bend or angular portion formed at the boundary between an arm member and a tread portion of a U-shaped step coated with the synthetic resin. The reflection plate of this type involves a plastic transparent plate whose underside surface is formed with prism-like rugged portions. Problems inherent in this disc-like small reflection plate, however, arise because the plate is difficult to see on account of its smallness, and the plate is apt to separate from the plastic coating member.
In the specification of Japanese Patent Laid-Open No. 82838/1979, there is disclosed a climbing step having such a structure in which "retroreflection tapes" are bonded with the aid of a bonding agent to grooves formed in the upper surface of the step. The "retroreflective tape" is thin, and adhesion thereof entirely depends on the bonding agent which is previously applied to its hidden surface. Consequently, when employing this kind of tape for the climbing step, the tape is likely to be damaged or peeled off. In addition, the step portion to which the tape is bonded needs to be smooth. The tape is adhered after construction of the step and hence its manufacture undesirably requires one extra process.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a climbing step comprising: a metal core member including a pair of legs having their end portions adapted to be embedded in the wall surface and a tread portion provided between the two legs; a pair of synthetic resin for coating at least the tread portion and a part of the legs; and a transparent plastic reflection plate having an undersurface formed with prism-like rugged portions which are embedded in the resin, the upper surface of the plate being exposed at least in the upper surface of the layer of synthetic resin which covers the tread portion, and the surface of the plastic reflection plate being provided with non-slip protrusions.
According to one aspect of the invention, there is provided a climbing step wherein the synthetic resin with which the tread portion is coated involves polypropylene or the like, and a material of the reflection plate involves polycarbonate or the like.
According to another aspect of the invention, there is provided a climbing step wherein, when manufacturing the climbing step, the reflection plate is disposed along the predetermined wall surface of a molding tool, and the synthetic resin is injected in the molding tool while supporting the tread portion of a step body on the central portion of the molding tool.
According to still another aspect of the invention, there is provided a climbing step wherein the reflection plate is bonded by use of a bonding agent to the tread portion of the metal core member which is coated with the previously molded layer of synthetic resin.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be described in detail with reference to the appended drawings in which like reference numerals designate like elements, and wherein:
FIGS. 1A and 1B are perspective views of a climbing step according to the present invention;
FIG. 2 is an enlarged sectional view taken substantially along the line II--II of FIG. 1;
FIG. 3 is a view showing an underside surface of a transparent plastic reflection plate, the underside surface being formed with prism-like rugged portions utilized for the present invention;
FIG. 4 is a perspective view showing another embodiment of the present invention;
FIG. 5 is an enlarged sectional view taken substantially along the line V--V of FIG. 4; and
FIGS. 6A-6B, 7A-7B and 8A-8B are explanatory views illustrating a method of manufacturing the climbing step according to the present invention, FIGS. 6A, 7A and 8A being front elevation views of a metal mold for forming the climbing step, and FIGS. 6B, 7B and 8B being taken along the line X--X in FIGS. 6A, 7A, and 8A, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the present invention will hereinafter be described with reference to FIGS. 1A, 1B and 2.
As illustrated in FIGS. 1A and 1B, a metal core member 2 having a tread member 1 as a step is formed in such a way that a round iron bar is bent in a substantial U-shape, and both end portions 3 thereof are also bent up in a direction perpendicular to the plane made by the U-shaped step. Such end portions 3 are embedded into an unillustrated side wall of a manhole to prevent it from being removed therefrom. A pair of legs 4 of the metal core member 2 are coated with a synthetic resinous layer 10 composed of polypropylene or the like, covering two-thirds of the overall length of each leg (one-third from each end portion 3 is left bare) and further an entire tread portion 5.
The tread portion 5 coated with the synthetic resinous layer 10, as illustrated in FIG. 2, assumes a substantially rectangular configuration in cross-section to define a top surface 10t and a bottom surface 10b. However, a side surface 10s on the inside of the U-shaped portion has a series of wave-like projections 6 so that a hand does not deviate in the axial direction when seizing the tread portion with the hand. This provides the side surface 10s with a rugged surface when grasped.
A plurality of substantially X-shaped non-slip protrusions 7 are formed to protrude from a tread surface 5a which is formed flat on each of the upper and lower surfaces of the tread portion 5. The illustrated configuration of the protrusion 7 is not particularly limited and other configurations and designs are possible.
To the center of the tread surfaces 5a are integrally attached rectangular reflection plates 8 with a length of approximately one-half of the overall length of the tread portion 5. The underside of each individual reflection plate 8 is, as illustrated in FIG. 3, formed with prism-like recessed portions and embedded in a recess in the center of the tread portion 5 to form a flush surface with the tread surfaces 5a. The reflection plate 8 is composed of transparent plastic, and the upper surface thereof is provided with non-slip protrusions 8a which are identical both in configuration and in size with the foregoing protrusions 7. This reflection plate 8 may be so disposed as to extend over the entire surface of the flat tread portion 5a. The arrangement may be such that a sheet of large-sized reflection plate 8 is provided, or a plurality of small-sized reflection plates 8 are intermittently disposed. Furthermore, conventionally used small and circular reflection plates 9 each having a diameter of 2 mm or thereabouts may be disposed on both ends of the tread surface 5a. The reflection plate 8 may also be fitted to any one of the top and bottom surfaces of the resinous tread layer 10 on the tread portion 5.
There are at least two ways in which the reflection plate 8 is integrally attached to the tread portion 5 of the tread member:
1. One of the ways is as illustrated in FIGS. 6A, 6B to 8A, 8B.
FIGS. 6A, 7A and 8A show respectively front elevational views in which a metal mold half is shown and the other metal mold half is omitted. FIGS. 6B, 7B and 8B shows respectively cross sectional view taken along the line X--X of FIGS. 6A, 7A and 8A in which the (set of) metal mold halves are clamped.
In FIGS. 6A and 6B, a set of metal mold halves 20, 21 of an injection molding machine are formed with recessed portions 22 in which the metal core member 2 bent in the substantially U-shape is set and a cavity 23 into which synthetic resin is injected. A gate 24 is provided for injecting synthetic resin. A pattern 25 is also provided for forming non-slip protrusions 7.
As shown in FIG. 7A, the metal mold halves 20, 21 are first opened; then, a reflection plate 8 having U letter shape in cross-section and flat surface and its underside surface assuming the prism-like ruggedness is set in the metal mold halves so as to be located adjacent the tread portion of the metal core member 2. Then, the metal core member 2 is set in the recessed portion 22. In this state, the metal mold halves are clamped. (FIG. 7B)
Melted synthetic resin is injected into the cavity 23 defined by the clamped mold halves, i.e., into the outer periphery of the metal core member 2 and between the metal core member 2 and the reflection plate 8, from the injection gate 24 by normal method. During the injection molding process, the reflection plate 8 is softened, and each non-slip protrusion 8a is formed on the flat surface of the reflection plate 8 by pressing the plate against complementary non-slip protrusions in the metal mold halves. Except for the portion on which the protrusions 8a are formed by the patterns 25 for the non-slip protrusions, the prism like recessed portions remain as they are and hence the reflection plate maintains its reflective function in the portion exclusive of the protrusions 8a after the molding process has been completed. (FIGS. 8A, 8B).
2. Alternatively, the reflection plate 8 which is provided beforehand with the protrusions 8a is bonded by employing adhesives to the inside of the recessed portion of the tread portion 5 of the tread member 1. The protrusions 8a of the plate 8 are aligned with the protrusions 7 of the tread portion 5, the plate 8 overlying a rectangular portion of the step.
It is easy to recognize the position of the tread portion 5 of the tread member 1 with the help of the reflection plate 8 by making use of the thus constructed tread member 1. This facilitates the motion of putting the foot on the tread portion 5, which leads to easy ascent and descent.
It is therefore possible to readily go up and down even in dark places by seizing the tread portion with a hand or by putting the foot thereon while being guided by the light reflected on the reflection plate 8. As a result, the climber does not fail to set the foot on the tread portion because of mistaking its location whereby he is able to ascend and descend surely and quickly.
Even if the reflection plate 8 increases in size, it is feasible to prevent slippage from the tread portion on account of the non-slip protrusions 7 formed on the surface of the reflection plate 8 for obtaining the security when going up and down.
Referring to FIGS. 4, 5, there is shown another embodiment of the present invention. In this embodiment, the same components as those shown in the first embodiment are marked with the same numerals and the description thereof is herein omitted. A reflection plate 18 is a channel having a substantially U-shape in transverse cross section. The reflection plate 18 is attached to the top 10t, bottom 10b and front 10f surfaces of the resinous layer 10 on the tread portion 5 to cover them and provide a coating therearound. The reflection plate 18, as in the case of the first embodiment, includes the prism-like rugged portions formed on the underside or inside surfaces thereof. Non-slip protrusions 8a are respectively provided on the parts corresponding to the top and bottom surfaces of the layer 10 on the tread portion 5. The method of attaching the reflection plate 18 to the tread portion 5 is much the same as that of the first embodiment.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since there are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the invention.
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A climbing step and its manufacturing method are disclosed. The climbing step which is installed on wall surfaces of a manhole, pier or the like for ascent and descent is arranged such that a part of the step is coated with a layer of synthetic resin, and a reflection plate including protruding portions for preventing slippage are formed in the synthetic resinous surface. The reflection plate is embedded in the resinous surface over the tread portion while causing the surface to be exposed.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional patent application Ser. No. 61/845,621 filed on Jul. 12, 2013, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The present invention relates generally to roller cone drill bits.
SUMMARY
[0003] The present invention is directed to a bit. The bit comprises a body, a plurality of bit arms, a cone and a pin. The body comprises a center axis and a mounting pad and is connectible to a drill string. The bit arms are mounted on the body at the mounting pad. The cone is rotatable attached to each bit arm and comprises a plurality of teeth. The pin is located within each bit arm and the body through the mounting pad.
[0004] In another embodiment the invention is directed to a method for lubricating internal components of a bit having a bit body, a plurality of removable arms attached to the bit body, rolling elements attached to each of the removable arms, and at least one ball bearing located between the rolling elements and each of the removable arms. The method comprises connecting a removable arm with the bit body using a pin comprising a hollow passage, providing grease to a pressurized reservoir in the bit body, conveying grease into the removable arm through the hollow passage of the pin, providing a continuous passage through the removable arm proximate the ball bearings, and rotating the rolling elements to distribute grease from the continuous passage to the ball bearings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a side perspective view of a tricone rolling element bit.
[0006] FIG. 2 is a side perspective view of a ⅓rd segment of a tricone bit.
[0007] FIG. 3 is a perspective view showing three preassembled segments of a tricone bit.
[0008] FIG. 4 is a perspective view of an alternative tricone bit.
[0009] FIG. 5 is a sectional side view of the tricone bit of FIG. 4 .
[0010] FIG. 6 is another sectional side view of the tricone bit of FIG. 4 .
[0011] FIG. 7 is a detail view of the joint shown in FIG. 6 labeled “A”.
[0012] FIG. 8 is a side view of a horizontal directional drilling apparatus.
DESCRIPTION
[0013] With reference to FIG. 1 , shown there in is a tricone drill bit 10 . A tricone hit 10 is characterized by three rolling cone cutting elements 24 . A tricone bit, used in the oilfield, may have a useful life of a single bore. Tricone bits are also used in installation of buried utilities. This application, known as Horizontal Directional Drilling or “HDD”, typically has shorter length runs and less economic consequence in the case of bit failure. HDD typically involves bores between 300 and 1,200 feet, allowing for inspection, evaluation and service of the bit between bores. To improve the per-foot cost of operation of tooling, parts are typically rebuilt and reused to the limit of endurance and wear. A brief discussion of HDD is given with reference to FIG. 8 .
[0014] With reference to the figures in general and FIG. 1 specifically, a tricone bit 10 is shown therein. The bit 10 comprises a body 12 and a plurality of arms 14 . The body 12 comprises a base 16 and a mounting pin 18 . The mounting pin 18 is threaded as shown herein for connection to a drill string ( FIG. 8 ). Alternatively, the mounting pin 18 may be splined or geometrically aligned for connection to a drill string. The base 16 supports a fluid delivery system 20 and the plurality of arms 14 . As shown, the fluid delivery system 20 comprises a plurality of nozzles 22 . The plurality of nozzles 22 supply a fluid, such as drilling mud, for lubrication of the bit 10 . As shown, each of the plurality of nozzles 22 is directed to a corresponding one of the plurality of arms 14 .
[0015] Each of the plurality of arms 14 comprises a rolling element 24 comprising carbide teeth 26 , a ball port 28 , and a grease port 30 . The carbide teeth 26 engage material to be moved by the tricone bit 10 . The teeth 26 may be equalized and dispersed about the rolling elements 24 . The precise pattern of the teeth 26 may vary by size of the bit 10 and material being removed. The teeth 26 may take on various profiles as a function of the insert orientation. For some bits 10 , this may result in three different unique rolling elements 24 a, 24 b, 24 c making up bit assembly 10 .
[0016] Bearing balls ( FIG. 5 ) may be used to reduce friction and facilitation rotation of rolling elements 24 . These may be assembled through the ball port 28 . Preferably, the ball port 28 is closed with a plug ( FIG. 5 ) after assembly. Drilling mud is used by the fluid delivery system 20 to facilitate removal of the cuttings and clean the rolling elements 24 a, 24 b, 24 c . Drilling mud is discharged through the nozzles 22 , which are supplied with mud through the drill pipe bolted to mounting pin 18 . Grease port 30 allows access to an internal reservoir for lubrication. Grease may be added through grease port 30 , and the reservoir is pressure balanced to maintain lubricant pressure similar to that of the bore hole. Bore hole pressure is accessed through a pressure port 32 .
[0017] In operation, the bit 10 of FIG. 1 bores through a subsurface by rotation of the rolling elements 24 and grinding of the subsurface by the carbide teeth 26 . Drilling fluid provided by the nozzles 22 softens the area being drilled and prolongs the life of the carbide teeth. As material is removed from the subsurface, forming a borepath, the bit 10 is advanced along the bore path by sections of drill string (not shown).
[0018] With reference now to FIG. 2 , shown therein is one third of the tricone bit 10 of FIG. 1 . This section is referred to as a “shirttail sub-assembly” 40 . The shirttail sub-assembly 40 comprises one third of the cylindrical bit body 12 with one arm 14 and one nozzle 22 . Each shirttail sub-assembly 40 is joined into the tricone bit 10 ( FIG. 1 ) via welding along split plane 42 . After welding, the mounting pin 18 may be threaded or geometrically formed. Alternatively, the threads or geometric characteristics of the mounting pin 18 may exist on the shirttail subassembly 40 prior to welding. Three shirttail sub-assemblies 40 are formed into the tricone bit 10 of FIG. 1 through welding at the split plane 42 , as shown in FIG. 3 . With reference now to FIG. 4 , an alternative tricone bit 10 a comprising a mounting pad 50 is shown. The mounting pad 50 is generally the interface between the arms 14 and bit body 12 . The arms 14 are attached to the bit body 12 at the mounting pad 50 by bolts 54 . As shown, there are three bolts 54 in each arm 14 . The arms 14 are disposed about a center axis 58 . The grease port 30 provides access to internal lubrication systems ( FIG. 5 ) from the outside of the bit body 12 . The ball port 28 provides access to internal ball bearings ( FIG. 5 ) located proximate each rolling element 24 .
[0019] With reference to FIG. 5 , the tricone bit 10 a comprises a fluid delivery system 60 in each of the arms 14 and the bit body 12 . The fluid delivery system 60 comprises a pressurized pocket 62 , a spring 64 , a lubrication piston 66 , a shear pin 68 comprising a hollow central passage 69 , a middle grease passage 70 , an upper grease passage 72 , and a bushing 74 . The lubrication piston 66 produces grease pressure within the fluid delivery system 60 by the applied load of the spring 64 . As shown, the piston 66 and spring 64 are at the full range of travel within the pressurized pocket 62 . Thus, grease pressure may only be increased further by addition of additional grease pressure through grease port 30 .
[0020] Grease flows through the central passage 69 of shear pin 68 . This cylindrical pin 68 is a close fit seal through mounting pad 50 , a shear pin to resist shear forces due to bit torque and as a conveyance tube. Grease from pocket 62 is able to flow to the bushing 74 through middle grease passage 70 and upper grease passage 72 . A plug 76 is shown within ball port 28 . Preferably, the plug 76 has a reduced diameter proximate the central passage 70 and upper grease passage 72 to enable flow of grease through the fluid delivery system 60 . Fluid for lubrication reaches the bushing 74 and greases ball bearings 80 to allow free rotation of the rolling elements 24 relative to the bit arms 14 . In this way, fluid for lubrication, or grease, travels through a continuous passage from the shear pin 68 to the bushing 74 .
[0021] The bit arms 14 further comprise a cone seal 82 . The cone seal 82 seals the bushing 74 and limits lubricant leakage as the rolling element 24 rotates in operation. Preferably, the grease port 30 is formed inside a pocket 84 formed in the bit body 12 to protect the grease port from damage when bit 10 a rotates in use.
[0022] The bit 10 a defines a central fluid cavity 90 and nozzle feed passages 92 . Drilling fluid enters the central fluid cavity 90 from the drill string (not shown), is discharged into the nozzle feed passages 92 , and exit the bit 10 a through nozzles 22 . As shown in the figures, three independent nozzles 22 exist, one feeding each bit arm 14 and rolling element 24 . Alternative designs are contemplated, including the use of a greater number of nozzles 22 to direct drilling fluid at the rolling elements 24 .
[0023] With reference now to FIG. 6 , the bit 10 a is shown in cross-section. The bit arms 14 comprise a counterbore 100 . Connectors, such as bolts 54 are shown within the counterbores 100 . The counterbore 100 protects the bolt 54 from wear as the bit 10 a operates. The bolt 54 extends through bit arm 14 through the mounting pad 50 into the bit body 12 . The bit body 12 comprises a threaded hole 102 corresponding to the counterbore 100 of each bit arm 14 . Insertion of the bolt 54 into the threaded hole produces a clamping load between the arm 14 and bit body 12 , engaging the features of the mounting pad 50 .
[0024] The mounting pad 50 comprises lands 110 located on each bit arm 14 and grooves 112 located on the bit body 12 . The lands 110 and grooves 112 correspond and may be straight, circular, curved, geometrically shaped, or any other corresponding configuration. With reference now to FIG. 7 , detail section “A” of the mounting pad 50 is shown in greater detail. The lands 110 of arm 14 engages groove 112 of bit body 12 upon tightening of bolt 54 . The grooves 112 comprise a front-facing wall of the bit body 12 for engagement of the lands 110 at a corresponding surface. Note that a reference line 114 , parallel to a center axis 58 ( FIG. 4 ) of the bit body 12 , creates an angle 116 with a line 118 collinear to one of the grooves 112 . The angle 116 as shown is 105 degrees. Preferably, this angle is not less than 90 degrees. With an angle 116 greater than 90 degrees, thrust loads applied primarily to the front of the bit 10 a and generally directed along its central axis encounter greater stability.
[0025] With reference now to FIG. 8 , a horizontal directional drilling system 200 for use with the bit 10 disclosed herein is shown. The system comprises a drilling machine 202 , a drill string 204 , and the bit 10 . The bit 10 is advanced through a subsurface 205 by thrust and rotation of the drill string 204 provided at the drilling machine 202 . As a result of this operation, a borehole 206 is created in the subsurface 205 . The bit 10 exits the borehole 206 at an exit side 208 . A utility line (not shown) may be pulled in behind the drill string 204 , or alternatively, a separate backreaming assembly (not shown) is attached at the exit side 208 and pulled back through the borehole 206 to the drilling machine 202 .
[0026] Various modifications can be made in the design and operation of the present invention without departing from its spirit. Thus, while the principal preferred construction and modes of operation of the invention have been explained in what is now considered to represent its best embodiments, it should be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.
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A roller cone drill bit having detachable rotatable arms. The arms are connected at a mounting pad to the bit body. Each arm has its own grease delivery system to provide lubrication to the interface between the arms and rolling elements at an end of each arm. The forward-facing contact surface between the bit body and the arms is at an angle, relative to the central axis of the bit, that is ninety degrees or more.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of awnings and specifically to a vehicle awning with components facilitating improved assembly and operation.
2. Description of the Related Art
There are a number of known retractable assemblies that support an awning to create a sheltered area. The awning is usually supported in a generally horizontal position with a slight slope to facilitate runoff of rainwater. Commonly, one edge of the awning is attached to a wall. The opposite edge is attached to a tube, rod, rail or other similar elongated member, which is supported by two support arms. The support arms rest on the ground or are mounted to a lower part of the wall. Tension rafter arms are disposed between the wall and the tube or rail to stretch the awning and hold it in position. In this way, a convenient shelter is formed adjacent the wall to protect people and objects beneath the wall from rain and direct sun.
Shifting roll type awnings have a roller tube suspended between the support arms. The tube is moved laterally to unroll or roll the awning on the tube. One edge of the awning is rigidly attached to the wall. It is less common, but still possible, for this type of awning to be enclosed in a case in its retracted position. U.S. Pat. No. 4,658,877 to Quinn shows an example of such an awning assembly. In both types the roller tube may be spring balanced or spring biased to aid rolling.
Retractable awnings can be divided into two general classes. Box type awnings have a stationary roller tube mounted to the wall. The awning is rolled around the tube for storage. The box comprises a stationary enclosure for the awning, a cover of which is opened to permit access to the awning which is unrolled to an extended position. Alternatively, a movable cover is attached to the free end of the awning to complete the enclosure when the awning is retracted.
A popular application for such awnings is on recreational vehicles. The awning creates a convenient outdoor shelter next to the vehicle. Simple and fast assembly and disassembly of the awning are important, especially in vehicle applications. Vehicle awnings also must be rugged and durable because they are constantly exposed to the elements.
Different hardware and assemblies are used to construct and mount the awning assemblies. The need exists for improvements in the hardware and assemblies to facilitate mounting, assembly, and erection of the awning and to improve the operation of the awning.
SUMMARY OF THE INVENTION
The present invention provides improved features for awning assemblies including a roller for an awning having a bead along an edge of the awning. The roller is an elongated member having a longitudinal channel adapted for receiving and retaining the bead therein. A notch is disposed at an end of the channel, said notch being adapted for receiving an end of the bead therein in a compressed state, frictionally retaining the end of the bead, and preventing substantial longitudinal movement thereof.
An awning assembly according to the invention includes an awning having a leading edge and a trailing edge, said trailing edge being attachable at a wall. A support arm is adapted for supporting the leading edge of the awning and has an upper end spaced from the wall in a retracted position of the awning. A rafter is disposable between the support arm and the wall. A pivot support having an end of the rafter pivotably attached thereto is mounted at the wall and spacing the rafter from the wall substantially the same distance as support arm is spaced from the wall. A mounting bracket has a flange and is adapted for securing the pivot support to the wall. The pivot support includes a plurality of slots adapted for receiving the flange of the mounting bracket, each of said slots being adapted for positioning the mounting bracket differently depending on a desired mounting configuration. An awning rail is used for attaching the trailing edge of the awning at the wall. The pivot support includes a locating tab adapted for positioning the pivot support relative to the awning rail.
Another construction of the awning assembly includes an awning having a leading edge and a trailing edge, said trailing edge being attachable at a wall. A support arm is adapted for supporting the leading edge at a support axis of the awning and having a slide channel on an external face thereof. A rafter is disposable between the support arm and the wall. A slider is pivotably attached to the rafter at a pivot axis and adapted for sliding in the slide channel. A stop is adapted for positioning the pivot axis collinearly with the support axis in an extended position of the awning.
The invention also comprehends a lock assembly for an awning roller. A roller adapted for having an awning rolled thereon has an end cap mounted on an end of the roller. A rod defines a longitudinal axis of rotation of the roller. A stop is rigidly mounted to the rod. A lock has a pawl adapted for engaging the stop so as to prevent relative rotation of the roller and rod in at least one direction. Spring means is provided for biasing the lock toward engagement with the stop.
The description of the invention refers to a shifting roll type awing assembly. However, the features and components can be adapted to other types of awnings, as well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a vehicle having an awning assembly according to the invention mounted thereon;
FIG. 2 is a top view of a mounting bracket according to the invention;
FIG. 3 is an end view of the mounting bracket of FIG. 2;
FIG. 4 is a top view of a pivot support according to the invention;
FIG. 5 is a side view of the support of FIG. 4;
FIG. 6 is a perspective view of an end of the awning assembly showing the manner of mounting to the vehicle;
FIG. 7 is an end view of the mounting components of FIG. 6;
FIG. 8 is an end view of the mounting components of FIG. 6 according to another embodiment;
FIG. 9 is an end view of the mounting components of FIG. 6 according to a third embodiment;
FIG. 10 is an end view of a roller tube having an awning attached thereto;
FIG. 11 is a partial front view showing an end of the roller tube shown in FIG. 10;
FIG. 12 is a partial end view of the roller tube shown in FIG. 10;
FIG. 13 shows a section of the roller tube and awning taken from line 13--13 of FIG. 12;
FIG. 14 shows the view of FIG. 13 with the awning omitted;
FIG. 15 is an end view of the awning assembly in a partially assembled, partially retracted position;
FIG. 16 is a top view of an end of the awning assembly showing the roller tube, a support arm, and a rafter arm according to the invention taken from line 16--16 in FIG. 15;
FIG. 17 is a front view of the end of the awning assembly taken from line 17--17 in FIG. 15;
FIG. 17A is an exploded view of the rafter arm, support arm, and a slider assembly;
FIG. 18 is an end view of the awning assembly in a fully extended position;
FIG. 19 is an end view of the awning assembly is a partially retracted position;
FIG. 20 is a front elevational view of a support arm and a rafter arm in a retracted position;
FIG. 21 is an end view of the support arm and rafter arm in a retracted position;
FIG. 22 shows an inside face of an end cap of the roller tube and roller lock components mounted therewith;
FIG. 23 is a front section of the end cap and a torsion rod taken from line 23--23 of FIG. 22;
FIG. 24 shows the roller lock in a "roll up" position; and
FIG. 25 shows the roller lock in a "roll down" position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a vehicle 10 has a generally vertical wall 12 with an awning assembly 14 mounted thereon. Generally, the awning assembly 14 includes an awning rail 16 mounted on the wall 12 and an awning 18 rollable on a roller 20 such as a roller tube. A leading edge of the awning 18 is supported by respective support arms 22. The support arms are preferably secured to ends of the roller 20 and are removably mounted on the wall 12 or rested on a ground surface. Rafter arms 24 are disposed between leading and trailing edges of the awning 18 to maintain the awning in tension.
Referring to FIGS. 2 and 3, a mounting bracket 30 is preferably made of corrosion resistant steel or other durable, rigid material. The bracket 30 has a mounting flange 32 and a support flange 34 disposed at opposite ends of a body 36 of the bracket 30. Reinforcing flanges 38 are provided at ends of the body 36. Downwardly projecting dimples 40 are provided on the body 36. First and second pairs of oval mounting holes 42, 44 are located through the bracket 30 at or near the respective flanges 34, 32.
Referring to FIGS. 4 and 5, a pivot support 46 is made with aluminum or other durable, rigid material. The pivot support 46 has a body 48 with first, second, and third slots 50a, 50b, and 50c located on upper and lower faces thereof. The slots 50 are adapted to receive the support flange 34 of the mounting bracket 30. A positioning tab 52 projects from a recess 54 on an inboard face of the body 48. A brace arm 56 having a foot 58 extends from below the positioning tab 52. A generally cylindrical pivot slot 60 is located at an outboard end of the pivot support 46.
Referring to FIGS. 6 and 7, the rafter arm 24 is mounted to the pivot support 46 by a pivot pin 62 extending through the pivot slot 60. The awning rail 16 is mounted to a frame or brace 64 of the vehicle wall 12 in a conventional manner. The awning rail 16 defines a C-channel adapted for mounting awning components.
Referring to FIG. 7, the positioning tab 52 projects into the C-channel of the awning rail 16. The recess 54 receives the awning rail 16 therein. A plastic pad 66 is provided over the foot 58 to prevent marring of the wall 12. The foot 66 preferably rests against the wall 12. The support flange 34 of the mounting bracket 30 is located in the first slot 50a of the pivot support 46. The pivot support 46 and bracket 30 are held in place by a pair of lag screws 68 extending through the holes 42 and the wall 12 into the brace 64.
Referring to FIG. 8, for a different orientation of the awning rail 16, the mounting bracket 30 is located above the pivot support 46 with the support flange 34 inserted in the second slot 50b. The screws 68 extend through the mounting holes 44 into the brace 64 above the rail 16. The dimple 40 rests beside the body 48 of the pivot support.
Referring to FIG. 9, for a differently constructed awning rail 16 having the C-channel spaced from the wall 12, the support flange 34 is inserted in the third slot 50c. The foot 58 is spaced from the wall or can be braced against a spacer (not shown).
The pivot support 46 and mounting bracket 30 are adapted for use with different configurations of awning rails 16 and advantageously space the pivot of the rafter arm 24 from the wall, as described below.
Referring to FIG. 10, the roller 20 is a roll-formed, steel tube, as described, for example, in U.S. Pat. No. 5,351,736. An edge of the awning 18 (the leading edge in the example shown) has a pocket 70 defined by a hem 72. A flexible, compressible, cylindrical rope 74, preferably made of polypropylene, is located in the pocket 70 and extends slightly beyond both ends of the pocket 70. The rope 74 and pocket 72 define a bead disposed in a slideway 76 of the roller 20. The diameter of the rope and the dimensions of the slideway are such that the rope retains the edge of the awning in the slideway.
Referring to FIGS. 11 through 14, a notch 78 is provided in a side wall 80 of the slideway 76. Alternatively, the notch 78 can be provided in a base wall or a corner of the slideway 76, for example. The notch 78 is slightly narrower than the diameter of the rope. The end of the rope 74 is compressed and wedged into the notch 78 and retained therein by friction to prevent longitudinal movement of the rope. Preferably, complementary notches are provided at opposite ends of the roller 20 so that the edge of the awning can be pulled taut and opposite ends of the rope 74 wedged into the respective notches 78 to hold the awning taut in the slideway 76.
Referring to FIG. 15, each of the support arms 22 includes an upper arm 82 and a lower arm 84 slidingly received therein. The arms 82, 84 are frictionally locked relative to each other by a screw and knob assembly 86. Each of the rafter arms 24 includes an inboard arm 88 and an outboard arm 90 slidingly received therein. The arms 88, 90 are frictionally locked relative to each other by a screw and knob assembly 92. As previously described, the inboard end of the rafter arm 24 is pivotably mounted at the wall 12 on the pivot support 46. The lower end of the support arm 22 has a foot 94 removably and pivotably mountable at the wall in a foot bracket 96. The outboard arm 90 is slidingly and pivotably mounted to the upper arm 82, as described in more detail below. The roller 20 is rotatably mounted near the top of the support arm 22.
Referring to FIGS. 16 and 17, the roller 20 is rotatably supported on a torsion rod 98, which can be solid or hollow. The torsion rod 98 extends longitudinally through the center of the roller 20 and through end caps 100 disposed at ends of the roller. The torsion rod 98 defines collinear support and rotational axes of the roller 20. Ends of the torsion rod 98 are supported on the upper arm 82 and secured by a nut and bolt assembly 102.
An outside face of each upper arm 82 is provided with a pair of arm flanges 104 defining a longitudinal slide channel 106. A slider 108 is pivotably mounted to the outboard arm 90 on a post 110, such as a rivet. The slider 108 is made of a durable, low friction material, such as plastic. The slider has pairs of inner flanges 112 and outer flanges 114 cooperating with the arm flanges 104 to retain the slider in the slide channel 106 and permit longitudinal sliding therein. A support arm cap 116 is disposed on the top end of the upper arm 82 to limit upward travel of the slider 108. Alternatively, another blocking member, such as a screw, can be used to limit upward travel of the slider 108. As shown in FIG. 18, when the slider 108 abuts the cap 116, the post 110 defines a pivot axis substantially collinear with the torsion rod 98 and support axis of the roller 20.
As shown in FIGS. 17 and 17A, a slider stop 118 is mounted on the post 110 between the slider 108 and the upper arm 82. The slider stop 118 has a detent 120 projecting from an inner face of the stop toward the upper arm 82. An exposed end of the stop 118 defines a lever 122 projecting from behind the slider 108 to a manually accessible location. The detent 120 is biased toward the upper arm 82 by a compression spring 124, for example. As shown in FIGS. 17 and 19, a slot 126 adapted to receive the detent 120 is located near the top of the slide channel 106 of the upper arm 82. The slot 126 is positioned such that the detent 120 is biased into the slot and locks the rafter 24 in the position shown in FIG. 18 when the slider abuts the support arm cap 116. The rafter 24 is releasable by actuating the lever 122 to remove the detent 120 from the slot 126.
The rafter arms 24 and support arms 22 are relatively slidable and pivotable between an extended position, shown in FIG. 18, and a retracted position, shown in FIGS. 20 and 21. The rafter and support arm assemblies at opposite ends of the roller 20 are mirror images of each other.
Referring to FIGS. 22 and 23, idler bearings 128 are rotatably mounted on the torsion rod 98 and support the roller 20 for rotation about the rod. A coiled torsion spring (not shown) is connected between the torsion rod and the idler bearing to bias the roller toward a retracted position with the awning rolled thereon. The end caps 100 close the ends of the roller. One of the end caps 100 is provided with a roller lock assembly 130. As shown and described below, the lock assembly is located in the right hand end cap 100, as viewed in FIG. 1. A gear 132 having a plurality of teeth defining stops is mounted on the torsion rod 98. A pin 134 extending through the rod 98 prevents relative rotation of the rod and gear 132.
A truss 136 is rotatably mounted on the torsion rod 98 adjacent the gear 132. The end cap 100 is fastened to the truss 136 by a pair of screws 138 threaded into apertures 140 of the truss 136. A lock 142 having a first pawl 144 and an opposed second pawl 146 is pivotably mounted on the truss 136 by a post 148 extending through a passage 150 through the truss and the end cap 100. The lock 142 is operable by a handle 151 disposed on an end of the post 148 outside the end cap 100. Opposed elements of a torsion spring 152 or leaf springs bear against bushings 154 mounted on the lock 142. The bushings 154 are symmetrically on opposite sides of the post 148 by a pair of shoulder screws 156. The elements of the spring 152 bear inwardly against the bushings 154 to resist any tendency of the lock to remain in the neutral position shown in FIG. 22.
Referring to FIG. 24, by operation of the handle 151, the lock is movable to a "roll up" position wherein the roller and end cap 100 are rotatable clockwise about the torsion rod 98. In this position, the first pawl 144 engages a tooth of the gear 132 to prevent counter-clockwise rotation of the roller and end cap about the torsion rod. The opposed elements of the spring 152 bear inwardly against the bushings 154 of the lock 142 to keep the lock in position.
Referring to FIG. 25, by operation of the handle 151, the lock is also movable to a "roll down" position wherein the roller and end cap 100 are rotatable counter-clockwise about the torsion rod 98. In this position, the second pawl 146 engages a tooth of the gear 132 to prevent clockwise rotation of the roller and end cap about the torsion rod. The opposed elements of the spring 152 bear inwardly against the bushings 154 of the lock 142 to keep the lock in position.
In operation, the support arms 22 and rafter arms 24 are normally stowed as shown in FIGS. 20 and 21. The arms 22, 24 are spaced from the vehicle wall 12 by the feet 94 and pivot support 46 so that the arms are generally parallel. A releasable strap and buckle assembly 158 holds the arms in the parallel, stowed position. To extend the awning, the strap and buckle 158 are released, the rafter knob 92 is loosened, and the lock assembly 130 is moved to the roll down position shown in FIG. 25. As shown in FIG. 19, the roller 20 is pulled away from the vehicle and the awning unrolls therefrom. Each outboard arm 90 slides out from its inboard arm 88 to extend the rafters 24. When the awning 18 is fully extended, the rafter arms 24 are slid to the tops of the support arms 22 until the slider stop 118 engages in the slot 126, as shown in FIG. 18. The awning is pulled to a desired tension and the rafter knobs 92 are screwed in to lock the rafters 24. The supports arms 22 are extended to a desired length and locked with the support arm knobs 86. As shown in FIG. 1, the support arms 22 can remain locked in the foot brackets 96 or the feet 94 can rest on the ground. Referring to FIGS. 1 and 18, because the outboard pivot axis of the rafter 24 and support arm 22 defined by the post 110 is coaxial with the support axis of the roller 20, pivoting the support arms 22 between the wall 12 and the ground does not substantially change the tension of the awning 18.
To retract the awning, the feet 94 are replaced in the foot brackets 96 and the support arms 22 are shortened. The rafter knob 92 is loosened and the slider stop is released by lifting the lever 122, shown in FIGS. 17 and 18. The outboard end of the rafters 24 are slid down to the support arm knobs 86. The lock assembly 130 is moved to the roll up position shown in FIG. 24 by operation of the handle 151. The awning 18 is then rolled on the roller 20 as the roller is moved toward the vehicle wall. The arms 22, 24 are returned to the positions shown in FIGS. 21 and 22, the knobs 92 and 86 are tightened, and the strap and buckle assemblies 158 are used to secure the arms in the parallel, stowed position.
The present disclosure describes several embodiments of the invention, however, the invention is not limited to these embodiments. Other variations are contemplated to be within the spirit and scope of the invention and appended claims.
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A retractable awning is provided with a multiple position pivot support adapted for mounting the awning in different installations. A flange of a mounting bracket fits in one of several slots in the support according to a wall and awning rail structure. A roller is provided with a notch into which is wedged a rope in a hem pocket of the awning. The notch retains the rope and holds the awning taut. Rafter arms a pivotably attached to slides held in slideways on external faces of support arms. A stop and latch mechanism hold the rafter in an extended position so that pivoting of the support arms does not change tension of the awning. An improved roller lock uses a pair of pawls engaging a gear. A spring biases the lock to either of two engaged positions.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a tool utilized to remove particulate matter from perforations immediate formations in a subterranean well.
2. Description of the Prior Art
During the flow of production fluid into a well casing or while injecting secondary or tertiary recovery fluids into the formation, perforations in the well casing or the face of the producing formation may oftentimes become plugged with sand, silt, or other substances, restricting fluid flow between the formation of the casing bore. Heretofore, it has been common practice to utilize a valve apparatus which creates a high pressure differential to produce a sudden high velocity flow or surge of the formation fluid through the perforations and into the casing bore, thereby carrying sand, silt, and the like, into the tubing for subsequent elevation to the top of the well. As a result, the formation and perforations are washed or cleared, facilitating subsequent well production or the injection of secondary or tertiary recovery fluids into the formation.
Some of the prior art backsurge valving assemblies require drill or work string rotation to manipulate one or more of the valves. Such mechanically-activated manipulations may be undesirable in deviated holes and/or in wells of extreme depth. Moreover, some valving assemblies heretofore utilized in backsurge systems incorporate a diaphragm or disk-like element as a valve head which is ruptured by pressure, or is "cut" to open the valve, thus possible contributing to foreign particulate matter in the well which also could adversely affect subsequent operation of the valve assembly by becoming jammed between two moving parts.
Backsurge well-cleaning tools are known which are activated by pressure, one such tool being shown in U.S. Pat. No. 4,185,690, issued on Jan. 29, 1980 to the assignee of the present application. As disclosed therein, the backsurge tool generally comprises a tubing string having an upper normally closed valve communicating with a lower normally closed valve through an atmospheric pressure chamber. Although this backsurge well-cleaning tool is similar to the cleaning tool of the present invention in that it is activated by pressure, it includes a valve assembly having a blanking plug.
SUMMARY OF THE INVENTION
The backsurge well-cleaning tool of the present invention generally comprises first (lower) and second (upper) valve assemblies interconnected by a surge chamber at atmospheric pressure and includes a conventional packer extending to the first valve assembly. The backsurge tool is adapted to be run into a well on a tubing string with both valves closed. Initially the packer is set to isolate the annulus between the backsurge tool and the well formation. The lower valve assembly then is opened, thus communicating the well formation and the surge chamber. This action produces a vacuum-like action to pull a surge of fluid into the surge chamber and thus remove debris from the formation and the well casing perforations. The upper valve is then opened for producing a reverse circulation of the well fluid in the surge chamber containing the dislodged debris. Concurrently, the packer is released and fluid pressure applied through the tubing-casing annulus and debris containing fluid passes upwardly through the open valve assemblies.
The upper valve assembly has a body which is connected to the tubing string. The operative valving element is a flapper valve mounted in the lower portion of the body. The upper valve assembly also includes a longitudinally movable, actuating sleeve carrying a valve seat at its lowermost end for selective sealing engagement with the flapper valve. The actuating sleeve is normally retained in its valve closing position by a segmented locking ring. A longitudinally movable, segment retainer sleeve mounted in the valve body is responsive to pressurization of tubing fluid to release the segmented locking ring, allowing the actuating sleeve to be shifted away from the flapper valve by fluid pressure. The flapper valve is thus opened by a torsion spring to allow fluid flow through the valve assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B and 1C together constitute a longitudinal schematic view illustrating the present apparatus after the apparatus has been run into the well, the packer being anchored and set against the casing and each of the valves being in closed position.
FIGS. 2A, 2B and 2C are similar to the views illustrated in FIGS. 1A, 1B and 1C, showing each of the upper and lower valves in open position with circulation being initiated to clean out the well bore subsequent to the cleaning operation, the packer being released from the casing.
FIG. 3 is an enlarged sectional view of the upper valve assembly in closed position prior to the initiation of circulation.
FIG. 4 is an enlarged sectional view illustrating the upper valve assembly in its open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1A, 1B and 1C, a tubing string TS is lowered into a well bore having a casing C. The tubing string TS carries an upper valve assembly V1 and a lower valve assembly V2, the valve assemblies V1 and V2 being separated by an atmospheric pressure chamber CH. The tubing string TS is terminated at its lower end by a conventional packer assembly PR which is designed to hold pressure from above and below when set. The tubing string is run into the well, and the packer PR landed immediate a bridge plug BP within the bore of the well and above perforations P which communicate with production zone Z1.
As particularly illustrated in FIGS. 1B and 2B, the lower valve assembly V2 is essentially the same as that described in U.S. Pat. No. 4,185,690. Such assembly includes an outer longitudinally extending housing 10 containing an axially extended annular piston mandrel 11 therein. The housing 10 is defined at its uppermost end by a top sub 12 which is secured by threads 13 to the lowermost tubular section forming the pressure chamber CH thereabove. The outer housing 10 also includes an annular piston housing 14 which is secured by threads 15 to the top sub 12. The bottom portion of outer housing 10 comprises an annular valve housing 16 which is secured to the piston housing 14 by threads 17. The lower end of valve housing 16 is secured by threads 18a to an internally threaded sleeve 18 which in turn is threadably connected to the upper end of the packer PR.
The top sub 12 in addition to having threads 15 defined thereon for securement to the piston housing 14 therebelow, also has an interior circumferentially extending grooveway 19 for housing an elastomeric ring element 20 to prevent fluid communication between the top sub 12 and the piston mandrel 11. A similar grooveway 21 and ring element 22 is also defined on the exterior of top sub 12 to prevent fluid communication between the top sub 12 and the piston housing 14. An elastomeric spacer or shock absorber 23 is carried by the top sub 12 at its lowermost end and defines the limit of upward travel of a piston head 24 carried by the piston mandrel 11 as the valve assembly V2 is manipulated to open position.
The annular piston housing 14 has a smooth cylindrical inner wall 25 for slidable longitudinal movement of the piston head 24 thereon as the valve V2 is manipulated to open position. Somewhat below the inner wall 25, and immediately interior of the valve housing 16, is a series of inwardly contracted ring segments 26 having their inner faces resting on a shoulder 27 on the piston mandrel 11. The ring segments 26 are shearably secured to a longitudinally extending segment retainer sleeve 28 carried within the outer housing 10 between the valve housing 16 and the piston mandrel 11, the segments 26 being secured to the retainer 28 by means of a guard 28'. The guard 28' receives within a groove 29 thereof a shear screw 30 which is inserted through the segment retainer 28 by means of a threaded bore 31. When the segments 26 shoulder upon the shoulder 27 of the piston mandrel 11, the upper longitudinal end of the segment retainer sleeve 28 is positioned upwardly and over the segments 26 and contacts the lower end of the piston housing 14. With the shear screw 30 engaging the guard 28', the segments 26 are urged interiorly of the segment retainer 28 such that a beveled shoulder on the piston mandrel 11 contacts and shoulders upon a compansion stop on the segments so that upward longitudinal movement of the piston mandrel 11 is arrested. When in engaged position, the outer face of the ring segment 26 is interfaced with the upper end of the segment retainer 28.
The segment retainer 28, normally locked interior of the housing 16 as described above, contains a radial port 32 defined thereacross which is always in communication with companion port 33 in the housing 16, the ports 32 and 33 communicating with the annular area between the casing C and the outer housing 10 to permit annulus pressure to selectively act upon the piston head 24 and the segment retainer 28 when it is desired to manipulate the valve V2 to open position.
An elastomeric O-ring 34 contained within a groove 35 on the lowermost end of the segment retainer 28 prevents fluid communication between the piston mandrel 11 and the segment retainer 28 while a similar O-ring 36 contained within its groove or boreway 37 on the segment retainer 28 prevents fluid communication between the retainer 28 and the housing 16.
The lowermost end 38 of the segment retainer 28 will, upon application of fluid pressure upon the segment retainer 28 and the piston head 24, shift the segement retainer 28 longitudinally downwardly until such time as the lower end thereof rests upon an upwardly facing companion shoulder 39 on the housing 16.
The valve housing 16 contains a flapper-type valve assembly which normally is maintained closed by the piston mandrel 11 as shown in FIG. 1B. The flapper valve assembly consists of flapper head 40 which, when in closed position, completely bridges the internal diameter of the bore of the outer housing 10 near the bottom of the valve housing 16.
The structure and operation of the lower valve assembly V2 is described in detail in U.S. Pat. No. 4,185,690, and further discussion thereof is not necessary.
Referring now to FIGS. 1A, 2A, 3 and 4, the upper valve assembly V1 basically consists of an annular outer housing 100 enclosing a longitudinally elongated actuating sleeve 101 having a radially projecting piston head 102 integral therewith. The outer housing 100 includes a top sub 103 at its uppermost end, which is secured by threads 104 to the lower end of the tubing strings TS. The top sub 103 is secured by threads 105 to the top end of an upper cylindrical piston housing 106. The bottom end of the piston housing 106 is secured by threads 108 to a connector element 107. The outer housing 100 is terminated at its lowermost end by a valve housing 109 which is secured to the connector 107 by means of threads 110. The valve housing 109 is secured by means of threads 111 to a bottom sub 112 which is secured by threads 113 to the uppermost tubular section 99 forming the atmospheric chamber CH therebelow.
The top sub 103 has an exterior circumferentially extending grooveway 114 for housing of an elastomeric O-ring 115 to prevent fluid communication between the top sub 103 and the piston housing 106. An elastomeric spacer or shock absorber 116 abuts the bottom end of the top sub 103 and defines the limit of upward travel of the piston head 102 carried by the actuating sleeve 101 as the valve V1 is manipulated into its open position. Further, the top sub 103 has a smooth inner wall 117 which slidably cooperates with the uppermost end of the actuating sleeve 101 as the valve V1 is manipulated into open position.
The upper annular piston housing 106 has a smooth inner wall 121 for slidably cooperating with the piston head 102 carried by the actuating sleeve 101 as the valve V1 is manipulated into open position. Somewhat below the inner wall 121 and immediately interior of the upper housing 106 is a series of inwardly contracted ring segments 122 having their bottom faces resting upon a shoulder 123 on the actuating sleeve 101. The segments 122 are secured in such position by the top end of an axially movable segment retainer sleeve 124 carried within the outer housing 100 between the upper piston housing 106 and the actuating sleeve 101. When the segments 122 engage the shoulder 123 of the actuating sleeve 101, the upper longitudinal end of the retainer sleeve 124 surrounds the segments 122 and contacts the lower surface of a segment stop ring 125 seated against a shoulder 126 defining the lower end of the inner housing wall 121.
Somewhat below the ring segments 122, the retainer sleeve 124 is provided with a number of circumferentially spaced shear screws 127 (only one shown). The shear screws 127 project inwardly of the retainer sleeve and overlie a shoulder 128 on the actuating sleeve 101.
A transversely extending port 129 is provided through the wall of the retainer sleeve 124, the purpose of which will be described hereinafter. Above the port 129, the retainer sleeve 124 has an interior circumferential grooveway 130 for housing an elastomeric O-ring 131 to prevent fluid communication between the sleeve 124 and the actuating sleeve 101. A similar exterior grooveway 132 and O-ring 133 also are defined on the sleeve 124 below the port 129 to prevent fluid communication between the sleeve 124 and the upper housing 106. Above O-ring 131, a plurality of radial ports 98 are formed in the wall of actuating sleeve 101. An exterior peripheral groove 97 in the actuating sleeve 101 and an O-ring 96 prevent fluid leakage between retainer sleeve 124 and actuating sleeve 101.
The lowermost end of the retainer sleeve 124, together with the upper housing 106 and the connector 107 define a chamber 134 therebetween communicating with the annular area between the outer housing 100 and the casing C through a port 135 in the upper housing 106. Thus, the chamber 134 is vented for permitting the retainer sleeve 124 to be moved by the application of tubing pressure. Also, the lowermost end of the retainer sleeve 124 has an exterior circumferential grooveway 136 for housing an elastomeric O-ring 137 to prevent fluid communication between the connector 107 and the sleeve 124.
Somewhat below the uppermost end of the connector 107, the connector has an interior circumferential grooveway 138 for housing an elastomeric O-ring 139 to prevent fluid communication between the actuating sleeve 101 and the outer housing 100.
The bottom sub 112 has an exterior circumferentially extending grooveway 118 for housing of an elastomeric O-ring 119 to prevent fluid communication between the bottom sub 112 and the valve housing 109. The bottom sub 112 is also provided with a counterbore 120, the purpose of which will be described hereinafter.
The valve assembly V1 contains a flapper-type valve 140 which normally is maintained closed by the bottom end of a cup element 147. This valve 140 may be frangibly constructed so that the head may be pierced to open it in emergency situations, by means of a wireline tool, a rod, or the like. The flapper valve, when in closed position, completely bridges the interior of the outer housing 100. More specifically, the lowermost end of the connector 107 carries a spacer sleeve 141 by means of a drive lock pin 142, and the lowermost end of the spacer sleeve carries a locator ring 143 by means of the drive lock pin 144. The locator ring 143 pivotally mounts the flapper valve 140. The locator ring 143 is urged upwardly by a stack 145 of Belleville spring washers 146 disposed in the counterbore 120 of the bottom sub 112 against the bottom face of the locator ring 143, for urging the flapper valve 140 to a sealed position, as best illustrated in FIG. 3.
Referring now to FIGS. 3 and 4, a cup element 147 having a seal ring or valve seat 148 is carried on the lowermost end of the actuating sleeve 101 by threads 149. Valve seat 148 securely seals the flapper valve 140 with respect to the bore 95 of the actuating sleeve 101 when the flapper valve 140 is in the closed position bridging the interior of the outer housing 100. The cup element 147 has an interior circumferential grooveway 150 for housing an elastomeric O-ring 151 to prevent fluid communication between the actuating sleeve 101 and the cup element 147.
Referring particularly to FIGS. 3 and 4, one leg 152 of a torsion spring 153 contacts the lower side of the flapper valve 140 and is carried around a hinge pin 154 within the locator ring 143 to urge and shift the flapper valve 140 upwardly away from the locator ring 143 when the valve V1 is manipulated to open position, as shown in FIG. 4, such that the flapper valve is fully open with respect to the interior of the housing 100 of the valve assembly V1. A spring-loaded retainer pin may be carried within the locator ring 143 and is shifted to locked position within the ring 143 when the flapper valve 140 is shifted to open position to prevent inadvertent movement of the flapper valve 140 towards the "Closed" position as the result of pressure surges, or the like.
As previously indicated, the actuating sleeve 101 is carried within the outer housing 100 and its piston head 102 is permitted to slide longitudinally along the smooth inner wall 121 of the upper valve housing 106 as the valve V1 is manipulated to open position. A circumferentially extending elastomeric O-ring 157 is contained within an external peripheral grooveway 158 on the uppermost end of the actuating sleeve 101 to prevent fluid communication between the top sub 103 and the actuating sleeve 101 as it slides along the smooth bore wall 117 of the top sub 103. A circumferentially extending elastomeric O-ring 159 is contained in an external peripheral grooveway 160 on the piston head 102 to prevent fluid communication between each opposed side of the piston head 102 as it slides along the smooth bore wall 121 of the outer housing 106. As the actuating sleeve is shifted upwardly toward the top sub 103 as the valve V1 is manipulated to the open position, the upper face of a shoulder 161 integrally formed on the sleeve 101 will encounter the lower face of the shock absorber 116 which defines the upper limit of longitudinal travel of the actuating sleeve 101.
It should be noted that an upper atmospheric chamber 162 is defined between the outer housing 106 and the actuating sleeve 101, between the upper O-ring 157 carried by the actuating sleeve and the O-ring 159 carried by the piston head 102 of the actuating sleeve 101 and the ring 115. Similarly, a lower atmospheric chamber 163 is defined between the bore of the outer housing 106 and the actuating sleeve 101, between the O-ring 159 carried by the piston head 102 and the O-ring 139 located in the connector 107, together with rings 137, 132 and 131.
The valve assembly V1 is normally closed as illustrated in FIGS. 1A and 3, and locked in this position by the ring segments 122 as previously described. The valve assembly V1 is opened by pressurizing the tubing pressure sufficiently to shear the shear screws 127. The tubing pressure acting on the segment retainer sleeve 124 through the port 98 will move the retainer sleeve 124 downwardly, releasing the ring segments 122 to move outwardly and dumping tubing pressure into the lower chamber 163. Tubing pressure acting on the lower face of piston head 102 will move the actuating sleeve 101 upwardly until the shoulder 161 bottoms out on the shock absorber 116. The ring segments 122 will then drop into a lower circumferentially extending groove 164 on the actuating sleeve 101, locking the actuating sleeve in an open position.
It should be noted that the seal on the flapper valve 140 is broken as soon as the actuating sleeve 101 begins to move and the torsion spring 153 will move the flapper valve 140 upwardly to its open position as illustrated in FIG. 4.
If for any reason the flapper valve 140 fails to open or does not open completely, the valve 140 is preferably manufactured from a frangible material and easily broken out by use of an auxiliary tool (not shown).
OPERATION
When it is desired to clean debris from the perforations P and the formation face within the zone Z1 the backsurge apparatus of the present invention is run in the well on tubing string TS. The valve assembly V1, being affixed to the tubing string TS, is carried down into the well in its closed position as shown in FIGS. 1A and 3. A series of the tubular sections are carried below the valve assembly V1 to define the atmospheric surge chamber CH.
The lower valve assembly V2 is secured below the lowermost tubular section forming the surge chamber CH, the valve assembly V2 being in closed position. The packer PR is affixed to the lowermost end of the valve assembly V2.
Referring now to FIGS. 1A, 1B, and 1C, the assembly is carried into the well and the lower end of the packer PR is located above the perforations P. Thereafter, the packer PR is set above the zone Z1. Thereafter, the valve assembly V2 is manipulated to open position thus implosionly exposing the zone Z1 to the atmospheric chamber CH.
When it is desired to manipulate the flapper head 40 of the valve assembly V2 to open position to connect the production zone Z1 and the perforations P with the low pressure surge chamber CH, pressure within the annulus between the casing C and the tubing string TS is increased. The increased pressure passes through the outer housing 10 by means of the port 33 within the valve housing 16, thence through the port 32 within the segment retainer 28.
It should be noted that since the effective piston areas across the piston head 24 and the ring 34 in the segment retainer 28 are equal, pressure will act upon each of these piston areas simultaneously. However, the segment retainer 28 and the piston mandrel 11 will not move with respect to one another until such time as the increased annulus pressure causes the shearing of the shear screws 30. When the shear screws 30 are sheared, the segment retainer 28 will be urged downwardly until its lower end 38 is shouldered upon the shoulder 37 of the valve housing 16. In this shifted position, the upper end of the segment retainer 28 has passed below the lower end of the segments 26, and the segments 26 are now free to expand outwardly and away from the piston mandrel 11, thus freeing the piston mandrel 11 to travel longitudinally upwardly. Accordingly, as annulus pressure is increased and transmitted through the ports 32 and 33, pressure will continue to act upon the piston head 24 until its upper end rests upon the lower face of the shock absorber 23. Now, correspondingly, the piston mandrel 11 has been shifted to the up position, releasing the flapper head 40 from its engaged or closed position. As the flapper head 40 is manipulated to open position, the piston mandrel 11 is shifted upwardly, pressure within the chamber CH and pressure immediate the zone Z1 and below the chamber CH will begin to equalize, thus providing a vacuum-like action upon the perforation surfaces to draw a surge of fluid therethrough to remove particulate matter from perforations P and formation Z1.
After the pressure has been equalized between the zone Z1 and the chamber CH and debris and contaminant removed from the surface of the perforations P, reverse circulation may be initiated after manipulating the upper valve assembly V1 to open position.
When it is desired to open the upper valve assembly V1 to, for example, provide a complete passage for reverse circulation to clean the well after the zone Z1 and the perforations P have been exposed to the chamber CH, pressure within the tubing string TS is increased and is transmitted through the port 98. As pressure is increased, the strength of the shear pins 127 will be overcome and the pins 127 will shear, thus enabling the increased pressure to act upon the piston head 102 and shift the piston head 102 and actuating sleeve 101 longitudinally upward until the upper face of the shoulder 161 contacts the lower face of the elastomeric shock absorber 116, whereby further upward longitudinal movement is prevented. As the actuating sleeve 101 is shifted upwardly, the segments 122 and the groove 164 will come in latitudinal alignment and the segments 122 will contract into locking engagement with the groove 164 and prevent reverse downward longitudinal movement of the actuating sleeve 101. As the actuating sleeve 101 is shifted longitudinally upward, the port 98 will dump pressure into the chamber 163. Since the passage through the valve V1 is always in communicating with the interior of the chamber CH, the interior of the valve assembly V2, the interior of the packer PR and the internal diameter of the casing C immediate the perforations P, the zone Z1 may be placed in fluid communication with the tubing string TS to the top of the well by pulling the tubing string TS to release the packer PR from its sealed engagement with the casing C. Reverse circulation may be initiated by pumping fluid down the casing annulus, around the packer PR and into the valve assemblies V1 and V2 and to the top of the well through the tubing string TS.
After the remedial operation has been conducted, the tubing string TS and the backsurge apparatus are removed from the well and production may be initiated through a production string or the like.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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An apparatus is provided for accomplishing pressure surging operations to remove particulates from the casing perforations and formation face of a subterranean well production zone. The apparatus includes two normally closed valve assemblies separated by a surge chamber maintained at atmospheric pressure. The uppermost valve assembly is connected to the end of a tubing string. A packer secures the lower valve assembly in sealing relationship to the casing bore. The lower valve assembly incorporates means for opening a flapper valve disposed between the atmospheric pressure surge chamber and the open bottom bore of the lower valve assembly. Such flapper valve is shiftable to an open position by movement of an actuator which responds to an increase in annulus fluid pressure. The opening of the flapper valve in the lower valve assembly produces a surge of production fluid from the formation and through the casing perforations into the atmospheric pressure surge chamber. The freed particulate matter is removed from the well by pressure actuation of an actuator sleeve in the upper valve assembly which moves upwardly to permit a spring-biased flapper valve to move to an open position. Thereafter, the packer is released from sealing engagement with the casing and fluid is pumped in a reverse circulation path downwardly through the casing annulus and around the valve assemblies and the interconnected surge chamber and then upwardly to the top of the well through the tubing string.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a division of application Ser. No. 200,581 filed Oct. 24, 1980 now U.S. Pat. No. 4,362,430 which in turn is a continuation-in-part of prior U.S. application Ser. No. 174,457 filed Aug. 1, 1980, now abandoned.
The present invention relates to an expansion joint and more particularly to the use of a resinous composition and mechanical anchorage means for fixing of a sealing element to a structure such as a roadway or a bridge deck. The new joint is suitable for joint movement ratings of 2 to 8 centimeters. In temperate climates, this will allow use of the joints for spans of 25 to 300 meters.
BACKGROUND OF THE INVENTION
An expansion joint is a small bridge over an expansion gap which is provided between a bridge abutment and a bridge deck, or between two segments of the bridge deck; the small bridge extends beyond the edges of the expansion gap. The expansion gap has a width which changes with the temperature of the structure, and the small bridge of the expansion joint is constructed to adjust its width to accommodate the variations in the width of the gap. The allowable variations in the width of the expansion joint will be referred to herein as its movement rating.
The edges of the upper surfaces of the bridge deck, abutment, or other roadway segments are not always in the same horizontal plane, and they can vary as traffic moves over the structure. These variations can be 0.5 cm or more.
The expansion joint and its anchorage should be constructed to adapt to these conditions, and to resist the effects of traffic, particularly that of heavy vehicles, which are especially destructive when the top of the expansion joint is set at the same level as the roadway.
Various types of expansion joints have been used or proposed. They can be summarized as follows:
The components constituting the mini-bridge can be either a sliding metal element, for example, in a finger joint or a sliding plate joint, or an elastomer joint, or an elastomer honeycomb joint.
The various sliding elements or elements of variable width are fastened either directly or by metal elements, to the roadway of a bridge or to an abutment.
The anchorage itself generally comprises metal bolts fixed in the concrete of the roadway, or rods buried in the concrete. This involves long and delicate work because of the tolerances on the order of millimeters may be required in concrete work, and it is burdensome because of the small amounts of material used at the time of installation of the joint in a previously constructed concrete roadway.
It has been proposed to use thermosetting resins to remedy these drawbacks. For example, it is known to use thermosetting resins to anchor the bolts in concrete. Others have used thermosetting resins to make the edges of the joint, to avoid their erosion by traffic. Also, others have made more advanced proposals such as in French Pat. No. 71/43,203, in which a joint comprising metal slides is simply glued to the roadway structures using resins; this eliminates the need for concrete when joints are installed in a previously-constructed roadway, and thus the problem of supplying small amounts of concrete at the site at that time and the problems caused by slow setting of concrete.
The last-mentioned joint does indeed eliminate fatigue problems. On the other hand, problems arise because of the difference between the expansion coefficients of the resin and concrete, that of the resin being about 10 times higher. Mortar composed of about 20% by weight of resin and 80% aggregate are less of a problem in this respect. However, they nevertheless have coefficients of expansion three to five times higher than that of concrete in the roadway. During temperature variations, these differences lead to stresses at the concrete/resin mortar interface. Since concrete is the more fragile material, it generally cannot support these stresses. These generally produce transverse fissures, and ultimately tearing away of the surface part of the roadway concrete.
SUMMARY OF THE INVENTION
The main object of the present invention is to remedy these problems while preserving the advantages of using resin mortar in sealing the joint. This object was achieved by two means that constitute basic elements of this invention. These means are directed at eliminating the effects of the difference in coefficients of expansion by reducing, on the one hand, the level of stress at the interface between resin and concrete, and, on the other hand, by avoiding the concentration of these stresses at particular points. In known installations which use epoxy resins, the concentration of stresses is reflected by the appearance of transverse fissures.
In accordance with the present invention, these results are achieved by means of an anchorage employed with an expandable element. The anchorage includes a gripping element which is attached securely to the expandable element, and the gripping element in turn anchors the expandable element to the resin mortar which is on or in the roadway. The expandable element is an elastomeric sealing element and it can be attached to the gripping element by various means well-known to those skilled in this art. For example, a mechanical interlock can be formed by wedging a part of the elastomeric sealing element in a grooved component attached to the gripping element, and/or vice versa. The elastomeric sealing element also may be bonded by adhesive, with or without mechanical interlock, although a mechanical interlock is preferred.
The gripping element preferably is flat on the side opposite the sealing element, and may be provided with one or more anchoring rods on that side. In the preferred form, the anchorage includes one or more sinusoids of rods, such as concrete reinforcing rods, of diameter about 6 to 12 mm. The rods extend lengthwise along the gripping element, generally parallel to the horizontal surface of the roadway so as to distribute stresses along the length of the body of resin mortar. They preferably are wound into a sinusoidal or spiral shape, and welded to the surface of the gripping element opposite the elastomeric sealing element at a succession of points. Therefore, the rods are buried in the resin mortar. The rods are cleaned, for example with abrasives, and coated with an organic material which adheres to the resin motar, e.g., an epoxy paint. Preferably the gripping element is flat, e.g., one side of a flat plate, on the side opposite the expandable element, and the rods are welded to that flat surface.
These rods serve an important function in eliminating transverse fissures by avoiding concentrations of stresses due to differences in expansion between concrete and resin mortar. The reason for this effect may be associated with the fact that the expansion coefficient of steel is close to that of concrete. Therefore, a considerable part of the stresses arising from the difference in coefficients of expansion between the resin mortar and the concrete can be absorbed by the reinforcement rods, and distributed by it into the resin mortar.
A further feature of the invention is the selection of a specific category of thermosetting resin, in the resin mortar, which exhibits a great elasticity, even at low temperatures, less than -10° C., while retaining good tensile strength at normal ambient temperatures such as 20° to 40° C. In contrast, epoxy resins, which have desirable features such as good adherence to concrete and easy use, become fragile and brittle at low temperatures. The modulus of elasticity of a mortar obtained from epoxy resins is high at low temperatures, which results in unacceptable stresses at the interface of the road concrete and the mortar. Plasticizers and diluents can be added to epoxy resins to minimize this problem, but the resistance of the resulting binder is then insufficient to assure sealing.
Polyurethanes retain elasticity at low temperatures, and therefore, offer the potential of giving best results from this standpoint. Unfortunately, their sensitivity to moisture, both during installation and later during the life of the joint, make their use essentially impossible at a site exposed to the weather.
In accordance with the present invention, a resin mortar is employed which contains a complex base resin containing two components and also a granular filler such as gravel or crushed stone. Great flexibility is achieved even at temperatures as low as -20° C. The resin is polymerizable at ambient temperatures. It exhibits both the elasticity of polyurethanes and the ease of use of epoxy resins; on the other hand, it avoids the disadvantages of both of these resins. The base resin which makes up the essential part of the binder or sealing mortar is made up essentially of a mixture of polyureides and epoxy resin, in proportions of 45-80% polyureide and 20-55% epoxy resin; to which may be added diluents and plasticizers to reduce the cost and adjust the physical characteristics.
The base resin is made at the time of installing the joints by forming a liquid mixture which is poured into place and allowed to harden. The liquid mixture is made by combining two components, namely a component A and a component B.
Component A is composed of
1. A liquid epoxy resin
2. A blocked polyisocyanate
3. Optionally plasticizers and diluents to reduce viscosity.
Component B is composed primarily of an aliphatic or cycloaliphatic primary or secondary amine which will induce curing of the resin mixture, preferably at ambient or slightly elevated temperature.
BRIEF DESCRIPTION OF FIGURES OF DRAWING
In the drawing:
FIG. 1 illustrates an expansion joint in accordance with the invention, in perspective and partially in cross-section.
FIG. 2 illustrates another embodiment of an expansion joint, in accordance with the invention, in perspective and partially in cross-section.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The expansion joint illustrated in FIG. 1 comprises an expandable sealing element 1 and an anchorage comprised of steel gripping elements 3 and 3 1 and a resin mortar 2. The resin mortar rests on a concrete roadway 5 which is covered with an asphalt overlay 6, to the same level as the resin mortar 2.
The expandable sealing element 1 may be composed of a neoprene rubber composition which withstands low temperatures, and it may have the cross-section shown. Alternatively, it may have a variety of other cross-sections such as an upstanding arch or descending arch, or still others, such as those illustrated in the textbook "Expansion Joints in Bridges & Roads" by Waldemar Koster (1969).
At the sides of the expandable element there are wings 7 and 7 1 which are held by the gripping elements 3 and 3 1 . Numerous constructions for these components may be used, such as those illustrated in U.S. Pat. Nos. 3,626,822, 3,570,378 and 4,111,584,the disclosures of which incorporated herein by reference.
The gripping elements 3 and 3 1 are illustrated with a top which is level with the roadway and a lower portion which rests on a layer of resin mortar. However, these are not essential requirements. For example, the gripping elements can rest directly on the concrete or be covered with a layer of resin mortar. It is desirable to have the gripping element at the level of the roadway to provide a metal edge of the expansion gap 8, to protect the area which is struck forcefully by the wheels of vehicles which travel over the joint.
The gripping elements preferably have a flat surface 9 opposite from the expandable element 1. To this surface there is welded a steel rod 4 which has been formed into a spiral extending generally along the length of the gripping element. It will be understood that the steel rod may have a different shape, for example, a zig-zag shape. Also, one can use several straight rods, welded to the surface 9 at one end, and extending obliquely away from that surface, but generally along the length of the gripping element so as to distribute stresses lengthwise between the resin mortar and the gripping element.
FIG. 2 illustrates another embodiment. In this case, the sealing element 101 is a depending arch and the wings 107 and 107' are held between two plates 103 and 110 which comprise the gripping elements. A bolt 111 connects the plates 103 and 110 to hold the wing 107. The steel rod 104 is of zig-zag shape.
The resin mortar comprises a coarse filler such as crushed stone and a resin composition made from Components A and B. Component A in turn is composed of two low molecular weight prepolymers, that is, a liquid epoxy resin and a polyisocyanate. The resin mortar comprises 15 to 45% by weight resin and 55 to 80% by weight of course aggregates and filler, preferably 15 to 25% by weight of resins and 75 to 85% by weight course aggregate and filler, the proportions being chosen to give a flowable liquid mortar.
The liquid epoxy resin may in principle be of any type. Preferably it is a condensate of epichlorohydrin and a bis phenol. Particularly useful are those resins made from a mixture of bis phenol A and bis phenol F, as these will tend to provide a lower viscosity product. The epoxy equivalent weight of such a polymer is preferably of the order of 180-200. Typical commercial epoxy resins which may be used are Epikote 828, Shell DX 214, Versamidle 140 of Schering and Dow DER 74.75.
The polyisocyanate constituent is a blocked polyisocyanate which may be a prepolymer of a simple polyisocyanate with a polyether. The polyisocyanate constituent is selected so that, in unblocked form, it contains about 2-6% free isocyanate groups. It may be made from a simple polyisocyanate such as tolylene diisocyanate, diphenyl methane diisocyanate, or mixtures of the latter with low molecular weight polyphenylene polymethylene polyisocyanates known as crude MDI or PAPI. The polyether preferably is polyoxypropylene glycol, polyoxybutylene glycol or a copolymer of propylene oxide and/or butylene oxide with ethylene oxide. Polyoxyethylene glycols themselves tend to impart moisture sensitivity to the composition and therefore are less suitable. Polymers of propylene oxide or butylene oxide with a triol or higher polyol is less desirable because they tend to increase viscosity, although a small amount may be present. Molecular weights of 600 to 2500 are suitable for the polyether. It is possible also to employ polyesters to make the polyisocyanate constituent. However, such materials tend to be more sensitive to moisture and therefore are less desirable. The proportions of simple polyisocyanate and polyether are chosen so that the polyisocyanate prepolymer contains about 2-6% free isocyanate groups. Also, the constituents should be selected for low viscosity, preferably in the range of 20,000 to 150,000 centipoises at 20° C.
The polyisocyanate prepolymer is employed with the isocyanate groups blocked with a phenol in known manner. Suitable phenols include phenol, cresols, tertiary butyl phenol and nonyl phenol.
Component A may also include a small amount of plasticizer and/or diluent. Examples of such materials include butyl phthalate, octyl phthalate, the Shell aromatic plasticizer Dutrex and others. These materials are added to reduce viscosity, but, if used in excess, may permanently soften the product.
The proportions of the respective constituents of component A may be as follows:
20 to 50 parts liquid epoxy resin
50 to 80 parts blocked polyisocyanate prepolymer
3 to 20% of the resin portion of the resin mortar of plasticizer or diluent, if that constituent is used.
Component B contains, as its essential ingredient, an aliphatic or cycloaliphatic polyamine comprised of primary or secondary amine groups. This constituent should be chosen to unblock the polyisocyanate constituent, and to react with it to form polyureide while at the same time curing the epoxy resin, at room temperature or at slightly elevated temperature which can be created at the job site. Suitable polyamines include trimethylhexamethylene diamine, aminoethylpiperazine, bis-aminocyclohexylmethane and 3,3'-dimethyl 4,4' diaminodicyclohexylmethane.
The polyamine is used in amounts which are approximately stoichiometric with the total of reactive groups in the epoxy resin and the polyisocyanate prepolymer. This generally requires about 7 to 20% of the total weight of epoxy resin and polyureide which is formed.
Component B may also contain diluents which reduce the cost of the binder and reduce viscosity at the time the components are mixed. Diluents also improve the wetting of the coarse aggregates and the concrete roadway. Preferred diluents are coal tar pitch of viscosity between 10 and 40 EVT, or coumarone or coumarone indene resins such as that sold under the name Nacirea EPXL by Cindu Neuville Chimie, or others. Diluents which react with the constituents of component A may also be used.
Such diluents generally are added to Component B at a rate of 10% to 100% of the total of epoxy resin and polyureide to be formed with the use of such diluents.
The coarse aggregate may be gravel, coarse stone, or the like. For example, it may have a standard continuous particle size distribution curve between 0.08 and 15 mm. having 30-65% which passes a 2 mm. screen, 12-15% passing an 0.08 mm. screen and 100% passing a 15 mm. screen.
Installation of the joint according to the invention is rather simple. The sealing element 1 and the metal components of the anchorage may be fabricated at a factory and delivered at a site. Ledges are provided in the concrete roadway as shown in the drawing, and the concrete is cleaned and free of any debris. The assembly of sealing element and anchorage components is set into place on the ledges and the width of the joint is set in conventional fashion. Components A and B are combined and mixed with the coarse aggregate, although the latter may previously be combined with one of the resin components. Then the resin mortar is poured into place where it adheres to the metal components and the concrete. Preferably, if an asphalt overlay is to be used, in lieu of ledges formed in the concrete, it is laid against a dam before the joint is installed, so that the resin mortar will adhere to the asphalt.
The binder for the coarse filler which is obtained from the above-described resin composition has unique qualities. These qualities can be evaluated by tensile-elongation tests, which reveal substantial improvement over a standard epoxy resin.
A typical resin composition which may be made up of
50% polyureide obtained by reaction of a tolylene diisocyanate polyether prepolymer having 3% isocyanate groups, 20% DX214 epoxy resin, 3,3'-dimethyl-4,4'-diaminodicyclohexylmethane reacted with the prepolymer and epoxy resin in stoichiometric amount (proportion included in proportions of resins), 30% coal tar pitch of EVT 30. The properties of such a material, compared with a standard epoxy resin, are as follows:
at 20° C. elongation is:
(a) 30-45% for the standard epoxy resin
(b) more than 200% for the binder of the present invention.
tensile strength is:
(a) 30 to 45 bars for the epoxy resin
(b) about 45 bars for the binder of the present invention.
at -15° C. elongation is:
(a) nearly 0% for the epoxy resin
(b) greater than 100% for the binder of the present invention.
tensile strength is:
(a) greater than 300 kg for the epoxy resin
(b) between 100 and 150 bars for the binder of the present invention.
It can be seen that the stresses transmitted to the concrete pavement will be much less for the composition of the present invention.
A specific example of the composition is as follows:
Component A
30 parts of Dow DER 74.75 epoxy resin
70 parts of liquid isocyanate prepolymer having an average molecular weight of 2,000, containing 3% free isocyanate groups, obtained by reaction of tolylene diisocyanate on polypropylene glycol, using an excess of tolylene diisocyanate, blocked with phenol.
5 parts butyl phthalate.
Component B
15 parts 3,3'-dimethyl-4,4'-diaminodicyclo-hexylmethane
50 parts coal tar pitch of 30 EVT viscosity
When Components A and B have been mixed, and they have polymerized (which polymerization can be accelerated by heating, the resin obtained has the following characteristics:
at 20° C.: tensile strength 40-50 bars, elongation more than 150%.
at -15° C.: tensile strength 100 to 150 bars, elongation more than 100%.
The mortar can be made from a mixture of 17% of this composition and 83% aggregate sized in the range 0 to 13 mm. Before polymerization, it is like a viscous paste that strongly adheres to the roadway concrete, the sides of the joint and the asphalt. The material can be tested by pouring the mixture to form a coating having a thickness of 3 mm on a slab of concrete 10×50 cm. If a series of thermal shock tests are performed between -40° C. and +20° C., neither delamination nor rupture of the concrete occurs. If standard epoxy resin is substituted for the resin of the present invention, rupture of the concrete occurs.
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An expansion joint for bridges and similar structures comprising an elastomeric sealing element, anchoring means gripping the sealing element and resin mortar connecting the anchoring means to the structure. The resin mortar is comprised of a mixture of ureide and epoxy resins and aggregate. The anchoring means has rods embedded in the resin mortar to distribute stresses therein.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF INVENTION
It is well known in the art how to manufacture blue gas, sometimes called water gas, in surface facilities. In the typical case aboveground, coal is prepared by removing the fines, so that the charge to gas producer will be reasonably uniform in lump size, for example, 2 to 4 inch thicknesses. Once the gas producer is charged, the fuel is set afire, followed by alternate cycles of blowing with air and runs with steam. Once the gas producer becomes stabilized the alternating cycles are established in rhythm, a set time period for the blow, for example three minutes, followed by a set time period for the run, for example, five minutes, then the cycles are repeated until the fuel is substantially consumed. Then the ash is disposed of and the gas producer is recharged to repeat the process. In this manner during the run cycle blue gas with a calorific content of about 300 BTU per standard cubic foot is manufactured. In reviewing the steps of the method of the prior art it should be noted that there are numerous costly batch operations on the fuel side beginning with the coal which include grub, convey, size, sort, transport, offload; then at the gas producer site: pickup, sort, charge, blow, run and clean up.
In the combustion of a hydrocarbon such as coal, the combustion process occurs either in an oxidizing environment or a reducing environment or a combination of the two. In the oxidizing environment hydrogen combines with oxygen to form water vapor, carbon combines with oxygen to form carbon dioxide, and any sulfur present will combine with oxygen to form sulfur dioxide. In the reducing environment the hydrogen combines with oxygen to form water vapor, carbon combines with oxygen to form carbon monoxide, carbon dioxide (if present) combines with hot carbon to form carbon monoxide, and sulfur combines with hydrogen to form hydrogen sulfide.
Of the products of combustion the ones that are likely to become injurious to plant and animal life are the sulfur compounds. Hydrogen sulfide is a noxious poison which is easily contained in a closed system and can be removed from the exit gases and converted into elemental sulfur by a number of commercial processes. Sulfur dioxide is not so easily separated although there are many noncommercial methods for extracting it from the products of combustion. In reviewing the methods of manufacture of sulfuric acid, a common first step is to convert elemental sulfur into sulfur dioxide in essentially pure form. The sulfur dioxide content of the products of combustion when burning coal, while often in sufficient strength to cause environmental problems, is quite weak in comparison to the strength required for processing into sulfuric acid by processes heretofore known.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a new and improved method of manufacturing combustible gases from coal in situ thereby eliminating many of the costly batch operations from the processes of the prior art.
It is an object of the present invention to provide a new and improved method of enriching the sulfur dioxide content of the products of combustion from coal in situ so that the sulfur dioxide may be recovered in useful form.
Other objects, advantages and capabilities of the present invention will become more apparent as the description proceeds and in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagrammatic vertical section taken through the earth showing coal formation as it exists during an in situ gasification program, together with associated facilities normally located above ground and shown in block forms.
FIG. 2 is a diagrammatic vertical section taken through a gasholder.
SUMMARY OF INVENTION
By way of example only a subbituminous coal deposit is described containing approximately 1.5% sulfur by weight and located several hundred feet below the surface of the ground. Preferably the project has been operating as an in situ project designed to generate low BTU gas such as taught in my copending U.S. Pat. application Ser. No. 531,453, and a channel in the coal bed between two wells has enlarged to the point that it is difficult to maintain a reducing environment. Under these circumstances the products of combustion will have decreasing quantities of carbon monoxide content with a corresponding decrease in calorific content of combustible exit gases, sometimes called flue gas. Initially the passage between the two wells may have generated low BTU gas in the order of 200 BTU per standard cubic foot, while in the latter stages of the gasification program the passage between the two wells may be generating gas in the order of 50 BTU per standard cubic foot. With an open channel in the coal formation between the two wells, combustion is taking place in a predominantly oxidizing environment and is ideally suited to the methods of the present invention.
No particular novelty is claimed in the use of an oxidizer such as air to increase the temperatures of residual coal, nor the use of steam to react with the hot coal. The reactions with air include:
1 C+O 2 + 3.8N 2 = CO 2 + 3.8N 2 + 174,250 BTU
2 c+co 2 = 2co - 70,010 btu and with steam:
3 C+H 2 O = H 2 + CO - 51,100 BTU
4 c+2h 2 o = 2h 2 + co 2 - 32,180 btu
in the open channel through the coal underground, by injecting air into one well and removing the products of combustion through the second well, the exothermic reaction (1) above serves to raise the temperature of the coal as well as to generate considerable sensible heat in the exit gases, while the embodiment reaction 2) moderates the amount of heat added. It is not unusual to find the temperature of the coal and the exit gases in the order of 2000° F and higher. At a convenient time the air injection is terminated and steam injection is begun. During the steam run the endothermic reaction (3) is predominant until the temperature of the coal diminishes to in the order of 1700° F, where the predominant reaction (4) continues to about 800° F, at which point very little of the steam enters the reaction. Maximum hydrogen output occurs at about 1350° F, a useful temperature marker if a project is designed for the primary purpose of generating low cost hydrogen to be used as a synthesis gas. Underground reaction temperatures at the beginning of the steam run can be lowered more quickly to approach the optimum hydrogen generation temperature by injecting water in the first part of the run and changing to steam as the reaction zone temperature approaches 1350° F. Another method of lowering temperature is to reinject the exit gases that contain a high percentage of carbon dioxide so that reaction (2) above becomes active.
Thus it may be seen that a pair of wells from an in situ gasification project that were declining in commercial productivity and approaching economic depletion, may be revitalized using the methods of the present invention, resulting in greater production of coal reserves within the influence of the wells than has been possible heretofore. It must be appreciated that the methods of the present invention can also be applied to virgin underground coal deposits by creating underground passages for the purposes intended. Also it may be seen that the present invention teaches methods that provide greater flexibility in the commercial processes available for use in production of coal in situ, as will become more apparent as the disclosure proceeds.
In reviewing the coal cited in the example above with 1.5% sulfur content, for each 100 pounds of coal approximately 1.5 lb. of sulfur is available for conversion into sulfur dioxide when combustion is conducted in an oxidizing environment. It is recognized that low concentrations of sulfur dioxide in a gas stream makes difficult the separation of sulfur dioxide for a useful purpose. With increasing concentrations of sulfur dioxide, the likelihood of using it for commercial purposes also increases. It is well known that concentrations of sulfur dioxide approaching 100% make an excellent feedstock for sulfuric acid plants. Lesser concentrations also are useful for the manufacture of sulfuric acid and other commercial products.
The sulfur dioxide content of the exit gases produced by the oxidizer injection cycle hereinafter called the blow cycle of the present invention may be increased by capturing the exit gases at the surface and storing them temporarily in appropriate facilities, for example a conventional gasholder. In a subsequent blow cycle the gases may be withdrawn from the gasholder for reinjection in their present state for a reducing environment or for reinjection by adding oxygen to the mixture of gases in the proper proportions to make the reconstituted gases an appropriate substitute for air or other oxidizer used in the blow cycle (oxidizing environment). By repeating the sequence of capturing a portion of the exit gases, adding oxygen and reinjecting the mixture, the concentration of sulfur dioxide may be strengthened in the exit gases.
In practicing the methods of the present invention a considerable amount of sensible heat will be contained in the exit gases, particularly in the blow cycle and with lesser amounts in the reducing environment cycle hereinafter called the run cycle. Sensible heat thus produced may be captured in part for useful work by using methods taught in my copending U.S. Pat. Application Ser. No. 531,453 or by directing the exit gases through a waste heat boiler at the surface.
One of the basic purposes of producing coal in situ is to generate combustible gases that are delivered to the surface for further useful work. The state of the art has not yet advanced to the point where calorific content of the combustible gas from an individual well can be stabilized at the design level of the overall project. For example if the project is designed for delivering combustible gas with a BTU content of 100 BTU per standard cubic foot using air as the oxidizer, among the multiplicity of gas recovery wells operating in the project one may be delivering 150 BTU gas, another 80 BTU, another 50 BTU and so on. It would be a most fortuitous circumstance if the full output capacity of all wells resulted in a gas of 100 BTUs. Should this not be the case in the prior art it is necessary to adjust the output of various wells to achieve a composite delivered gas of the proper calorific content. In some cases it may be necessary to abandon wells that are making very low BTU gases, for example those making gas with a content of 50 BTU per standard cubic foot or less. As pointed out previously these wells are good candidates for continued production using the methods of the present invention.
An improvement in gas quality control can be made over the prior art by providing suitable gasholders at the surface. One gasholder can be used to receive the exit gases from the blow cycle of the present invention, while a second gasholder can be used to receive the exit gases from the run cycle of the present invention. The first gasholder then would contain, for example, produced gases with a calorific content of 50 BTU per standard cubic foot while the second gasholder would contain produced gases with a calorific content of, for example, 300 BTU per standard cubic foot. Thus by apportioning the gas from the first and second gasholders into a third gasholder, the calorific content of the gas in the third gasholder can be stabilized at the design level, for example, a composite delivered gas at 100 BTU per standard cubic foot. Should there be insufficient quantities of gas available from the first gasholder, for example, to make a proper blend into the third gasholder, the blow cycle on one or more wells can be lengthened compared to the run cycle. Those skilled in the art will envision other adjustments to the methods of the present invention in order to achieve a final delivered gas that meets project design specification.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, two or more wells 11 and 12 are drilled from the surface of the ground into an underground coal formation 13. A protective casing 14 is set in each well and cemented in place to provide a hermetic seal. An appropriate wellhand 15 is affixed to the top of the casing at convenient point above the surface of the ground so that the hermetic seal is maintained and to provide control for passages of the gases. From the wellhead of well 11 a flow line 16 containing valves 47 and 18 is connected to gasholder 17, and an alternate flow line 45 containing valve 19 is connected from flow line 16 to gasholder 20. Also from the wellhead of well 11 a flow line 21 containing valve 22 is connected to gasholder 23. From the wellhead of well 12 a flow line 24 containing valve 25 is connected to compressor 26. Compressor 26 is also connected by flow line 27 containing valve 28 to oxidizer plant 29, and by flow line 30 containing valve 31 to gasholder 20. Gasholder 20 is also connected by flow line 32 containing valve 33 to sulfur plant 43. Gasholder 23 is is further connected by flow line 34 containing valve 35 to gasholder 36. Gasholder 17 is further connected by flow line 37 containing valve 38 to gasholder 36, and by flow line 41 containing valve 42 to flow line 30.
Preferably wells 11 and 12 have been operated as in situ gasification wells and a channel 39 has been burned through coal bed 13 to provide a free flowing conduit between the lower portions of the wells. If such is the case the coal abutting onto the channel will be above its ignition temperature and will readily burn when an oxidizer is injected into channel 39. If the coal bed 13 has not been subjected to gasification a suitable channel can be established by igniting the coal and burning a channel using methods taught in my copending U.S. Pat. Application Ser. No. 531,453 or other appropriate in situ gasification methods.
The process begins by closing all valves, starting compressor 26 using intake air and opening valve 25. The system will soon come up to operating pressure, for example 100 psig, at which point valve 18 is fully opened and valve 47 is opened to the extent necessary to maintain back pressure for the desired mine pressure. If coal bed 13 is an aquifer the preferred mine pressure in the reaction zone channel 39 is slightly above the hydraulic head pressure to exclude the flow of encroachment water. In this mode air is supplied to channel 39 through well 12, the coal bed 13 burns in a predominantly oxidizing environment and the products of combustion are delivered through well 11 to gasholder 17. The blow cycle continues underground for an appropriate period of time, for example 20 minutes, and the cycle is terminated with all valves closed. The blow cycle duration is selected with due regard for the amount of coal exposed to the reaction zone in channel 39, which in turn is a function of the average periphery of the cross section of channel 39 and the distance between wells 11 and 12.
The process continues by opening valve 40 and injecting steam from steam generator 46 through flow line 44 into channel 39 through well 12 at appropriate pressure, for example 100 psig. Valve 22 is opened to the extent necessary to maintain mine pressure, and the gas from the reaction zone in channel 39 is delivered through well 11 to gasholder 23. The run cycle continues for an appropriate time, for example 30 minutes, and the cycle is terminated by closing all valves. The duration of the run cycle is selected with due regard for the amount of hot coal that is available for reaction.
Should it be desirable to optimize the amount of hydrogen produced in the run cycle, the temperature of the reaction zone may be lowered more rapidly by reducing the mine pressure below hydrostatic head pressure to permit ingress of formation water into the reaction zone, or by injecting water into the reaction zone through well 12. As the reaction zone temperature approaches the optimum temperature for generation of hydrogen, for example 1350° F, mine pressure is restored to normal, for example 100 psig, by terminating water injection and proceeding with steam injection for the balance of the run cycle.
An alternate method of the run cycle in reducing the temperature in the reaction zone is to maintain mine pressure, for example 100 psig, and inject products of combustion from gasholder 17 through flow line 41 and valve 42 into flow line 30 through compressor 26, through flow line 24 into well 12 through channel 39 and on to the surface via well 11. Using this alternate method the carbon dioxide in the gas mixture is available to combine with hot carbon in channel 39 to form carbon monoxide. The exit gases from this alternate method may be directed from well 11 at the surface to gasholder 17, gasholder 20 or gasholder 23, depending on the plan for gas utilization. Again should the plan be for maximum hydrogen generation, this alternate run method can be terminated when the reaction zone temperature nears the optimum temperature, for example 1350° F, then continuing the run cycle with injection of steam into the reaction zone.
Should it be desirable to increase the content of sulfur dioxide in the exit gases the blow cycle may be undertaken as described above except rather than collecting all of the exit gas in gasholder 17, a portion is diverted into gasholder 20 from well 11 through flow line 45 by opening valve 47, partially opening valve 19 and holding proper back pressure on valve 18. At the conclusion of the blow cycle all valves are closed. For the next blow cycle gas from gasholder 20 is directed through flow line 30 through valve 31 where it is blended with an oxidizer from oxidizer plant 29 through valve 28 into compressor 26. The resultant blended gas would have preferably the approximate amount of oxygen as contained in the air. By repeating this alternate blow cycle the sulfur dioxide content of exit gases from reaction zone 39 can be increased to an appropriate level and delivered to sulfur conversion plant 43 through flow line 32.
Using the air blow and the steam run cycles, collecting the air blow gases in gasholder 17 and the steam run gases in gasholder 23, an appropriate end product combustible gas can be delivered to gasholder 36. If the end product gas is specified, for example, to contain 100 BTU per standard cubic foot, such a gas may be blended by apportioning the gas streams from gasholder 17 through flow line 37 and from gasholder 23 through flow line 34 with appropriate settings of valves 38 and 35.
Additional flexibility in the overall project can be gained by adjusting the elements of the methods described above to achieve the project objective, for example to deliver 100 BTU gas for commercial use. Each well in the multiplicity of wells may be operated up to their maximum capabilities with each well contributing its proportionate part to the overall project. For example if it is necessary to have a larger volume of gases in gasholder 17 for blending purposes into gasholder 36, this larger volume can be attached by increasing the length of the blow cycle in one or more pairs of wells. The blow cycle could be extended for example from 20 minutes to for example 30 minutes. If it is desirable to increase the calorific content of the gas mixture in gas holder 17, this can be accomplished by directing a portion of the gases in gasholder 17 to the reaction zone underground for the first part of each run cycle, then directing the exit gases back to gasholder 17. The temperatures in the reaction zone may be increased for a longer run cycle and consequently more volume of gases for delivery to gasholder 22, by increasing the oxygen content of the oxidizer for the blow cycle, and the like.
The gases directed to the various gasholders aboveground will contain both condensible and non-condensible components. Referring to FIG. 2 when the temperature of the gases is lowered, some of the component gases will reach their dew point and liquids 58 will collect in the lower section of gasholder 52. These liquids contain valuable coal chemicals and may be removed by placing a suitable outlet 54 in the gasholder. Generally it is preferable to remove condensible gases from the gas stream to avoid plugging the outbound pipeline 57 that delivers the gases from the project to the point of use. By placing a suitable heat exchanger 51 in gasholder 52, temperature of the gases can be reduced to a point, for example a temperature lower than the lowermost temperature expected in the outbound pipeline, so that substantially all of the condensible gases are converted to liquids before the gases are delivered to the outbound pipeline. In some cases the temperature desired may be low enough to cause the condensed liquids to become semisolids or solid substances. In these cases it may be necessary to add heat in heat exchanger 53 for brief periods to fluidize the congealed substances so that they may be captured apart as liquids through conduit 54. Another method of lowering the temperature of the gases delivered to gasholder 52 is to expand inbound gases in pipeline 56 through orifice 55 so that liquids are removed from the gas and are collected in the lower section 58.
Thus it may be seen that the present invention provides many advantages and capabilites over the prior art. Since the coal is consumed in situ, it is not necessary to perform the many costly batch operations inherent in removing coal from underground, preparing it for use and delivering the coal to an above ground gas producer which may be many miles apart from the coal mine. The above ground gas producer which is comprised of costly equipment with many moving parts has been eliminated because the reaction zone has been established in the coal bed itself where the ash remains in situ instead of causing a disposal problem above ground. Many limitations imposed by prior art for gasification of coal in situ also have been eliminated.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof.
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This invention relates to the production of combustible gases from coal in situ, in which one or more passages are established between the surface of the ground and an underground coal deposit. The coal is set afire and the fire is sustained by injection of an oxidizer for a period of time. Oxidizer injection is terminated, followed by injection of steam for a period of time into the hot coal bed. Produced gases are captured at the surface. Products of combustion from the burn cycle are saved at the surface, reconstituted by the addition of oxygen, then reinjected for subsequent burn cycles until the sulfur dioxide content is sufficiently high to warrant recovery in surface facilities. Condensible gases are cooled in surface facilities with liquids captured apart from noncondensible gases.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The field of the present invention relates to latches and latch systems.
Many latch systems are mounted to panels and doors in a manner such that some protruding handle or knob is required to open and close the latch. When such a panel or door doubles as a working surface or is used in a crowded area, such a protruding object can be hazardous or inconvenient.
In the aircraft industry when a panel or door is mounted to the exterior of an aircraft, any protruding object becomes aerodynamically undesirable, creating unnecessary drag. Thus, it is beneficial to provide a latch which can be mounted flush with the panel or door, and does not require an external handle. Additionally, the need for unique tools is bothersome; and the ability to operate a latch without a tool or removable handle is also desirable.
Another problem with many latch systems is that they can hold a panel or door in a semi-locked or closed but unlatched position. A door using such systems may appear locked when, in fact, the latch is only partially secured. Thus, it is advantageous in circumstances where complete closure is required that the panel or door not be capable of closure without latching fully.
Finally, the designs of many latch systems are not air and water tight. Such latches would be of little value on certain aircraft applications where a complete seal is required. Thus, latches which can be sealed against internal air pressure and external moisture are advantageous.
SUMMARY OF THE INVENTION
The present invention is directed to a latch system for joining two structures. A hook may be pivotally mounted in a first structure and arranged so as to engage a keeper mounted in a second structure to be joined with the first. When the two structures are appropriately positioned, the hook is intended to automatically engage the keeper, securing the two structures together. A retaining mechanism may be provided, incorporating an overcenter mechanism, to hold the hook biased in either the fully open or fully closed position. To actuate the hook, an actuation mechanism is contemplated.
The invention lends itself to latch designs preventing closure without latching. Also flush mounting may be achieved without the need for special tools. Sealing of the latch can also be achieved.
Accordingly, it is an object of the present invention to provide an approved flush latch system which has particular utility with aircraft panels, hatches and doors. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front sectional view of the latch system on a panel in an open position arranged for association with a structure to which the panel may be assembled.
FIG. 2 is front sectional view of the latch system of FIG. 1 in a closed position.
FIG. 3a is a transverse sectional view through 3a--3a of FIG. 1 illustrating the retaining mechanism in an open position.
FIG. 3b is a transverse sectional view through line 3b--3b of FIG. 2 illustrating the retaining mechanism in a closed position.
FIG. 4 is a transverse sectional view through line 4--4 of FIG. 1 illustrating the biasing mechanism.
FIG. 5 is a transverse sectional view through line 5--5 of FIG. 2 illustrating the releasing mechanism.
FIG. 6 is a plan view of the hook element.
FIG. 7 illustrates the latch in an open position in relation to the guide bracket.
FIG. 8 is a detailed end view of the latch in a closed position securing a keeper.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, FIG. 1 illustrates a latch system which is intended to join a first structure 10, in this embodiment shown to be a panel, to a second structure 12, in this embodiment shown to be a body. The panel 10 and the body 12 are illustrated in an open position in FIG. 1 and in a closed position in FIG. 2. This particular embodiment of the latch system includes a pair of hooks. However, the panel 10 may be arranged such that one end is pivotally mounted to the body 12 in which case only one hook would be needed. The structures, therefore, may take various forms.
Fixed to the panel 10 are brackets for support of the latch system. A central bracket 14 is disposed centrally of the latching mechanism and includes a formed plate extending downwardly to form two support members 16 and 18. Each support member 16 and 18 includes a bearing aperture 20 which are preferably mutually aligned. Also fixed to the panel 10 are outer brackets 22 and 24. Each of the brackets 22 and 24 includes an inner guide plate 26 and an outer guide plate 28. The inner and outer guide plates 26 and 28 each include a bearing aperture 30 and 32, respectively. The several bearing apertures 20, 30 and 32 are all preferably aligned to define an axis.
Rotatably mounted in the bearing apertures are connecting shafts 34 and 36. The inner end of each of the shafts 36 and 38 is located in the bearing aperture 20 and rotatably mounted thereby. The outer end of each of the connecting shafts 34 and 36 extends through the inner and outer guide plates 26 and 28. The inner bearing aperture 30 is larger than the outer bearing aperture 32 to accommodate a change in shaft diameter. The connecting shafts 34 and 36 each have a reduced diameter end portion 38 and 40, respectively. This reduction defines a shoulder 42 and 44 of each connecting shaft 34 and 36 for mounting purposes.
The latch mechanism includes an identical pair of hooks 46 and 48. As best illustrated in FIG. 6, each of the hooks 46 and 48 is a solid, generally triangularly-shaped member provided with a mounting hole 50, a bite 52 and a drive ramp 54. The mounting hole 50 is located displaced from the bite 52 and serves to mount the hook to the associated linkage of the latch. The bite 52 is formed into the hook structure 46 and 48 is in the drive ramp 54. A channel 56 is formed between the bite 52 and the drive ramp 54 to accommodate and retain a keeper. A seat 58 is located at the inner end of the channel 56 where a keeper is retained when in the latched position. The drive ramp 54 begins at the seat 58 and extends outwardly, displaced from the bite 52.
The hooks 46 and 48 are fixed to the connecting shafts 34 and 36 by securing the hooks 46 and 48 at the mounting hole 50 to the reduced diameter end portions 38 and 40. The shoulders 42 and 44 provide a surface against which the hooks 46 and 48, respectively, may be located and fixed.
Located on the second structure or body 12 are keepers 60 and 62. The keepers 60 and 62 are positioned to engage the hooks 46 and 48, respectively. Each of the keepers 60 and 62 is defined by an adjustable block member 64 having a keeper pin 66 extending laterally therefrom. The block members 64 are retained by means of studs 68 and nuts 70. A guide plate 72 is also fixed to the body 12 associated with each keeper such that the keeper pin 66 extends generally along a normal to the guide plate 72.
Turning to FIGS. 7 and 8, the inner and outer guide plates 26 and 28 are shown to include converging guide ramps 74 and seats 76. The converging guide ramps 74 are designed to provide a wide entrance which tapers to the seat to insure that the keeper pins 66 may be easily positioned in the seats 76. The seats 76 are somewhat elongate with substantially parallel sides to eliminate relative lateral motion between the panel 10 and the body 12 through the seats 76 and guide pins 66. The guide plates 72 cooperate against the outer guide plates 28 to eliminate relative lateral motion perpendicular to that controlled by the seats 76. Each of the keeper pins 66 is of sufficient length to span across between the inner and outer guide plates 26 and 28 such that each keeper pin 66 is retained in two seats 76.
The hooks 46 and 48, each positioned between an inner guide plate 26 and an outer guide plate 28, are positioned to engage the keeper pins 66. Again, as best illustrated in FIGS. 7 and 8, the hooks 46 and 48 are mounted to the rotatable connecting shafts 34 and 36. With the hooks 46 and 48 rotated to an open position, the opening between the bite 52 and the drive ramp 54 aligns with the elongated seat 76. In this position, the drive ramp 54 extends diagonally across the open area of the seat 76 such that it interferes with the seating of the keeper pin 66. Thus, the panel 10 cannot be closed on the body 12 with the hooks 46 and 48 in the open position. As the panel is forced into the closed position, the keeper pins 66 ride against the drive ramp 54 and cause the hooks 46 and 48 to rotate. This rotation results in the hooks and keepers being arranged in the closed position as illustrated in FIG. 8. The closed position of the hooks 46 and 48 is such that the hook seat 58 presents a surface which is roughly perpendicular to the direction of extraction from the seat 76. The mounting hole 50 and the seat 58 of each of the hooks 46 and 48 are also arranged such that no opening moment is imposed on the hooks 46 and 48 when the panel 10 is forced outwardly away from the body 12. With this arrangement, the hook seat 58, the guide plate seat 76 and the guide plate 72 all cooperate to eliminate motion in any direction with the system in the latched position.
An actuator mechanism is employed to control operation of the latch. The actuator mechanism is made up of an actuator assembly and an overcenter mechanism. The overcenter mechanism includes two overcenter linkages, each being associated with a connecting shaft 34 and 36. The overcenter linkage associated with the connecting shaft 34 is the same as the overcenter linkage associated with the connecting shaft 36. The linkage associated with the connecting shaft 34 includes a first arm 78 which is fixed to the connecting shaft 34 and extends laterally from the axis of the shaft. A second arm 80 is pivotally mounted on the connecting shaft 34 and also extends laterally from the axis of the shaft. The arms 78 and 80 are adjacent to one another and preferably spaced by a small amount so that there is no possibility of interference therebetween. Each of the arms 78 and 80 includes a mounting hole 82 and 84, respectively, adjacent the distal ends thereof. The arrangement of these arms 78 and 80 are best seen in FIG. 3a and FIG. 3b. Extending between mounting holes 82 on corresponding arms 78 on each overcenter linkage is a first rod 86. A second rod 88 is similarly positioned between mounting holes 84. The rods 86 and 88 may be fixed to the arms 78 and 80 such that the corresponding arms on the two overcenter linkages will operate together.
Extending between the rods 86 and 88 are two spring assemblies 90 and 92. The spring assembly 90 is illustrated in cross section in FIG. 4 as comprising a spring cylinder mechanism including an outer cylinder 94 and a piston 96. The piston 96 includes an outwardly extending flange 98 while the cylinder 94 includes an inwardly extending flange 100. The piston 96 is shown to be coupled with the first rod 86 while the cylinder 94 is shown to be coupled with the second rod 88. Thus, as the rods 86 and 88 move apart, the flanges 98 and 100 move toward one another. A spring 102 is positioned between the flanges 98 and 100 and placed in compression therein. Thus, the spring 102 provides resistance to the rods 86 and 88 being drawn apart from one another. The spring biases the rods toward one another.
The overcenter links thus make up two systems for drawing the distal ends of the arms 78 and 80 toward one another. The mechanism illustrated in FIG. 3a and in FIG. 3b illustrates the open and closed positions of these links, respectively. To move from the open position to the closed position, the connecting shaft 34 is required to move upwardly to cross between the distal ends of the arms 78 and 80. This stretches the spring assemblies 90 and 92 creating an overcenter operation whereby once the connecting shaft 34 moves to either one side or the other of directly between the mounting holes 82 and 84, the device will either snap fully open or fully closed. As the connecting shaft 34 is fixed to the arm 78, this movement of the overcenter mechanism results in rotation of the hook 46 either to or from the latched position. The same result is achieved with regard to the hook 48.
The actuator mechanism also includes the actuator assembly comprising an actuator button 104. The button 104 is aligned with an access hole 106 in the panel 10. Preferably, the button 104 closely fits within the access hole 106 to avoid a substantial gap therebetween. The button 104 is shown in substantial detail in FIG. 5 as including a sealing flange 108 having a gasket 110. The gasket 110 thus is positioned completely around the button 104 to engage and form a seal with the panel 10 around the access hole 106. The button 104 also includes a bracket 112 fixed to the button 104 by means of a fastener 114 engaged with a nut 116, which in turn is fixed by rivets 118 to the bracket 112. The bracket 112 extends downwardly from the button to engage the rods 86 and 88. The rods are free to rotate in the bracket but are constrained to move downwardly when the button 104 is pushed inwardly from the panel 10.
The preferred embodiment illustrated includes a panel 10 which has a seal 120 about the periphery thereof. A well 122 is created in the body 12 to receive the seal 120 and panel 10 such that in the closed position the panel 10 is flush with the surface of the body 12, as seen in FIG. 2.
In operation, the panel 10 may be placed on the body 12 by first insuring that the button 104 is depressed. If the button 104 is not depressed, the hooks 46 and 48 will interfere with the keepers 60 and 62 such that the panel 10 cannot be placed in a flush position in the body 12. With the button depressed, the hooks are oriented as in FIG. 7 in preparation for receiving the keepers 60 and 62. As the panel 10 is forced into a flush position on the body 12, the keepers 60 and 62 engage the inner and outer guide plates 26 and 28. The conveying guide ramps 74 receive the keeper pins 66 forcing the panel 10 to be oriented such that the keeper pins 66 will engage the seats 76. As the panel 10 is forced into a flush position, the keeper pins 66 engage the drive ramps 54 and force the hooks 46 and 48 to rotate toward the latched position. As this occurs, the overcenter mechanism forces the spring assemblies 90 and 92 to extend until the overcenter mechanism passes through center. At this point, the spring assemblies 90 and 92 will act to draw the hooks 46 and 48 into the latched position as seen in FIG. 8. Thus, as the panel 10 is positioned, resistance to that positioning is first encountered and then the panel is forcefully drawn into the flush position. Removal of the panel requires actuation of the button 104 until the overcenter mechanism is again drawn through center. At this time, the mechanism aids in the opening process and withdraws the hooks 46 and 48 into the retracted or open position.
Thus, an improved flush latch system is disclosed. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore is not to be restricted except in the spirit of the appended claims.
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A latch system for coupling a panel or access door to a structure, having a hook, a keeper, an overcenter mechanism and an actuator. When the hook engages the keeper, the keeper drives a ramp formed into the hook causing the hook to pivot. The hook, torsionally linked to the overcenter mechanism, activates the overcenter mechanism securing the hook in a closed position. When the actuator is depressed it reverses the overcenter mechanism pivoting the hook into an open position. Multiple hooks are shown associated with the latching assembly.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims a benefit of priority to Japanese Application No. 2002-262311 filed on Sep. 9, 2002, now abandoned, and Japanese Application No. 2003-84232 filed on Mar. 26, 2003, currently pending, and a continuation-in part of U.S. application Ser. No. 10/664,266 filed Sep. 17, 2003, currently pending, the contents of these applications are incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] Guardrails are installed along roadsides in order to prevent cars from jumping into oncoming lanes, sidewalks and rolling down steep embankments. Collision with a guardrail normally occurs when a driver looses control of a vehicle through inattention, poor road conditions or collision with another vehicle.
[0003] One type of guardrail generally consists of a long sheet fence, a support post, and a rigid mid-filler attachment connected between the first two components. Such a guardrail can be made more rigid only by narrowing the span of the support posts. This type of guardrail absorbs collision energy mainly by deformation of the fence or support post.
[0004] Japanese Patent No. 6-280222 modifies an ordinary guardrail to include a modified support post with an elastically recoverable elastic body. Japanese Patent No. 7-150529 discloses a guardrail having a housing with several pipes connected into the cushion cover and that covers the support post. Japanese Patent No. 10-18257 discloses a guardrail made with components having different rigidities, a rigid face to end portion and a relatively brittle face to others.
SUMMARY OF THE INVENTION
[0005] The invention is a shock-absorbing device for use in a guardrail that can be situated, for example, at a median or parapet of a bridge. This device absorbs the shock of a car collision and prevents components of the guardrail, such as support posts and parapets of a bridge, from collapsing.
[0006] One type of guardrail that can reduce the shock of impact transmitted to its support post by reduces the speed of a colliding car by absorbing shock via deformation of the rail or collapse of its support post. Using more support posts increases the rigidity of the guardrail's entire structure, but the support posts do not have the capability of absorbing much shock.
[0007] If more support posts are to be employed, however, extra area for the collapse of the support post is required to allow for an appropriate guardrail area. Failure to provide this area may endanger cars driving on the opposite side of the roadway or pedestrians walking on the outside of the guardrail.
[0008] If the collision energy is excessive, collapse of the support post may increase the possibility of the colliding car bursting through the guardrail and causing further damage to property and/or individuals. If the guardrail collapses, the colliding car may exit the travel lane making it difficult to bring the car safely back into the travel lane.
[0009] When repairing a bent support post by bending it in an opposite direction of the bend to bring it back to a vertical position often results in a break at the bend. Metal fatigue is often the cause. This necessitates replacement of the damaged foundation and the need to mount a new support post, which is inconvenient and costly when combined with replacement of any breakage in the guardrail. If the damaged support post is left in a state of disrepair, it can become an obstacle for the passage of vehicles and pedestrians.
[0010] One way these problems are addressed is by increasing the rigidity of the support post to reduce the amount of deformation. The rigid guardrail, however, loses the capability of absorbing enough collision energy and allows the transmission of collision shock. This reduces the safety of the occupants of car that collides with the rigid guardrail.
[0011] When the support post has an elastically recoverable elastic body, it has the ability to absorb shock by reducing the speed of a colliding car before it collides into the support post. The elastically recoverable body, however, may cause severe secondary injuries and damage due to the elastic restoring force that can transmit elastic force to the occupants of the colliding car after the car has come to a stop.
[0012] The present invention solves the above-mentioned problems by providing a shock-absorbing guardrail device that has a simple structure. The structure can prevent the support post from collapsing by absorbing the shock caused by the collision of a car.
[0013] A further goal is to reduce the necessity of repairing damaged foundations and the need for new support posts during reconstruction of the guardrail. This invention utilizes a mid-filler attachment that undergoes an irreversible deformation during collision. The attachment has either an ohm-shaped cross-section or a vertically-opened, pipe-shaped cross section attached to a support post or structure. The guard fence attaches to and bridges each support post by connection parts to absorb colliding energy of a car, which overcomes the problems mentioned above.
[0014] In one embodiment, irreversible deformation of the mid-filler attachment with either the ohm-shaped cross section or the vertically-opened, pipe-figured cross-section and is utilized and connected to a construct. The back of the guard fence faces and is attached to, the surface of the construct by connection parts and absorbs the collision energy of the car, which overcomes the above-mentioned problems.
[0015] A further embodiment utilizes a shock-absorbing pipe or shock-absorbing resin along with the shock-absorbing elements mentioned above.
[0016] Another embodiment involves attaching the shock-absorbing guardrail device, discussed above, onto a construct located at a hydrant, a semaphoric pole, a bifurcation (diverging point), an anti-collision section, and a sectional wall.
[0017] A further embodiment utilizes a mid-filler attachment characterized by its cross section comprising a layered, laminated, or stratified ohm figure in place of the mid-filler attachment or pipe discussed above.
[0018] The above-described shock-absorbing guardrail device can absorb collision energy of a car by an irreversible deformation of a mid-filler attachment and deformation of the guardrail itself. The deformation absorbs the impact of the collision transmitted to the support post by reducing the speed of a colliding car.
[0019] The shock-absorbing guardrail device does not employ an elastic body and prevents transmission of elastic force to the occupants of a colliding car when stopped. The shock-absorbing guardrail device will not cause secondary injury or damage caused by the elastic restoring force as is common with guardrails having elastic bodies.
[0020] The shock-absorbing guardrail device has a simple structure that is easy to install and remove, even after an impact by a vehicle. The device has the capability of preventing the support post from collapsing by absorbing shock through the deformation of a collision energy absorbing pipe or mid-filler attachment. The substantial absorption of crash energy reduces the necessity of repairing damaged post foundations and setting up new support posts during repairs, which therefore reduces costs.
[0021] When an excessive load is applied to the guardrail as with a high speed collision or collision with a vehicle having excessive weight, the collision energy can be absorbed by deformation or collapse of the support posts that enables the car to safely return to the travel lane so as to secure the safety of the cars occupants.
[0022] This shock-absorbing device can be installed on hydrants, semaphoric poles, bifurcations (diverging point), column-shaped safety drums located at bifurcations, anti-collision sections in front of toll booths, and sectional building blocks (i.e. walls at parking lots, concrete walls) and so on. The shock-absorbing device can be attached to those structures and provide the same benefit as explained above by covering the surface of the structure either partially or fully with the device.
BRIEF DESCRIPTION OF THE FIGURES
[0023] [0023]FIG. 1( a ) shows side view of one embodiment shock-absorbing device. (Guard fence is shown as shape of cross section.)
[0024] [0024]FIG. 1( b ) is a cross-sectional view of the main portion of the shock-absorbing device.
[0025] [0025]FIG. 2 is a cross-sectional view showing one embodiment of the shock-absorbing device in a squashed condition after a collision.
[0026] [0026]FIG. 3 is a cross-sectional view of one embodiment of the shock-absorbing device.
[0027] [0027]FIG. 4 is a cross-sectional view of a main part of another embodiment of the shock-absorbing device.
[0028] [0028]FIG. 5 is a cross-sectional view of a main part of a mid-filler attachment embodiment.
[0029] [0029]FIG. 6 is a graph showing the results of static experimentation of one embodiment of the shock-absorbing device wherein the horizontal axis represents change in vertical size (mm), and the vertical axis represents a load (kg) placed on a top surface.
[0030] [0030]FIG. 7( a ) is a side view of an ordinary guardrail. The guard fence is shown in cross section.
[0031] [0031]FIG. 7( b ) shows a cross-sectional view of a main part of an ordinary guardrail.
DETAILED DESCRIPTION OF THE INVENTION
[0032] [0032]FIG. 1( a ) is a side view of one possible embodiment of the shock-absorbing device shown generally as 10 . A guard fence 14 is shown in cross section. FIG. 1( b ) is a cross-sectional view of the main portion of the shock-absorbing device 10 .
[0033] Shock-absorbing device 10 comprises support post 12 that is erected parallel to the roadside with certain span. A back surface 14 a of guard fence 14 back 14 a is attached to support post 12 and bridges each support post 12 . A mid-filler attachment 16 is installed in-between each support post 12 and guard fence 14 and acts as a connecting element between them. Connector 17 , which can be a bolt, rivet, screw or other equivalent fastener, connects support post 12 and mid-filler attachment 16 . When connector 17 is a bolt or other releasable type of equipment, it allows for faster repair and installation. Guard fence connector 18 attaches guard fence 14 to mid-filler attachment 16 .
[0034] As shown in FIG. 1( b ), an elliptical Mid-filler attachment 16 a conforms to the shape of an ellipse.
[0035] Support post 12 can be a rust proofed steel product or other material having equivalent properties of strength and is affixed on the roadside by mounting a lower portion into a foundation such as concrete. The support post 12 may also be attached at its lower portion to the foundation via bolting or other means of attachment.
[0036] In one potential embodiment, a through-Hole 17 is placed at an upper part of the support post 12 so that connector 17 can perforate support post 12 and connect support post 12 and mid-filler attachment 16 . Other means of mounting the mid filler attachment 16 to the support post 12 (not shown) can be accomplished without the perforation of support post 12 by the use of a U-bolt passing around the body of the post 12 or the use of a cap containing a perforation and connector 17 that could be mounted over the top of the support post 12 by such method as a friction fit to perform the identical function of attaching the mid-filler attachment 16 to the support post 12 . It should be understood that many other means of fastening the mid-filler attachment 16 to the support post 12 can also be envisioned by one skilled in the art to provide similar function.
[0037] Guard fence 14 may be a rust proofed steel product or a material having similar properties, having a flat or a contoured deck plate as displayed in FIG. 1( a ). One method of attaching guard fence 14 is by the placement of a through-hole 18 to receive fence connection parts 18 in order to affix mid-filler attachment 16 . Conversely, fence connector parts 18 could be welded or affixed to guard fence 14 so that a through-hole 18 could be omitted if desired. There are many possible methods of attaching guard fence 14 to incorporate the mid-filler attachment 16 between the support posts 12 .
[0038] In FIG. 3, the Mid-filler attachment 16 comprises a collision energy absorbing pipe 16 a (having a closed elliptical cross section that changes shape with irreversible deformation) and arm parts 16 b (which may be welded or otherwise affixed to the guard fence 14 side). A through-hole 19 may be placed on each of the arm parts 16 b at corresponding positions of through-Hole 18 a.
[0039] It should be understood and appreciated that the one possible embodiment described and explained above, is by way of illustration and not limitation. There are other obvious design changes that can be employed to accomplish the same ends.
[0040] [0040]FIG. 3 shows another embodiment of installing a collision energy absorbing pipe 16 a between the support post 12 and guard fence 14 . These elements are connected directly by connection parts 17 and connection parts 18 . (This is designated as shock-absorbing device 10 ′)
[0041] The material, size, and shape of the support post 12 , guard fence 14 , and mid-filler attachment 16 can be modified to direct a car that has collided with the guardrail to be brought safely back to the travel lane. The optimization of the cushioning performance influenced by the type of car, its speed at collision, its weight, angle of impact, etc.
[0042] When a car collides into a guardrail, made in accordance with the invention, it absorbs the energy of the moving car and irreversibly deforms the collision energy absorbing pipe 16 a . The absorption of energy results in a reduction of the speed of the colliding car. (See FIG. 2) Absorbing collision energy through deformation of the collision energy absorbing pipe 16 a reduces the likelihood of the support post 12 being bent. The remaining collision energy that is transmitted to support post 12 after deformation of the collision energy absorbing pipe 16 a reduces the possibility of collapsing the support post 12 during impact. The prevention of damage to the support post 12 will prevent the need for replacing the support post 12 or fixing damaged foundations thereby reducing the costs of maintaining and repairing the guardrail.
[0043] When an excessive load is applied such as that which occurs when a vehicle with excessive speed or excessive weight collides with the guardrail, the excess collision energy can be absorbed by deformation or collapse of the support posts 12 .
[0044] It should be understood that if the rigidity of the mid-filler attachment is either too small or too large, it cannot absorb the energy of the colliding car in some circumstances. This may reduce the safety of the occupants of the vehicle.
[0045] [0045]FIG. 4 shows a cross-sectional view of a main portion for a shock-absorbing device 20 . Shock-absorbing device 20 is similar to shock-absorbing device 10 except that the mid-filler attachment 26 has an ohm-shaped cross-section that is comprised of an integrated combination of a collision energy absorbing pipe 16 a and arm parts 16 b . The mid-filler attachment 26 may optionally contain the mid-filler attachment 16 a either within the center of the hollow of the mid-filler attachment 26 between the guard fence 14 and the mid-filler attachment 26 or positioned between the support post 12 or structure and the outside top of the mid-filler attachment 26 . Furthermore, the above combinations can include a shock absorbing resin within any hollow section between the back of the guard fence 14 and the support post 12 or structure.
[0046] The mid filler attachment 26 having the ohm-shaped cross-section has a body that is a portion of a radius of a circle or an ellipse that transitions into at least one integrated arm. The arm has an angle of about 5 to 90 degrees to that of the body. The mid-filler attachment 26 with a short length can be oriented in any direction and at least one of the integral arms is attached to the back of the guard fence 14 . The mid-filler attachment 26 can have a length similar to the diameter of the support post 12 or be oriented so that it can span the entire length of any portion thereof of the guard fence 14 .
[0047] Optionally the ohm-shaped mid-filler attachment 26 can have a means for propagating crash energy along the length of the ohm-shaped mid-filler attachment by providing a thicker area along the length of the mid-filler attachment that intersects with the point of attachment of the mid-filler attachment 26 to either the support post 12 or structure (not shown).
[0048] [0048]FIG. 5 shows a cross-sectional view of a shock-absorbing device 30 having at least two of the ohm-shaped mid-filler members comprising a large mid-filler member 36 and a small mid-filler member 26 . The small mid-filler member 26 can be arranged or positioned within the large mid-filler member 36 .
[0049] Materials, sizes, and shapes of ohm-shaped mid-filler attachments 26 and mid-filler attachments 36 can be changed to maximize the ability to bring a car safely back to the travel lane. The mid-filler attachment can be optimized for cushioning performance according to the kind of car, its speed at collision, its weight, etc.
[0050] Optionally, a shock-absorbing resin can be employed and installed within the collision energy absorbing pipe 16 , or the U-shaped portion of mid-filler attachment 26 or within the back portion of the guardrail 14 . The structure can be designed so that only the shock-absorbing resin changes shape or both the shock-absorbing resin and collision energy absorbing pipe or U shape portion of mid-filler attachment change shape. (No Figure shown).
[0051] This shock-absorbing device can be installed not only in the space between the support post 12 erected in line with the ground and guard fence and bridging several support posts, but also on hydrants, semaphoric poles, bifurcations (diverging point), column-shaped safety drums located at bifurcations, anti-collision sections in front of toll booths, and sectional building blocks such as walls at parking lots, concrete walls and so on. The shock-absorbing device can be attached to these structures and provide the same benefits as explained above by covering the surface either partially or fully with it.
[0052] Static experimentation was carried out to determine the static performance of the mid-filler attachment. Two kinds of mid-filler attachments were tested, a mid-filler attachment 26 (made of SS400 steel [Height: 50 mm], made by folding a plate having a thickness: 4.5 mm, and Width: 50 mm] into an ohm shape) and a mid-filler attachment 36 (made of SS400 steel [Height: 100 mm], made by folding a plate [Thickness: 4.5 mm, and Width: 50 mm] into an ohm shape) outside and a mid-filler attachment 26 inside. The attachments were examined by setting each attachment onto a base plate and applying a load (kg) from above. The relationship between load and the change in vertical size (mm) was monitored and measured.
[0053] [0053]FIG. 6 shows that when a 330 kg load was applied to a mid-filler attachment 26 the change in vertical size reached 5 mm, and when 710 kg load was applied, the change in vertical size reached 40 mm. (A mid-filler attachment 26 can change vertical size only up to about 40 mm.)
[0054] When a 500 kg load was applied to the mid-filler attachment 36 the change in vertical size reached 20 mm, and when 865 kg load was applied the change in vertical size reached 25 mm. FIG. 6 shows that a mid-filler attachment 36 is capable of absorbing the collision energy equivalent to a load of 1830 kg.
[0055] Materials, size (thickness, width, etc.), shape, and the number of mid-filler attachments used can be varied to optimize the cushioning performance according to the kind of car, collision speed, the car's weight, and so on.
[0056] A method of producing a shock-absorbing guardrail comprises the step of providing a guard fence having a back. Attaching a mid-filler attachment to the back of the guard fence.
[0057] The method can further comprising the step of attaching the mid-filler attachment to a support post so that the mid-filler attachment is positioned between the back of the guard fence and the support post. The method can further comprise attaching a shock absorbing resin between the back of the guard fence and the support post. The method can also further comprise attaching the mid-filler attachment to a structure so that the mid-filler attachment is positioned between the back of the guard fence and the structure.
[0058] The practical examples provided above of the shock-absorbing device described in detailed description is but just a representative example of the possible combinations or assembly of elements disclosed. The examples provided should not be used to limit the usage of the shock-absorbing device. The scope of this invention should be determined by the claims. Therefore, implementation of this invention varies with design change according to the requirements of the specific application.
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A shock-absorbing guardrail that is easy to install and remove that prevents a support post from collapsing by absorbing the shock caused by a car collision thus reducing repair time. The shock-absorbing device is attached to the guard fence between the structure or support post. A mid-filler attachment may have an ohm-shaped cross-section or vertically opened pipe-shaped cross-section. The guard fence and mid-filler attachment may be attached to the support post or structure with removable connectors for faster installation and removal. The shock-absorbing device is designed to absorb collision energy by irreversible deformation of the mid-filler attachment.
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BACKGROUND
[0001] This invention relates to a fencing system, and more particularly to a two-piece rail system, which can be incorporated into a picket fence. A picket fence comprising a pair of spaced apart parallel rails, supported by horizontal posts, and having a plurality of pickets incorporated between the rails.
[0002] Picket fences are found in a variety of uses and construction types. Picket fences made of metal or plastic have a number of performance features, which make them especially desirable, including low maintenance, durability, and aesthetics. Typically the pickets of the fence are adhered to rails running nearly parallel to the ground via welding (metal) or other post attachment technique. This invention details a two-piece rail for a picket fence, and a construction method for this fence system, which can easily be constructed at a construction site. The pickets of the fence are incorporated into the system without the need for welding, or other attachment hardware and can be done by a professional or homeowner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0004] FIG. 1 shows a cross sectional view of the two pieces of the two-piece fence rail
[0005] FIG. 2 shows a longitudinal view of one piece of the two-piece rail
[0006] FIG. 3 shows the incorporation of a picket into the two-piece rail
[0007] FIG. 4 shows a diagram of the assembled two-piece fence rail incorporated into a picket fence
DETAILED DESCRIPTION
[0008] Referring now to the figures, and in particular to FIG. 1 , there is shown an enlarged cross-sectional view of the two pieces 100 and 200 of the two part fence rail. In a preferred embodiment, the second piece 200 of the two part rail is fabricated identical to the initial piece 100 . Piece 100 and piece 200 of the two part rail are fabricated in such a manner that first piece 100 and second piece 200 can be interlocked to form rail 300 also shown in FIG. 1 . Utilization of a two part rail in which pieces 100 / 200 are identical, allows for a reduction in cost and ease of construction. These cost reductions include extrusion tooling, manufacturing costs, and inventory carrying costs.
[0009] Again referring to FIG. 1 , the key design features of the individual rail pieces 100 / 200 can be seen. The terminal edges 110 / 120 and 210 / 220 of the cross section of the fence rail component 100 / 200 are designed such that the individual edges will interlock with their opposing edge from another rail component. That is terminal edge 110 will interlock with terminal edge 220 ; and conversely terminal edge 120 will interlock with terminal edge 210 . The terminal edges 110 / 120 and 210 / 220 typically include a thickened bead of extruded material, to facilitate the rail-rail interlock of the two rail components 100 / 200 and to provide rigidity in the length direction of the component. Protrusions 130 / 230 are positioned on the components 100 / 200 such that they will facilitate the interlocking of the terminal edges and reduce the ability of the interlocked edges to move and or unfasten. Additionally a screw boss component 150 / 250 is included to allow for the rail to be affixed to a terminal fence post and to allow for seating of a fence picket into the rail system.
[0010] In one embodiment, the two part rail is made from extruded aluminum. Other material which may be used include extruded thermoplastic polymers. Typically the materials used for the two part rail will also be used in the production of the other components of the fence system.
[0011] Now referring to FIG. 2 , there is shown a longitudinal view of piece 100 of the two part rail. Incorporated into the rail section 100 at regular intervals are picket cutouts 101 . These cutouts are typically spaced regularly along the rail at standard intervals for pickets in a picket fence system (i.e. 4 inches). The dimensions of the cutout 101 are such that they will allow a specifically sized picket 400 to be incorporated through the rail, while not affecting the dimensional stability of the rail 300 or the individual components 100 / 200 .
[0012] The incorporation of picket 400 into the cutout 101 of the rail section 100 is aided by dimples and/or tabs 401 in the picket 400 . These dimples/tabs 401 allow the picket 400 to be seated into the screw boss 150 of the rail section 100 . Additionally the seating of these dimples/tabs 401 in the screw boss 150 secure the picket into the completed rail 300 in such a manner that the picket 400 is secured.
[0013] The dimples/tabs 401 are placed on the picket 400 at a distance from the terminal ends of the picket 400 that allow for the two part rail to be incorporated into the picket fence system at whichever height fits the design requirements of the fence system. In a typical fence system, two rails 300 are incorporated into the fence system. It can be seen that in the invention described, any number of rails 300 could be incorporated into the fence, only requiring the appropriate number of matching dimple/tab pairs 401 be incorporated in the pickets 400 .
[0014] Referring now to FIG. 3 , there is shown the incorporation of a picket 400 in an assembled two piece rail 300 . It can be seen that the tabs 401 project out from the picket 400 and lodge in the two screw-boss' 150 / 250 of the rail 300 . The seating of these tabs 401 in the two screw-boss' 150 / 250 of the rail 300 secure the picket 400 in the rail 300 . By securing the picket 400 to the rail 300 using this method, external hardware such as screws can be eliminated for securing the picket. This enhances the ease of assembly and aesthetics of the fence.
[0015] Referring now to FIG. 4 , the incorporation of the two part rail 300 and the pickets 400 into a fence section 500 can be seen. The two part rail 300 , and the pickets 400 to be incorporated therein, are designed such that multiple sections of the fence system can be easily assembled with minimal tools required at the job site. The length of the rail components 100 / 200 and thus the assembled rail 300 and fence section 500 is variable and will typically be chosen for aesthetic and ease of assembly considerations. Additionally the design of the individual rail components 100 / 200 of the fence rail 300 , allow for the easy construction of the section 500 via laying one of the individual rail components 100 / 200 for each rail 300 to be incorporated onto the ground, then lying the pickets 400 into the picket cutouts 101 . The opposing component 100 / 200 of the fence rail 300 is then snapped into place, locking in the placed pickets 400 . The completed fence section 500 can then be easily lifted into place and secured to the fence posts 600 .
[0016] The fence sections 500 can be easily assembled into a fence system by attachment of the individual sections 500 to fence posts 600 located at regular intervals in the fence system. This attachment can be, but is not limited to, attachment via screws through the post 600 and into the rail component 100 / 200 at the screw boss 150 / 250 . The design structure of the individual fence sections 500 also allow for the individual sections to easily be racked at an angle of up to fifty degrees. That is to allow the use of the fence system on an up or down grade of up to fifty degrees with no substantial loosening of the fence parts or undue torque on the fence components.
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A picket fence system using two part parallel rails to enclose and secure intermittent pickets, which can be assembled without screws or fasteners is described.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
[0001] This disclosure relates generally to thermoplastic polyolefin (TPO) membrane roofing materials and methods and more particularly to TPO outside corner patches for sealing around vents and other structures that protrude from a roof structure.
BACKGROUND
[0002] It is common for commercial and other roofs that are substantially flat to seal the roof with a waterproof membrane such as polymer coated membranes, more commonly referred to as thermoplastic polyolefin membranes or simple TPO membranes. Almost all such roofs include various protrusions that project upwardly from the roof deck such as, for instance, vents, ductwork, air conditioning units, and the like. Providing a water-tight seal around such protrusions, and particularly where the corners of a protrusion meet the flat roof deck, can be a challenge. More specifically, it is possible to wrap the protrusion at least partially with a skirt of TPO membrane with the bottom edge portion of the skirt flaring out to cover and be heat sealed to the roof membrane. However, this requires that the skirt be slit at the bottom of the corners of the protrusion, which leaves a region where the corners meet the flat roof unsealed and subject to leaks.
[0003] Corner pieces made from TPO have been developed to address this problem. For example, the Firestone® ReflexEON® inside/outside corner patch is a molded piece of TPO plastic with the general shape of a right angle corner permanently molded in. The molded corner is placed around the bottom corner of a protrusion and the patch is heat sealed to the surrounding TPO membranes to seal the corner. In contrast, GenFlex® TPO reinforced outside corners are factory fabricated corners made from high performance TPO roofing membrane. These are generally made by slitting a square piece of TPO membrane from its center to a corner and then spreading the membrane out at the slit to cause the opposite corner to form a loose pleat. The gap between the spread edges of the slit is then filled in with another piece of TPO membrane, which is heat sealed in place to form a unitary corner patch. In use, the loose pleat is applied around the bottom corner of a protrusion and the patch is heat sealed to surrounding TPO membranes on the roof and the protrusion to form a water-tight seal.
[0004] Other examples of attempted solutions can be found in U.S. Pat. Nos. 4,700,512; 4,799,986; 4,872,296; and 5,706,610. It also has been common in the past for installers of membrane roofs to custom make their own corner patches on-site by heating, stretching, cutting, and otherwise manipulating small pieces of TPO membrane. Corner patches and other solutions in the past have not been entirely satisfactory for a number of reasons including that they do not fit well around corners, they must be “bunched up” to fit a corner properly, thus jeopardizing the ability for form a reliable seal, and/or they contain heat sealed joints that can fail and result in a leak. There is a need for a corner patch that addresses satisfactorily the shortcomings and problems of the prior art.
SUMMARY
[0005] Briefly described, a patch is disclosed for flat TPO sealed roofs that seals the outside bottom corners of roof protrusions such as vents, ductwork, air conditioning units, where the corners meet the flat roof. In one embodiment, the patch is made of a circular blank of TPO material that is vacuum formed to produce a plurality of radially extending flutes or peaks and valleys in the patch. This is referred to herein as a daisy wheel configuration. The number of flutes, the depth of each flute, and the radius of the blank are optimized according to methods of the invention so that the patch fits an outside bottom corner of a roof protrusion perfectly when the flutes are spread out. The patch can then be heat sealed to surrounding TPO membranes on the protrusion and the roof to provide a water-tight seal where corners of protrusions meet the flat roof. The TPO daisy wheel corner patch of this disclosure also can be optimized for corners that are not orthogonal; i.e. where the sides of the protrusion and the roof do not form right angles with respect to each other. This has not generally been possible with prior art prefabricated corners and has required tedious custom fabricating of corner patches on sight for acceptable results. The patch of this invention also is easily and efficiently packaged because the daisy wheel shape of the patches allows them to be nested together in a compact stack.
[0006] Thus, an improved prefabricated TPO corner patch is now provided that fits a corner for which it is designed perfectly to provide a reliable water-tight seal, that is compact and efficient to stack, store, and transport, and that can be optimized for orthogonal and other outside corner shapes commonly encountered in flat or semi-flat commercial roofs. These and other aspects, features, and advantages will be better understood upon review of the detailed description set forth below when taken in conjunction with the accompanying drawing figures, which are briefly described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a section of a flat TPO sealed roof with a protrusion and illustrates one preferred application of the TPO outside corner patch.
[0008] FIG. 2 is a perspective view of a TPO outside corner patch that embodies principles of the disclosure in a preferred form.
[0009] FIG. 3 a perspective view of a circular TPO blank from which the corner patch of this disclosure is molded illustrating design variables for optimizing the number and depth of flutes for a particular corner.
[0010] FIG. 4 shows a generic protrusion with a corner patch and illustrates how a design circumference is determined for a patch of a give radius.
[0011] FIG. 5 is a graph illustrating the results of the optimization methodology of the present disclosure.
DETAILED DESCRIPTION
[0012] Referring now in more detail to the drawing figures, wherein like reference numerals indicate like parts throughout the several views, FIG. 1 illustrates a section 11 of a flat roof having a protrusion 13 . The protrusion is illustrated as a generic square upward projection from the roof deck. In reality, such projections take many forms and protrusion 13 may represent, for example, a chimney, a vent pipe, a duct, and air conditioning platform or unit, or otherwise. In any event, the protrusion 13 and the flat roof deck form outside corners 20 where the corners of the protrusion meet the roof deck. In the illustrated embodiment, the outside corners 20 are orthogonal; that is, the faces of the protrusion and the roof deck all meet at approximately right angles. However, the outside corner patch of this disclosure is not limited to use with orthogonal outside corners but may be optimized for non-orthogonal outside corners.
[0013] The flat portion of the roof 11 is covered and sealed with a TPO membrane 14 as is known in the roofing art to prevent water from leaking into the building below. A cutout (not visible) is formed in the membrane at the location of the protrusion and the peripheral edges of the cutout extend up to the bottom of the protrusion. In order to seal along these bottom edges, a skirt or apron 16 of TPO membrane material is wrapped around and sealed to the protrusion 13 with the bottom of the skirt 16 flaring out to overly the membrane 14 . More particularly, the skirt 16 , when installed, includes an upper portion 17 that covers at least the lower section of the protrusion and flaps 18 that flare outwardly to overly and cover the membrane 14 , to which the flaps 18 are thermally welded to form a watertight seal. In order to allow the flaps 18 to extend outwardly, the TPO membrane forming the skirt 16 is slit during installation at the bottom corners of the protrusion, as indicated by reference numeral 19 . This leaves an outside corner 20 where the corners of the protrusion and the end of the slit meet the roof deck that is subject to leaks unless properly sealed. Outside corner patches 21 according to the present disclosure are applied to seal these outside corners 20 , as detailed below.
[0014] An outside corner patch 21 according to the present disclosure is applied at each of the outside corners 20 of the protrusion to form a watertight seal at these corners. Referring to the foreground outside corner in FIG. 1 , the outside corner patch 21 comprises a specially formed circular piece of TPO membrane material that has been fluted, as detailed below, to conform to the shape of the outside corner when the patch is spread out. In this illustration, the corner patch 21 is applied beneath the upper portion 17 of the skirt and beneath the two adjacent flaps 18 . It will be understood, however, that the patch also may be applied over the top of the upper portion 17 of the skirt and over the top of the two adjacent flaps 18 if desired. In either event, the corner patch 21 is thermally welded to the TPO material of the skirt 16 and the roof membrane 14 , as indicated at 22 , thus forming a watertight seal at the bottom outside corner of the protrusion. Thermal welding or heat sealing of TPO corners and other members to membranes is well known in the commercial roofing trade and thus the details of this process need not be discussed in detail here.
[0015] FIG. 2 illustrates a preferred configuration of the outside corner patch of this disclosure before being applied to the outside corner of a protrusion, as illustrated in FIG. 1 . The patch 21 is generally circular in shape with a central region 26 and a periphery 27 and is radially fluted to define an array of radially extending peaks 28 and corresponding radially extending valleys 29 . This forms the daisy wheel configuration of the patch. The peaks and valleys expand in amplitude from substantially zero amplitude at the central region 26 of the patch to a maximum amplitude at the periphery 27 of the patch. The patch 21 can be fabricated in a variety of ways. Preferably, however, a circular cutout of standard TPO membrane material is heated and vacuum formed to generate the daisy wheel configuration with a predetermined number of peaks and valleys. Other possible fabrication methods might include injection molding, thermoforming, pressure molding, or similar known techniques. The patch shown in FIG. 2 is illustrated with 10 peaks and 10 valleys defining the daisy wheel configuration. However fewer or more peaks and valleys might be selected based upon the optimization techniques described in detail below.
[0016] For installation of the outside corner patch of this disclosure, the patch is positioned with its central region 26 aligned with and covering the corner where the faces of the protrusion meet the flat roof. The flutes of the patch are then spread out substantially flat as the patch is conformed to the contour of the outside corner. More specifically, the flutes are spread out until the patch lies flat against both of the faces of the protrusion and also lies flat against the flat roofing membrane in the region of the corner. With the number of flutes and the sizes of the flutes optimized for the three dimensional shape of the outside corner, the patch conforms perfectly to the faces of the protrusion and the roof when fully spread out. The patch can then be thermally welded or heat sealed to the underlying or overlying, as the case may be, TPO material of the upper portion 17 of the skirt, the flaps 18 , and the roof membrane 14 thus forming a watertight seal at the outside corner of the protrusion.
[0017] As mentioned above, in order for the outside corner patch of this disclosure to conform perfectly to an outside corner, its configuration, i.e. the number and sizes of the flutes should be optimized for the shape of the outside corner and the diameter of the patch. Most outside corners are orthogonal, but the patch may also be optimized for non-orthogonal outside corners if desired. The optimization methodology described below is for an orthogonal outside corner. FIG. 3 illustrates the design variables that enter into the optimization process. The starting circular blank of TPO material 31 from which the patch is to be formed has a center O, a periphery 33 and can be divided into pie-shaped sections 34 , each of which will be deformed into a generally cone-shaped peak or a valley of the final fluted patch, as illustrated by phantom line 36 . An imaginary plunge circle 37 may be constructed as an aid in deriving the optimization algorithms. The variables shown in FIG. 3 that are relevant to the optimization process of this invention are defined as follows.
n: number of flutes (total of peaks plus valleys) r b : radius of circular TPO blank r p : radius of plunge circle α: flute blank angle h: depth of draw β: flute depth angle a, b, c, d, and e identify various useful points on the construction
[0025] With these optimization variables identified, and with reference to FIG. 3 , we see that for triangle oac:
[0000] sin(α/2)= ab/ 2/ oa=ab/ 2 /r b
[0000] Thus: ab= 2 r b sin(α/2) (1)
[0000] where: α=2π /n (2)
[0026] Assume that a plunge circle will generate arc aeb when the flat blank is deformed so that the edge of the flute conforms to the plunge circle. Then, for triangle acd, we can see from the Pythagorean theorem for right triangles that:
[0000]
ad
2
=ac
2
+cd
2
[0000] or: r p 2 =( ab/ 2) 2 +cd 2 but cd+h=r p
[0000] so: r p 2 =( ab/ 2) 2 +( rp−h ) 2
[0000] solving this equation for r p gives:
[0000] r p =(( ab) 2 /4+ h 2 )/2 h (3)
[0000] and: sin(β/2)= bc/db=ab/ 2 /r p
[0000] so that: β=2 sin −1 ( ab/ 2 r p ) (4)
[0027] Hence, for a given depth of draw “h,” the plunge circle radius r p can be calculated from equation 3. Then, the plunge circle circumference is:
[0000] 2πr p
[0000] and the length of the flute edge that will follow the contour of the plunge circle when the blank is deformed is:
[0000] ↑/2π×2πr p or just βr p
[0000] Finally, the total length of the perimeter edge of a fluted patch with n flutes, which we shall designate the “fluted circumference” or c f , is given by the total of the lengths of each individual flute, or:
[0000] c f =nβr p (5)
[0000] Now, referring to FIG. 4 , which shows a fluted circular patch stretched flat and conformed to an outside orthogonal corner, and considering that the radius of the fluted patch is equal to the radius of the blank r b , we can determine, using the equation below, the total length of the perimeter of a fluted patch required for the patch to conform perfectly to the corner. We shall call this perimeter length the “design circumference” or simply the “target.”
[0000] (2 πr r )+¼(2 πr b )=5/4 (2 πr b ) (6)
[0000] The design circumference also can be derived by considering that A in FIG. 4 is ¾ of a circle while B and C are each ¼ of a circle. Adding the circumferences of each of these partial circles gives:
[0000] ¾(2 πr b )+¼(2 πr b )+¼(2 πr b )=5/4(2 πr b )
[0028] Hence, optimization routines can be run for a blank of a given radius by selecting various values of flute draw h and, for each value of h, varying the number of flutes n until the combination of h and n generate a fluted circumference c f that is equal or very close to the design circumference given by equation 6. FIG. 5 illustrates, in the form of a graph, the results of such an iteration to determine the optimum combination of flutes n and flute draw h required for a corner patch having a 4 inch diameter radius to conform perfectly to an outside orthogonal corner. The design circumference or target calculated from equation 6 is represented by the dark horizontal line on the graph. Each curve of the graph represents the fluted circumference c f for one of the flute draw values shown in the box at the upper right of the graph for various values of the number of flutes n. It will be noted that only the data points on each graph represent a realistic combination of h and n since n must be an even integer.
[0029] It can be seen from FIG. 5 that the following combinations of number of flutes n and flute draw h generate, for a four inch radius blank, a fluted circumference that is very close the design circumference:
[0000] n=12 and h=0.69 inch
[0000] n=16 and h=0.5 inch
[0000] and n=20 and h=0.4 inch
[0000] Either of these combinations would result in a fluted patch that would conform to an outside orthogonal corner when stretched out flat. However, due to manufacturing considerations, and to produce a relatively rigid and robust final product, the first combination of n=12 and h=0.69 is considered most optimal.
[0030] A four inch radius TPO blank was formed according to the above optimization methodology with 12 flutes and a flute draw of 0.69 inches and was tested on an orthogonal outside corner of a protrusion. The test patch proved to conform perfectly to the corner when placed with its center directly at the corner and its flutes stretched out flat to cover the deck and contiguous sides of the protrusion. Of course, patches of radii other than 4 inches such as, for instance, 2, 6, or 8 inches, can be optimized according to the forgoing methodology so that the radius of the starting TPO blank is not a limitation of the methodology or the invention.
[0031] The invention has been described herein in terms of preferred embodiments and methodologies considered by the inventors to represent the best mode of carrying out the invention. However, numerous additions, deletions, and modifications of the illustrated embodiments might be made by those of skill in the art without departing from the spirit and scope of the invention as set forth in the claims. For example, the patch has been described within the context of flat commercial roofing. However, the invention is not limited to flat roofs or commercial roofing but may be adapted for sealing corner protrusions in non-flat roofs. Indeed, the invention may be applied in non-roofing scenarios such as in sheet metal structures, tub and shower basins, and the like where it is desired to seal outside corners of protrusions.
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An outside corner patch for TPO roofing is formed from a circular piece of TPO membrane material being vacuum formed to define an array of flutes that extend from the center of the piece toward its edges. The flutes form ridges and valleys that generally are shaped as conical sections with the apex of the conical sections located at the center of the patch. The number and size of the flutes is optimized in such a way that, when the flutes are stretched flat, the patch conforms to and fits flat against the surfaces of an outside corner formed by the intersection of a roof deck with an upward protrusion from the roof. The TPO outside corner patch is applied over the corner and thermally welded to surrounding TPO membranes on the roof deck and the protrusion to form a watertight seal at the outside corner.
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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. 07/566,659, filed on Aug. 13, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains generally to the field of reinforced concrete construction and in particular is directed to certain improvements in three-piece couplings for end-to-end splicing of concrete reinforcement bars.
2. State of the Prior Art
A reinforcement bar or, in trade parlance, a rebar, is a long cylindrical steel rod with surface deformations or ribs, the purpose of which is to impede turning or axial displacement of the rod when embedded in concrete. One typical rib configuration includes one or two continuous longitudinal ribs traversed by a plurality of spaced apart annular ribs. Various rib configurations and designs are in use, including oblique annular and helical ribs. A summary of rebar usage may be found at pages A1 through A5 in the appendix to the "Manual of Standard Practice" published by the Concrete Reinforcing Steel Institute (Jan. 1980).
Rebars have been in widespread use for many years as reinforcing elements in poured or cast concrete structures. In construction of large structures it is often necessary to splice together two or more such rebars end-to-end. This often occurs in large concrete form-work which is carried out in steps or stages. The reinforcing bars used at each stage must be joined to rebars for subsequent stages in order to achieve a monolithic concrete structure.
Many rebar splicing devices and couplers have been devised for this purpose. In so-called three piece couplers machine threads are cut or rolled in the ends of the rebars and an internally threaded sleeve joins two bars in an end-to-end splice. This general type of coupler has long been in use. In its most basic form, crude screw threads are cut into the irregular, ribbed surface at each end of a rebar, and two such ends are joined by a threaded cylindrical sleeve. The resulting joint tends to be loose and of low quality because of the rough-cut rebar threading. A better joint is obtained by removing the ribbing to make a smooth cylindrical surface before cutting the threads cut.
Variations of this basic scheme have been adopted in efforts to improve the quality of the splice. One approach is to create a conical taper at each end of the rebar which is then threaded. The threaded ends screw into a sleeve which has equally tapered internal threading, to provide a higher grade joint.
Still another approach has been to enlarge the rebar ends by upset forging or other means, before threading is cut or rolled into the enlarged cylindrical ends. The upset forging of rebar ends was disclosed by this applicant in U.S. Pat. No. 4,619,096 issued Oct. 28, 1986, which however relates to two-piece rebar splicing, in which one rebar end is hot forged to define an integral female threaded receptacle which mates to a male upset threaded rebar end to effect a splice joint. Two-piece couplings can be advantageous in certain applications because a separate coupler sleeve, i.e. a third (piece, is eliminated. In this applicant's prior patent, it is recognized that the upset ends prevent weakening of the rebar's tensile strength after the threads are cut into the enlarged ends. This is because the rebar ends are upset or enlarged in diameter before the threads are cut. This initial thickening of the rebar ends counteracts the effect of the subsequent cutting and prevents the rebars effective cross-section from being reduced by the screw threading.
The '906 patent disclosure is, however, limited to two-piece couplings and does not address the special advantages of upset threaded rebar ends when used in conjunction with a separate coupler sleeve in three-piece couplings.
A considerable shortcoming in conventional three-piece rebar couplings is the necessity to rotate at least one of the rebars about its longitudinal axis in order to make the splice joint. In the typical situation, one rebar may already be in place, embedded in concrete, with one end protruding. The coupler sleeve is then threaded onto the exposed end of the fixed rebar, and the rebar to be joined is then threaded into the free end of the coupler sleeve to make the splice. There are occasions however, when it is inconvenient or impossible to proceed in this manner. For example, it may be impossible to rotate a twenty foot long rebar bent to a right angle at a mid-point in a confined area.
This shortcoming results from the fact that, in conventional three-piece couplers, the coupler sleeve can only be threaded a limited distance onto the rebar, which distance is the length of the threaded portion of the rebar end. This length in turn is no more than can be accepted by the coupler sleeve, as it is undesirable for smooth machine threading to remain exposed outside the sleeve in the completed splice because this results in a weak rebar section of lesser net cross-section than the ribbed rebar body. Movement of the coupler sleeve beyond the threaded end portion is blocked by the surface deformations or ribbing of the rebar which rise above the thread edges and consequently beyond the inside diameter of the coupler sleeve.
Fatigue considerations and cyclic loading presently are not a factor in the construction codes applicable to the design of concrete reinforcement bars. This is changing however and, in anticipation of stricter design codes, the U.S. Government has tested currently used rebar splices under cyclic loading and fatigue conditions. It was found that all rebar splices now on the market fall short of the performance of an unspliced reinforcement bar. It was further found that an unspliced reinforcement bar has approximately a 50% chance of meeting the new cyclic loading standards being considered. Under the old standards for e.g. highway projects such as bridges which are subject to cyclic loading by heavy vehicles passing over these structures, a rebar was acceptable if it survives 2 million cycle of 10-12 thousand psi loading. It is anticipated that the new standards will require 5 million cycles at 30,000 psi.
The ability to achieve a rebar splice through rotation of the coupler sleeve exclusively depends on the ability of the coupler sleeve to move onto the ribbed area of the rebar, unimpeded by the raised rib deformations on the rebar surface.
In the past this has been achieved by "over threading" the rebar: a first machine thread on an upset end portion of the rebar continuing the thread cut over the adjacent ribbed section of the rebar.
Empirical testing has revealed however, that even a small cut or nick in the ribbing of the rebar produces a "cherpe" effect, by which stress force acting along the rebar is focused or concentrated by relatively minute changes in the geometry of the rebar. Even a shallow thread cut in the ribs has been found to create a plane of weakening in the rebar, and under protracted cyclic loading of the rebar as may occur for example, on a concrete bridge subject to heavy loads moving across it, creates a metal fatigue condition at the site of the surface cut which in turn eventually leads to structural failure of the rebar. Consequently, the expedient of extending the machine thread onto the rib deformations in order to allow the coupler sleeve to move onto the ribbed rebar area, sometimes referred to as double threading, is undesirable if a rebar splice is to approximate the performance of a continuous rebar.
For these same reasons, the three-piece coupler system described herein is preferable to a two-piece coupler system such as described in this applicant's prior Pat. No. 4,619,096 in applications where reliability under metal fatigue conditions is of concern. The elements in a three-piece coupling are straight cylindrical rods or sleeve with no abrupt changes in geometry, in contrast to the abrupt transition between the nominal rebar area and the enlarged integral end socket in the two-piece system.
SUMMARY OF THE INVENTION
According to this invention, the aforementioned difficulties can be overcome by upsetting the rebar ends sufficiently so that the end threading is of a diameter greater than the maximum diameter achieved at any point of the surface ribs. The enlarged diameter of the upset threaded portion can be achieved by hot forging of the rebar or any equivalent method. The inside end of the coupler sleeve can then be advanced onto the nominal rebar area, beyond the end threading, until the rebar end protrudes from the outside end of the coupler sleeve. This allows splicing of two rebars without necessity of axially turning either rebar. The second rebar is simply brought end-to-end with the protruding end of the fixed rebar and the coupler sleeve is turned in the opposite direction to bring it back over the joined rebar ends, thereby making the splice joint.
In a presently preferred form of the invention, the upset end of the rebar is enlarged to a diameter such that a coupler sleeve can be threaded beyond the male threads and clear the deformations on the ribbed area of the area. In other words, the bottom of the thread groove in the upset rebar end has a diameter at least slightly greater than the maximum diameter of the rib deformations. In another form of the invention, the rebar end is upset to a lesser degree such that the bottom of the thread groove does not exceed the maximum diameter of the rib deformations of the rebar. In order to allow the coupler sleeve to be moved beyond the upset threaded portion and onto the ribbed area, the ribs on a rebar segment immediately adjacent to the upset threaded portion are flattened by means of dies to a lesser height but without removing any significant amount of the rib material, so that the effective cross-sectional area of the rebar at the flattened portion remains substantially unchanged, thereby maintaining the tensile strength of the rebar.
A further improvement according to this invention is the provision of a pilot nose at the threaded end of the rebar. The pilot nose is an axial protrusion of reduced diameter which leads the threaded portion into the coupler sleeve, or other female threaded element, in order to facilitate the insertion and alignment of the mating threads. Because of the long length of the typical rebar, construction workers often have some difficulty in threading a second rebar into a coupler sleeve previously fitted on a fixed first rebar. The novel pilot nose ensures that, once it is inserted into the coupler sleeve, the male threads following behind it will be in proper axial alignment with the internal female threading of the sleeve. Proper engagement of the threads will then occur simply by then turning the rebar. Without the pilot nose, it is often a matter of several ineffectual attempts before proper engagement of the threads is achieved. The pilot nose is preferably a smooth cylindrical stub with a bevelled leading edge terminating in a circular end face of smaller diameter than either the cylindrical stub portion or the screw threads on the rebar, in order to facilitate entry of the pilot nose into the coupler sleeve or female coupling element being joined to the rebar.
Still another feature according to this invention is that the pilot nose is sized and configured so as to support a rebar vertically erect on a vertically aligned coupler sleeve or other female coupling, without engaging the threads of the rebar with those of the female element. The rebar can be left otherwise unsupported and free standing simply by inserting the pilot nose into a securely anchored female coupler. This is a useful feature in construction work since it allows the personnel to quickly set up a number of rebars and clear an area before individually twisting the rebars into the corresponding coupler element. Without provision of such a pilot nose, each rebar must be threaded into the coupling element before the worker can pick-up another rebar for placement into its socket or coupler. This pilot nose is useful not only with coupler sleeves but with any coupling element , socket or fixture having a threaded bore into which the rebar is to be mated.
These and other advantages and improvements of this invention will be better understood by reference to the following detailed description of the invention and attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a rebar end with upset threading and a pilot nose according to this invention:
FIG. 1a shows an alternate rebar end with upset threading but without a pilot nose;
FIG. 2 is a cross-section of the rebar taken along line 2--2 in FIG. 1 showing the normal ribbing height in the nominal rebar area;
FIG. 3 is a cross-section taken along line 3--3 in FIG. 3 showing ribbing flattened adjacent to the upset threaded portion of the rebar;
FIG. 4 is an axially exploded view showing a coupler sleeve between two upset threaded rebar ends;
FIG. 5 shows the elements of FIG. 4 joined to make a splice between the two rebars;
FIG. 6a illustrates how a bent rebar can joined to a fixed rebar without turning either rebar;
FIG. 6b shows a completed splice between the rebars of FIG. 6a;
FIG. 7a shows the pilot nose of the rebar leading the threading into a female fitting and supporting the rebar in free standing upright condition on the fitting;
FIG. 7b shows the rebar of FIG. 7a threaded into the female fitting.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, FIG. 1 shows one end of a concrete reinforcement bar or rebar 10 which has a basic cylindrical body 12 with an outer cylindrical surface 13 from which rise deformations or ribs 14 as best seen in the cross section of FIG. 2. The ribs 14 may take different shapes and in the illustrated example include two diametrically opposed longitudinal ribs 16 and axially spaced, crisscrossed pairs of oblique annular ribs 18 which intercept each other at the longitudinal rib 16.
FIG. 1 shows the left hand end of a rebar which is considerably longer than shown and terminates in an opposite, right hand end which may or may not be similar to the left hand end. In the typical rebar, both ends will be substantially similar and approximately mirror images of each other. Between the two ends is a long nominal rebar area, and which is characterized by the aforementioned rib deformations 14 on the cylindrical surface 13. The rib deformations 14 are hot rolled on an originally cylindrical rebar body in a manner well-known in the industry. Rebar lengths range to 60 feet or greater, with more typical lengths ranging between 20 and 40 feet. Shorter lengths are also used. Rebar diameters vary and are available in standard sizes which in the industry are designated by numerals in the range of 4 through 14, for the standard commonly used sizes. The height of the ribbed deformations 14 are typically 2/10 of the nominal rebar diameter.
According to this invention, an end segment 20 of the rebar has been enlarged in diameter by upset forging, and a machine thread 22 has been cut or rolled into the upset section 20. The extent of the upset i.e. the degree of diametric enlargement of the rebar along section 20 is such that the bottom 24 of the thread 22 has a diameter which is intermediate the diameter of the cylindrical rebar surface 12 and the maximum diameter achieved by the highest point of the rib deformations 14, including the longitudinal ribs 16 and the annular ribs 18. The height of the threading 22 above the thread bottom 24 will be determined by the thread size which in turn may relate to the diameter of the rebar, among other factors. The absolute dimensions of the thread 22 and upset diameter of section 20 consequently vary in proportion to the rebar diameter. The threaded upset section 20 of the rebar has a preferred length of one rebar diameter plus 1/4 inch.
The up-sized section 20 is formed by holding the hot rebar in a die which defines a cylindrical compartment surrounding an exposed three inch end segment of the rebar. An axial hydraulic ram strikes the still-hot end of the rebar with sufficient force and as many repetitions as needed to expand the exposed rebar segment to the diameter of the die chamber, shortening the exposed segment in the process. The machine thread 22 is then either cut or rolled on the up-sized segment 20.
The preferred extent of up-sizing of the end segment 20 is typically to a final diameter which is 1/8th of 1 inch in diameter greater than the nominal rebar diameter. The nominal diameter, a figure which is arrived at in a specific manner known in the industry, and given in Table 1 below for each rebar size, is approximately the diameter of the rebar body at surface 13, but may vary somewhat therefrom for certain rebar sizes. The rib deformations 14 in this area and, for the smaller rebar e.g. sizes 4-8, will rise to a maximum rib height typically less than the 1/8 inch up-sizing of section 20. This extent of up-sizing will allow an internally threaded cylindrical sleeve to be moved past the threaded end segment 20 and onto the ribbed area of the rebar without being obstructed by the deformations 16, 18.
As an alternative, particularly in the larger rebar sizes 9 through 14 in which substantial up-sizing is more difficult, a lesser enlargement of the threaded section 20 may be combined with a flattening or squeeze-down of the rib deformations 14 to a diminished rib height along a segment 25 of the nominal rebar area 12 adjacent to the up-sized section 20. This flattening can be accomplished, for example, by means of a hydraulic gripper arrangement including two semi-cylindrical dies configured to each cradle one longitudinal half of the rebar segment being treated. Two such dies are applied in diametrically opposed relationship to the rebar segment while the rebar is at hot forging temperatures with sufficient hydraulic force to achieve a flattening of the rib deformations 16, 18. Such hydraulic grippers are effective in reducing the height of the ribbed deformations without however, removing any significant amount of rebar material. As a result, the effective or net cross-sectional area of the rebar remains constant as illustrated in FIGS. 4 and 5. FIG. 4 shows the cross-section taken along line 4--4 in FIG. 1, where the rib deformations retain their original shape and height above the rebar body 12. In FIG. 5, the ribs have been flattened by means of the aforedescribed hydraulic grippers, resulting in rib deformations which are of reduced height and also somewhat spread out in a circumferential direction as compared to the original shape of FIG. 4. While the cross sectional shape is changed somewhat by this flattening, the net cross sectional area remains substantially unchanged, so that the tensile strength of the rebar is not impaired by this process.
__________________________________________________________________________ G (2) I J K D E F THD. H (3) NOMIN- OVER- LA B C COUP- STARTING O.D. CLR. THD. REDUC- AL ALL (1)BAR THREAD DRILL LER UPSET/ UPSET LGTH. CLR. TION BAR BAR MIN. AVG.SIZE SIZE DIA. OD ROLLED CUT REQD. DIA. REQD. DIA. DIA. HGT OF__________________________________________________________________________ D#4 5/8"-11 0.531 7/8" 0.568 0.625 1.000 0.527 0.035 0.500 0.562 0.020#5 3/4"-10 0.656 11/8" 0.687 0.750 1.125 0.642 0.045 0.625 0.688 0.028#6 7/8"-9 0.766 11/4" 0.805 0.875 1.250 0.755 0.120 0.750 0.875 0.038#7 1"-8 0.875 11/2" 0.921 1.000 1.375 0.875 0.125 0.875 1.000 0.044#8 11/8"-8 1.000 15/8" 1.046 1.125 1.500 1.000 0.125 1.000 1.125 0.050#9 11/4"-8 1.125 17/8" 1.171 1.250 1.625 1.125 0.125 1.128 1.250 0.056#10 1 7/16"-8 1.313 21/8" 1.359 1.437 1.813 1.302 0.135 1.270 1.438 0.064#11 1 9/16"-8 1.438 21/4" 1.484 1.562 2.208 1.427 0.198 1.410 1.625 0.071#14 17/8"-8 1.750 25/8" 1.796 1.875 2.250 1.740 0.135 1.693 1.875 0.085__________________________________________________________________________ NOTE: (1)THE MINIMUM AVERAGE HEIGHT OF DEFORMATIONS IS FOR EACH DEFORMATION. (2)THE LENGTH OF SQUEEZE DOWN GIVEN ALLOWS FOR THREADING THE COUPLER ENOUGH TO ALLOW DI'S TO TOUCH TIP TO TIP AND PILOTS WILL STILL FUNCTION. (3)THE REDUCTION REQUIRED FROM OVERALL BAR DIAMETER TO CLEAR THE COUPLER INSIDE DIAMETER
TABLE 1 lists presently preferred dimensions for the upset end threading, rib squeeze-down, and related data for rebar sizes 4 through 14.
Column B gives the thread size, in inches as well as in industry-recognized thread number. The thread numbers become smaller for larger sized threads. The thread dimension in inches indicates the diameter, A--A in FIG. 2, of the thread 22 from crest to crest in the upset threaded segment 20 in FIG. 1. Column D gives the drill diameter i.e., the thread diameter measured at the thread bottom 24 of section 20 in FIG. 1. This dimension corresponds to the crest diameter of the female threading in the coupler sleeve 40 of FIGS. 4 and 5.
Column C provides the outside diameter of the coupler 40 in FIGS. 4 and 5 for each rebar size. This is dimension B--B in FIG. 4. Columns E and F indicate the degree of diametric enlargement along the upset section 20 prior to formation of the thread 24: column E gives the outside diameter required for rolled thread 24, while Column F gives the same dimension for thread 24 which is cut instead of rolled. Column G gives the length of the rebar segment 25 in FIG. 1, adjacent to threaded segment 20, along which the ribbing 14 is squeezed down from the normal height C--C in FIG. 2 to a flattened condition C'--C' in FIG. 3, to allow the coupler sleeve 40 to be threaded onto this squeezed down ribbed area of the rebar, past the inside end of the thread 24. Column I gives the rib height squeeze-down reduction required i.e. the reduction from overall bar diameter required to clear the inside diameter of the coupler sleeve 40 for each rebar size.
Columns J and K respectively provide the nominal and overall rebar diameters along the ribbed portions of the rebar in FIG. 1 for each industry standard rebar size, while Column L gives the industry minimum average height of the deformations 14 above the cylindrical rebar surface 15.
The length of the squeeze down indicated in Column I allows threading of the coupler sufficiently over the ribbed area to allow two rebar ends to touch tip to tip, while retaining function of the pilot noses 30 on each rebar being joined.
In a preferred form of this invention, the rebar 10 has a pilot or lead-in nose 30 at each end, which is a cylindrical end stub extending axially from the upset threaded rebar segment 20. The pilot nose 30 is integral with the rebar 10 and is formed by hot forging, hot rolling or other convenient process. The nose 30 terminates in a circumferentially bevelled edge 32 and an end face 34. The cylindrical body 36 of the nose 30 has a diameter slightly lesser than the crest of the threading 42 on the female element to be screwed onto the rebar thread 22. In other words, the diameter of the nose is slightly lesser than the diameter at the bottom 24 of the rebar thread 22. The lead-in nose 30 may be omitted in an alternate form of this invention illustrated in FIG. 1a, which shows an alternate rebar 10, without the pilot nose 30 so that the upset thread 22 terminates in a blunt end face 44, but which is otherwise analogous to the rebar 10 of FIG. 1.
Turning now to FIG. 2, two rebars 10a and 10b each have an upset threaded end segment 20 and pilot nose 30 as described in connection with FIGS. 1, 4 and 5. The two rebar ends are shown on either side of a coupler sleeve 40. The sleeve is an internally threaded cylindrical tube open at both ends. The internal threading 42 is sized to mate with the rebar end threading 22. The sleeve is made of the same material as the rebars and preferably has an outside diameter (B--B in FIG. 4) such that the net cross-sectional area of sleeve 40 is at least 40% greater than the net cross-sectional area of the rebars. It has been found through empirical testing that this relationship between the coupler and rebar net cross sectional areas is critical to reliability of the splice joint in situations where metal fatigue must be taken into account. Metal fatigue occurs most commonly in structures which are cyclically stressed by heavy loads, such as bridges. The axial length of the coupler sleeve 40 is preferably no greater than required to fully admit the threaded end segments 20 of both rebars being joined as illustrated in FIG. 5. With this length, a worker can easily gauge that the sleeve is properly mounted to a rebar as soon as none of the threading of end segment 20 remains visible. This will be true regardless of which end of the coupler is threaded to either one of the rebars being joined.
An end-to-end rebar splice is made between rebars 10a and 10b by screwing the sleeve 40 onto the end of one rebar, e.g. 10a, and then screwing the end of the other rebar 10b into the opposite end of the coupler sleeve 40. A completed splice joint is shown in FIG. 5 where the threaded ends of both rebars 10a and 10b have been rotated into the coupler sleeve 40 until the threading 22 on each rebar is fully engaged with the internal threading 42 of the coupler sleeve 40.
Turning now to FIGS. 6a and 6b, is a situation is illustrated where one of the rebars, 10c is pre-bent to a right angle, as is common in construction practice. When the bent rebar 10c is to be engaged to rebar 10a which may have already been embedded in concrete (not shown) it will usually be found that rebar 10c cannot be rotated about the splice axis because of its length. This difficulty is easily overcome by threading the coupler sleeve 40 onto the end of the bent rebar 10c until a substantial portion of the sleeve 40 extends over the ribbed area 14 of the rebar, well past the up-sized threaded section 20. The exposed end of rebar 10c can now be brought end-to-end, or nose-to-nose, with the fixed rebar 10a and the coupler sleeve 40 then rotated back onto the end of the fixed rebar, to complete a splice joint as in FIG. 6b, without rotating either rebar in the process.
The pilot nose 30, aided by the bevelled edge 32 is useful in easily aligning a rebar into the open end of a coupler sleeve, a task which otherwise is not easy due to the considerable length and clumsy handling of the rebars once correct axial alignment has been achieved, threading of the rebar into the coupler sleeve is greatly facilitated in that cross threading of the rebar with the coupler sleeve is avoided. All of this translates into quicker handling and assembly of the rebars at the construction site which is directly reflected in time and cost savings.
The presently preferred length of lead-in nose 30 is one-half inch in length from the end face 34 to the transition 38 with the up-sized threaded section 20. The diameter of the nose 30 makes a close sliding fit with the crest of the thread 42 in the coupler sleeve 40. The close fit enables the rebar 10 to be left upright and free-standing on a female fitting 50 having an internally threaded bore 52 adapted to engage the rebar threading simply by sliding the lead-in nose 30 into the open end of the fitting. This is shown in FIG. 7a. The pilot nose 30 inserted in female threading 52 supports upright the rebar 10 without engagement between threads 22 and 52. In the case of larger rebars, a somewhat longer nose 30, e.g. 3/4 inch long, may be required to achieve this result. FIG. 7bshows the rebar 10 of FIG. 7a after threading rebar thread 22 into the female fixture 50.
From the foregoing, it will be appreciated that various improvements have been disclosed to facilitate the splicing or end-to-end coupling of concrete reinforcement bars in an expeditious and reliable manner. While particular dimensions and other details of the presently preferred embodiments have been described and illustrated for purposes of clarity and example, it must be understood that many changes, substitutions and modifications will be readily apparent to those individuals possessed of ordinary skill in the art without thereby departing from the scope and spirit of the present invention which is defined only by the following claims.
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The threaded end of a concrete reinforcement bar is enlarged in diameter so that the thread bottom exceeds the diameter of the surface ribs of the rebar. A coupler sleeve can then be advanced past the end threading and over the rib area, until the rebar end protrudes from the coupler sleeve. This allows splicing of two rebars without axially turning either rebar. Alternatively, the thread bottom does not exceed the maximum diameter of the rib deformations of the rebar but an immediately adjacent rib segment is flattened without removing rib material to preserve the net cross-sectional area of the rebar and maintain the tensile strength of the rebar. A pilot nose of reduced diameter leads the threaded portion into the female thread to facilitate thread alignment and can support a free standing rebar on a female coupling before engaging the threads.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a form unit and its method of manufacture that is used when pouring concrete when building a concrete building, and to a concrete building that is constructed using the concrete-building construction form.
[0003] 2. Description of the Related Art
[0004] Conventionally, when building a concrete building, after the foundation has been formed, many vertical reinforcements and horizontal reinforcements are arranged in a box-like shape on top of the foundation, and then after wooden or metal forms are arranged on the inside and outside of these vertical and horizontal reinforcements, concrete is poured onto the forms and hardened, then by removing the forms, the walls and partitions of the concrete building are completed, and finally the work of finishing these walls and partitions is
[0005] However, in the case of constructing a concrete building using this kind of conventional method, the following problems that need to be improved remain.
[0006] In other words, before pouring the concrete, it is necessary to perform the work of putting reinforcing bars in place, and then placing the forms on both sides of these reinforcing bars, then after the poured concrete has hardened, it is necessary to perform the work of removing the forms.
[0007] Therefore, since it is necessary to perform work inside and outside the wall, scaffolding 2 is assembled on the outside of the concrete building 1 to be constructed, as shown in FIG. 16, and this scaffolding 2 is used to perform the outside work.
[0008] In order to do this, space must be maintained on the outside of the concrete building 1 to be constructed in order to assemble the scaffolding 2 , and the area of the floor space of the concrete building 1 becomes smaller by the amount of this space.
[0009] In other words, the width L1 of the scaffolding 2 requires at least 50 cm, and when there are other buildings on the sides of the building site, the outer wall must be constructed 50 cm inside the building site on one or both sides of the building site from the other buildings, and thus the constructed floor space is reduced by this amount.
[0010] Moreover, since the concrete wall after removing the forms is bare, waterproofing must be performed for the outer surface.
[0011] Also, it is necessary to apply an insulating material to the inner surface of the wall in order to insulate the inside and outside, then to cover this insulating material by applying an interior-wall material such as plasterboard, and to apply cloth as in interior material, so there is a problem in that the entire work process becomes prolonged.
[0012] As described above, in the conventional construction method, insulating material is applied to the inside wall, which is inside insulation construction, and the outside temperature being transmitted by way of the floor slabs and ceiling slabs, creating the so-called ‘heat bridge’ phenomenon, which causes condensation inside the walls.
[0013] Moreover, when applying the interior material to the surface of the inside wall, a chemical substance such as adhesive is used, which not desirable from a health aspect.
SUMMARY OF THE INVENTION
[0014] Taking the problems of the prior technology into consideration, it is the object of this invention is to make it possible to greatly reduce the working time, increase the floor space of the building and to make it possible to easily use outside insulation construction.
[0015] The concrete-building construction form unit of this invention comprises form panels that consist of a faceplate that is rectangular in shape and has a specified thickness, a concrete layer that is laminated to and integrated with one of the surfaces of this faceplate, and metal supports that are anchored in the concrete layer; and where a pair of the form panels are arranged such that sides with the metal supports face each other, and both form panels are connected together by connecting the space between metal supports with metal connectors to form a space between these panels for pouring the concrete, such that each of the form panels is integrated with the concrete poured into this concrete-pouring space to form a wall of a concrete building.
[0016] In this way, it possible to construct the form by stacking the concrete-building construction form units, and the wall is constructed by pouring concretes in this form.
[0017] Also, the front and back surfaces of the formed wall is covered by the faceplates of the concrete-building construction form unit so finishing the front and back surfaces of the wall is omitted, and as a result, the work time is greatly shortened.
[0018] Moreover, the work of raising the concrete-building construction form unit can be performed on the inside of the concrete building being constructed, so there is no need to set up scaffolding on the outside, thus the space of the building lot can be used to the maximum, and the floor space of the concrete building can be increased.
[0019] Furthermore, the inner surface of the formed wall is covered by the faceplate, so there is no need to performed interior processing, and therefore the use of chemical substances such as adhesive is greatly suppressed, which prevents bad health effects on the tenants.
[0020] Also, outside insulation construction can be easily performed by installing insulating material to cover the laminated concrete layer on one of the form panels, and thus condensation inside the room is suppressed.
[0021] The metal supports protrude from the concrete layers and comprise a cylindrical connecting section in which the metal connectors fit, and an anchor section that is formed in a radiating shape at the base of the connecting section and is anchored in the concrete layer; and these metal supports and metal connectors are connected at the connecting section by fastening pins that penetrate through in the radial direction, and this makes it possible to easily assemble the concrete-building construction form unit; and also when moving the form panels from the factory to the construction site, the form panels can be moved being placed very close together, thus improving the transport efficiency.
[0022] Also, the thermal conductivity of the metal connectors is reduced by forming them into a cylindrical shape having a small cross-sectional area, and this makes it possible to suppress heat from being transferred between the inside and outside of the wall.
[0023] Moreover, the metal connectors are such that the reinforcing rods anchored in the poured concrete are placed on them, and by installing fastening pins that secure the positions of the reinforcing rods, the work of installing the reinforcing rods can be performed at the same time when assembling the concrete-building construction form unit, and this simplifies the work of installing the reinforcement.
[0024] By installing frame members on the pair of parallel edge sections of the pair of connected form panels for forming opening sections in the concrete building, it is possible to easily install window frames or doors.
[0025] Furthermore, this invention is characterized by a manufacturing device for manufacturing the concrete-building construction form unit that comprises form panels consisting of a faceplate that is rectangular in shape and has a specified thickness, a concrete layer that is laminated to and integrated with one of the surfaces of this faceplate, and metal supports that are anchored in the concrete layer; and where the faceplate is contained in the manufacturing device, and the manufacturing device comprises: a formation mold that is open at the top for pouring in the concrete to cover the faceplate, and a support plate that is fastened to the edges of the opening of the formation mold and that holds the metal supports, and where there is an opening in the center of this support plate for pouring in the concrete.
[0026] When forming the form panel with this kind of manufacturing device, it is easy to pour the concrete on top of the faceplate through the opening in the support plate, and to firmly anchor the metal supports into the concrete layer.
[0027] Also there are pressure pieces on the support plate that are located such that they run along both side surfaces on the inside of the formation mold, and are positioned parallel with and separated from the faceplate contained in the formation mold by a specified space, and these pressure pieces press the surface of the concrete poured into the formation mold to make that surface smooth.
[0028] In this way, when the concrete-building construction form unit is located at an opening such as a window or entrance of the concrete building, there is a good fit with the support frame for installing the window frame or door frame for this opening section, and thus the support frame can be firmly installed.
[0029] Moreover, the construction method for the concrete building of this invention is a method of constructing a concrete building using concrete-building construction form units comprising form panels that consist of a faceplate that is rectangular in shape and has a specified thickness, a concrete layer that is laminated to and integrated with one of the surfaces of this faceplate, and metal supports that are anchored in the concrete layer; and where a pair of the form panels are positioned such that the surfaces having the metal supports face each other, and the space between the metal supports is connected using metal connectors to connect the form panels of the concrete-building construction form unit; and where after a plurality of the concrete-building construction form units are arranged in the horizontal direction such that they surround the vertical reinforcements that are separated at specified intervals in the horizontal direction, the work of placing horizontal reinforcements on the metal connectors of these concrete-building construction form units is performed gradually in the vertical direction to create the form, and then concrete is poured into the space formed by these concrete-building construction form units, and by connecting a plurality of concrete-building construction form units together, the outer walls and partition walls are formed.
[0030] When constructing a concrete building with this kind of construction method, by putting the horizontal reinforcements into place at the same time as putting the concrete-building construction form unit into place, the work of constructing the forms and the work of installing the horizontal reinforcements are performed at the same time, and this makes it possible to shorten the work time.
[0031] Also, by placing faceplates on the inside and outside of the concrete building that is constructed, it is possible to omit finishing processes for the inside and outside sections, and from this aspect as well, it is possible to shorten the work time.
[0032] Moreover, by inserting the concrete-building construction form units from the horizontal side between the installed vertical reinforcements and rotating them horizontally such that the vertical reinforcements are surrounded between the concrete-building construction form units, the work of stacking the concrete-building construction form units can be performed from the side of the vertical reinforcements, and this simplifies the work of installing the concrete-building construction form units, and thus makes it possible to simplify the work of constructing the concrete building.
[0033] Also, by putting insulating material on the concrete layer that is positioned on the outside side of the concrete-building construction form unit, it is possible to easily construct a concrete building having outside-insulation construction.
[0034] Furthermore, the concrete building of this invention is a concrete building that uses concrete-building construction form units comprising form panels that consist of a faceplate that is rectangular in shape and has a specified thickness, a concrete layer that is laminated to and integrated with one of the surfaces of this faceplate, and metal supports that are anchored in the concrete layer; and where a pair of the form panels are positioned such that the surfaces having the metal supports face each other, and the space between the metal supports is connected using metal connectors to connect the form panels of the concrete-building construction form unit; and where a plurality of vertical reinforcements are installed on the foundation of the concrete building such that they are spaced apart at specified intervals, and after a plurality of the concrete-building construction form units are arranged in the horizontal direction such that they surround the vertical reinforcements, the work of placing the horizontal reinforcements on the metal connectors of these concrete-building construction form units is performed gradually in the vertical direction to create the form, and then concrete is poured into these concrete-building construction form units, and by connecting a plurality of concrete-building construction form units together, the outer walls and partition walls are formed.
[0035] With this concrete building, it is possible to effectively use the building site to obtain a building with a large floor space, as well as it is possible to obtain a building that little effect on health due chemical substances.
[0036] Also, the faceplates are natural stone, stucco, or terra cotta, and are appropriately selected according to the purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] [0037]FIG. 1 is a pictorial drawing showing the form unit of this invention.
[0038] [0038]FIG. 2 is a vertical cross-section view of the major parts of the form unit of this invention.
[0039] [0039]FIG. 3 is a vertical cross-section view of the manufacture device for the form panels of this invention.
[0040] [0040]FIG. 4 is a top view of the manufacture device for the form panels of this invention.
[0041] [0041]FIG. 5 is a vertical cross-section view of the manufacture device for the form panels of this invention.
[0042] [0042]FIG. 6A and FIG. 6B show the form unit of this invention, where FIG. 6A is a front view and FIG. 6B is a horizontal cross-section.
[0043] [0043]FIG. 7 shows the form unit of this invention, and is a horizontal cross-section view of the end section of the form unit that is located at an opening section of the concrete building.
[0044] [0044]FIG. 8 is a drawing showing the process of the construction method for the concrete building of this invention.
[0045] [0045]FIG. 9 is a drawing showing the process of the construction method for the concrete building of this invention.
[0046] [0046]FIG. 10A and FIG. 10B are drawings showing the process of the construction method for the concrete building of this invention.
[0047] [0047]FIG. 11 is a drawing showing the process of the construction method for the concrete building of this invention.
[0048] [0048]FIG. 12 is a pictorial drawing of part of construction of the concrete building of this invention during construction.
[0049] [0049]FIG. 13 is a vertical cross-section view of the slab formation used in the concrete building of this invention.
[0050] [0050]FIG. 14 is a simplified vertical cross-section view of an example of the concrete building of this invention.
[0051] [0051]FIG. 15 is a simplified vertical cross-section view of a concrete building using the form unit of this invention.
[0052] [0052]FIG. 16 is a simplified cross-section view of an example of a prior concrete building.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0053] In order to explain the invention in more detail, the invention will be explained with reference to the supplied drawings.
[0054] [0054]FIG. 1 is a pictorial drawing showing the exterior of the concrete-building construction form unit 10 of an embodiment of the invention.
[0055] This concrete-building construction form unit 10 (hereafter referred to as the form unit) comprises form panels 14 that consist of a rectangular-shaped faceplate 11 having a specified thickness, a concrete layer 12 that is integrally laminated to one of the surfaces of the faceplate 11 and metal supports 13 that are anchored in the concrete layers 12 ; and as shown in FIG. 2, a pair of form panels 14 are arranged such that the surfaces on which the metal supports 13 are located face each other, and both form panels 14 are connected by connecting the space between the metal supports 13 using metal connectors 15 , and this forms a concrete-pouring space S between these form panels 14 , and the form panels 14 are integrated with the concrete (C) that is poured into this concrete-pouring space S to form a wall of the concrete building (B).
[0056] More particularly, the faceplates 11 are made of marble, granite, sandstone, stucco or terra cotta, and are formed into a rectangular shapes where the vertical (short side)×horizontal (long side) dimensions are 200 mm×400 mm, and the thickness is approximately 10 mm.
[0057] Also, the concrete layers 12 that are laminated to these faceplates 11 have a contour shape that is identical to the faceplates 11 , and have a thickness of approximately 15 mm.
[0058] Moreover, it is possible to use a combination of mutually different materials for the faceplates 11 that are located on the outside of the concrete building B and for the faceplates 11 that located on the inside, and the dimensions of the form panels 14 can be changed according to the installation location with respect to the wall that is formed; for example, the length of the long side can be 200 mm and the panels 14 can be squared having vertical x horizontal dimensions that are 200 mm×200 mm.
[0059] As shown in FIG. 2, the metal supports 13 protrude from the concrete layers 12 and comprise a cylindrical connecting section 13 a in which the metal connector 15 fits, and a anchor section 13 b the is formed into a radiating shape on the base end of the connection section 13 a and is anchored inside the concrete layer 12 ; and the metal supports 13 and metal connectors 15 are connected by a connecting pin 16 that installed such that it penetrates through the fitting section in the radial direction.
[0060] Also, in this embodiment, the metal connectors 15 are formed into a cylindrical shape, and as shown in FIG. 2, are such that the reinforcing bars 17 (hereafter referred to as horizontal reinforcement) that are embedded in the poured concrete C are placed on them, and there are fastening pins 18 for positioning the horizontal reinforcements 17 .
[0061] Furthermore, insulating material 19 is located on the inside surface of one of the form panels 14 such that it covers the laminated concrete layer 12 .
[0062] This insulating material 19 is made of an non-woven cloth made of inorganic fiber such as glass wool, and is formed having a thickness of about 20 mm and an external contour shape that nearly matches that of the concrete layer 12 and face plate 11 .
[0063] On the other hand, the width of the space (concrete-pouring space S) that is formed inside the pair of form panels 14 that are connected by the metal connectors 15 between the insulating layer 19 and the concrete layer 12 is set to be approximately 180 mm.
[0064] Also, in the case of a form unit 10 having a longwise dimension that is set at 400 mm, there are four sets of metal supports 13 and metal connectors 15 , which are located symmetrically around the center point of the faceplates 11 , and they are spaced apart by approximately 170 mm along the long side and approximately 100 mm along the short side.
[0065] Moreover, in the case of a form unit 10 having a square shape, there are two sets of metal supports 13 and metal connectors, which are located symmetrically around the faceplates 11 on one side, and they are spaced apart by approximately 100 mm.
[0066] On the other hand, the form panels 14 are manufactured by a manufacturing device 20 such as shown in FIG. 3 or FIG. 5.
[0067] In other words, this manufacturing device 20 comprises: a formation mold 21 in which the faceplate 11 is stored and which is open at the top where the concrete is poured in to cover this faceplate 11 ; and a support plate 22 that is held by the pair of parallel edges of the opening of the formation mold 21 and supports the metal connectors 13 ; and where there is a pouring inlet 23 formed in the center section of this support plate 22 through which the concrete is poured.
[0068] At the positions on the support plate 22 where the metal supports 13 are mounted, fastening rods 24 protrude in the direction toward the bottom surface of the formation mold 21 , and these fastening rods 24 fit with the connecting sections 13 a of the metal supports 13 , and the metals supports 13 are fastened to the fastening rods 24 so that they can be removed, by fastening pins 25 (see FIG. 5) that penetrate in the radial direction through these fitting sections.
[0069] Also, when the metal supports 13 are fastened to the support plate 22 , they are supported such that the anchor sections 13 b are suspended above the bottom surface of the formation mold 21 by a specified distance (for example 10 mm, or equal to the thickness that the faceplates 11 are inserted in the formation mold 21 ).
[0070] Moreover, pressure pieces 26 are formed on the support plate 22 along both side surfaces inside the formation mold 21 (side surfaces other than the sides that fasten to the support plate 22 ), and located such that they are parallel and separated from the faceplate 11 contained inside the formation mold 21 by a specified distance (a distance that is a little less than the thickness of the poured concrete); and these pressure pieces 26 press the surface of the concrete that is poured into the formation mold in order to make that surface smooth.
[0071] Next, the procedure for using this kind of manufacturing device 20 to manufacture the form panels 14 will be explained.
[0072] First, the formation mold 21 is set so that the opening section is at the top, and the faceplate 11 is inserted inside it; also the metal supports 13 are fastened to the fastening rods 24 that are located on the support plate 22 with the fastening pins 25 .
[0073] Next, the support plate 22 is mounted to the formation mold 21 such that it covers the opening.
[0074] With this operation, the pressure pieces 26 of the support plate 22 are located at both side sections of the formation mold 21 such that they are above the bottom surface of the formation mold 21 by a specified distance, and the metal supports 13 are supported such that the anchor sections 13 b are above and separated from the bottom surface of the formation mold 21 by a specified distance, or are held such they come in contact with the rear surface of the faceplate 11 that is inserted into the formation mold 21 .
[0075] From here, the concrete is poured through the pouring inlet 23 in the support plate 22 , such that its front surface is located such that it comes in contact with the pressure pieces 26 that are located inside the formation mold 21 .
[0076] By doing this, the concrete layer 12 is formed on the rear surface side of the faceplate 11 , and the ends of the anchor sections 13 b of the metal supports 13 are embedded in the concrete layer 12 , and the connecting sections 13 a protrude out at a specified length; also both side sections of the concrete layer 12 are pressed by both pressure pieces 26 such that form panel 14 having a smooth surface 12 a is formed as shown in FIGS. 6A and 6B.
[0077] On the other hand, the form unit 10 shown in FIG. 1 is formed by connecting together the form panels 14 that are formed as described above by connecting the metal supports 13 using the metal connectors 15 , and as shown in FIG. 7, a frame member 27 is mounted on the ends of form units 10 , where an opening section (a window, door etc.) of the concrete building is to be located, in order to form the opening section.
[0078] The frame member 27 is formed out sheet metal into a cylindrical shape, and by using the smooth surfaces 12 a that are formed on the inside ends of the form panels 14 , it is located such that it has surface contact with the form panels 14 ; also it is secured by connecting the metal supports 13 , which are located such that they protrude toward the inside of the form units 10 , to the metal connectors 15 using the connecting rods 28 .
[0079] Next, the work of constructing a concrete building (B) using form units 10 , which are formed in this way, will be explained.
[0080] First, as shown in FIG. 8, a plurality of vertical reinforcements 29 are set up and spaced apart at specified intervals (this interval is normally set at 200 mm) on the foundation Z of the concrete building (B).
[0081] This foundation Z is formed by pouring concrete into the concrete-pouring spaces that are formed inside a plurality of form units that are arranged in the horizontal direction and that have the same shape as the form unit 10 and whose width of the concrete-pouring space is nearly the same as the entire width of the form units 10 used for forming the walls.
[0082] Next, a form unit 10 is placed with the insulating material 19 on the outside, and as shown in FIG. 9, is placed such that it is vertical; and by inserting the form unit 10 between the vertical reinforcements 29 and rotating the form unit 10 90-degrees, the vertical reinforcements 29 are surrounded by the form panels 14 , then the form unit 10 is placed on top of the foundation Z.
[0083] This work is performed gradually in the horizontal direction, and as shown in FIGS. 10A and 10B, the first layer of form units 10 are put in place.
[0084] Next, as shown in FIG. 11, on the inside of the form units 10 that have been put in place in the horizontal direction, horizontal reinforcements 17 are placed on the metal connectors 15 that connect the form panels 14 , and by fastening the fastening pins 18 in the metal connectors 15 as shown in FIG. 2, the horizontal reinforcements 17 are temporarily secured between the fastening pins 18 and the vertical reinforcements 29 .
[0085] By performing the work described above gradually moving upward, the form units 10 are stacked upward to a specified height and width, and the horizontal reinforcements 17 are put in place.
[0086] Next, by pouring the concrete C into the concrete-pouring space S that is formed on the inside of the form units 10 that have been stacked up as described above and hardened, the outer wall and partitions are constructed as shown in FIG. 12.
[0087] Here, after performing the work of stacking the form units 10 along the outer wall and partitions according to the floor plan of the lower floor, a truss-shaped slab member 31 is placed on these form units 10 as shown in FIG. 13, and the internal space of the slab member 31 and the concrete-pouring space S of the form units 10 are connected together, and by the concrete C continuously flowing from the inside of the slab member 31 to the concrete-pouring space S of the form units 10 , it is possible to construct the walls and ceiling at the same time.
[0088] Furthermore, a frame member 27 is fitted on the end section of the form unit 10 that is located at the opening section of the concrete building B, and this frame member 27 is temporarily secured by the connecting rod 28 , and by the concrete C, which is poured inside the concrete-pouring space S of the formed unit 10 and the inside of the slab member 31 , continuously flowing to the inside of the frame member 27 , all of these members are integrated as one.
[0089] The concrete building (B) is constructed in this way, and by performing the work of stacking the form units 10 on one side of the wall or the like being constructed, it is possible to perform this work from inside the building site.
[0090] Also, by covering the inner and outer surface of the wall being constructed with faceplates 11 that are located on the inside and outside of the form panels 14 , the exterior work and interior work of the wall is completed at the same time as construction of the wall.
[0091] Therefore, as shown in FIG. 14, when constructing the concrete building B, there is no need to set up scaffolding around the building side, and even when there are other buildings or structures near the building site, the construction location of the wall can be set almost right up to the outside of the building site.
[0092] This makes it possible to increase the floor space of the concrete building B being constructed.
[0093] Moreover, in the case of a wall that is constructed as described above, when pressure is applied to the poured concrete C in the vertical direction as shown in FIG. 15, that pressure is supported by both form panels 14 by way of the metal connectors 15 and metal supports 13 , and as a result, the strength of the wall itself is increased, which improves the resistance to earthquake.
[0094] On the other hand, as described above, faceplates 11 are integrated with the inner and outer surfaces of the constructed wall, so there is no need of interior or exterior processing, and particularly, there is no need for applying cloth for the interior as was necessary in prior construction, and this greatly reduces the amount of chemical substance used.
[0095] As a result, damage to health due to chemical substances, such as in the case of allergies to chemical substances, is suppressed.
[0096] Also, insulating material 19 is placed on the inside of the concrete layer 12 that is on the outer surface side of the form unit 10 , so outside-insulation construction is used for the concrete building B being constructed, and the concrete C that is poured inside the form unit 10 plays the role of a heat-accumulating layer, and this makes it possible to efficiently perform air conditioning inside.
[0097] Moreover, by using outside-insulation construction as described above, condensation on the inner wall surface is prevented, and this prevents the occurrence of mold inside, and from this aspect, a sanitary condition on the inside is maintained.
[0098] Also, by using natural stone such as marble or granite or an inorganic material for the faceplates 11 that are integrated with the concrete layers 12 , the waterproof characteristics of that material can be utilized, making possible to easily form a bathroom, bathtub, Jacuzzi, or kitchen sink.
[0099] On the other hand, by integrating frame members 27 with the opening sections of the concrete building B, it is possible to easily install window frames and doors; and by forming smooth surfaces 12 a on both sides of the concrete layer 12 , the frame members 27 can be smoothly connected with the form units 10 , and as a result, the window frame or door can be firmly secured.
INDUSTRIAL APPLICABILITY
[0100] As described above, with this invention, when constructing walls and partitions of a concrete building, all of the work can be performed from the inside of the building, and there is no need to set up scaffolding on the outside of the building being constructed, so even when there are other buildings or the like around the building site, it is possible to construct a building using all of the building site.
[0101] Also, it is possible to complete the interior processing and exterior processing at the same time as the wall is constructed, so it is possible to greatly shorten the work time; and since there is no need to apply cloth, which uses chemical substances, a concrete building that is human friendly can be obtained.
[0102] Moreover, it is possible to easily use outside-insulation construction for the concrete building, and thus it is possible to prevent condensation on the inside, and from this aspect as well, a concrete building that is human friendly can be obtained.
[0103] [0103]FIG. 15
[0104] Pressure
[0105] Typhoon
[0106] Earthquake
[0107] Ground pressure
[0108] Soil pressure
[0109] Water pressure
[0110] Tensile strength
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A pair of form panels each consisting of a faceplate, a concrete layer integrally laminated to one surface of the faceplate, and a metal supports erected in the concrete layer are disposed so that the surfaces on the side where the metal supports are installed are opposed to each other, and the metal supports are connected by using metal connectors, thereby connecting both form panels and defining a concrete-pouring space there between, the form panels being integrated by concrete poured in this concrete-pouring space so as to form a wall for the concrete building; thus a concrete building can be obtained which requires a short construction period, has a wide floor area and is friendly to the human body.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a leader angle control device for a civil foundation engineering works machine, for example, a pile driver, an earth auger, and so forth.
2. Description of the Prior Art
FIGS. 1 and 2 show a pile driver, wherein an upper body 2 of the pile driver 1 is rotatably mounted on a tractor (typically caterpillar type) 3, and a leader 5 is mounted on a bracket 4 rigidly held to the front part of the turning assembly 2, the leader 5 being supported by two backstays 6 and 7 having backstay cylinders 6a and 7a respectively. The tops of the backstays 6 and 7 are pivotally attached to the upper positions 5a and 5b of the leader 5 respectively, and the bottoms of the backstays 6 and 7 are pivotally held to points S and T in the rear side parts of the upper body. The bottom part of the leader 5 is pivotally mounted on the front end 4a of the bracket 4. The two back-stay cylinders 6a and 7a are designed to keep the leader 5 in the vertical position by the extend/retract control. For bringing the leader 5 in the vertical position, a person measures the inclination angle of the leader 5 from the front, rear, left or right of the leader 5 at a certain distance from the pile driver 1 using a transit or other suitable means, the measuring person then notifies the operator of the direction in which the leader 5 is to be moved for the correction of inclination by signalling, and in response to the signal the operator operates a backstay cylinder control lever by hand, thus controlling the left and right backstay cylinders 6a and 7a.
The prior art method described above has such drawbacks as that it requires a person to measure the inclination angle in addition to the pile driver operator, and the vertical setting of the leader is a difficult and time-consuming work. Another type of the leader angle control device is known in the art. This device uses nine divided areas in vertical view. Due to the area which upper portion of the leader belongs to, operation of both stay cylinders, that is, extension, retraction and stop are uniquely determined. The area to which the leader belongs is logically judged by a logical circuit to which output signals from the inclinometers are applied.
The device, however, the course which the upper portion of the leader follows to return to the vertical position is of L form. Therefore the distance of the course is long and thus time required to return to the vertical position is long. The device has the disadvantage that it is difficult to eliminate the dangerous state of the leader.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a leader angle control device capable of speedy and safe leader vertical alignment.
Another object of the present invention is to provide a leader angle control unit designed to indicate the working length of the backstay cylinder to be controlled at all times.
Still another object of the present invention is to provide a leader angle control device capable of maintaining the stability of the foundation civil engineering works machines by keeping the acceleration to be applied to the leader at the control start-up small through the temporary reduction of the control system deviation at the automatic control start-up and the gaining of the true value by the gradual increase with time.
Still another object of the present invention is to provide a highly safe leader angle control device which allows the operator to know the inclination of the leader easily on the indicator and can help to enhance the work efficiency.
According to a preferred embodiment of the present invention, the leader angle control device comprises two inclinometers for measuring the leader inclinations in two different directions, an arithmetic unit for calculating the working length of each backstay cylinder to be corrected based on the detected inclination angle, and a means to control the flow of the backstay cylinder driving oil.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention will be made with reference to the accompanying drawings, wherein same numerals designate corresponding parts in the several figures.
FIG. 1 is a side view of the pile driver.
FIG. 2 is a front view of the pile driver.
FIG. 3 is a plan view of the pile driver showing the relationship between a leader, backstays and inclinometers according to the present invention.
FIG. 4 and FIG. 5 are views for explaining a principle of the leader angle control device according to the present invention.
FIG. 6 is a block diagram showing an embodiment of the leader angle control device according to the present invention.
FIGS. 7 and 8 are timing charts for explaining a operation of the embodiment shown in FIG. 6.
FIG. 9 is a block diagram showing an another embodiment of the leader angle control device according to the present invention.
FIGS. 10, 11(a and b) and 12(a and b) are timing charts for explaining an operation of the embodiment shown in FIG. 9.
FIG. 13 is a circuit diagram showing a modification of the MAN-OUTO switching circuit shown in FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is of the best presently contemplated mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention since the scope of the invention is best defined by the appended claims.
In FIG. 3, in the specified positions at the bottom of the leader 5, inclinometers 9 and 10 for detecting the inclination angles of the leader 5 in two directions are disposed, and these two inclinometers 9 and 10 detect leader inclination angles about line l1 and l2 extending from a fulcrum O of the leader inclining to the points S and T of the backstays 6 and 7 being held respectively.
Referring to FIG. 3, when the cylinder 6a is extended or retracted, the leader 5 turns about the line l2 (turning fulcrum is point O), while when the cylinder 7a is extended or retracted the leader 5 thus about the line l1.
Now, if the leader 5 inclines, and the leader center O, which is in the middle of positions 5a and 5b where the backstays are mounted shifts to a point P shown in FIG. 4 departing from the vertical line of the mounting point O of the leader 5, when the cylinder 7a is caused to retract, the leader 5 would turn about the line l1 and as the center O' comes to a point Q, the cylinder 7a would be stopped. Then, cylinder 6a is caused to retract, the leader 5 would turn about the line l2 and as the center O' comes to the vertical line of the mounting point O, the cylinder 6a is stopped. In this manner, the leader 5 can be made vertical. In this case, by controlling both cylinders 7a and 7a concurrently, the center O', can be shifted onto the vertical line of the mounting point O from the point P directly. The displacements corresponding to segment PQ and QO can be obtained by calculation from the outputs of the inclinometers 9 and 10 (shown in FIG. 3). Accordingly, by supplying the oil in the amount corresponding to the displacements PQ and QO to the backstay cylinders 7a and 6a respectively, the center O' can be shifted from the position of point P to a position on the vertical line of the mounting point O directly, thus enabling the leader 5 to become vertical. In addition, by controlling the backstay cylinders 6a and 7a concurrently, the time required for making the leader 5 can be shortened.
Referring now to FIG. 5, L 1 (=SO') and L 2 (=TO') are the lengths of the backstays 6 and 7, and (Xs, Ys, Zs) and (Xt, Yt, Zt) are the coordinates of the points S and T. Further, when L(=OO') is assumed to be the distance between O and O' of the leader 5, the point O' becomes the intersection of three sphericals having the centers O, S, and T and the radii L, L 1 , and L 2 respectively, and the following equations are established.
X.sup.2 +Y.sup.2 +Z.sup.2 =L.sup.2 (1)
(X-Xs).sup.2 +(Y-Ys).sup.2 +(Z-Zs).sup.2 =L.sub.1.sup.2 (2)
(X-Xt).sup.2 +(Y-Yt).sup.2 +(Z-Zt).sup.2 =L.sub.2.sup.2 (3)
where X, Y, Z, L 1 , and L 2 are variables, and Xs, Ys, Zs, Xt, Yt, Zt and L are constants.
When Zs=Zt=0, Xs=Xt, and Ys=-Yt, the above Eqs. (1) to (3) may be written as
X.sup.2 +Y.sup.2 +Z.sup.2 =L.sup.2 (4)
(X-Xs).sup.2 +(Y-Ys).sup.2 +Z.sup.2 =L.sub.1.sup.2 (5)
(X-Xs).sup.2 +(Y-Ys).sup.2 +Z.sup.2 =L.sub.2.sup.2 (6)
When the leader angle δ is small, the value of Z may be taken as substantially equal to the distance L. from the above Eqs. (4) to (6), X, Y, and Z can be expressed as follows: ##EQU1##
In FIG. 5, direction of the inclinometer 9 (shown in FIG. 3) is represented by the unit vector . The end point coordinates of the unit vector is (Xe, Ye, Ze), and the coordinates of the point which the inclinometer 9 is disposed is (nX, nY, nZ), where 0<n<1.
Since vector is orthogonal to vector ¢ and $ respectively (where vector ¢ is 00, and vector $ is OS) the following equations are established:
X(Xe-nX)+Y(Ye-nY)+Z(Ze-nZ)=0 (10)
Xs(Xe-nX)+Ys(Ye-nY)+Zs(Ze-nZ)=0 (11)
On the other hand, the detected angle A by the inclinometer 9 is given by the following equation: ##EQU2##
Eq. (12) can be rewritten using Eqs. (10) and (11) as follows:
From (10)x Ys-(5) x Y ##EQU3##
From (10) x Xs-(11) x X ##EQU4##
Then, Eqs, (13) and (14) are squared, and addition thereof is made as follows: ##EQU5##
By substituting Eq. (15) into Eq. (12), the A can be expressed as follows: ##EQU6##
Then substituting Eqs. (7), (8), and (9) into Eq. (16), and assuming that Zs=0, ##EQU7##
Now, when the lengths of the backstays 6 and 7 are L 10 and L 20 when the leader 5 is vertical and working lengths of backstay cylinders 6a and 7a for setting the leader 5 vertical are ΔL 1 and ΔL 2 , the length of the backstays L 1 , L 2 are generally expressed as
L.sub.1 =L.sub.10 +ΔL.sub.1 (18)
L.sub.2 =L.sub.20 +ΔL.sub.2
and when the upper body 2 (shown in FIGS. 1 and 2) is horizontal or can be approximated as horizontal, following equation is established between the values L 10 and L 20 :
L.sub.10 =L.sub.20 (20)
Accordingly,
L.sub.1.sup.2 ≈L.sub.10.sup.2 +2L.sub.10 ΔL.sub.1 (21)
L.sub.2.sup.2 ≈L.sub.20.sup.2 +2L.sub.20 ΔL.sub.2 (22)
Further, when the leader 5 is vertical, the following equation is established.
Xs.sup.2 +Ys.sup.2 +L.sup.2 =L.sub.10.sup.2 (23)
Accordingly, the following equations is obtained rearranging by substituting Eqs. (21), (22), and (23) into Eq. (17). ##EQU8##
In the same manner, the detected angle β by the inclinometer 10 can be given by the following equation. ##EQU9##
From Eqs. (24) and (25) ΔL 1 and ΔL 2 are given by the following equation. ##EQU10##
In Eq. (26), each element of the first matrix of the right side is constant, and ΔL 1 and ΔL 2 can be determined from the detected angles A and B of the leader inclinometers 9 and 10. Though Eq. (26) is established when the upper body 2 is horizontal, it was found as a result of tests performed by the use of the actual machine that even when the upper body 2 (vehicle body) is more or less inclined, the working lengths ΔL 1 and ΔL 2 of the backstay cylinders can be approximated by Eq. (26) without any effect on the control system of the invention.
FIG. 6 is a block diagram of the leader angle control device of the present invention. The outputs of the inclinometers 9 and 10 are fed to arithmetic circuits 21 and 22 respectively. The arithmetic circuits 21 and 22 perform arithmetic operation according to Eq. (26) based on the output of the inclinometers 9 and 10. calculate values ΔL 1 and ΔL 2 , and output signals ea and eb corresponding thereto. The signals ea and eb are amplified at amplifiers 23 and 24 respectively, and then fed to absolute value circuits 25 and 26, and comparators 27 and 28 respectively. The absolute value circuits 25 and 26 output absolute value signals |ea| and |eb| of the input signals ea and eb, and apply these signals to comparators 31 and 32, respectively. A dead zone setter 29 is for setting a dead zone corresponding to the tolerance of perpendicularity, and outputs a specified dead zone signal ±Δe. On the other hand, a triangular wave generator 30 is for outputting a reference triangular wave signal ET (FIG. 7(a)) of the specified cycle T and output peak level H. The comparator 27, typically a window comparator compares signals eb and ±Δe, when eb<Δe, outputs signal "1", and makes an AND circuit 35 enable, and when eb<-Δe, the comparator 27 makes an AND circuit 36 enable. The comparator 31 compares signals |ea| and ET, and outputs a pulse signal Pa of the pulse width corresponding to the difference between the working length of the cylinder when the leader is vertical and the working length of said cylinder when the leader is presently tilted (FIG. 7(b)) when |ea|>ET, applying it to the AND circuits 33 and 34. The comparator 32 compares signals |eb| and ET, and when |eb|>ET, outputs a pulse signal Pb (FIG. 8(b)) of the pulse width corresponding to the difference, applying the signal to the AND circuits 35 and 36. Driving circuits 38, 37, 39, and 40 are for delivering signals to control the extension and retraction of the back-stay cylinders 6a and 7a. When a pulse signal Pa is fed from the AND circuits 33 and 34, the driving circuits 37 and 38 output a retract/extend signal Sa or Sb of the corresponding back stay cylinder 6a, while the driving circuits 39 and 40 output an extend/retract signal Sc or Sd of the corresponding backstay cylinder 7a when a pulse signal Pb is fed from the AND circuit 35. These signals Sa, Sh, Sc and Sd are applied to each electromagnetic coil C1a, C1b and C2a, C2b of solenoid valves 105 and 106 in the hydraulic circuits of the backstay cylinders 6a and 7a. The oil flow is controlled by controlling the spools of the solenoid valves 105 and 106. Double check valves 107 and 108 open only when the pressure on the solenoid valve side is high, and close when the pressure is low, thus preventing the leader 5 from inclining due to oil leak.
A switch 102 mounted on the control device is a meter indication mode selector. When the switch 102 is positioned to the backstay cylinder mode, the valves ΔL1, and ΔL2 of the cylinder length calculated according to Eq. (26) are indicated on meters 100 and 101 respectively. When the switch 102 is positioned to the inclination angle mode, the inclination angles A and B of the leader are directly indicated. A leader length setting switch 103 is for setting the gains of the amplifiers 23 and 24. A switch 104 is a MAN/AUTO change-over switch.
Now, let's assume that the leader 5 is inclined, and that the center O' is at the point P as shown in FIG. 4. From the arithmetic circuits 21 and 22, signals ea and eb corresponding to the valves ΔL1 and ΔL2 are output respectively. When the relationship between the signal ea and the dead zone setting signal ±Δe and that between the signal eb and the signal ±Δe are ea>Δe and eb>Δe, the AND circuits 33 and 36 become enable. Accordingly pulse signals Pa (FIG. 7(b)) and Pb (FIG. 8(b)) outputted from the comparators 31 and 32 are fed to the driving circuits 37 and 40 through the AND circuits 33 and 36 respectively. The driving circuits 37 and 40 output control signals Sa and Sd corresponding to the input signals Pa and Pb. The backstay cylinders 6a and 7a are retraction-controlled by the quantity of oil corresponding to the pulse widths of the control signals Sa and Sd, and the shift control of the center O' of the leader 5 (FIG. 4) is performed so that said center O' shifts from the position of point P to the vertical line of the point O. When the inclination angle of the leader 5 comes within the dead zone set value ±Δe, the AND circuits 33 and 36 become disable, and the control signals Sa and Sb cease to be output. Accordingly, the backstay cylinders 6a and 7a stop, and the leader 5 is firmly held in that position. Thus the leader 5 is set vertically by driving the two backstay cylinders 6a and 7a concurrently and directly displacing the center O' of the leader 5 from the position of point P to the vertical line of the point O, thereby setting the leader 5 vertical.
Although the preferred embodiment the inclinometers 9 and 10 are disposed so as to intersect orthogonally to the lines l1 and l2 respectively, it is also feasible that those are disposed so as to be in parallel with the X axis and Y axis of FIG. 3 and the values when disposed so as to intersect orthogonally to the lines l1 and l2 are obtained from individual outputs.
In this case, the following relationship exists: ##EQU11## where θX is the output of inclinometer detecting the inclination in parallel with the X axis, θY is the output of inclinometer detecting the inclination in parallel with the Y axis, and ρ is an angle formed between the lines l1 and l2 in FIG. 4. By substituting the above equation (27) into Eq. (26), the relationship between the inclination angle and cylinder length in the case of the inclinometers disposed so as to be in parallel with the axes X Y can be obtained as follows: ##EQU12##
FIG. 9 shows another embodiment of the leader angle control device of the present invention, which is designed so that when the leader is operated manually to a certain extent and then shifted to the automatic range, acceleration to be applied to the leader at the automatic control start-up is kept small by reducing the output of said comparators 31 and 32 temporarily and then gradually increasing the acceleration.
For the above purpose, start control circuits 50 and 60 are provided between the absolute value circuit 25 and the comparator 31 and between the absolute value circuit 26 and the comparator 60 respectively.
The output signal |Va| of absolute value circuit 25 is fed to an arithmetic circuit 55 through a switch 51 and the contact a of an analog switch 52 in the start control circuit 50. The switches 51 and 52 are closed during the automatic control mode of operation. The arithmetic circuit 55 is comprised of a primary or a secondary delay element, typically an integrating circuit, integrates the input signal |Va|, and outputs the signal thus integrated as a signal Vx (FIG. 10), This signal Vx can be expressed by the following equation. ##EQU13## where K 1 is an integration constant. This signal Vx is fed to the one input of a comparator 56 and the contact a of an analog switch 53. The signal |Va| is fed to the other input of the comparator 56 and the contact b of the analog switch 53. The comparator 56 compares the input signal Vx with the signal |Va|, outputs a signal when Vx<|Va| to transfer the analog switches 52 and 53 to the contact a, and when Vx>|Va|, outputs a signal to transfer the switches 52 and 53 to the contact b. Accordingly, when Vx<|Va|, Vx is fed from the analog switch 53 to the comparator 31, and when Vx>|Va|, |Va| is applied from the analog switch 53 to the comparator 31.
The start control circuit 60 is configured similar to the start control circuit 50. An arithmetic circuit 65 integrates the signal |Vb| fed through a switch 61 and and analog switch 62, and outputs the signal thus integrated as a signal Vy. The signal Vy can be expressed as follows: ##EQU14## where K 2 is an integration constant.
A comparator 66 compares the input signal Vy with |Vb|, transfers the analog switches 62 and 63 to the contact a when Vy<|Vb|, and transfers to the contact b when Vy>|Vb|. The signal Vy or |Vb| outputted from the analog switch 63 is fed to a comparator 32. The Switches 51 and 61 becomes ON when an automatic start command signal SA is fed in the automatic control mode. The automatic start command signal SA is output when the operator turns on automatic start switch 104 (FIG. 6).
A comparator 31 compares the signal Vx or |Va| with VT, initially outputs signals of the pulse width corresponding to Vx, and when Vx becomes larger than |Va|, outputs pulse signals Pa1 to Pa6 (FIG. 11b) of the pulse width corresponding to VA, applying those signals to AND circuits 33 and 34. A comparator 32 compares the signal Vy or |Vb| with VT, and outputs similar pulse signals Pb1 to Pb6 (FIG. 12b), applying those signals to AND circuits 35 and 36. The output signals of the AND circuits 33 to 36 are fed to driving circuits 37 to 40 through swtiches 71 to 74 of an MAN-AUTO switching circuit 70 respectively. Each switch 71-74 of the switching circuit 70 becomes ON when the automatic start command signal SA is applied to the switches 51 and 61.
The hydraulic circuits of the back-stay cylinders 6a and 7a are designed so that the manual operation has priority over the automatic control, and the leader 5 can be controlled manually even in the automatic control mode of operation.
As described above, through the control using the signals Vx and Vy in lieu of signals |Va| and |Vb| at the automatic control start-up, acceleration to be applied to the leader 5 can be reduced to a small value, enabling to maintain the stability of the vehicle.
FIG. 13 shows a modification of the MAN-AUTO switching circuit 70 shown in FIG. 9. AND circuits 80 to 83 are used in lieu of the AND circuits 33 to 36, and are designed to become ready condition when an automatic start command signal SA is fed. The circuit configuration can be simplified by such arrangement.
Though in the embodiment shown in FIG. 9 arrangement has been made to provide the switches 51 and 61 in the start control circuits 50 and 60 respectively and to cause the switches 51 and 61 to become ON at the automatic start-up, other alterations and modifications may be made, for example, it is feasible to provide a switch circuit in the input side of arithmetic circuits 21, 22, or to cause the power switch of the control device to be turned on.
Further, though in each embodiment, description has been made regarding the proportional control system, the leader angle control device of the present invention can be applied to other control systems. For example, in the case of the ON-OFF control system, all that is required is to make the system a three level control system providing an additional level between ON and OFF.
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A leader angle control device comprises two inclinometers for measuring inclination of a leader in two directions, an arithmetic unit for calculating the length of two backstays which support the leader based on the detected inclination of the leader and a control unit for controlling backstay cylinder driving oil.
In one embodiment of the leader angle control device, the leader angle is controlled manually to a certain extent before automatic control takes place, whereby the acceleration applied to the leader at the time of shift to automatic control is kept small and then gradually increases, thus enabling smooth control of the inclination of the leader.
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[0001] This application is a continuation of U.S. patent application Ser. No. 12/802,717 filed Jun. 14, 2010, which was a continuation in part of PCT/US 2009/038711 filed Mar. 29, 2009.
BACKGROUND
[0002] Machines originally designed as front end loaders with tracks or wheels, whether having skid-steering wheels or turnable wheels, such as Bobcat brand machines, have been adapted to become general purpose tool carriers that can receive a variety of controllable tool attachments to be attached to the front or back of the machine and controlled by an operator sitting in the operator's seat. This tool attachment carrying system can be improved upon. So that the swivel can rotate without limitation, electrical control signals may pass via wireless radio signal to the tool. The tool may be hydraulically adjusted in response to a sensor that senses the earth, such as location of a string datum line or a curb or gutter or GPS coordinates. The adjustment may move the tool vertically without pivoting to stay plumb or it may pivot the tool about a pivot point.
[0003] In the commonly available prior art, a central controller communicates with remote controllable actuators by switchable wired electronic communications or by multiple hydraulic lines coming from a controlled multiport hydraulic valve. These solutions require either expensive additional hydraulic lines which are subject to failure, or an electric wire running from the controller to the controllable electronics near the remote actuators, which wire is likely to be damaged during rough use of the heavy equipment on which it is mounted. The wire is susceptible to weather. The wire can get caught on branches and other obstacles. The wire can melt when touching the exhaust stack.
[0004] Where the controller receives position information from a terrestrial position sensor, there are two sets of wires subject to damage: those from the sensor to the controller and those from the controller to the actuators. This problem is particularly severe where the cab swivels and the actuators are mounted below the swivel, as the wires then need to pass through contact rings on the swivel to allow the cab to swivel without limitation.
SUMMARY OF THE INVENTION
[0005] The invented solution is to replace both of these sets of wires with two (or three) wireless radio transceivers that carry both the terrestrial sensor information to the controller and the control information to the actuators. The remote transceiver(s) get their power from a battery, which may be charged by a generator powered from hydraulic fluid flowing to an actuator.
[0006] The machine may be an excavator, particularly a mini-excavator. So that the swivel can fully swivel any number of rotations without limitation, the system may include an electrical circuit coupling the controls with the moving parts of the mounting support for the tool. The control signals may be communicated with a wireless link that carries radio communications from the controls to the mounting support or the tool. In this case, electrical power to operate a wireless communication component coupled to the mounting support or tool may be provided by a hydraulic generator which receives power from flow of hydraulic fluid passing through the swivel from a hydraulic pump on the engine mounted above the swivel.
[0007] The swiveling tool may be an earth moving bucket or a claw or a rake or vibratory compactor or any similar implement. The first and second linear acting tools may be any of: a curb and gutter grading blade; a curb and gutter extruder; a sidewalk and shoulder grading blade; an asphalt paver; a concrete paver; a fence installer; a trencher; a concrete/asphalt saw; a side roller/compactor; a vibratory roller; a snow plow; and other similar tools.
[0008] The tool carrying and controlling machine may further include a hydraulic actuator coupled to the mounting support and configured for adjusting the support or an attached linear acting tool in response to a control, which may be an operator control or an automated control that responds to location relative to a string datum line or that responds to a slope sensor or that responds to position with respect to global positioning system satellites.
[0009] A curb and gutter extruder may further comprise a hydraulic actuator coupled to a hydraulic valve that is automatically controlled by a controller that adjusts height of the extruder relative to one of: location with respect to a datum line string, tilt with respect to gravity, or location with respect to global positioning system satellites.
[0010] A sidewalk grading machine may further comprise a sonar position detector that detects position of a datum line relative to the detector which detected information is used to adjust the vertical adjusting component. The datum line may be a string or a concrete curb or gutter or a laser line or plane, a road surface, or an established grade.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 shows a prior art sidewalk grader.
[0012] FIG. 2 shows a mounting base and tool's mating attachment surface.
[0013] FIG. 3 shows a quick coupling component for coupling hydraulic lines to a detachable tool.
[0014] FIGS. 4A and 4B show wireless components for controlling a detachable tool from the cab.
[0015] FIG. 5 shows a curb and gutter extruder.
[0016] FIG. 6 shows an extruder for a second curb.
[0017] FIG. 7 shows a laterally extendable edge blade.
[0018] FIGS. 8A , 8 B, 8 C, 9 A, 9 B, and 9 C show a multi-coupling plate and retainers of the tool mount.
[0019] Originally filed informal FIG. 4A in the parent application included the following text which is omitted from formal FIG. 4A :
[0020] Beside the handgrip control:
[0021] SureGrip Inputs
[0022] 1. Extension Out
[0023] 2. Extension In
[0024] 3. Wheel Up
[0025] 4. Wheel Down
[0026] 5. Komatsu Blade Up
[0027] 6. Komatsu Blade Down
[0028] Beside the Topcon user interface display box:
[0029] 2 way communication
The Topcon receives a signal from the slope sensor (The communication is a proprietary protocol on an RS-485 port). It in turn drives the Danfoss proportional valve on the SGS tool.
20% of system voltage shifts the spool to maximum one way 50% of system voltage is neutral 80% of system voltage shifts the spool to maximum the other way
[0034] Originally filed informal FIG. 4B included the following text which is omitted from formal FIG. 4B :
[0035] Beside the Danfoss multiport proportional valve:
[0036] Outputs
[0037] 1. Extension Out
[0038] 2. Extension In
[0039] 3. Wheel Up
[0040] 4. Wheel Down
[0041] 5. Komatsu Blade Up
[0042] 6. Komatsu Blade Down
[0043] 7. Slope Proportional
[0044] On the valve port blocks, left to right:
[0045] Extension, Wheels, Slope Proportional, Komatsu Blade, Inlet
[0046] Beside the slope sensor with a control knob:
[0047] Slope Sensor (4 Wires)
[0048] 12 Volt Power
[0049] Ground
[0050] 2 communication
[0051] The communication is a proprietary protocol on an RS-485 port
[0052] On the wires to the slope sensor:
[0053] 2 way communication
DETAILED DESCRIPTION
The Prior Art
[0054] Referring to FIG. 1 of the drawings which shows the prior art sidewalk grading machine, numeral 20 generally designates the sidewalk grading blade and support structure, called the sidewalk grader 20 . The sidewalk grader 20 is used to grade sidewalk base material 22 , which sometimes includes crushed rock 24 , to a predetermined specified grade and elevation to form the base 26 of a designed sidewalk (not illustrated). Typically, the sidewalk grader 20 accommodates grading activity for sidewalks that extend adjacent to and along an existing road structure 30 of the type that incorporates a curb 32 as a border.
[0055] More specifically, the sidewalk grader 20 comprises a tracking assembly 34 adapted for fixable engagement with a vertically movable accessory 36 extending from below the swivel in a piece of construction excavation equipment 38 . Commonly, a vertically adjustable backfill blade extending from a common compact excavator 42 is effective 36 for this purpose. When a compact excavator 42 is used, the bucket 43 thereof, can be very useful to either remove or add additional sidewalk base material 22 depending on the condition of the site reserved for the sidewalk. In addition, as the sidewalk grader 20 advances along the road structure 30 , the bucket 43 can be used to break-up native hard-pan type soil, and to remove large rocks and the like.
[0056] The construction equipment 38 is generally positioned to move forward over an existing road structure 30 to advance the sidewalk grader 20 in a direction along the existing road structure 30 , substantially parallel thereto. This forward movement is indicated by arrow 46 . Importantly, the excavation equipment 38 so provided is disposed and operated over an existing road structure 30 thereby minimizing the impact it has on the base 26 . Accordingly, the tracking assembly 34 is configured to extend from the vertically movable accessory 36 in a transverse direction to the course of advancement (indicated by an arrow 46 ), transversely across the road structure 30 and the curb 32 thereof.
[0057] In addition, the tracking assembly 34 further comprises a vertically adjustable tracking means 48 disposed for engagement with the top surface of the curb 32 portion of the road structure 30 . With this configuration, the top surface 50 of the curb 32 provides a point of reference for operation of the sidewalk grader 20 .
[0058] A grading assembly 54 is mounted and fixed to the tracking assembly 34 so that the grading assembly 54 extends outward, beyond the curb 32 , positioned over the location of the area reserved for the designed sidewalk and base 26 thereof. More specifically, the grading assembly 54 comprises a frame 56 , and a grading blade 58 rotatingly mounted to the frame 56 to permit adjustment of slope of the grading blade 58 according to the specified sidewalk design grade. In order to lock or fix the rotation of the grading blade 58 in relation to the frame 56 , according to a predetermined grade, a fixing means 60 for fixing the blade rotation is provided.
[0059] As noted above, the tracking means 48 is vertically adjustable. This feature is provided to enable the tracking means 48 to engage with the top surface 50 of a curb 32 to provide a relative reference, or point of reference, for precise vertical and horizontal adjustment of the sidewalk grader 20 , to position the grading assembly 54 , and for maintaining the grading assembly in the desired position in relation to the curb as the sidewalk grader 20 advances along the existing road structure 30 as indicated by arrow 46 .
[0060] Because the top surface 50 of the curb 32 is usually rough concrete, the preferred tracking means 48 is constructed for rolling engagement along the top surface 50 of the curb 32 , such as a wheel 94 .
[0061] In a simplified embodiment of the sidewalk grader 20 , the tracking assembly 34 comprises a pivot joint 64 , disposed adjacent the backfill blade to enable the sidewalk grader 20 to fold from a first unfolded position to a folded position. An additional pivot joint 65 is provided to form an additional folding point to fold the sidewalk grader 20 for storage and transportation. As will be discussed more fully below, a second pivot joint 65 can provide an additional pivot axis for up and down movement of the grading assembly 54 to provide greater flexibility thereof.
[0062] A cylinder support 82 is fabricated from solid steel for strength and is welded directly to the support tube 76 . At the top of the cylinder support 82 is an upper eye to provide a connection point for the upper portion of a vertical hydraulic cylinder. Similarly, at the opposing end, its ram is connected to a vertically movable wheel carriage having a wheel 94 . With this arrangement, the ram 88 can be operated to vertically adjust the wheel 94 to the proper elevation to rest on the top surface 50 of curb 32 to track the curb 32 as the sidewalk grader 20 advances along the road structure 30 . Adjusting the vertical hydraulic cylinder causes pivoting of the blade 58 rather than vertical movement of the blade.
[0063] As the sidewalk grader 20 advances along the road structure 30 , the wheel 94 should be adjustable between a first lower limit and a second upper limit, thereby lowering the sidewalk grader 20 to enable the sidewalk grader 20 to follow the curb 32 as it drops to an area reserved for a driveway (not illustrated), i.e., where the curb transitions downward and fades into the driveway. This movement causes pivoting of the blade 58 in an arc, such that its distant end moves more than its nearer end, rather than vertical movement of the blade.
Slope Sensor and Automatic Control
[0064] To compensate for the pivoting of the blade, a slope control system including a slope sensor 220 , a pivot 180 , and a hydraulic cylinder 226 (all not shown in FIG. 1 ) were added to the prior art system. The preferred slope sensor is the Topcon model number 9620 . This slope control system compensates for any deviation in slope of the grading blade 58 caused by bumps in the road structure 30 , change in slope of the road structure, and excavator load changes and the like. Accordingly, the slope sensor 220 senses any change in slope and communicates the change via a wireless transmitter/receiver 461 to a control box 222 which then wirelessly signals an electronically controlled valve stack 492 to activate the hydraulic slope control link 226 to compensate for the change. A preferred control box is the Topcon model #9164. The preferred wireless components at both ends of the wireless link are Cervis SmaRT wireless transceiving base units (model BU-216F-INT). These units carry both the signals from the slope sensor and the commands to the valve stack. In this way, the grading blade 58 is automatically controlled to provide a smoothly graded base 26 for the sidewalk.
Converting the Excavator to a Multi-Attachment Side Tool Carrier
[0065] As described below, as an improvement over the above described prior art, the present invention encompasses a tool carrying and controlling system wherein an operator can control a swiveling tool and either a first attachable linear acting controllable tool or a second attachable linear acting controllable tool to operate in coordination with the first tool. For use in this system, the excavator is modified to include a side tool mounting base or support affixed below the swivel for attaching any linear acting tool, and a set of hydraulic line quick couplers 494 are mounted proximate to the side mounting base as shown in FIG. 2 . The couplers maybe ganged as shown in FIG. 3 . The quick coupler hydraulic connections may be color-coded to correspond to the function control buttons on a Suregrip handle 465 in the cab with corresponding colors as shown in FIG. 4A . Attachment hydraulic hoses may also have corresponding colors.
[0066] On the excavator, the two hydraulic hoses 496 , 498 that operate the stock backfill blade are rerouted to an electronically controlled valve stack 492 with proportional and/or on/off sections for supplying hydraulic pressure to any number of attachment hydraulic circuits 494 . Accordingly, the tool support mount on one end of the backfill blade is now connected to, and controlled by the valve stack. In this way, the operator can electronically control the valve stack 492 from within the cab of the excavator, above the swivel, to control all hydraulic circuits below the swivel that effect any attachment function. The valve stack 492 is located in a protective housing 460 between the lower side of the swivel and the quick couplers, and any number of hoses 494 are routed from the valve stack to the set of hydraulic couplers for the side attachment.
[0067] Electric control wires from the cab to the valve stack 492 may couple the two together as in the prior art. However, this limits rotation of the swivel and risks damaging the wires. An improvement is to pass the control wires through the swivel with slip rings, an electromechanical device that allows the transmission of power and electrical signals from a stationary to a rotating structure, also called a rotary electrical joint, collector or electric swivel.
[0068] Alternatively, A transmitter/receiver mounted in the cab can wirelessly transmit all commands from an installed control handle 465 mounted on the right or left joystick as well as any other switches or any controls in the machine's cab. A receiver/transmitter 463 capable of driving the hydraulic valve stack decodes the signal and controls the valve stack 492 . A hydraulic generator that is installed in the return hydraulic line generates power to keep a large capacitor charged. This capacitor supplies power to operate the electric control valves and supplies power to the wireless receiver/transmitter module 461 . A battery may be used instead of a capacitor. The battery can be charged as mentioned above or removed each night and charged the conventional way. A pair of rechargeable batteries similar to those used on a cordless drill can be used to power the wireless system below the swivel. A 12 volt charger can be used in the cab to recharge the spare and the batteries can be swapped when the battery in use runs low.
[0069] As another alternative, instead of manifolding one hydraulic circuit into many with a control valve stack placed below the swivel and then routing electric or wireless controls through or around the swivel, the excavator swivel can be modified to add more hydraulic circuits through the swivel, allowing the valve stack to be placed above the swivel.
[0070] For use with this multi-tool carrier, several linear acting attachable side tools are described below.
Curb or Curb and Gutter Extruder
[0071] On a road and sidewalk construction job, the first linear acting tool that is useful when mounted on the side tool carrier described above is a curb and gutter extruder as shown in FIG. 5 .
[0072] After a first curb is extruded and hardened, the extruder head may be changed to extrude a second curb on the far side of the sidewalk grade as shown in FIG. 6 . A trimmerhead 430 and auger 435 can be used in conjunction with or ahead of the curb and gutter extruder.
[0073] As shown in FIG. 5 , a sonar sensor 525 may be set up on an arm 520 to wirelessly actuate controllers that adjust height and lateral location relative to a string 522 set up as a datum line.
Sidewalk Grader Improvements
[0074] The next tool to be used on the job is a sidewalk grader. As an improvement to the prior art grader, the blade width may be made adjustable with a sliding blade extension 304 guided by guide bars 315 and 316 and actuated by a hydraulic cylinder 318 as shown in FIG. 7 .
[0075] As another improvement, a detachable fin 302 shown in FIG. 7 may be added to the distant end of the blade.
[0076] Then a second curb may be extruded as shown in FIG. 6 .
[0077] Also, a sonar sensing and guiding system may be added to sense the curb top or the gutter or a guide string. The preferred model is Topcon #9142. A laser sensor may be added to sense a laser beam for guidance.
Multi-Coupling Plate
[0078] FIG. 3 shows a fixed hydraulic multi-coupling plate 871 and a mating mobile hydraulic multi-coupling plate 870 .
[0079] FIGS. 8 c , 9 b , and 9 c show a multi-coupling plate 871 mounted on the tool mounting base (which is preferably also an earth moving blade). This prevents hydraulic hoses from being incorrectly coupled. As shown in these figures, it also is engaged by the action of engaging a tool mount 872 with a tool multi-coupling plate 870 onto the mounting base. Thus, one action both attaches the tool and couples hydraulic lines for actuating the tool.
[0080] FIGS. 8 c and 9 c show how retainers 873 of the tool mount may be powered with a hydraulic cylinder 874 . The retainers 873 engage and retain steel pins 875 with are part of the tool mount 872 . A third pin 876 may be added beside the multi-coupler to ensure alignment.
Red Zone Auto Controls
[0081] A system with a programmable controller in the cab with a custom graphic display can be used to create a “Red Zone” that the excavator components cannot enter, thereby protecting the tool and people near it or using it. Inclinometers, potentiometers, rotation sensors, and cylinder stroke sensors are some of the means to indicate to the controller the position of the cab, arm, boom, and bucket, to enable the machine to stay out of the “Red Zone”. When the machine enters the “Red Zone” the pilot valve cuts the oil supply between the excavator control handles and the excavator control valve.
[0082] In particular, the controller can be programmed to give specific directions for each attachment using a look-up table for each attachment to specify:
location of “Red Zone”, restriction on flow rate and psi of hydraulic oil to each hydraulic actuator, down to zero when appropriate, allowed characteristics of each function of each hydraulic actuator of the excavator or the tool, limitations on or specification of track speed and direction (the Leica Sonar system can read a string line and direct the controller to drive the machine's direction and speed automatically) as with the side grader and the curb and gutter extruder; and alignment of control handle buttons to correspond with attachment functions.
[0088] IFM Electronics makes a suitable inclinometer, model EC 2045, and cylinder stroke sensors. They also offer a suitable programmable controller, model CR 1050.
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An auto-powered mobile machine with controls for a riding operator and a system for carrying and making efficient use of a variety of attachable tools. Wireless radio communication from the controls to a lower tool may allow the swivel to spin any number of times without limitation. Hydraulic tool position controls are wirelessly coupled to a remote sensor that responds to a string datum line, a curb, direction of gravity, or GPS data.
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BACKGROUND
[0001] Field
[0002] The present disclosure relates to well completion in general and in particular to a method and apparatus for operating a high pressure shifting tool within a well.
[0003] Description of Related Art
[0004] Hydrocarbon fluids such as oil and natural gas are obtained from a subterranean geologic formation, referred to as a reservoir, by drilling a well that penetrates the hydrocarbon-bearing formation. Once a wellbore is drilled, various forms of well completion components may be installed in order to control and enhance the efficiency of producing the various fluids from the reservoir.
[0005] Fracturing is used to increase permeability of subterranean formations. A fracturing fluid is injected into the wellbore passing through the subterranean formation. A propping agent (proppant) is injected into the fracture to prevent fracture closing and, thereby, to provide improved extraction of extractive fluids, such as oil, gas or water.
[0006] The disclosure pertains to methods of treating an underground formation penetrated by either vertical wells or wells having a substantially horizontal section. Horizontal well in the present context may be interpreted as including a substantially horizontal portion, which may be cased or completed open hole, wherein the fracture is transversely or longitudinally oriented and thus generally vertical or sloped with respect to horizontal. The following disclosure will be described using horizontal well but the methodology is equally applicable to vertical wells.
[0007] The industry has privileged, when it comes to hydraulic fracturing, what is known as being “plug-and-perf” technique. Horizontal wells may extend hundreds of meters away from the vertical section of the wellbore. Most of the horizontal section of the well passes through the producing formation and are completed in stages. The wellbore begins to deviate from vertical at the kickoff point, the beginning of the horizontal section is the heel and the farthest extremity of the well is the toe. Engineers perform the first perforating operation at the toe, followed by a fracturing treatment. Engineers then place a plug in the well that hydraulically isolates the newly fractured rock from the rest of the well. A section adjacent to the plug undergoes perforation, followed by another fracturing treatment. This sequence is repeated many times until the horizontal section is stimulated from the toe back to the heel. Finally, a milling operation removes the plugs from the well and production commences.
[0008] The common practice in the art is to perforate 4-6 clusters, and push a slickwater laden fluid at or above fracture pressure to create fractures; it is estimated that 30 to 60% of these perforations do not produce due to for example screen out, geological constraint, etc., and thus for every 100 perforations in a wellbore, commonly only 30 to 70 of the conventional perforations are useful for production.
[0009] To respond to that, some operations now involve what is known as pin-point fracturing, which may be defined as the operation of pumping a fluid above the fracturing pressure of the formation to be treated through a single entry. The entry may be a perforation, a valve, a sleeve, or a sliding sleeve. Generally, sliding sleeves in the closed position are fitted to the production liner. The production liner is placed in a hydrocarbon formation. An object is introduced into the wellbore from surface, and the object is transported to the target zone by the flow field or mechanically, for example using a wireline or a coiled tubing. When at the target location, the object is caught by the sliding sleeve and shifts the sleeve to the open position. A sealing device, such as a packer or cups, is positioned below the sleeve to be treated in order to isolate the lower portion of the wellbore. The sealing device is set, fluid is pumped into the fracture and then the sealing device is unset and moved below the next zone (or sleeve) to be treated. Representative examples of sleeve-based systems are disclosed in U.S. Pat. No. 7,387,165, U.S. Pat. No. 7,322,417, U.S. Pat. No. 7,377,321, US 2007/0107908, US 2007/0044958, US 2010/0209288, U.S. Pat. No. 7,387,165, US2009/0084553, U.S. Pat. No. 7,108,067, U.S. Pat. No. 7,431,091, U.S. Pat. No. 7,543,634, U.S. Pat. No. 7,134,505, U.S. Pat. No. 7,021,384, U.S. Pat. No. 7,353,878, U.S. Pat. No. 7,267,172, U.S. Pat. No. 7,681,645, U.S. Pat. No. 7,066,265, U.S. Pat. No. 7,168,494, U.S. Pat. No. 7,353,879, U.S. Pat. No. 7,093,664, and U.S. Pat. No. 7,210,533, which are hereby incorporated herein by reference. A fracturing treatment is then circulated down the wellbore to the formation adjacent the open sleeve.
[0010] One difficulty experienced in the actuation of sleeve valves within an oil well is that the shifting tool required to open and close the sleeve relies upon a pressure being maintained within commonly used shifting tools. In particular, when such shifting tools are utilized with long tool strings, it may be difficult to provide sufficient pressure to activate such shifting tool due to the pressure losses associated with such long tool strings. Additionally, it is also undesirable to move the tool string in such a pressurized state as such pressurized states are known to cause increased stress and wear on the pipe reducing the lifespan of such components. Improvements in actuating such tools would be welcome by the industry.
SUMMARY
[0011] In embodiments the disclosure pertains to methods for actuating a sleeve valve without requiring the tool string to remain in a pressurized state.
[0012] According to embodiments there is disclosed an apparatus for selectably engaging a longitudinally slidable sleeve within a well comprising a tool string slidably locatable within the well and a shifting tool slidably locatable within the sleeve at an end of a tool string. The shifting tool has a central bore therethrough and keys operable to be extended from an outer surface of the shifting tool when the central bore is supplied with the fluid above a predetermined pressure. The keys are engagable upon the sleeve so as to permit the shifting tool to move the sleeve longitudinally within the tubular body. The apparatus further comprises a reservoir in fluidic communication with the central bore of the shifting tool and being operable to contain and hold a quantity of a fluid at a predetermined pressure sufficient to actuate the shifting tool.
[0013] The apparatus may further include an isolation body adapted to retain the fluid in the reservoir after the pressure has been reduced in the tool string. The isolation body may comprise a check valve adapted to permit a flow of fluid into the reservoir in a downward direction only. The check valve may be located above the shifting tool.
[0014] The reservoir may be formed between an inner mandrel and an outer housing of the tool string. The inner mandrel and outer housing may be longitudinally movable relative to each other along the tool string. The outer housing may be operably connected to the tool and wherein the inner mandrel is operably connected to a pipe extending to a ground level of the well. The reservoir may be formed between an end wall and a lead protrusion extending radially outward from the inner mandrel. The end wall may slidably seal against the outer housing.
[0015] The outer housing may include a bypass protrusion extending radially inwardly therefrom at a position adapted to seal against the lead protrusion of the inner mandrel when the inner mandrel and outer housing are at a first position relative to each other. The bypass protrusion may be adapted to longitudinally disengage from the lead protrusion as the inner mandrel is slidably displaced relative to the outer housing so as to compress the reservoir. The bypass protrusion may include a bleed passage therethrough sized to permit a predetermined flow rate of fluid therethrough.
[0016] According to further embodiments there is disclosed a method for selectably engaging a longitudinally slidable sleeve within a well comprising providing a tool string slidably locatable within the well and providing a shifting tool slidably locatable within the sleeve at an end of a tool string. The shifting tool has a central bore therethrough and keys operable to be extended from an outer surface of the shifting tool when the central bore is supplied with the fluid above a predetermined pressure. The keys are engagable upon the sleeve so as to permit the shifting tool to move the sleeve longitudinally within the tubular body. The method further comprises providing a reservoir in fluidic communication with the central bore of the shifting tool and being operable to contain and hold a quantity of a fluid at a predetermined pressure sufficient to actuate the shifting tool.
[0017] According to further embodiments there is disclosed a method for selectably engaging a longitudinally slidable sleeve within a well comprising locating a tool string having a shifting tool therein within the well, wherein the shifting tool has a central bore therethrough and keys operable to be extended from an outer surface of the shifting tool when the central bore is supplied with the fluid above a predetermined pressure, the keys being engagable upon the sleeve so as to permit the shifting tool to move the sleeve longitudinally within the tubular body. The method further comprises pressurizing a reservoir in fluidic communication with the central bore of the shifting tool and being operable to contain and hold a quantity of a fluid at a predetermined pressure sufficient to actuate the shifting tool to extend the keys from the outer surface of the shifting tool into engagement with a sleeve valve. The method further comprises reducing the pressure in the tool string above the reservoir and slidably displacing the shifting tool and sleeve valve within the well by displacing the tool string therein.
[0018] Other aspects and features of the present disclosure will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying drawings illustrate only the various implementations described herein and are not meant to limit the scope of various technologies described herein. The drawings show and describe various embodiments of the current disclosure.
[0020] FIG. 1 is a cross-sectional view of a wellbore having a plurality of flow control valves according to a first embodiment of the present disclosure located therealong.
[0021] FIG. 2 is a cross sectional view of a control valves of for use in the system of FIG. 1 .
[0022] FIG. 3 is a longitudinal cross-sectional view of the control valve of FIG. 2 as taken along the line 3 - 3 .
[0023] FIG. 4 is a detailed cross-sectional view of the extendable ports of the valve of FIG. 2 in a first or retracted position.
[0024] FIG. 5 is a detailed cross-sectional view of the extendable ports of the valve of FIG. 2 in a second or extended position with the sleeve valve in an open position.
[0025] FIG. 6 is a cross sectional view of the valve of FIG. 2 as taken along the line 3 - 3 showing a shifting tool located therein.
[0026] FIG. 7 is an axial cross-sectional view of the shifting tool of FIG. 6 as taken along the line 7 - 7 .
[0027] FIG. 8 a lengthwise cross sectional view of the shifting tool of FIG. 6 taken along the line 8 - 8 in FIG. 7 with a control valve located therein according to one embodiment with the sleeve engaging members located at a first or retracted position.
[0028] FIG. 9 is a cross sectional view of the shifting tool of FIG. 6 taken along the line 8 - 8 with a control valve located therein according to one embodiment with the sleeve engaging members located at a second or extended position
[0029] FIG. 10 is a perspective view of a shifting tool according to a further embodiment.
[0030] FIG. 11 is a side view of a well at a first step of engaging a sleeve valve according to the present method.
[0031] FIG. 12 is a side view of a well at a second step of opening a sleeve valve according to the present method.
[0032] FIG. 13 is a cross sectional view of a sleeve valve of an optional design having a reservoir formed inside according to the present disclosure at a first or initial position.
[0033] FIG. 14 is a detailed cross sectional view of a portion of a sleeve valve of FIG. 13 at a second or pressurized position.
[0034] FIG. 15 is a detailed cross sectional view of a portion of a sleeve valve of FIG. 13 at a second or pressurized position.
DETAILED DESCRIPTION
[0035] 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 and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possessed knowledge of the entire range and all points within the range.
[0036] 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 disclosure.
[0037] In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and “downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the disclosure.
[0038] Embodiments herein relate to methods of completing an underground formation using multi-stage pin-point fracturing for treating a well without using any sealing element.
[0039] Referring to FIG. 1 , a wellbore 10 is drilled into the ground 8 to a production zone 6 by known methods. The production zone 6 may contain a horizontally extending hydrocarbon bearing rock formation or may span a plurality of hydrocarbon bearing rock formations such that the wellbore 10 has a path designed to cross or intersect each formation. As illustrated in FIG. 1 , the wellbore includes a vertical section 12 having a valve assembly or Christmas tree 14 at a top end thereof and a bottom or production section 16 which may be horizontal or angularly oriented relative to the horizontal located within the production zone 6 . After the wellbore 10 is drilled the production tubing 20 is of the hydrocarbon well is formed of a plurality of alternating liner or casing 22 sections and in line valve bodies 24 surrounded by a layer of cement 23 between the casing and the wellbore. The valve bodies 24 are adapted to control fluid flow from the surrounding formation proximate to that valve body and may be located at predetermined locations to correspond to a desired production zone within the wellbore. In operation, between 8 and 100 valve bodies may be utilized within a wellbore although it will be appreciated that other quantities may be useful as well.
[0040] Turning now to FIG. 2 , a perspective view of one valve body 24 is illustrated. The valve body 24 comprises a substantially elongate cylindrical outer casing 26 extending between first and second ends 28 and 30 , respectively and having a central passage 32 therethrough. The first end 28 of the valve body is connected to adjacent liner or casing section 22 with an internal threading in the first end 28 . The second end 30 of the valve body is connected to an adjacent casing section with external threading around the second end 30 . The valve body 24 further includes a central portion 34 having a plurality of raised sections 36 extending axially therealong with passages 37 therebetween. As illustrated in the accompanying figures, the valve body 24 has three raised sections although it will be appreciated that a different number may also be utilized.
[0041] Each raised section 36 includes a radially movable body or port body 38 therein having an aperture 40 extending therethrough. The aperture 40 extends from the exterior to the interior of the valve body and is adapted to provide a fluid passage between the interior of the bottom section 16 and the wellbore 10 as will be further described below. The aperture 40 may be filled with a sealing body (not shown) when installed within a bottom section 16 . The sealing body serves to assist in sealing the aperture until the formation is to be fractured and therefore will have sufficient strength to remain within the aperture until that time and will also be sufficiently frangible so as to be fractured and removed from the aperture during the fracing process. Additionally, the port bodies 38 are radially extendable from the valve body so as to engage an outer surface thereof against the wellbore 10 so as to center the valve body 24 and thereby the production section within the wellbore.
[0042] Turning now to FIG. 3 , a cross sectional view of the valve body 24 is illustrated. The central passage 32 of the valve body includes a central portion 42 corresponding to the location of the port bodies 38 . The central portion is substantially cylindrical and contains a sliding sleeve 44 therein. The central portion 42 is defined between first or entrance and second or exit raised portions or annular shoulders, 46 and 48 , respectively. The sliding sleeve 44 is longitudinally displaceable within the central portion 42 to either be adjacent to the first or second shoulder 46 or 48 . At a location adjacent to the second shoulder, the sliding sleeve 44 sealably covers the apertures 40 so as to isolate the interior from the exterior of the bottom section 16 from each other, whereas when the sliding sleeve 44 is adjacent to the first shoulder 46 , the sliding sleeve 44
[0043] The central portion 42 includes a first annular groove 50 a therein proximate to the first shoulder 46 . The sliding sleeve 44 includes a radially disposed snap ring 52 therein corresponding to the groove 50 a so as to engage therewith and retain the sliding sleeve 44 proximate to the first shoulder 46 which is an open position for the valve body 24 . The central portion 42 also includes a second annular groove 50 b therein proximate to the aperture 40 having a similar profile to the first annular groove 50 a . The snap ring 52 of the sleeve is receivable in either the first ore second annular groove 50 a or 50 b such that the sleeve is held in either an open position as illustrated in FIG. 5 or a closed position as illustrated in FIG. 4 . The sliding sleeve 44 also includes annular wiper seals 54 which will be described more fully below proximate to either end thereof to maintain a fluid tight seal between the sliding sleeve and the interior of the central portion 42 .
[0044] The port bodies 38 are slidably received within the valve body 24 so as to be radially extendable therefrom. As illustrated in FIG. 3 , the port bodies are located in their retracted position such that an exterior surface 60 of the port bodies is aligned with an exterior surface 62 of the raised sections 36 . Each raised section may also include limit plates 64 located to each side of the port bodies 38 which overlap a portion of and retain pistons within the cylinders as are more fully described below.
[0045] Each raised section 36 includes at least one void region or cylinder 66 disposed radially therein. Each cylinder 66 includes a piston 68 therein which is operably connected to a corresponding port body 38 forming an actuator for selectably moving the port bodies 38 . Turning now to FIGS. 4 and 5 , detailed views of one port body 38 are illustrated at a retracted and extended position, respectively. Each port body 38 may have an opposed pair of pistons 68 associated therewith arranged to opposed longitudinal sides of the valve body 24 . It will be appreciated that other quantities of pistons 68 may also be utilized for each port body 38 as well. The pistons 68 are connected to the valve body by a top plate 70 having an exterior surface 72 . The exterior surface 72 is positioned to correspond to the exterior surface 62 of the raised sections 36 so as to present a substantially continuous surface therewith when the port bodies 38 are in their retracted positions. The exterior surface 72 also includes angled end portions 74 so as to provide a ramp or inclined surface at each end of the port body 38 when the port bodies 38 are in an extended position. This will assist in enabling the valve body to be longitudinally displaced within a wellbore 10 with the vertical section 12 under thermal expansion of the production string and thereby to minimize any shear stresses on the port body 38 .
[0046] The pistons 68 are radially moveable within the cylinders relative to a central axis of the valve body so as to be radially extendable therefrom. In the extended position illustrated in FIG. 5 , the exterior surface 72 of the port bodies are adapted to be in contact with the wellbore 10 so as to extend the port body 38 and thereby enable the wellbore 10 to be placed in fluidic communication with the central portion 42 of the valve body 24 . The pistons 68 may have a travel distance between their retracted positions and their extended positions of between 0.10 and 0.50 inches although it will be appreciated that other distances may also be possible. In the extended position, it will be possible to frac that location without having to also fracture the concrete which will be located between the valve body 24 and the wellbore wall thereby reducing the required frac pressure. Additionally, more than one port body 38 may be utilized and radially arranged around the valve body so as to centre the valve body within the wellbore when the port bodies are extended therefrom.
[0047] The pistons 68 may include seals 76 therearound so as to seal the piston within the cylinders 66 . Additionally, the port body 38 may include a port sleeve 78 extending radially inward through a corresponding port bore 81 within the valve body. A seal 80 may be located between the port sleeve 78 and the port bore 81 so as to provide a fluid tight seal therebetween. A snap ring 82 may be provided within the port bore 81 adapted to bear radially inwardly upon the port sleeve 78 . In the extended position, the snap ring 82 compresses radially inwardly to provide a shoulder upon which the port sleeve 78 may rest so as to prevent retraction of the port body 38 as illustrated in FIG. 5 . The pistons 68 may be displaceable within the cylinders 66 by the introduction of a pressurized fluid into a bottom portion thereof. It will also be appreciated that other sleeve valves may be utilized which do not include extendable pistons as illustrated herein as are commonly known in the art.
[0048] With reference to FIG. 3 , the entrance bore 94 intersect the central passage 32 of the valve body 24 . As illustrated each entrance bore 94 may be covered by a knock-out plug 102 so as to seal the entrance bore until removed. In operation, as concrete is pumped down the bottom section 16 , it will be followed by a plug so as to provide an end to the volume of concrete. The plug is pressurized by a pumping fluid (such as water, by way of non-limiting example) so as to force the concrete down the production string and thereafter to be extruded into the annulus between the horizontal section and the wellbore. The knock-out plugs 102 are designed so as to be removed or knocked-out of the entrance bore by the concrete plug passing thereby. In such a way, once the concrete has passed the valve body 24 , the concrete plug removes the knock-out plugs 102 so as to pressurize the entrance bore 94 and fluid bore 90 and thereafter to extend the pistons 68 from the valve body 24 once the pressurizing fluid has reached a sufficient pressure.
[0049] Turning now to FIG. 6 , a shifting tool 200 is illustrated within the central passage 32 of the valve body 24 . The shifting tool 200 is adapted to engage the sliding sleeve 44 and shift it between a closed position as illustrated in FIG. 4 and an open position in which the apertures 40 are uncovered by the sliding sleeve 44 so as to permit fluid flow between and interior and an exterior of the valve body 24 as illustrated in FIG. 5 . The shifting tool 200 comprises a substantially cylindrical elongate tubular body 202 extending between first and second ends 204 and 206 , respectively. The shifting tool 200 includes a central bore 210 therethrough (shown in FIGS. 7 through 9 ) to receive an actuator or to permit the passage of fluids and other tools therethrough. The shifting tool 200 includes at least one sleeve engaging member 208 radially extendable from the tubular body 202 so as to be selectably engageable with the sliding sleeve 44 of the valve body 24 . As illustrated in the accompanying figures, three sleeve engaging members 208 are illustrated although it will be appreciated that other quantities may be useful as well.
[0050] The sleeve engaging members 208 comprise elongate members extending substantially parallel to a central axis 209 of the shifting tool between first and second ends 212 and 214 , respectively. The first and second ends 212 and 214 include first and second catches 216 and 218 , respectively for surrounding the sliding sleeve and engaging a corresponding first or second end 43 or 45 , respectively of the sliding sleeve 44 depending upon which direction the shifting tool 200 is displaced within the valve body 24 . As illustrated in FIGS. 8 and 9 , the first and second catches 216 and 218 of the sleeve engaging member 208 each include and inclined surface 220 and 222 , respectively facing in opposed directions from each other. The inclined surfaces 220 and 222 are adapted to engage upon either the first or second annular shoulder 46 or 48 of the valve body as the shifting tool 200 is pulled or pushed there into. The first or second annular shoulders 46 or 48 press the first or second inclined surface 220 or 222 radially inwardly so as to press the sleeve engaging members 208 inwardly and thereby to disengage the sleeve engaging members 208 from the sliding sleeve 44 when the sliding sleeve 44 has been shifted to a desired position proximate to one of the annular shoulders. In an optional embodiment, one or both of the catches 216 or 218 may have an extended length as illustrated in FIG. 10 such that the sleeve engaging members are disengaged from the sliding sleeve at a position spaced apart from one of the first or second annular shoulders 46 or 48 and thereby adapted to position the sliding sleeve at a third or central position within the valve body 24 .
[0051] Turning to FIG. 7 , the sleeve engaging members are maintained parallel to the tubular body 202 of the shifting tool 200 by a parallel shaft 230 . Each parallel shaft 230 is linked to a sleeve engaging member 208 by a pair of spaced apart linking arms 232 . The parallel shaft 230 is rotatably supported within the shifting tool tubular body 202 by bearings or the like. The linking arms 232 are fixedly attached to the parallel shaft 230 at a proximate end and are received within a blind bore 234 of the sleeve engaging members 208 . As illustrated in FIG. 6 , the linking arms 232 are longitudinally spaced apart from each other along the parallel shaft 230 and the sleeve engaging member 208 so as to be proximate to the first and second ends 212 and 214 of the sleeve engaging member 208 .
[0052] Turning now to FIG. 8 , the tubular body 202 of the shifting tool includes a shifting bore 226 therein at a location corresponding to each sleeve engaging member. The shifting bore 226 extends from a cavity receiving the sleeve engaging member to the central bore 210 of the shifting tool 200 . Each sleeve engaging member 208 includes a piston 224 extending radially therefrom which is received within the shifting bore 226 . In operation, a fluid pressure applied to the central bore 210 of the shifting tool will be applied to the piston 224 so as to extend the piston within the shifting bore 226 and thereby to extend the sleeve engaging members 208 from a first or retracted position within the shifting tool tubular body 202 as illustrated in FIG. 8 to a second or extended position for engagement on the sliding sleeve 44 as discussed above as illustrated in FIG. 9 . The parallel shafts also include helical springs (not shown) thereon to bias the sleeve engaging members to the retracted position.
[0053] The first end 204 of the shifting tool 200 includes an internal threading 236 therein for connection to the external threading of the end of a production string or pipe (not shown). The second end 206 of the shifting tool 200 includes external threading 238 for connection to internal threading of a downstream productions string or further tools, such as by way of non-limiting example a control valve as will be discussed below. An end cap 240 may be located over the external threading 238 when such a downstream connection is not utilized.
[0054] With reference to FIGS. 8 and 9 , a first control valve 300 according to a first embodiment located within a shifting tool 200 for use in wells having low hydrocarbon production flow rates. The low flow control valve 300 comprises a valve housing 302 having a valve passage 304 therethrough and seals 344 therearound for sealing the valve housing 302 within the shifting tool 200 . The low flow control valve 300 includes a central housing extension 306 extending axially within the valve passage 304 and a spring housing portion 320 downstream of the central portion 310 . The central housing extension 306 includes an end cap 308 separating an entrance end of the valve passage from a central portion 310 of the valve passage and an inlet bore 322 permitting a fluid to enter the central portion 310 from the valve passage 304 .
[0055] The central portion 310 of the valve passage contains a valve piston rod 312 slidably located therein. The valve piston rod 312 includes leading and trailing pistons, 314 and 316 , respectively thereon in sealed sliding contact with the central portion 310 of the valve passage. The leading piston 314 forms a first chamber 313 with the end cap 308 having an inlet port 315 extending through the leading piston 314 . The valve piston rod 312 also includes a leading extension 318 having an end surface 321 extending from an upstream end thereof and extending through the end cap 308 . The valve piston rod 312 is slidable within the central portion 310 between a closed position as illustrated in FIG. 8 and an open position as illustrated in FIG. 9 . In the closed position, the second or trailing piston 316 is sealable against the end of the central portion 310 to close or seal the end of the central passage and thereby prevent the flow of a fluid through the control valve. In the open position as illustrated in FIG. 9 , the trailing piston 316 is disengagable from the end of the central portion 310 so as to provide a path of flow, generally indicated at 319 , therethrough from the central passage to the spring housing.
[0056] A spring 324 is located within the spring housing 320 and extends from the valve piston rod 312 to an orifice plate 326 at a downstream end of the spring housing 320 . The spring 324 biases the valve piston rod 312 towards the closed position as illustrated in FIG. 8 . Shims or the like may be provided between the spring 324 and the orifice plate 326 so as to adjust the force exerted by the spring upon the valve piston rod 312 . In other embodiments, the orifice plate may be axially moveable within the valve body by threading or the like to adjust the force exerted by the spring. In operation, fluid pumped down the production string to the valve passage 304 passes through the inlet bore and into the central portion 310 . The pressure of the fluid within the central portion 310 is balanced upon the opposed faces of leading and trailing pistons 314 and 316 such that the net pressure exerted upon the valve piston rod 312 is provided by the pressure exerted on the end surface 321 of the leading extension 318 and on the leading piston 314 from within the first chamber 313 . The resulting force exerted upon the end surface 321 is resisted by the biasing force provided by the spring 324 as described above.
[0057] Additionally, the orifice plate 326 includes an orifice 328 therethrough selected to provide a pressure differential thereacross under a desired fluid flow rate. In this way, when the fluid is flowing through the central portion 310 and the spring housing 320 , the spring housing 320 will have a pressure developed therein due to the orifice plate. This pressure developed within the spring housing 320 will be transmitted through apertures 330 within the spring housing to a sealed region 332 around the spring housing proximate to the shifting bore 226 of the shifting tool 200 . This pressure serves to extend the pistons 224 within the shifting bores 226 and thereby to extend the sleeve engaging members 208 from the shifting tool. The pressure developed within the spring housing 320 also resists the opening of the valve piston rod 312 such that in order for the valve to open and remain open, the pressure applied to the entrance of the valve passage 304 is required to overcome both the biasing force of the spring 324 and the pressure created within the spring housing 320 by the orifice 328 .
[0058] The valve 300 may be closed by reducing the pressure of the supplied fluid to below the pressure required to overcome the spring 324 and the pressured created by the orifice 328 such that the spring is permitted to close the valve 300 by returning the valve piston rod 312 to the closed position as illustrate in 11 as well as permitting the springs on the parallel shaft 230 to retract the sleeve engaging members 208 as the pressure within the spring housing 320 is reduced. Seals 336 as further described below may also be utilized to seal the contact between the spring housing 320 and the interior of the central bore 210 of the shifting tool 200 .
[0059] A shear sleeve 340 may be secured to the outer surface of the valve housing 302 by shear screws 342 or the like. The sheer sleeve 340 is sized and selected to be retained between a pipe threaded into the internal threading 236 of the shifting tool 200 and the remainder of the shifting tool body. In such a way, should the valve be required to be retrieved, a spherical object 334 , such as a steel ball, such as are commonly known in the art may be dropped down the production string so as to obstruct the valve passage 304 of the valve 300 . Obstructing the flow of a fluid through the valve passage 304 will cause a pressure to develop above the valve so as to shear the shear screws 342 and force the valve through the shifting tool. The strength of the sheer screws 342 may be selected so as to prevent their being sheered during normal operation of the valve 300 such as for pressures of between 1000 and 3000 psi inlet fluid pressure. The valve illustrated in FIGS. 8 and 9 is adapted for use in a low hydrocarbon flow rate well. In such well types, the flow of fluids such as hydrocarbons or other fluids is low enough that the fluid pumped down the well to pressurize the central portion 310 is sufficient to overcome the flow of the fluids up the well so as to pass through the orifice 328 . It will be appreciated that for wells of higher well pressure or flow rates, such a valve will be limited in its application.
[0060] Turning now to FIGS. 11 and 12 , a system for pressurizing the shifting tool 200 is illustrated within the production tubing 20 . In operation, as will be described further below, the shifting tool may be formed with a reservoir 500 operable to contain a fluid above the activation pressure of the shifting tool. The tool string 510 may include an isolation element 502 operable to selectably retain a fluid pressure within the reservoir 500 after it has been reduced within the tool string 510 such that the tool string may be moved in a lower pressure state thereby reducing wear and stress thereon. In particular as illustrated in FIG. 11 , the reservoir may be initially pressurized to extend the shifting keys on the shifting tool. Thereafter the pressure above the reservoir 500 may be reduced while maintaining the pressure within the reservoir by the isolation element 502 and moved as illustrated in FIG. 12 . Thereafter, the pressure within the reservoir 500 may be released by a release element 504 downstream of the shifting tool 200 .
[0061] Turning now to FIG. 13 , a cross sectional view of the shifting tool and reservoir assembly is illustrated. The tool string is formed with an inner mandrel 520 and an outer housing 530 forming a cavity 522 therebetween. The cavity 522 spans the shifting tool 200 and is adapted to retain the outer housing at an extended position relative to the inner mandrel under pressure of a fluid contained therein and be released therefrom at a controlled rate to release the outer housing 530 relative to the inner mandrel thereby releasing the pressure applied to the shifting tool 200 . In such a manner the shifting tool 200 may be maintained at a pressurized while the tool string state is allowed to reduce to a lower pressure for movement thereof.
[0062] Turning now to FIGS. 14 and 15 the inner mandrel 520 includes an end wall 524 extending therefrom into engagement with the outer housing 530 . The inner mandrel 530 also includes a lead protrusion 526 extending annularly outward therefrom wherein the cavity 522 is formed between the lead protrusion 526 and the end wall 524 . The outer housing 530 includes a bypass protrusion 532 extending radially inward therefrom at a position adapted to engage against the end protrusion 526 extending from the inner mandrel. As illustrated one or both of the bypass protrusion 532 or end protrusion 526 may include a seal 534 for sealing the contact between the bypass protrusion 532 and end protrusion 526 . Similarly, the end wall 524 includes a seal 528 at a position therein adapted to engage upon and seal the end wall against the outer housing. The bypass protrusion 532 includes at least one bypass passage 540 extending therethrough to permit fluid to flow therethrough into and out of the cavity 522 .
[0063] At a first or closed position as illustrated in FIG. 14 , the bypass protrusion 532 and lead protrusion 526 are aligned so as to enclose the cavity 522 therebehind. As illustrated in FIG. 15 , the inner mandrel is longitudinally movable relative to the outer housing in a direction indicated at 550 to a second position to disengage the bypass protrusion 532 from the lead protrusion 526 such that fluid is permitted to flow out of the cavity 522 in a direction generally indicated at 552 .
[0064] In operation, the shifting tool 200 may be located at the desired location. Thereafter, the inner mandrel 520 may be positioned relative to the outer hosing 530 at the initial position as illustrated in FIG. 14 with the bypass protrusion 532 and lead protrusion 526 aligned. Thereafter, the cavity 522 may be pressurized with the fluid so as to engage the shifting tool as set out above. Optionally, the cavity 522 may be pressurized before the bypass protrusion 532 and lead protrusion 526 are aligned to seal the cavity 522 . In this position, the shifting tool will be engaged upon a sleeve valve permitting the sleeve to be opened or closed as desired by an operator. For such movement, the annulus, generally indicated at 560 as the annual region between the inner mandrel 520 and the outer housing 530 above the may be depressurized so as to depressurize the tool string for such movement in a depressurized state. It will be appreciated that such depressurized state will reduce wear and damage to the tool string during such movement.
[0065] After the annulus 560 of the tool string has been depressurized, the fluid within the cavity 522 will be permitted to escape therefrom through the bypass passage 540 . The size of the bypass passage 540 will be selected such that the rate of fluid escape therefrom will be low so as to retain a sufficient volume of fluid within the cavity 522 to keep the cavity 522 at a pressure to keep the shifting tool activated as well as to prevent the volume of the cavity 522 from significantly decreasing. During this period, the inner mandrel 520 may be pulled in a direction generally indicated at 562 such that the pressure within the cavity 522 will maintain the relative positions between the inner mandrel 520 and outer housing 530 . While the inner mandrel is pulled in the direction 560 , fluid within the cavity will, as set out above maintain the positions between the inner mandrel and outer hosing. During this movement, after the pressure within the annulus 560 is reduced the fluid within the cavity 522 escapes from the cavity 522 through the pyass passage 540 at a controlled rate thereby reducing the pressure within the cavity. When the pressure within the cavity 522 reaches a predetermined level, the bypass protrusion 532 will be permitted to move relative to the lead protrusion 526 to an amount sufficient to disengage the two protrusions from each other as illustrated in FIG. 15 whereupon the remaining fluid may escape from the cavity 522 in a direction generally indicated at 552 . After this remaining fluid has escaped the shifting tool will be disengaged. It will be appreciated that the size of the bypass passage 540 will be selected to provide a desired time delay to keep the shifting tool activated.
[0066] While the present disclosure has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations there from. It is intended that the appended claims cover such modifications and variations as fall within the true spirit and scope of the disclosure.
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The disclosure pertains to engaging a longitudinally slidable sleeve within a well. The apparatus comprises a tool string slidably locatable within said well and a shifting tool slidably locatable within said sleeve at an end of a tool string. The shifting tool has a central bore therethrough and keys operable to be extended therefrom. The apparatus further includes a reservoir in fluidic communication with said central bore of said shifting tool and being operable to contain and hold a quantity of a fluid at a predetermined pressure sufficient to actuate said shifting tool. The method comprises comprises pressurizing the reservoir, reducing said pressure in said tool string above said reservoir slidably displacing said shifting tool and sleeve valve within said well by displacing said tool string therein.
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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 diverters of flowing fluid and more particularly, although not exclusively, to rigid assemblies configured to entrain ambient fluid into a fluid jet and to divert fluid without need for flexible components or attachments.
BACKGROUND OF THE INVENTION
U.S. Patent Application Publication No. 2010/0011521 of Collins discloses an example of a deflector of water exiting a sweep tail hose of an automatic swimming pool cleaner. The deflector is “a relatively flexible structure in comparison with the sweep tail hose,” see Collins, p. 1, ¶ 0008, and includes a mounting collar and multiple “elongated and highly flexible fingers projecting in a downstream direction.” See id., p. 3, ¶ 0029 (numerals omitted). As noted in the Collins application:
During normal submerged operation as the pool cleaner and sweep tail hose travel over submerged pool floor and side wall surfaces, water jetted from the sweep tail hose flows substantially without restriction through the deflector. However, when the discharge end of the sweep tail hose breaks the surface of water within the swimming pool, the relatively flexible deflector falls by gravity over the otherwise open discharge end of the sweep tail hose to deflect water jetted therefrom. Accordingly, the deflector effectively knocks down and prevents water jetted from the sweep tail hose from spraying over any significant distance or area of a surrounding pool deck region.
See id., p. 1, ¶ 0008.
Described in U.S. Pat. No. 5,996,906 to Cooper is another deflector likewise designed to exploit principles of gravity. Detailed as being a “hole filled cover,” see Cooper, Abstract, 1.3, the flexible device of the Cooper patent moves, under force of gravity, to intercept a flowing water stream when a sweep tail hose exits a pool. Preferred devices are tubular bags of flexible woven metal material that supposedly allow water to pass through unaffected when the sweep tail is underwater. See id., col. 4, 11.31-45.
Water exits sweep tail hoses of at least some automatic swimming pool cleaners under significant pressure. Indeed, such pressure often may be sufficient to separate the flexible fingers of the deflector of the Collins application when the hoses break the surfaces of pool water. If this separation occurs, no deflection of flow will occur thereafter, and the stream of exiting water will continue unabated. Additionally, the tubular bags of the Cooper patent likely produce back pressure when the sweep tail hoses are underwater, reducing the effectiveness of the hoses and the associated cleaners. Accordingly, need exists for deflectors that function satisfactorily when sweep tail hoses are both underneath and above pool water surfaces.
SUMMARY OF THE INVENTION
The present invention provides such deflectors as alternatives to those of the Collins application and the Cooper patent. The deflectors do not operate principally based on gravitational forces. Consequently, they need not necessarily employ flexible components or attachments such as the fingers of the Collins application or the hole-filled bags of the Cooper patent.
Instead, rigid deflectors of the present invention continually position a fixed obstacle in a central portion of a fluid stream. Perforations in a rigid wall, moreover, draw fluid into the deflectors, creating a greater volume of exiting stream when an associated pool cleaner is underwater. This greater volume substantially offsets the power lost by the underwater stream contacting the fixed obstacle, avoiding much of the underwater performance degradation otherwise occurring through addition of a deflector. Hence, pool cleaners and their sweep tail hoses continue to operate well underwater notwithstanding attachment of deflectors of the present invention.
It thus is an optional, non-exclusive object of the present invention to provide deflectors of flowing fluid.
It is another optional, non-exclusive object of the present invention to provide fluid flow deflectors for use with sweep tail hoses of automatic swimming pool cleaners.
It is also an optional, non-exclusive object of the present invention to provide fluid flow deflectors omitting functional flexible components or attachments.
It is a further optional, non-exclusive object of the present invention to provide fluid flow deflectors not predominantly dependent on gravitational forces to divert flowing fluid.
It is, moreover, an optional, non-exclusive object of the present invention to provide rigid deflectors with centrally-positioned, fixed obstacles at which flowing fluid is directed.
It is an additional optional, non-exclusive object of the present invention to provide fluid flow deflectors entraining ambient pool water into an exiting stream when the deflectors are underwater.
Other objects, features, and advantages will be apparent to those skilled in appropriate fields with reference to the remaining text and the drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an automatic swimming pool cleaner utilizing an exemplary deflector assembly consistent with the present invention.
FIG. 2 is a close-up view of the deflector assembly shown as encircled in FIG. 1 .
FIG. 3 is another close-up view of the deflector assembly of FIGS. 1-2 shown with an optional scrubber removed.
FIGS. 4-5 are perspective views of the deflector assembly depicted in FIG. 3 .
FIG. 6 is an end view of the deflector assembly depicted in FIG. 3 .
FIG. 7 is a cross-sectional view of the deflector assembly depicted in FIG. 3 .
FIGS. 8-9 are perspective views of an alternate deflector assembly of the present invention.
DETAILED DESCRIPTION
Illustrated in FIG. 1 is an exemplary automatic swimming pool cleaner 10 for use in connection with the present invention. Cleaner 10 may include body 14 , sweep tail hose 18 and, if desired, a debris filter such as bag 22 and a motive mechanism such as wheels 26 . Cleaner 10 preferably is a “pressure-side” cleaner, to which pressurized water exiting a pump is routed. The pressurized water may travel through a hose (not shown) to entrance 28 of body 14 . Thereafter, some of the pressurized water may be used to create a low pressure region (via the Venturi effect) drawing debris-laden pool water into the body 14 through an inlet (not shown) and thence into bag 22 . By contrast, some of the pressurized water exits body 14 into and through sweep tail hose 18 , causing the sweep tail hose 18 to sweep along a pool surface and disturb debris into suspension in the pool water.
Optimal underwater performance of sweep tail hose 18 occurs when the pressurized water travels through it generally unobstructed. Hence, any fluid obstruction attached to exit 30 of sweep tail hose 18 will degrade performance of the hose 18 underwater. Conversely, any obstruction attached to exit 30 conceivably could “improve” performance of sweep tail hose 18 above the waterline, at least in the sense of inhibiting water jetted from the hose 18 from spraying over any significant distance or area of a surrounding pool deck region, as noted in the Collins application.
Deflector assembly 34 ( FIGS. 1-7 ) seeks to inhibit spray from hose 18 above the waterline yet reduce, if not minimize, degradation in its performance underwater. Assembly 34 may include deflector 38 together with optional scrubber 42 . Persons skilled in the art will recognize that other components may be included as part of assembly 34 if necessary or desired.
The illustrated version of deflector 38 shows it as generally cylindrical in shape, albeit with differing cross-sectional diameters along portions of its length. This represents a presently-preferred configuration of deflector 38 , although other shapes may be permissible. Likewise, although as illustrated deflector 38 is molded of plastic material as an integral unit, it may be constructed or assembled differently than shown or formed of different material.
Defined by deflector 38 may be first, second, and third sections 46 A-C, respectively. First section 46 A preferably is a fitting allowing attachment of deflector 38 to exit 30 . To facilitate attachment, first section 46 A may comprise multiple circumferential flanges 50 , four of which are shown in FIG. 5 . Each flange 50 advantageously may flex outward at least slightly and terminate in a ramp 54 , facilitating snap-fitting deflector 38 onto exit 30 . Numerous other means for attaching deflector 38 to sweep tail hose 18 may be employed instead, of course, as recognized by those skilled in the field.
Second section 46 B forms an entrainment region of deflector 38 . It comprises generally cylindrical wall 58 of diameter D 1 in which one or more openings 62 is present. Nine such openings 62 (arranged in three sets of three rows) are illustrated in FIG. 5 , although more or fewer openings 62 may exist instead. As depicted, each opening 62 may comprise an elongated, oval aperture or slot, although this particular shape—while advantageous—is not critical to the invention.
Whereas pressurized fluid from exit 30 enters deflector 38 through first section 46 A (and flows from left to right in FIG. 5 ), openings 62 function principally as entrances for ambient fluid into the deflector 38 . Indeed, flow of the pressurized fluid through inlet or restriction 66 of size less than D 1 creates below-ambient pressure regions adjacent openings 62 , drawing ambient fluid into second section 46 B. When deflector 38 is underwater, the ambient fluid is water, which is entrained with the pressurized fluid to create a larger volume of water travelling through third section 46 C and thereafter exiting deflector 38 . Air, by contrast, will be entrained when deflector 38 is above the water surface.
Third section 46 C may comprise generally cylindrical wall 70 of diameter D 2 . Diameter D 2 preferably is less than diameter D 1 , as no further fluid entrainment is necessarily needed. Instead, openings 74 of wall 70 , together with exit end 78 , function principally as exits for fluid travelling within deflector 58 . Although openings 74 —like openings 62 —are depicted as sets of elongated ovals, other shapes, sets, and arrangements may be employed instead.
Diametrically centrally located in third section 46 C adjacent end 78 is obstruction 82 . Obstruction 82 preferably is fixed in this position as, for example, by rigid beams 86 molded with or otherwise connected to wall 70 . As shown especially in FIG. 7 , obstruction 82 may extend longitudinally from end 78 into third section 46 C, with its contact surface 90 generally longitudinally aligned with at least some openings 74 . Presently-preferred is that contact surface 90 be rounded or curved, so that obstruction 82 resembles a teardrop. Contact surface 90 need not necessarily be rounded, however, nor must obstruction 82 resemble a teardrop.
Some fluid travelling through third section 46 C will exit deflector 38 via end 78 . Other fluid travelling through third section 46 C is directed toward and thus will encounter contact surface 90 of obstruction 82 . Such contact deflects fluid (radially outward) toward openings 74 , with the deflected fluid interacting with other flowing fluid as it moves laterally toward and out of openings 74 . Thus resulting is, generally, a laterally-oriented spray of fluid out of openings 74 and a longitudinally-oriented stream of fluid out of end 78 .
When deflector 38 is underwater, water spray from openings 74 and concurrent diminution of velocity of the stream exiting end 78 tend to diminish the sweeping action of sweep tail hose 18 , hence tending to degrade its performance. However, the entrained water entering via openings 62 creates a larger volume of flowing water than otherwise would be present, helping to offset the power lost by the underwater stream contacting obstruction 82 .
When deflector 38 is above water, diminishment of the stream velocity exiting end 78 is beneficial, as it reduces the distance the stream may travel over the surrounding pool deck. Combined with the fact that much of the spray out of openings 74 is likely to return to the pool, the stream diminishment decreases both the quantity and forcefulness with which water will exit a pool. Accordingly, deflector 38 solves the problems identified in the Collins application and Cooper patent while maintaining useful functioning of sweep tail hose 18 underwater.
Such is true as well for alternate deflector 138 of the present invention. Deflector 138 may be similar to deflector 38 in many respects and comprise, for example, first, second, and third sections 146 A-C, respectively. First section 146 A, like corresponding first section 46 A, preferably is a fitting permitting deflector 138 to be attached to exit 30 . It thus may, if desired, include circumferential flanges 150 terminating in ramps 154 to facilitate snap-fitting deflector 138 onto exit 30 .
Entrainment of ambient fluid likewise may occur via second section 146 B. This second section 146 B may comprise generally cylindrical wall 158 in which openings 162 are present. Unlike the nine openings 62 depicted in FIG. 5 , however, only three openings 162 are shown in FIGS. 8-9 . Spaced about the circumference of wall 158 , openings 162 provide less obstruction to entering fluid than does openings 62 , allowing entrainment of additional ambient fluid when needed.
Third section 146 C may comprise generally cylindrical wall 170 , preferably (although not necessarily) of diameter less than the diameter of wall 158 . Openings 174 may be similar to openings 74 of deflector 38 , and end 178 and obstacle 182 may be similar to respective end 78 and obstacle 82 . Wall 170 may, however, optionally include additional structure to reduce the possibility of any attached scrubber 42 being detached from deflector 138 in use. The structure may include “grippers” in the forms of either or both of laterally-oriented, circumferentially-spaced protrusions 194 and longitudinally-oriented, circumferentially-spaced ribs 198 . In addition to inhibiting rotation of scrubber 42 about wall 170 , ribs 198 also may function to strength the wall 170 . Other gripping and strengthening means may be included as well if desired.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. Additionally, the terms “pool” and “pools” as referenced herein need not be limited to swimming pools, but rather may include spas, hot tubs, and other bodies of water or fluid. Finally, contents of the Collins application and Cooper patent are incorporated herein in their entireties by this reference.
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Detailed are fluid flow deflectors principally for use with sweep tail hoses of automatic swimming pool cleaners. The deflectors do not function principally on gravitational forces and need not necessarily employ flexible components or attachments for purposes of effecting deflection. Instead, the deflectors may be rigid and continually position a fixed obstacle in a central portion of a fluid stream. Perforations in a rigid wall, moreover, draw fluid into the deflectors, creating a greater volume of exiting stream when an associated pool cleaner is underwater.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of working platforms and scaffolds. More specifically it relates to a working platform which allows for the adjustable attachment of scaffolds and the adjustable attachment of various platform leg members.
2. Description of the Prior Art
Scaffolds are used for a variety of purposes in the building construction and maintenance trades, such as painting, plastering, electrical, masonry, carpentry, etc. Once erected, scaffolds are difficult to move throughout a job site without disassembly. U.S. Pat. No. 2,360,999 to Wyen, attempted to solve this problem by adding rollers on the bottom of the scaffolds. Although the scaffolds can be rolled from location to location within the job site, the ground on which the scaffolds are rolled has to be relatively flat for the scaffold to properly roll such as interiors of concrete warehouses, for example. When the device is used on uneven surfaces, such as rough excavated ground surfaces, it becomes difficult to maintain a safe foundation for use of the device. The Wyen device also requires the scaffolds to be lifted off the rollers by using jack screws when a desired position is located.
Another device, shown in U.S. Pat. No. 4,216,933 to Cramer, shows a similar scaffold platform, but it too has deficiencies in its leveling process. Its vertical leveling corner supports require either a forklift, or similar piece of lifting machinery or actual man power to lift the platform to an elevation suited for use. The rigid vertical supports on this device have pre-drilled/pre-measured holes, where a pin is inserted for final adjustment. This requires the user to occasionally level the loose ground or use a leveling block under one or several of the corner supports. This arrangement could create a safety hazard to the overall stability of the unit if one or more of the leveling blocks would move or slide from under one of the vertical supports during usage.
The most common solution for mobility is to provide for an easily disassembled scaffold. An example of such a device is shown in U.S. Pat. No. 650,900 to Knopfe. This device is made of simple and interchangeable parts adapted to be quickly assembled and disassembled for transportation and movement within a job site. This unit uses adjusting shoes attached to the lower base beams for leveling on uneven surfaces. U.S. Pat. No. 3,071,204 to Piltingsrud also has adjustable legs as well as a variable length. Other mobility solutions but limited, are shown in U.S. Pat. No. 3,480,110 to Coleman and U.S. Pat. No. 3,850,264 to Salinas. In both designs, the devices provide for horizontal members extended from the main scaffolds on which a second platform is constructed. Instead of moving the scaffolds, they are extended. Both designs also have adjustable supporting legs and use a disassembly method for major mobility when in use.
Many of the above mentioned designs have adjustable supporting legs and some have extended horizontal members. Some of these designs use a disassembly method of the scaffolds for mobility purposes. The present invention will allow its unit to be moved while scaffolds are erected, together with tools and material being stored on the working platform, along with the safety side rails installed. This will allow the user to not only move the scaffolds without disassembly but also transport the tools and material needed for the job at hand.
While the prior art patents mentioned earlier offer some form of leveling support legs, the present invention utilizes screw type leveling jacks which allow exact leveling without the need for filler blocks which are required with the pre-drilled designs. Although several of the designs offer removable supporting legs, they are limited to only a few positions in which the supporting legs and supports can be positioned. This could cause difficult placement of the scaffold to a building or object when close confinement is inevitable. The present invention offers two positions for its screw jack bracket.
None of the prior art patents teach or suggest a movable scaffold base member to allow an in/out and circular side by side movement in their scaffold bases. The prior art devices are limited and can only be used with certain scaffolds offered in today's market due to size and adjustment confinements in accepting the vertical scaffold legs. The present invention offers an adjustable scaffold base allowing the majority of all scaffold designs which are using a four vertical leg support design to be used.
Without the supporting floor and safety rails, none of the previous mentioned patents can be used as an independent movable working platform, whereas this invention provides a safe and structurally secure working platform.
SUMMARY OF THE INVENTION
The present invention provides a working platform (referred to as the main platform) which can be leveled at ground level by hand turning the screw jacks located at all four corners. The safety side rails will allow the unit to become a mobile working platform by using a forklift or a similar type of equipment. This invention will also allow the user to level the working platform on stable ground and erect multiple sections of scaffolds horizontally which can be then moved in a fully assembled form to various locations on a job site. If the invention is being used on a hard and level surface such as concrete, optional rollers can be attached to the unit in place of the hand screw jacks. This will enable the unit to be “rolled” freely on top of the hard, level surface. The provision of a licensed trailer specially designed to secure a working platform permits the user to transport the unit to and from a job site. The working platform also provides additional space to haul tools and materials to a job site.
The present invention provides adjustable attaching means located near each of said four corners which in one embodiment of the invention comprises an adjustable scaffold leg member support which includes adjustable base plates to secure multiple level scaffolds.
A main platform is preferably provided with safety side rails which permit the invention to be used for a variety of tasks. Although many of the prior art devices are based on a mobile scaffold base design, the present invention can be used to establish a safe and secure mobile working platform which can be elevated to required heights to complete the job at hand by the use of a forklift or the like.
Depending on the actual job being completed, many manufactures require different distances between the bottom supports of their scaffold. The present invention offers adjustable base plates which allow the present invention to be used with a majority of the scaffolds offered in today's market.
The present invention provides novel adjustable screw leveling corner jacks which enable the user of said invention to level the main platform on uneven surfaces at any elevation. Such a design is a great improvement over the prior art which offers pre-drilled/pre-determined adjustable heights in their supporting vertical supports often requiring shims or blocks for leveling.
The present invention provides adjustable attaching means located near each of said four corners which in another preferred embodiment of the invention comprises angled tubular brackets which support the corner screw jacks. The angled tubular brackets are reversible and can be positioned in an outward or in an inward position. The inward position allows the working platform to be placed directly against a wall or work area assuring a safe environment since there will be little or no distance between the platform and object being worked on. When the invention is not attached to a forklift or the like, the unit can become its own working platform on level or uneven terrain.
With the main platform secured to a licensed trailer, the unit can be towed to and from a job site utilizing existing highway systems. The trailer also provides a means for the user to transport the tools and material to said job while the main platform is secured to the trailer.
In its simplest form, the present invention provides a multiple task mobile working platform comprising: a generally rectangular platform frame having four corners, a pair of spaced apart tubular end members, a pair of spaced apart tubular side members and plural spaced apart cross bar members extending between said side members, said frame adapted for use in a generally horizontal orientation; and adjustable attaching means provided near each of said four corners of said frame, each attaching means adapted to removably secure a functional vertical member to said frame in a selected one of a plurality of locations.
Preferably, said frame member and said crossbar members are formed from thick steel box tubing and are welded together and a floor member is provided to cover an upper side of said frame. Preferably, the floor member is formed from a thick steel mesh.
In one embodiment, said adjustable attaching means comprises an adjustable scaffold leg member support, said scaffold leg member support member being movable and adjustable to permit a user to selectively install any one of a variety of commercially available scaffolds onto the working platform. Preferably, said adjustable scaffold leg member support is bolted onto said frame and includes a base plate having an elongated opening therein and a vertically extending tubular post member adapted to receive and support a leg of a scaffold. Preferably, a screw member is threaded into said tubular post member whereby turning said screw member tightens a leg of a scaffold firmly into said tubular post member and further secures a scaffold on said frame.
In another embodiment, said adjustable attaching means comprises an angled tubular bracket which is removably inserted and attached to said frame. The angled tubular bracket has an insertion end and an extension end, said extension end extending from said insertion end at an angle of between 100° and 170°. Preferably, said angle is approximately 135°. Said angled tubular bracket is reversible and extends outwardly away from a longitudinal centerline of said frame when inserted in a first position and extends inwardly towards a longitudinal centerline of said frame when inserted in a second upside down position. Preferably, said angled tubular bracket further comprises a frame leg support bracket mounted for rotational movement on said extension end. Preferably, said frame leg support bracket is attached to a frame leg in the form of an adjustable screw leveling corner jack which permits the working platform to be leveling on uneven surfaces. Alternatively, said frame leg support bracket may be attached to a frame leg having a wheel on a lower end thereof. Preferably, said frame leg support bracket selectively secures a frame leg to the frame in a vertical position for use on the ground and in a horizontal position for storage or use above the ground.
Preferably, the present invention utilizes adjustable attaching means which comprises both an adjustable scaffold leg member support and which further comprises an angled tubular bracket. Such an arrangement provides an enormous amount of flexibility in the use of the working platform.
Preferably, said frame further comprises a pair of horizontal fork tubes mounted below the frame, said fork tubes being sized and spaced to receive fork tines of a fork lift whereby the platform may be lifted above the ground by a fork lift. Preferably, said frame further comprises plural safety rail brackets and said platform further comprises removable safety rails which surround an individual while using the working platform.
Finally, the present invention also preferably further comprises a trailer to which the working platform can be secured for the purpose of transporting the working platform and any scaffolds or equipment secured to or positioned on the working platform.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the main platform frame of the present invention having horizontally and vertically adjustable support legs with adjustable base plates for the erection of scaffolds.
FIG. 2 is a perspective view of an embodiment of a safety side rail design to be installed on FIG. 1 when the main platform frame is being used as a working platform.
FIG. 3 is a perspective view of a licensed trailer used to transport the main platform frame of FIG. 1 and side rails of FIG. 2 .
FIG. 4 is a perspective view of an angled bracket in an “out” position and a screw jack leg in a vertical position.
FIG. 5 is a perspective view of an angled bracket in an “out” position and a screw jack leg in a horizontal position.
FIG. 6 is a perspective view of an angled bracket in an “in” position and a screw jack leg in a horizontal position.
FIG. 7 is a perspective view of the main platform frame, safety rails and trailer of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-7 , the presently preferred embodiments of the present invention are depicted. In FIG. 1 , a standard sized 5′-6″×8′ portable working platform and scaffold support base referred to as the main platform is shown. The main platform comprises of a rectangular frame 100 formed by 3″×4″×⅜″ thick box steel tubing members 1 , 2 , 3 and 4 which are welded together at each of their ends. Reinforcing the rectangular working platform are seven cross bars 5 , which are made up of rectangular 2″×4″×⅜″ thick steel box tubing. All seven cross bars 5 are equally spaced and in a parallel spacing between the outside frame end tubes 2 and 4 . Each of the seven cross bars 5 are welded on each of their ends to the outside side frame tubes 1 and 3 . The main platform frame has a longitudinal center line 101 .
Eight sleeves 6 are fabricated from ⅜″ flat steel and are sized to receive the bottom of vertical posts 29 of safety rails 200 ( FIG. 2 ). Once the eight sleeves 6 are bent to shape they are drilled with a 9/16″ drill creating holes 7 which will accept the securing “T” handled pins 37 . Once the holes 7 are drilled, then all eight sleeves 6 are spaced, with two sleeves 6 per outside frame tubes 1 , 2 , 3 and 4 to assure proper spacing to accept the insertion of the vertical support posts 29 of the safety side rails 200 shown on FIG. 2 . Once properly spaced, the eight sleeves 6 are welded on the outside frame tubes 1 , 2 , 3 and 4 .
Two rectangular 3″×5″×½″ thick horizontal fork tubes 8 are cut to a 5′-6″ length for the purpose to receive the insertion of forks of a forklift or the like and once the fork tubes 8 are cut to length, they are spaced at 3′-6″ apart in a parallel position centered from outside frame tubes 2 and 4 . Once the fork tubes 8 are positioned, they are welded on both ends to the bottom side frame tubes 1 and 3 and any adjoining cross bars 5 .
Four ⅜″ thick steel angled corner braces 9 are fabricated and drilled to accommodate a ½″ course thread bolt 14 , ½″ flat washers 13 and a ½″ course thread nut 12 . The four angled corner braces 9 are then welded to each of the outside frame tubes 1 , 2 , 3 and 4 (as shown on FIG. 1 ).
A ¼″ thick steel meshed floor 20 is sized to the perimeter of the outside frame tubes 1 , 2 , 3 and 4 . Once cut to size, the floor 20 is placed on the top side of the outside frame tubes 1 , 2 , 3 and 4 and seven cross bars 5 and welded with a minimum of six inch spacing at all intersecting points to said frame tubes 1 , 2 , 3 and 4 and cross bars 5 .
An adjustable attaching means in the form of an adjustable scaffold leg member support includes a scaffold base plate 10 and is fabricated starting with a 90 degree ½″ thick piece of steel, with two of the sides of said plate to be a minimum length of 12″. The third side of the scaffold base plate 10 is cut on a slow outside radius. The scaffold base plate 10 is sized and notched with an elongated opening 11 to accommodate the diameter of the bolt 14 , creating an in/out and circular side by side adjustable motion at the corner of said scaffold base plate 10 . Following the cutting of the scaffold base plate 10 , a 2″ outside diameter, ⅜″ thick steel pipe 23 is cut to an 8″ length. Once the steel pipe 23 is cut, a hole is drilled and threaded to accommodate a ½″ course thread bolt 22 used to secure the bottom portion of a scaffold vertical leg. The steel pipe 23 is centered between the end of the opening 11 and the edge of the radius of the scaffold base plate 10 and welded in a perpendicular position on the scaffold base plate 10 . Finally, the four assembled scaffold leg member support base plates 10 are mounted at each corner of the main platform 100 and attached to said platform through the four ⅜″ thick steel angled corner braces 9 previously welded by asserting the bolt 14 , washers 13 and nut 12 .
An adjustable attaching means in the form of four angled tubular brackets 15 , which are the supports for attaching the adjustable screw leveling corner jacks 24 or, alternatively, the 360 degree rotating rollers 24 A, are fabricated. Each angled tubular bracket 15 has an insertion end which is designed to slide into each corners of the working platform at the ends of the box steel tubes 1 and 3 . The angled tubular brackets 15 are secured into a locking position with a ½″ “T” handled pin 16 which is inserted into a 9/16″ diameter drilled holes found on each corner of the main platform 100 through a pre-drilled hole found on the angled tubular brackets 15 . To fabricate angled brackets 25 , you begin with a tubular piece of steel sized to slide into each end of the tubes 1 and 3 . Said steel is then cut in half on one end at a 22½degree angle with a straight cut on the other end, whereas the other piece is cut on both ends at 22½degree angles. Once cut, the 22½degree angled cut ends of the angled tubular brackets 15 are welded together creating a 45 degree welded angle. On the straight cut insertion end of the bracket 15 , a 9/16″ hole is drilled to match the 9/16″ pre-drilled holes on both ends of tubes 1 and 3 . This allows the ½″ diameter “T” handled pin 16 mentioned earlier to be inserted to secure the bracket 15 . On the other extension end of the bracket 15 , a 2″ long, 1¼″ diameter, ¼″ thick pipe 18 is welded on the bracket 15 . A 9/16″ hole 119 is drilled and matched into said pipe 18 to allow the adjustable screw leveling corner jacks 24 to be secured with a ½″ “T” handled pin 19 when inserted. The insertion end and extension end of bracket 15 are joined at a 135° angle.
Two safety chains 21 used to secure the main platform to the forklift or the like are fabricated. First, two ⅜″ thick link chains 21 are cut to a 2′ length each. Then one ⅜″ thick snap ring is placed on one end of each 2′ safety chain 21 . Once the snap rings are installed, the other end of each safety chain 21 is welded three inches towards the center of rail 3 from the inside of each forklift rectangular tube 8 .
The safety side rails 200 of FIG. 2 are optionally attached to the main platform FIG. 1 by sliding the vertical side posts 29 into the two sleeves 6 found on each side tube 1 , 2 , 3 and 4 , are fabricated from 2″×3″×⅜″ thick box steel. First the top rails 25 , 26 , 27 and 28 are cut to a length to assure a proper measurement in order to fit outside the main platform. Then the ends of rails 25 and 27 are notched and a flange 34 is bent in a 90 degree downward angle. The notched flange 34 allows both ends of the 25 and 27 rails to fit over rails 26 and 28 and to be secured with a ½″ “T” handled pin inserted in a pre-drilled 9/16″ hole drilled through the flange 34 and the ends of rails 26 and 28 . Once the four top rails 25 , 26 , 27 and 28 are completed, eight vertical posts 29 are fabricated from 2″×3″×⅜″ thick box steel at a 43″ length each. Then two vertical posts 29 , spaced to slide into the sleeves 6 are welded per each top rail 25 , 26 , 27 and 28 . Once the vertical posts 29 are welded to the top rails, a 9/16″ hole is measured and drilled at the bottom of each post 29 to assure an exact alignment allowing a ½″ “T” handled pin to be placed through the said 9/16″ hole and the hole 7 previously drilled in the sleeves 6 . Once the 9/16″ holes are drilled on the bottom section of each vertical post 29 , the bottom rails 30 , 31 , 32 and 33 are fabricated by following the same procedure used when the top rails 25 , 26 , 27 and 28 were made, but one exception in the design of the bottom rails 30 , 31 , 32 and 33 from the top rails 25 , 26 , 27 and 28 is apparent. Each vertical post 29 runs continuous through the bottom rails 30 , 31 , 32 and 34 . This requires the bottom rails 30 , 31 , 32 and 34 to be cut into three spaced sections to complete the full length measurement required. Also rails 30 and 32 require the same flange and 9/16″ hole 34 design as is found on rails 25 and 27 . Once the bottom rails 30 , 31 , 32 and 33 are cut to size and flanges 34 are drilled, each appropriate section of the bottom rails 30 , 31 , 32 and 34 are welded to the vertical posts 29 at a six inch distance from the bottom of each vertical post 29 .
The next item to be fabricated is the trailer which is shown in FIG. 3 in which the main platform FIG. 1 and safety side rails FIG. 2 can be transported to and from job sites along with the ability to transport the unit within a job location. A center beam 38 fabricated from a 3″×4″×⅜″ thick piece of tubular steel and cut at an overall length of 96″. A rear cross member 41 , also a 3″×4″×⅜″ thick piece of tubular box steel, is cut at a 72″ length. The center beam 38 is placed in the center of the rear cross member 41 in a perpendicular angle and welded to the rear cross member 41 . Once the center beam 38 and rear cross member 41 are welded, two angle braces 39 and 40 , also 3″×4″×⅜″ pieces of tubular box steel, are cut with the appropriate angle shown on FIG. 3 . Immediately after the angle braces 39 and 40 are completed, they are positioned as shown on FIG. 3 and welded to the center beam 38 and the rear cross member 41 . The axle assembly, made up of a 7,000 pound capacity axle 42 equipped with a rubber suspension including two 7″ wide×15″ diameter wheels 44 covered with a 200/75R15 tires 43 which are secured to the axle 42 by five lugs 45 per wheel, are all installed to the base of the rear cross member 41 with supporting brackets. Following the axle assembly installation, the front screw jack 51 is installed 14″ back from the end of the center beam 38 by inserting over a receiving collar resembling the 2″ long, 1¼″ diameter, ¼″ thick pipe 18 welded on bracket 15 shown on FIG. 1 . Screw jack 51 is then secured on the center beam 38 with a “T” handle pin 52 when placed over the receiving collar 18 . Two fenders 46 are installed on the rear cross member 41 . To the rear of each fender 46 , tail lights 57 , required for licensing the trailer are installed. The required wiring from the rear tail lights 57 is then attached under each fender 46 and pulled through the center of each appropriate angle brace 39 and 40 and continued through the center beam 38 to the front of the trailer, with a 20″ piece of wire harness extending past the end of the trailer. On the end of the extended wire harness, an electrical male 12 volt trailer plug 55 is connected.
A 2″ trailer ball receiver 56 is then attached on the front of the center beam 38 by drilling two 9/16″ holes through the receiver 56 and center beam 38 . Once drilled, two ½″ course threaded bolts are inserted all the way through the receiver 56 and center beam 38 . Two ½″ flat washers are placed on the bolts, with two ½″ Nylock, course thread nuts tightened on said bolts. Following the attachment of the receiver 56 , two-⅜″ thick links, 24″ in length safety chains 53 are bolted with ⅜″ nuts and bolts to the front and bottom of the center beam 38 . Attached on each end of the safety chains 53 is a snap ring which is used to attach said trailer to the towing vehicle. Finally, 3″×3″×½″ thick steel angle securing plates 47 and 49 are cut and then placed as shown on FIG. 3 to accept the main platform FIG. 1 . Once the securing plates 47 and 49 are in position, they are then welded into position (the angle securing plates 47 onto the fenders 46 and the angle securing plates 49 onto the center beam 38 ).
When the user plans to transport the main platform FIG. 1 , said main platform is placed on the trailer FIG. 3 and secured with two “T” handled pins 48 in the rear through the securing plates 47 and one “T” handled pin 50 through the securing plates 49 .
Referring to FIG. 4 , the adjustable attaching means is in the form of an angled tubular bracket 15 which is removably inserted and attached to said frame. The angled tubular bracket has an insertion end and an extension end attached at an angle relative to said insertion end of between 100° and 170° preferably approximately 135°. In FIG. 4 the angled tubular bracket 15 extends outwardly away from a longitudinal centerline 101 of said frame 100 . The screw jack 24 is held by the frame leg support bracket 125 in a vertical position by placing T-handled pin in hole 18 A of collar 18 . Collar 18 connects the frame leg support bracket 125 for rotational movement on the extension end of bracket 15 . In FIG. 5 , the screw jack 24 is held by the frame leg support bracket 125 in a horizontal position by placing T-handled pin in hole 18 B of collar 18 . In FIG. 6 , the angled tubular bracket 15 extends inwardly towards a longitudinal centerline 101 of said frame 100 .
FIG. 7 shows the relative general location and orientation of the main platform frame 100 , safety side rails 200 and trailer 300 prior to connection and assembly thereof.
While I have shown and described the presently preferred embodiments of my invention, the invention is not limited thereto and may be otherwise variously practiced within the scope of the following claims:
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A multiple task mobile working platform having a generally rectangular platform frame is provided. An adjustable scaffold leg member support allows for attachment of a variety of scaffolds of different dimensions. An angled tubular bracket allows for attachment of legs members in different positions to allow for maximum stability where there is sufficient space and for a more compact foot print when the working platform must be placed close to a building or object. Precise leveling of the working platform, removable safety side rails and an optional trailer are also disclosed.
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[0001] This invention is related to elements employed in the petroleum industry in general, but it particularly refers to a free mandrel system with protected casing. Its main specific purpose is to be applied to petroleum exploitation for the selective injection of fluids in different formations of a specific well.
SUMMARY OF THE INVENTION
[0002] According to the characteristics of the invention, its main purpose is to achieve a free mandrel system which enables the setting up and simultaneous lifting of all Injection Valves from the surface by operating the valves of a surface component of the invention. This process is performed by only one operator without any kind of help, assistance or tool.
[0003] More precisely, this invention has as its main goal the embodiment of a free mandrel system with protected casing created to allow selective injection in several well formations. Consequently, the free mandrel assembly has as many Injection Valves as formations a specific well may have. In the present explanation for the embodiment of the invention, the system is applied to a 139.5 mm (5″½) casing and it has been simplified to only two formations, an upper and a lower one, to facilitate the explanation and comprehension of its constructive layout structure.
[0004] Said system is based on a dynamic main assembly, a Free Mandrel, through which Injection Valves are transported from the surface to their location on the bottom hole by means of injection fluid and an ordered surface valve handling. To this purpose, the Fixed Bottom Hole Assembly only allows fluid circulation from the annular to Tubing ( 9 ) in order to make the free mandrel return to the surface where all valves are placed, and remove them. Consequently, the purpose of the invention is achieved by an essential layout which comprises:
[0000] (A) A Surface Assembly (SA) made up of an installation Mast, a Lubricator with a Catcher to release and catch the Free Mandrel Assembly, Conventional Valves and the Impeller which enables it to operate.
(B) A Transport Assembly (TA) made up of a Fishing Neck which contains a Retention Valve, two Rubber Cups which slide over a central tube and a Lower Connector which allows it to be bound to the next assembly.
(C) The Free Mandrel Assembly (FMA), which is the dynamic element of the device, is made up of a mandrel for every formation to be selectively injected (only two in this simplified case), where each mandrel lodges its corresponding Injection Valve.
(D) A Fixed Bottom Hole Assembly (FBHA), which is the device that is screwed to the bottom of the 73.026 mm (2″⅞) tubing string and over the On Off. When the Free Mandrel Assembly is inserted into the Fixed Bottom Hole Assembly, the FMA complements the hydraulic circuits they both contain to accomplish selective injection in every formation.
(E) A Complementary Assembly (CA), which is screwed to the lower part of the Fixed Bottom Hole Assembly (D) and comprises, in its interior part, the Telescopic Union screwed to the central and lower part of the Fixed Bottom Hole Assembly (D); the Injector Tube; the Injector Plug and the Rupture Disc passage.
In its exterior part, the Complementary Assembly (E) is made up of the upper part of the On Off screwed to the outer and lower part of the Fixed Bottom Hole Assembly (D). The lower part of the On Off is screwed to the upper end of the Upper Packer while the Injector Plug is screwed at its lower end with the Rupture Disk passage. To complete the installation, the 60.325 mm (2″⅜) tubing string is screwed to the lower part of the Injector Plug to fix the Lower Packer in the adequate position to separate both formations.
[0005] One or two 60.325 mm (2″⅜) tubings are placed below the Lower Packer, and the Shear Out is placed on its end.
[0006] Some of the elements described in the above three paragraphs are commonly used in the industry, but they are essential for the operation of this invention.
[0007] Said Free Mandrel (C) runs together with all well valves from the Lubricator to its insertion in the FBHA, employing the Catcher of the Lubricator to remove or replace the Injection Valves during the upstroke or removal. For that purpose, its valve system is designed to allow fluid passage from the Annular to the tubing string, blocking the passage of the fluid from the tubing string to the Annular with the purpose of protecting the Casing even when this Free Mandrel is not inserted into the FBHA. In other words, it will keep the Casing totally isolated from the pressure and the contact of the injection fluid. This also facilitates protective fluid circulation (fresh water with germicide) in the Annular to fill it or use it during the upstroke of the Transport (B) and Free Mandrel (C) Assemblies.
[0008] Each of these elements has its special own characteristics to achieve the purpose of the invention.
BACKGROUND INFORMATION
[0009] In the search for background information, several embodiments have been found. Some of the documents are transcribed below:
[0010] US2004238218 (A1): Injecting a Fluid into a Borehole Ahead of the Bit, applied by Runia Douwe Johannes, Smith David George Livesey, Worrall Robert Nicholkas; Shell Oil Company.
[0011] It describes a method and system for introducing a fluid into a borehole, in which there is arranged a tubular drill string including a drill bit, wherein the drill bit is provided with a passageway between the interior of the drill string and the borehole, and with a removable closure element for selectively closing the passageway in a closing position, and wherein there is further provided a fluid injection tool comprising a tool inlet and a tool outlet, the method comprising passing the fluid injection tool outlet through the drill string to the closure element, and using it to remove the closure element from the closing position; passing the fluid injection tool outlet through the passageway, and introducing the fluid into the borehole from the interior of the drill string through fluid injection tool into the borehole.
[0012] It does not collide with the purpose of the present description.
[0013] US2005011678 (A1): Method and Device for Injecting a Fluid into a Formation. Applicant: Akinlade Monsuru Olratunji (NL), Lightelm Dirk Jacob (NL), Zisling Djurre Hans, Shell Oil company.
[0014] A method of injecting a stream of treatment fluid into an earth formation in the course of drilling a borehole into the earth formation, using an assembly comprising a drill string provided with at least one sealing means arranged to selectively isolate a selected part of the borehole from the remainder of the borehole, the drill string further being provided with a fluid passage for the stream of treatment fluid into the selected part of the borehole. The method involves: operating the drill string and stopping the drilling operation when a zone for which treatment is desired is arranged adjacent to the part of the selected part of the borehole; isolating the selected part of the borehole using the sealing means so as to seal the drill string relative to the borehole wall; and, pumping the stream of treatment fluid via the fluid passage into the selected part of the borehole and, from there, into the treatment zone.
[0015] The mentioned characteristics that identify this embodiment do not give rise to a concrete antecedent of this invention.
[0016] U.S. Pat. No. 4,050,516 (A): Method of Injecting Fluids into Underground Formations. Applicant: Dresser Ind.
[0017] A method of injecting fluids into underground formations such as oil wells, and particularly advantageous for treating low-pressure formations having bottomhole pressures below normal tubing hydrostatic pressure, utilizes the steps of lowering into the borehole a tubing string, locating near the formation to be treated a partially pressure-balanced valve adapted to support a column of fluid in the string of tubing, and applying pressure to the column of fluid in the tubing to inject fluid through the valve into the formation.
[0018] It does not interfere with the invention either.
[0019] U.S. Pat. No. 4,433,728 (A): Process for selectively reducing the fluid injection or production rate of a well. Applied by Marathon Oil Co (US).
[0020] This process improves the real conformance of fluids injected into or produced from a subterranean formation via a multi-well system wherein significantly greater amounts of fluid than desired are injected into or produced at least by one well of the multi-well system, in relation to other wells of the system. An aqueous caustic solution and an aqueous solution containing a polyvalent cation dissolved therein are caused to mix near the well bore environment of said one well, thereby forming an insoluble precipitate which reduces the permeability of the well bore environment substantially over the entire well bore interval. It has different characteristics that move it away from the embodiment being compared.
[0021] U.S. Pat. No. 4,433,729 (A): Process for selectively reducing the fluid injection rate or production. Applicant: Marathon Oil Co (US).
[0022] This patent is similar to the previous one. It utilizes a permeability-reducing chemical compound.
[0023] CA2086594 (A1): Selective Placement of a permeability-reducing material to inhibit fluid communication between a near wellbore interval and an underlying aquifer. Applicant: Marathon Oil Co. (US).
[0024] It's also based on injection of a permeability-reducing material.
[0025] FR 2855552 (A1): A hydraulic fracturing method for operating e.g. oil wells, includes sequential, pressure-controlled phases of fluid, and ballast injection with pause for relaxation or formation. Applicant: Despax Damien (Fr).
[0026] The method complies nine successive phases. Fracturing fluid loaded with ballast, ballast-free fluid, ballast mixed with fibers or coated adherents is used in the different phases.
[0027] It is clearly shown that there is no interference with this invention.
[0028] GB1179427 (A): Equipment for Injecting Fluids into an Underground Formation. Applied by Shell Int. research (NL).
[0029] Fluid injected into a well is directed into one or two formations of different resistances to injection and separated by impermeable formation The “soak process” of oil Transport is carried out in a well. Steam injected into the well through a tubing is used to make oil flow into the tubing. Packers and labyrinth seals are alternatively used.
[0030] These characteristics do not appear in this invention.
[0031] RU2002126207 (A): Oil Well. Method for Oil Extraction from the Well and Method for Controllable Fluid Injection into Formation through the Well. Inventors: Stedzhemejer D. L., Vajngar K. D., Bernett R. R., Sevendzh V. M., Karl F. G. M, Khersh D. M.
[0032] Well has casing pipe with a plurality of perforated sections and production string located inside the casing pipe. An alternating current source electrically linked with at least one of casing pipe and production string is located on ground surface and serves to conduct alternating current from ground surface into well. Controlled well section is also provided and it includes communication and control unit electrically linked with at least one of casing pipe and production string, having sensing means and electrically operated valves connected thereto. Communication and control unit is adapted to regulate flow between outer and inner production string parts.
[0033] It is unnecessary to go on describing in detail this patent structure as it evidently does not collide with the object of this invention.
[0034] U.S. Pat. No. 4,462,465 (A): Controlling injection fluids into wells. Applicant: Otis Eng. Co. (US).
[0035] In this patent, a Side Pocket Fix Mandrel is described. It consists of a constructive variable of mandrels fixed to the bottom of conventional wells.
[0036] In fact, the device is parallel with the main bore. A lateral side port communicates the receptacle with the exterior of the side pocket of the mandrel. A flow control assembly includes a sliding sleeve valve and a control valve, both designed to be removed from the receptacle. The sleeve valve is movable within the receptacle between a closed position and an open position relative to the side port, and includes collet fingers having outwardly projecting latching lugs for engagement in a receptacle latching recess in the closed position. The bore of the receptacle is slightly larger below the latching recess than it is above the recess, so that limited inward movement of the latching lugs, restrained by an insert within the sleeve valve, will permit movement of the valve downward to the open position but will not allow movement of the valve upward from the closed position, so long as the insert is in place. A control valve, to be selectively placed within the receptacle and latched with the sleeve valve includes a nose which is received within the sleeve valve and limits the inward deflection of the collet finger latching lugs. The control valve includes a latching lug for latching in another receptacle latching recess, when the sleeve valve has been moved to the lower open position. The control valve and sleeve valve have a coating latching mechanism so that when control valve is withdrawn, it lifts the sleeve valve to the closed position and then disengages from the sleeve valve. The sleeve valve includes an internal latching recess to enable withdrawal of the sleeve valve from the receptacle by a suitable pulling tool.
[0037] To conclude, U.S. Pat. No. 4,671,352 (A): Apparatus for selectively injecting treating fluids into earth formations. Applicant: Arlington Automatics Inc. (US).
[0038] The formation-treating apparatus described herein, is adapted to be dependently supported in a well bore from a pipe string and which includes upper and lower telescoped body members adapted to be selectively moved between upper and lower operating positions for controlling the injection of treating fluids into one or more earth formations traversed by the well bore. A pair of spaced packer elements are mounted on the lower member above and below a discharge port and cooperatively arranged for isolating a well bore interval that is to be treated by discharging one or more treating fluids in the pipe string from the port. To control the injection of treating fluids, retrievable valve means are also cooperatively arranged within the body members and adapted to be alternatively seated on upper and lower full-bore valve seats in the upper and lower bodies in response to movement of the bodies to their operating positions. In this manner, whenever the upper body member is moved to one of its operating positions, the valve means will be seated on the lower valve seated n the lower valve seat and unseated from the upper valve seat to open fluid communication between the pipe string and the treating tool. On the other hand, whenever the upper body member is moved to its other operating position, the valve means will be seated on the upper valve seat to trap treating fluids in the pipe string and discharge any unused fluids into the well bore.
[0039] According to the background information found, it is evident that in known conventional pieces of equipment, to which the analyzed variables refer, all of them use fixed installations in the bottom hole. Consequently, when it is necessary to repair or replace any of the valves placed inside the mandrel, they have to be brought up to the surface.
[0040] This necessarily demands the presence of specialized equipment at the well site to raise the mandrel by means of a cable or wire, and a jar socket or also other pieces of equipment used in the industry.
[0041] In order to perform this operation, production has to be stopped, the device has to be raised from the bottom hole, necessary replacements are made, it has to be lowered and then, production is resumed. This produces costs in personnel, down time (during which the well is not operating) and lead time (between order and delivery of the equipment) at the oil field.
[0042] This is the procedure for the maintenance of mechanical systems for conventional fixed installations.
[0043] With this invention, all these problems are advantageously solved because the complete mandrel installation is raised. The mandrel is not fixed to the bottom hole because it is free. This results in an important time and extra hand work advantage because it can be operated by only one person from the surface by simply handling the valve set provided by the invention.
[0044] To summarize, among other advantages of the invention described herein, the following can be mentioned:
1. Operational Advantage:
[0045] Fluid injection is continuous and it is not interrupted in any of the operational stages as the formations are kept constantly pressurized. That is to say, the fundamental purpose of fluid injection (secondary recovery) is to pressurize the formations to achieve a larger formation volume in the surrounding or adjacent producing wells.
2. Economic Advantages:
[0046] Minor investment or cost in initial equipment.
[0047] No additional equipment is required, as wireline or slikeline or external personnel because valve setting up or removal, and all operations to fix both assemblies are performed in a significantly shorter time. This results in reduced time for equipment use.
[0048] The operation is performed by control personnel of injector wells (either the operator or field supervisor) from the surface by handling the well head manifold valves. The change is immediately performed the moment it is required.
[0049] Consequently, for example, for 2500 m deep installations, the FMA described herein, reaches the surface with all valves installed in about 30 minutes and requires a slightly shorter time in the downstroke. Both strokes are attained with the same injection fluid. This process will be indicated in the operational relation by means of the attached figures.
[0050] This also implies that the installations are active during lead time and the time employed by the equipment to pull up every valve from the bottom hole and replace it for another. This operation is performed after the well is depressurized. This advantage is utilized several times while the well is producing, thus, accumulatively, adding a significant value. —It is worth noting that while the equipment is expected to reach the location and while the operation is being performed, the formation pressure is lost and so is its influence on the producing wells.
[0051] A blind plug (not shown in Figures) is provided so that the tubing tightness may be verified at the initial, intermediate and final stage of the installation.
[0052] Strokes can be performed to verify the accumulated depositions and in increasing periods, that is to say, beginning with short periods and increasing them in order to define the most suitable one for each well without depressurizing the formations, and with no additional equipment costs or external personnel.
[0053] The inhibited fluid lodged in the Annular can be changed for maximum Casing protection in case of long injection periods without replacing injection valves or employing pulling equipment to disconnect the On Off ( 43 ).
[0054] Besides, it can block any formation, examine or stimulate others. This is achieved by removing the FMA (C), leaving the formation circuit in service and blocking the other one. This also allows determining if there is any interference between any of the formations by injecting fluid in one and placing Amerada® Gauge, an instrument to measure pressure in the bottom hole, inside another mandrel to verify pressure variation in different injection flows.
[0055] In order to make this invention, a free mandrel with protected casing, more comprehensible so that it can be put into practise easily, a detailed description of a preferable embodiment will be given in the following paragraphs.
[0056] This will refer to the accompanying illustrative figures as a demonstrative example but not limiting the invention. Its components will be able to be selected among diverse equivalents without moving away from the invention principles as established in these documents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] The main invention components are schematically represented in different views in the Figures which accompany the present technical and legal description. As the component parts have a great length but a relatively small diameter, the Figures have been deliberately deformed so that the component parts can be distinguished to be explained. In some of the Figures hydraulic flow circulations, which are necessary for its operation, are identified with different conventional symbols:
[0000] +=Injection fluid, provided by the Power Plant with the highest pressure flowing into all injection valves to be regulated according to the conditions of every formation.
#=Controlled fluid to be injected in the upper formation. It comes out through the lower end of the upper valve.
*=Controlled fluid to be injected in the lower formation. It comes through the lower end of the lower valve.
x=Fluid injected at low pressure through the Annular (e 1 ) to achieve the return of the Free Mandrel Assembly.
[0058] The pressure is approximately 2 to 3 kg/cm 2 . (Obviously the higher the pressure, the faster the return speed, but the mentioned pressure is the recommended one). Again, 30 minute return time is achieved in a 2500 m deep installation.
[0000] --=Fluid removed from the tubing as the Free Mandrel assembly moves up to the surface. Its pressure is slightly lower than the one that pushes up the Free Mandrel Assembly.
[0059] =White/empty space=Settled fluid or only with hydrostatic pressure (for example, in the annular between the casing and the tubing during the injection process).
[0060] As an operative example of the invention, the simplest embodiment applied to purge water injection of only two formations: an upper and a lower one will be described hereinafter, as informed above.
[0061] In this description, the Fluid concept will be taken in its widest sense, that is to say, referring to any type of liquid or gas.
[0062] The invention equipment is essentially made up of the following operative assemblies.
A—Surface Assembly (SA)
B—Transport Assembly (TA)
C—Free Mandrel Assembly (FMA)
D—Fixed Bottom Hole Assembly (FBHA)
E—Complementary Assembly (CA)
[0063] The Figures are as follows:
[0064] FIG. 1 is an elevational longitudinal sectional view of the general layout of the invention. Here the position of a series of cross sections, numbers I to VIII, is shown to facilitate the functional explanation of the device.
[0065] FIG. 2 is an enlarged partial view of one section of FIG. 1 where the Surface Assembly (A), component of the invention, is shown in detail.
[0066] FIG. 3 is a detailed view of the Transport Assembly (B), component of the invention. When operating, the only fluid that circulates (+) is the one that comes in through 73.025 mm (2″⅞) tubing ( 9 ) (i), goes through the Fishing Neck ( 11 ) and connects with the Upper Free Mandrel (C).
[0067] FIG. 4 is an elevational sectional view where the characteristics of the Free Mandrel Assembly (C) and fluid circulation are shown.
[0068] FIG. 5 shows both Transport (B) and Free Mandrel Assembly (C) as they run through the well from the Lubricator ( 3 ) to the Fixed Bottom Hole Assembly (D) in their downstroke, and from the Fixed Bottom Hole Assembly (D) to the Lubricator ( 3 ), in their upstroke. Different fluids are shown inside both assemblies, the incoming one (+), the one to be injected (#) in the upper formation and the one to be injected (*) in the lower formation.
[0069] FIG. 6 is an elevational sectional view of the Fixed Bottom Hole Assembly (D) with its essential components.
[0070] FIG. 7A represents the Fixed Bottom Hole Assembly (D) in connection with the Free Mandrel (C) and Transport (B) Assemblies. The (+) fluid entering through the 73.025 mm (2″⅞) Tubing ( 9 ), the Upper Free Mandrel, the outcoming (#) fluid through the Middle Plug ( 17 ) radial passage ( 19 ), to be injected in the Upper Formation, in the plane of said Middle Plug radial passage ( 19 ).
[0071] FIGS. 7B and 7A are the same Figures but, in 7 B, the sectional plane is perpendicular to passage ( 19 ). The incoming fluid (+) path is shown. This reaches the lower valve through the middle plug ( 17 ) longitudinal passages (C 1 ) to be injected in the lower formation (*).
[0072] FIG. 8 shows the Fixed Bottom Hole Assembly (D) screwed to the Complementary Assembly (E). The Transport Assembly (B) is inserted inside it with the Free Mandrel Assembly (C) during simultaneous injection in both formations. Fluids are also shown as they circulate through different passages.
[0073] FIG. 9 only shows the injection in the upper formation (#) of the invention layout. The Transport (B), Free Mandrel (C), Fixed Bottom Hole (D) and Complementary Assemblies (E) are represented while showing operative hydraulic paths.
[0074] FIG. 10 , a transverse sectional view on line III-III ( FIG. 1 ), shows the Upper Formation injection fluid in the Middle Plug ( 17 ) axial passage plane ( 19 ), the Fixed Bottom Hole Assembly (D), vertical passages (C 1 ) (+) and (C 2 ) (#) and Casing ( 10 ). The Annulars (e 2 ) (white space) and (e 6 ) (#) are also shown.
[0075] FIG. 11 shows the injection in the Lower Formation (*) of the invention layout. In this Figure, The Transport (B), Free Mandrel (C), Fixed Bottom Hole (D) and Complementary (E) Assemblies are represented while showing operative hydraulic paths.
[0076] FIG. 12 , a transverse cross-sectional view on line IV-IV ( FIG. 1 ), shows lower formation (*) fluids flowing out of the Lower Injection Valve ( 21 ) and fluids involved in lower formation injection. As in the previous Figure the Casing ( 10 ), the Fixed Bottom Hole Assembly (D) and the Lower Plug ( 22 ) are also shown together with (C 2 ) (white space) and (C 3 ) (white space) passages, and the Annular (e 2 ) (white space).
[0077] FIG. 13 shows simultaneous injection in both formations. The incoming plant fluid (+) is controlled by the corresponding valves for Upper (#) and Lower (*) Formation injection.
[0078] The Transport (B), Free Mandrel (C), Fixed Bottom Hole and (D) and Complementary Assemblies (E) are represented while showing operative hydraulic paths with the above mentioned symbols (+, #, *).
[0079] FIG. 14 , a transverse cross-sectional view on line V-V ( FIG. 1 ), corresponds to Upper and Lower Formation simultaneous injection at the height of the Casing Protective Valve ( 36 ) of the Fixed Bottom Hole Assembly (D) lower end. Upper Formation injection fluid (#) goes through the Annular (e 9 ) defined by the FBHA (D), inner diameter and the outer diameter of the inner body of the Telescopic Union ( 37 ) and the (*) fluid through the inside of the Telescopic Union ( 37 ).
[0080] FIG. 15 , a transverse cross-sectional view on line VI-VI ( FIG. 1 ), corresponds to the lower part of the Fixed Bottom Hole Assembly (D) below the Casing Protective Valve ( 36 ) with the simultaneous injection fluids (e 9 ) acting in the Upper (#) and Lower Formations (*) through the inside of the Injection Tube ( 40 ).
[0081] FIG. 16 , a transverse cross-sectional view on line VII-VII ( FIG. 1 ), shows Upper and Lower Formation fluid injection, and fluid circulation in the Injector Plug ( 41 ) plane through the Rupture Disc passage ( 42 ). Casing Upper Perforations ( 49 ), Injection Tube ( 40 ) and the Injector Plug ( 41 ) together with Annulars (e 3 ) (#) and (e 11 ) (#) can also be seen. Lower Formation fluid (*) circulates through the inside of the Injection Tube ( 40 ).
[0082] FIG. 17 , a transverse cross-sectional view on line VIII-VIII ( FIG. 1 ), only shows Lower Formation injection (*) and fluid circulation in the Shear Out ( 48 ) passage plane and Casing Lower Perforations ( 50 ) in that area. Annular (e 5 ) (*) and the Shear Out inner passage (*) (C 4 ) are also shown.
[0083] FIG. 18 represents fluid distribution during the Free Mandrel Assembly (C) upstroke and when the System injects in both formations without flow control and with low pressure (x). It is only when the Free Mandrel Assembly (C) hooked in the Transport Assembly (B) is inserted in its position inside the Fixed Bottom Hole Assembly (D) that the injection in both formations is controlled.
[0084] The resulting hydraulic circuits can be identified with the symbols that represent the operating pressures. In the Annular (e 1 ) (x) and in the 73.026 mm (2″⅞) tubing ( 9 ) (i) (--).
[0085] FIG. 19 shows a transverse cross-sectional view on line I-I ( FIG. 1 ) with fluid circulation in simultaneous injection process in both formations. This takes place at the Well Head ( 8 ). The Casing ( 10 ) and the 73.026 mm (2″⅞) Tubing ( 9 ) (i) are shown. There is only hydrostatic pressure (white space) in the annular between them (e 1 ). There is (+) in the inside of the Tubing ( 9 ).
[0086] FIG. 20 , a transverse cross-sectional view on line II-II ( FIG. 1 ), shows fluid circulation in the Free Mandrel Assembly upstroke, (--) flowing inside the 73.026 mm (2″⅞) Tubing ( 9 ) (i), and (x) through (e 1 ).
DESCRIPTION OF THE INVENTION COMPONENTS
[0087] FIGS. 1-20 above, specially developed for this description, will be taken as reference. In these Figures, the main details of all the parts of the essential assemblies that make up the invention have been taken into account.
[0088] These parts are the following:
1 —Pipeline from Water Power Plant 2 —Catcher 3 —Lubricator 4 —Mast 5 —Impeller 6 1 —V1 (Standard Valve) 6 2 —V2 (Standard Valve) 6 3 —V3 (Standard Valve) 6 4 —V4 (Standard Valve) 6 5 —73.026 mm (2″⅞) conventional full passage Injection Valve 7 —Retention Valve 8 —Well Head 9 —73.026 mm (2″⅞) Tubing i—Tubing ( 9 ) Interior (Direct) e 1 —Annular between 9 and 10 10 —Casing 11 —Fishing Neck 12 —Retention Valve 13 —Rubber Cups 14 —Lower Connector 15 —Outer Jacket 16 —Seal Ring 17 —Middle Plug 18 —Upper Formation Injection Valve 19 —Middle Plug radial passage 20 —Seal Ring 21 —Lower Formation Injection Valve 22 —Lower Plug 23 —Seal Ring 24 —Upper Body 25 —Upper Packer Collar 26 —Seal Ring 27 —Lock Nut 28 —Lower Body 29 —Seal Ring 30 —Spacer 31 —Spacer Injection outlet Perforation 32 —Lower Packer Collar 33 —Seal Ring 34 —Seat 35 —Seal Ring 36 —Casing Protective Valve 37 —Telescopic Union inner body 38 —Seal Ring 39 —Telescopic Union outer body 40 —Injection Tube 41 —Injector Plug 42 —Rupture Disc passage 43 —On Off 44 —Upper Packer 46 —Lower Packer 47 —60.325 mm (2″⅜) Tubing 48 —Shear Out 49 —Casing Upper Perforations—Upper Formation 50 —Casing Lower Perforations—Lower Formation
[0144] In FIGS. 10 , 12 , 14 , 15 , 16 , 17 , 19 and 20 , which correspond to different transverse cross sectional views of the Casing, there are vertical passages and Annulars determined by different parts coupled together in the installation. Injection fluids circulate through these vertical passages:
[0000] C 1 —It is placed in the Middle Plug ( 17 ). They are passages in the Free Mandrel Assembly (C) central body.
C 2 —The Annular (e 6 ) where the regulated pressure (#) is discharged through the Upper Formation Injection Valve ( 18 ) and conducted to the Annular (e 9 ) placed between the Telescopic Union inner body ( 37 ) and the interior of the Fixed Bottom Hole Assembly (D). C 2 are eccentric vertical passages in the FBHA (D) which connect (e 6 ) with (e 9 ).
C 3 —Vertical passage containing Valve ( 36 )
C 4 Shear Out inner passage
[0145] Note: Annular space or Annular is the space between the inner diameter of an exterior tube and the larger diameter of an interior tube. Both tubes can or cannot be concentric. There are several Annulars in this invention layout:
[0000] e 1 Between the Casing ( 10 ) and the 73.026 mm (2″⅞) Tubing ( 9 )
e 2 Between the Casing ( 10 ) and the FBHA (D)
e 3 Between the Casing ( 10 ) and the Injector Plug ( 41 )
e 4 Between the Casing ( 10 ) and the 60.325 mm (2″⅜) Tubing ( 47 )
e 5 Between the Casing ( 10 ) and the Shear Out ( 48 )
e 6 Between the Middle Plug ( 17 ) and the FBHA (D)
e 7 Between the Upper Mandrel Jacket ( 15 ) and the Upper Injection Valve ( 18 )
e 8 Between the Lower Valve ( 21 ) and the FBHA (D) interior
e 9 Between the Telescopic Union inner body ( 37 ) and the inside of the FBHA (D)
e 10 Between the Telescopic Union outer body ( 39 ) and the On Off ( 43 )
e 11 Between the Injection Tube ( 40 ) and the Injector Plug ( 41 )
[0146] As all components and their characteristics have been defined, here follows their layout and existing relationships among them.
[0147] According to FIG. 1 , the equipment is composed of A, B, C, D, and E Assemblies. In this Figure, transverse cross-sectional lines are indicated (I-VIII) to facilitate the comprehension of the structures of said assemblies. Only some components are indicated to facilitate the comprehension of the invention structure:
[0000] 9 —73.026 mm (2″⅞) Tubing
i—Tubing ( 9 ) Interior. (Direct)
10 —Casing
[0148] 37 —Telescopic Union inner body
38 —Telescopic Union Seal Rings
[0149] 39 —Telescopic Union outer body
40 —Injection Tube
41 —Injector Plug
[0150] 42 —Rupture Disc passage
43 —On Off
44 —Upper Packer
46 —Lower Packer
[0151] 47 —60.325 mm (2″⅜) Tubing
48 —Shear Out
49 —Upper Formation Casing Perforations
50 —Lower Formation Casing Perforations
[0152] FIG. 2 corresponds to Surface Assembly (A) made up of:
[0000] 1 —Pipeline from Water Power Plant
2 —Catcher
3 —Lubricator
4 —Mast
5 —Impeller
6 1 —V1 (Standard Valve)
6 2 —V2 (Standard Valve)
6 3 —V3 (Standard Valve)
6 4 —V4 (Standard Valve)
[0153] 6 5 —73.026 mm (2″⅞) conventional full passage Injection Valve
7 —Retention Valve
8 —Well Head
[0154] 9 —73.026 mm (2″⅞) Tubing
I—Tubing Interior ( 9 ) (Direct)
[0155] e 1 —Annular between 9 and 10
10 —Casing
[0156] FIG. 3 corresponds to Transport Assembly (B) made up of:
11 —Fishing Neck
12 —Retention Valve
13 —Rubber Cups
14 —Lower Connector
[0157] In this Figure the injection fluid provided from the Plant is represented by the (+) symbol which crosses it all over.
[0158] FIG. 4 corresponds to the Free Mandrel Assembly (C) made up of:
15 —Outer Jacket
16 —Seal Ring
17 —Middle Plug
18 —Upper Formation Injection Valve
[0159] 19 —Middle Plug radial passage
20 —Seal Ring
21 —Lower Formation Injection Valve
22 —Lower Plug
23 —Seal Ring
[0160] Incoming injection fluid is represented here with the (+) symbol.
[0161] It is divided into two streams:
[0000] 1—It enters through the upper part of the Injection Regulating Upper Valve ( 18 ) which delivers the already controlled fluid (#) to be injected in the upper formation through the Middle Plug ( 17 ) radial passage ( 19 ).
2—It circulates through the Annular (e 7 ) to guide the fluid through the Middle Plug ( 17 ) vertical passages (C 1 ) (not shown in this view) and feed with injection fluid (+) the Lower Injection Valve ( 21 ) which delivers the controlled fluid (*) to inject in the Lower Formation through the Lower Plug ( 22 ).
[0162] In FIG. 5 , the fluid (+) goes through the Transport Assembly (B) and the Free Mandrel Assembly (C) and enters the injection fluid inlet (+) in its upper part. The controlled fluid (#) continues towards the Upper Formation by the lower part of the Upper Injection Valve ( 18 ) and comes out through the Middle Plug passage ( 19 ). Injection Fluid (+) continues through the vertical passages, not shown in this view, until it feeds the Lower Injection Valve ( 21 ) in its upper part and, from here, the controlled fluid (*) comes out to inject the Lower Formation through the Lower Plug ( 22 ).
[0163] FIG. 6 represents the Fixed Bottom Hole Assembly (D) made up of:
24 —Upper Body
25 —Upper Packer Collar
26 —Seal Ring
27 —Lock Nut
28 —Lower Body
29 —Seal Ring
30 —Spacer
[0164] 31 —Spacer Injection outlet Perforation
32 —Lower Packer Collar
33 —Seal Ring
34 —Seat
35 —Seal Ring
36 —Casing Protective Valve
10 —Casing ( 10 )
[0165] e 2 —Annular
C 2 —Vertical passage
C 3 —Vertical passage
[0166] In FIGS. 7A and 7B , injection fluid (+) enters through 73.026 mm (2″⅞) ( 9 ) (i) Tubing into the Assembly (B) upper end, goes through the Transport Assembly (B), then goes into the Free Mandrel Assembly (C) through the upper end of the Upper Injection Valve ( 18 ) and comes out already controlled (#) towards the Upper Formation going through the Annular (e 6 ) and the Spacer Injection outlet Perforation ( 31 ). Then it goes through vertical passages (C 2 ) of the FBHA (D) and the Annular (e 9 ). Simultaneously, the other injection fluid stream (+) coming into the Upper Mandrel flows through the Annular (e 7 ), the vertical passages of the Middle Plug (C 1 ), (only shown in FIG. 7B ) until it reaches the upper end of the Lower Injection Valve ( 21 ), which controls the fluid to be injected in the Lower Formation (*). Said injection fluid (+) stream goes through the Lower Plug ( 22 ) and continues through the Telescopic Union ( 37 ).
[0167] FIG. 8 corresponds to the B, C, D and E Assemblies. In addition to the already defined components and so as not to fall into repetitions, these are the remaining ones:
[0000] 37 —Telescopic Union inner body
39 —Telescopic Union outer body
40 —Injection Tube
41 —Injector Plug
[0168] 42 —Rupture Disc passage
43 —On-Off
44 —Upper Packer
[0169] In this Figure, the injector circuits of both formations are represented. The injection fluid (+) enters through 73.026 mm (2″⅞) Tubing ( 9 ) (i), goes through the Transport Assembly (B), gets into the Free Mandrel Assembly (C) through the upper end of the Upper Injection Valve and comes out as controlled fluid (#) towards the Upper Formation through the Middle Plug radial passage ( 19 ). It passes through the Annular (e 6 ) and the Spacer Injection outlet Perforation ( 31 ). Then it channels through the FBHA (D) vertical passages (C 2 ), the Annulars (e 9 ), (e 10 ) and (ell), and the Rupture Disc passage ( 42 ).
[0170] Simultaneously, the other injection fluid stream (+) that goes into the Upper Mandrel, flows through the Annular (e 7 ), the Middle Plug ( 17 ) vertical passages (C 1 ) until it reaches the upper end of the Lower Injector Valve ( 21 ) which controls the fluid to be injected in the Lower Formation. (*). It goes through the Lower Plug ( 22 ) and continues through the inside of the Telescopic Union ( 37 and 39 ), the Injection Tube ( 40 ) and the Injector Plug ( 41 ). Meanwhile the Annular (e 1 ), (e 2 ) and the vertical passage (C 3 ) are kept without pressure (white space).
[0171] In FIGS. 9 , 11 and 13 , the invention components that have not been mentioned follow below.
46 —Lower Packer
[0172] 47 —60.325 mm (2″⅜) Tubing
48 —Shear Out
[0173] 49 —Casing Upper Perforations—Upper formation
50 —Casing Lower Perforations—Lower formation
[0174] In FIG. 9 , it can be observed that there is no pressure in the Annulars (e 1 ), (e 2 ) and in the passage (C 3 ) (white space). The Upper Formation Injection is the only one represented, that is, the Upper Injection Valve ( 18 ) is regulating the flow (#) and the lower one ( 21 ) is blocked. So, the lower valve ( 21 ) is represented as if it were a solid body that blocks fluid passage. For that reason, the central passage (corresponding to the Lower Formation circuit) is shown without pressure or fluid (white space). Consequently, the Injection Plant pressure (+) acts through 73.026 mm (2″⅞) Tubing ( 9 ) (i), as the regulated fluid (#) is injected to the Upper Formation through the Casin Upper Perforations ( 49 ). Through the Annular (e 1 ), (e 2 ) and the passage (C 3 ) there is no fluid circulation. There is only hydrostatic pressure (white space).
[0175] In FIG. 10 , a transverse cross-sectional view on line ( FIG. 1 ), the Annulars (e 2 ) are marked as empty (white space). The Plant injection fluid circulation (+) goes through the Middle Plug ( 17 ) vertical passages (C 1 ) and comes out regulated (#) through the Middle Plug ( 17 ) transversal (radial) passage ( 19 ) to the Annular (e 6 ) and through the vertical passages (C 2 ) (#).
[0176] In FIG. 11 , it can be observed that in the Annulars (e 1 ),(e 2 ) and the passage (C 3 ) there is no pressure (white space) as only the Lower Injection Formation is represented. The injection fluid (+) that enters through 73.026 mm (2″⅞) ( 9 ) (i) goes through the Transport Assembly (B) and comes into the Free Mandrel Assembly (C) through the upper end of the blind Upper Injection Valve (it does not allow fluid passage and it is represented as a solid). The Annular (e 6 ), Spacer Injection outlet Perforation, the FBHA (D) vertical passages (C 2 ), the Annulars (e 9 ), (e 10 ) and (e 11 ) and the Rupture Disc passage ( 42 ) have no pressure. No fluid circulation is observed in the figure.
[0177] At the same time, the other injection fluid stream (+) coming into the Upper Mandrel flows through the Annular (e 7 ) and the Middle Plug vertical passages (C 1 ) until it reaches the upper end of the Lower Injector Valve ( 21 ), which controls the fluid to be injected in the Lower Formation (*). Said injection fluid stream (*) goes through the Lower Plug ( 22 ) and continues through the interior of the Telescopic Union ( 37 and 39 ), Injection Tube ( 40 ), Injector Plug ( 41 ), 60.325 (2″⅜) ( 47 ) Tubings, Lower Packer ( 46 ), the 60.325 mm (2″⅜) ( 47 ) and Shear Out ( 48 ).
[0178] Meanwhile, the Annulars (e 1 ) and (e 2 ), and the vertical passages (C 2 ) and (C 3 ) are kept without pressure (white space).
[0179] FIG. 12 , a transverse cross-sectional view on line IV-IV ( FIG. 1 ), shows the controlled fluid (*) circulation to be injected in the Lower Formation through the Lower Plug ( 22 ) central passages. Meanwhile the Annular (e 2 ) and the vertical passages (C 2 ) and (C 3 ) are kept without pressure (white space).
[0180] FIG. 13 shows that in the Annulars (e 1 ) and (e 2 ), and passage (C 3 ) there is no pressure as simultaneous Injection in the Upper (#) and Lower (*) Formations with regulated fluids are represented here. Valves ( 18 ) and ( 21 ) are regulating injection fluids in both formations. Consequently, the injection fluid (+) enters the 73.026 mm (2″⅞) Tubing ( 9 ) (i), goes through the Transport Assembly (B) and flows into the Free Mandrel Assembly (C) through the Injection Valve upper end ( 18 ) to the upper formation (#) and in the lower one (*), going out through perforations ( 49 ) and ( 50 ). To complete the regulated fluid circuit to be injected in the Upper Formation as shown in FIG. 9 , this fluid course is added as it comes out of the Rupture Disc passage ( 42 ) until it gets into the chamber delimited as follows:
[0000] 1. In the upper part by the lower side of the Upper Packer ( 44 )
2. In the outer part by the Casing ( 10 )
3. In the inner part by the Telescopic Union ( 37 and 39 ), Injection Tube ( 40 ) and Injector Plug ( 41 )
4. In the lower part by the upper side of the Lower Packer ( 46 )
[0181] That is to say, the regulated fluid (#) is forced to go through the Casing Upper Perforations ( 49 ) and enter the Upper Formation.
[0182] To complete the regulated fluid circuit to be injected in the Lower Formation (*) as shown in FIG. 11 , this fluid course is added as it comes out of the Injector Plug central passage ( 41 ), 60.325 mm (2″⅜) Tubings ( 47 ), Lower Packer ( 46 ), 60.325 mm (2″⅜) Tubings ( 47 ), and Shear Out ( 48 ), until it gets into the chamber delimited as follows:
[0000] 1. On the upper part by the lower side of the Lower Packer ( 46 )
2. On the outer part by the Casing ( 10 )
3. In the inner part by the 60.325 mm (2″⅜) Tubings and the Shear Out ( 48 )
4. On the lower part by the bottom hole
[0183] That is to say, the regulated fluid (*) is forced to go through the Casing Lower Perforations ( 50 ) and enter the Lower Formation.
[0184] FIG. 14 , a transverse cross-sectional view on line V-V ( FIG. 1 ), shows that there is no fluid circulation through the Annular (e 2 ) and the white (C 3 ) passage, that is to say, no fluid circulation is observed within them. Through the interior of the Telescopic Union ( 37 ) inner body, the controlled fluid (*) is conducted to the Lower Formation (*), and the controlled fluid (#) for the Upper Formation is conducted through the Annular (e 9 ).
[0185] FIG. 15 , a transverse cross-sectional view on line VI-VI ( FIG. 1 ), represents the Lower Formation injection fluid (*) circulation through the Injection Tube ( 40 ) central passage and the Upper Formation controlled fluid (#) through the Annular (e 9 ) while there is no circulation through the Annular (e 2 ).
[0186] FIG. 16 , a transverse cross-sectional view on line VII-VII ( FIG. 1 ), represents the Upper Formation fluid injection (#) that comes through the Annular (e 11 ), goes through the Rupture Disc passage ( 42 ), fills the Annular (e 3 ) and goes through the Casing Upper Perforations ( 49 ) until it gets to the Upper Formation. The Lower Formation injection fluid (*) goes through the Injection Tube ( 40 ) interior.
[0187] FIG. 17 , a transverse cross-sectional view on line VIII-VIII ( FIG. 1 ), shows injection fluid (*) flowing to the Lower Formation through the Shear Out ( 48 ) central passage (C 4 ) and the Annular (e 5 ), coming out through Casing Lower Perforations ( 50 ) until it (*) reaches the Lower Formation.
[0188] FIG. 18 represents the recovery chamber where it can be seen how low pressure fluid (x) is injected through the annular to recover el TA (B) and the FMA (C). Their upstroke is shown. Fluid (x) with the necessary pressure to perform the TA and FMA upstroke has too be injected through the annular (e 1 ). This fluid enters through the Casing Protective Valve ( 36 ). This makes the TA (B) and the FMA (C) move to the surface where they will finally insert into the Catcher ( 2 ). Fluid (---) with a pressure slightly lower than injection pressure flows over these assemblies. Low pressure (x) pressurizes both formations. This particularity has already been mentioned as a technical operational advantage of the invention. It is advantageous because the formations are never depressurized.
[0189] FIG. 19 , a transverse cross-sectional view on line I-I ( FIG. 1 ), shows how Injection Fluid (+) coming from the Water Plant (not shown here) is injected through 73.026 mm (2″⅞) Tubing ( 9 ) Interior (i) (Direct), whereas the annular (e 1 ) between the 73.026 mm (2″⅞) Tubing ( 9 ) and the Casing ( 10 ) shows no fluid circulation.
[0190] FIG. 20 , a transverse cross-sectional view on line II-II ( FIG. 1 ), shows that the dislodged fluid (---) returns through Tubing 9 (i) (Direct) due to the FMA (C) upstroke. Low pressure fluid (x) is injected through the annular (e 1 ) between ( 9 ) and ( 10 ) when the FMA (C) upstroke is required.
DETAILED DESCRIPTION OF THE INVENTION
[0191] According to the scheme represented in FIG. 1 of the Free Mandrel System, Protected Casing, the invention layout is composed of:
A—Surface Assembly (SA)
B—Transport Assembly (TA)
C—Free Mandrel Assembly (FMA)
D—Fixed Bottom Hole Assembly (FBHA)
E—Complementary Assembly (CA)
1 —(A)—Surface Assembly (SA)
[0192] It is schematically represented in FIG. 2 . It is the assembly of conventional parts such as valves ( 6 1 ), ( 6 2 ), ( 6 3 ), ( 6 4 ), ( 7 ) and ( 8 ) properly laid out to perform the required operation of the Free Mandrel System, Protected Casing, with additional parts specially designed to complement this operation. These parts are the Lubricator ( 3 ) with the Catcher ( 2 ), the Mast ( 4 ) to release and recover the Free Mandrel (C) and the Transport (B) Assemblies together by using the Mast ( 4 ) and the Impeller ( 5 ) to make the system work. The SA is screwed over the Well Head ( 8 ) in the 73.026 mm (2″⅞) Full Passage Conventional Injection Valve ( 6 5 ). The Lubricator ( 3 ) with the Mast ( 4 ) and the Catcher ( 2 ) in its lower end is screwed on Valve ( 6 5 ). Injection Fluid comes from the Pipeline ( 1 ) into the well through Valve ( 6 1 ). When this Valve is open, the well can inject simultaneously in all Formations. When it is shut, it does not allow the injection fluid flow and the well does not operate. (Stand-By stage).
[0193] The Pipeline ( 1 ) diverges into a second branch and Valve ( 6 2 ) is shut during that operation. When it is open, it allows the injection fluid to flow to the Impeller ( 5 ). This injects at low pressure in the Annular (e 1 ) to perform the FMA (C) upstroke which is required to recover all installed Injection Valves.
[0194] This procedure is used to drive the Impeller ( 5 ) Circulation Pump, which uses this fluid as driving power.
[0195] The Valve ( 6 3 ), placed at the upper end of the Lubricator ( 3 ) is kept closed during the injection. It is only opened to retrieve the FMA (C) (upstroke).
[0000] The Impeller ( 5 ) allows the injection fluid to circulate from the Casing ( 10 ) to the 73.026 (2″⅞) Tubing ( 9 ) (i), through the Casing Protective Valve ( 36 ) for the FMA (C) upstroke to the surface.
[0196] It is clarified that the Impeller is a low pressure pump, with no movable parts. It uses the Plant fluid as power fluid and injects it in the Annular (e 1 ) with the fluid it sucks from 73.026 (2″⅞) Tubing ( 9 ) (i).
[0197] This operation enables low pressure circulation to drive the Transport Assembly (B) and the Free Mandrel Assembly (C) in their upstroke from the FBHA (D) until it is trapped in the Catcher ( 2 ).
[0198] The Valve ( 6 1 ) is kept open for the downstroke whereas Valves ( 6 2 ), ( 6 3 ) and ( 6 4 ) are kept shut. The injection fluid push and the FMA (C) weight will insert the FMA (C) into the FBHA (D) while automatically beginning the selective injection in the Formations.
[0199] For this operation, a flow, not larger than 400 m 3 /a day, is recommended to go through Valve ( 6 1 ) to prevent the FMA (C) from inserting into the FBHA (D) with excessive impact. In most downstrokes, the Operator opens Valve ( 6 1 ). Then, he can leave the location as the operation is completely automatic.
[0200] Only in injected flows over 400 m 3 /a day, it is necessary for the Operator to liberate the flow completely after 30 minutes to leave the well in ideal operating conditions.
[0201] The above-mentioned Surface Assembly (A) is screwed to the Well Head ( 8 ). Its hydraulic circuit consists of conventional valves and the Impeller with a feeding line coming from the Water Plant.
[0202] The Pipeline separates into two branches. The first one goes into the SA (A) central passage through a first Valve ( 6 1 ) and the second branch connects with the Impeller ( 5 ) through a second Valve ( 6 2 ). The Impeller connects to the Annular (e 1 ) through the Well Head ( 8 ).
[0203] The third Valve ( 6 3 ) is placed at the Lubricator ( 3 ) outlet and is closed while operating. When it is open, it allows the 73.026 (2″⅞) Tubing ( 9 ) (i) fluid to re-circulate to the Annular (e 1 ) for the FMA (C) upstroke.
[0204] The 73.026 mm (2″⅞) Full Passage Injection Valve ( 6 5 ), connected to the Well Head ( 8 ), allows the FMA (C) to run in both strokes and the injection and return fluids flow to retrieve the FMA (C).
[0205] The Valve ( 6 4 ) is used to recover the FMA (C) without the Impeller ( 5 ) assistance or when it does not work properly. This process works by opening Valve ( 6 2 ) to let a small volume of injection fluid flow, keeping the Annular (e 1 ) pressure below 5 kg/cm 2 , and making the fluid circulate through Valve ( 6 4 ). A tank truck is used to collect the fluid coming from the FMA (C).
[0206] As a reference, it can be stated that for the mentioned depth, that is, 2,500 m, the fluid volume is approximately 7500 liters.
2—(B)—TRANSPORT ASSEMBLY—TA
[0207] It is schematically represented in FIG. 3 . It is one of the dynamic components that moves with the Free Mandrel Assembly (C) from the Surface Assembly (A) to its insertion in the Fixed Bottom Hole Assembly (D) during the FMA (C) downstroke or vice versa, upstroke. It consists of a Lower Connector ( 14 ), a Retention Valve ( 12 ) for the upstroke, Rubber Cups ( 13 ) and the Fishing Neck ( 11 ) screwed together. The Transport Assembly (B) is used to transport the Free Mandrel Assembly (C).
[0208] Obviously, said Assembly (B) is specially designed according to the operating requirements of the invention device.
[0209] It is essential in the FMA (C) upstroke as the Rubber Cups ( 13 ) expand against the 73.026 mm (2″⅞) Tubing ( 9 ) taking the utmost advantage of its volume when they receive the upward injection fluid push. This push also closes the Retention Valve ( 12 ) for the greatest fluid efficiency.
[0210] FIG. 5 shows the Transport Assembly (B) screwed to the Free Mandrel Assembly (C) upper end.
[0211] The TA ends in its upper extreme in a normalized Fishing Neck ( 11 ), according to API (American Petroleum Institute) specifications, which allows it to be trapped by the Catcher ( 2 ) ( FIG. 2 ) at the end of the upstroke and detached from it at the downstroke start.
[0212] In case of any inconvenience, TA (B) and FMA (C) can be trapped by means of Slickeline equipment.
[0213] The TA (B) ends in its lower extreme in the Lower Connector where it is screwed to the Free Mandrel Assembly (C).
[0214] The assembly of (B) and (C) is schematically represented in FIG. 5 .
3 (C)—Free Mandrel Assembly—FMA:
[0215] It is schematically represented in FIG. 4 . It is the main dynamic component that travels from SA (A), in its downstroke, and is inserted into the FBHA (D) to begin selective injection in different Formations.
[0216] In its upstroke, it moves injector valves to be examined or removed.
[0217] It is one of the five Assemblies composed of totally new parts. It has been graphically represented in FIGS. 4 , 5 , 7 A, 7 B, 8 , 9 , 11 , 13 and 18 .
[0218] It has been specially designed for the operation of the system applied to selective injection in different Formations. As it has been above-mentioned, it can be applied to several formations but in this specific explanation, it has been reduced to only two formations to facilitate the explanation.
[0219] Every Mandrel contains an Injection Valve in its interior, except the Lower one which is only integrated by an Injection Valve specially designed for this purpose.
[0220] In FIG. 4 , a Free Mandrel Assembly to inject in two formations is schematically represented.
[0221] The difference between the Upper Mandrel which contains an Upper Formation Injection Valve ( 18 ) in its interior and the Lower Mandrel composed only by a Lower Formation Injection Valve ( 21 ) specially designed, can be observed in FIG. 4 .
[0222] The Upper Free Mandrel is screwed at its upper end to the Transport Assembly (B) by the Outer Jacket ( 15 ). This closes with the FBHA (D) Upper Packer Collar ( 25 ) through the Seal Ring ( 16 ). It contains the Upper Formation Injector Valve ( 18 ) in its interior. It is screwed to the Middle Plug ( 17 ) in its lower end.
[0223] The Middle Plug ( 17 ) closes with the FBHA (D) Lower Packer Collar ( 32 ) with Seal Ring ( 20 ).
[0224] The Injection Valve ( 21 ) is screwed to the Middle Plug ( 17 ) lower end. This valve corresponds to the Lower Formation which ends in the Lower Plug ( 22 ). It closes with Seal Rings ( 23 ) in the Seat ( 34 ) in FIG. 6 of the Fixed Bottom Hole Assembly (D).
[0225] FIG. 4 shows the incoming fluid (+) which comes out regulated (#) from the Upper Formation Injection Valve lower end to fulfill the upper formation required conditions. Whereas, the incoming fluid (+) moves through the annular (e 7 ) limited on the outside by the Upper Mandrel Jacket ( 15 ), goes through the Middle Plug ( 17 ) passages (C 1 ) (not shown in this Figure), reaches the Lower Mandrel and is admitted by the Lower Formation Injection Valve ( 21 ) which transforms the fluid into (*).
[0226] As it has been previously described, the Upper Mandrel, which contains the Upper Formation Injection Valve ( 18 ), receives the Plant fluid (+) and the regulated fluid for upper formation (#) required conditions finally comes out from the Upper Injection Valve lower end.
[0227] The incoming fluid (+) moves through the annular (e 7 ) limited on the outside by the Upper Mandrel Jacket ( 15 ) and on the inside by the Upper Formation Injection Valve ( 18 ). This (+) fluid reaches the Lower Mandrel through the Middle Plug ( 17 ) passages (C 1 ) (not shown in FIG. 4 ) and is admitted by the Lower Formation Injection Valve ( 21 ). That is to say, the Lower Formation Injection Valve ( 21 ) receives the incoming fluid (+) and transforms it into the fluid with the necessary conditions to be injected in the Lower Formation (*).
4—(D)—Fixed Bottom Hole Assembly—FBHA:
[0228] It is schematically represented in FIG. 6 . This Assembly is static. The Workover Equipment installs it with its lower end screwed to the On Off ( 43 ) upper end, and its upper end to the first 73.026 (2″⅞) Tubing ( 9 ) (i) lower screw of the string that communicates it with the Well Head ( 8 ).
[0229] The FBHA (D) lodges the FMA (C) so that hydraulic circuits are completed. They allow the Upper Packer ( 44 ) and the Lower Packer ( 46 ) to be fixed from the surface without having to resort to Slickeline equipment or similar ones. Then Selective Injection is performed in every Formation.
[0230] The FMA (C) seals the Upper Packer Collar ( 25 ) with Seal Ring ( 16 ) ( FIG. 4-6 ) and separates the injection fluid (+) contained in the 73.026 mm (2″⅞) Tubing ( 9 ) (i) that enters the Upper Mandrel through the Transport Assembly (B).
[0231] The Upper Free Mandrel is provided with a Middle Plug ( 17 ) in its lower end. ( FIG. 4 ). This Middle Plug seals the Lower Packer Collar ( 32 ) with Seal Ring ( 20 ) ( FIG. 4-6 ) and prevents the fluid regulated by the Upper Formation Injection Valve from passing to the FBHA (D) lower chamber.
[0232] The Lower Formation Injector Valve ( 21 ) receives Injection fluid (+) through the Middle Plug ( 17 ) vertical passages (C 1 ), regulates the flow that is required for the Lower Formation Injection, and channels it through the Lower Plug ( 22 ) ( FIG. 4 ) and to the Injection Tube ( 40 ) through the Telescopic Union ( 37 ).
[0233] The Casing ( 10 ) Protective Valve ( 36 ) is located in this lower chamber. It allows fluid passage to go through the Annular (e 1 ) to 73.026 (2″⅞) Tubing ( 9 ) (i) Interior (Direct) but prevents the fluid from passing from the 73.026 mm (2″⅞) Tubing to the Annular (e 1 ). This keeps the Casing ( 10 ) totally isolated from injection fluid pressure and contact.
[0234] In the upstroke, it impulses the Free Mandrel Assembly (C) to remove injection valves.
[0235] FIGS. 7 A and B represent the TA (C) assembled with the FMA (C) inserted in the FBHA (D) in operating position, that is to say, ready to inject selectively in both Formations.
5—(E)—Complementary Assembly—CA:
[0236] It has been schematically represented in FIG. 8 where it is screwed in the lower part of the FBHA (D).
[0237] It is composed of specific parts that correspond to the invention equipment design. They are complemented by other parts of common use in Petroleum Industry.
[0238] On the outside, the lower part of the FBHA (D) screws in the upper part of the On Off ( 43 ) which, in its lower part screws in the Upper Packer upper end ( 44 ). (Both are common use parts). The Injector Plug ( 41 ) screws in the Upper Packer lower part. This Plug lodges the passage where the Rupture Disc is located ( 42 ). Both are specific parts of this equipment. This Rupture Disc is used to fix the Upper Packer ( 44 ) and, once it has been fixed, the pressure is raised until it bursts and enables the circuit to perform Upper Formation Injection.
[0239] The Telescopic Union Inner Body ( 37 ) is screwed to the FBHA (D) internally and in a concentric pattern. It slides and seals inside the Telescopic Union Outer Body ( 39 ).
[0240] The Telescopic Union has two functions:
[0000] I) When the Upper Packer ( 44 ) fixes, there is a longitudinal displacement that is absorbed by the Telescopic Union.
II) It allows On Off ( 43 ) rotation and longitudinal displacement to remove the FBHA (D) with the tubing string.
[0241] The Injection Tube ( 40 ) is screwed in the lower part of the Telescopic Union Outer Body ( 39 ) and is screwed in the Injector Plug ( 41 ) in its lower end.
[0242] The 60.325 mm (2″⅜) ( 47 ) Tubings that connect the Injector Plug ( 41 ) with the Lower Packer ( 46 ) are schematically represented in FIG. 9 . The required quantity of 60.325 mm (2″⅜) ( 47 ) to separate both packers are screwed in the lower part of the Injector Plug ( 41 ) and the Lower Packer ( 46 ), in its upper part.
[0243] Other sections of 60.325 mm (2″⅜) ( 47 ) Tubings connect the Lower Packer ( 46 ) with the Shear Out ( 48 ).
[0244] The 60.325 mm (2″⅜) ( 47 ) Tubing is screwed in the lower part of the Lower Packer ( 46 ) and, at the other end, in the upper part of the Shear Out ( 48 ) which is also used to fix the Lower Packer ( 46 ). This circuit is closed by the Shear Out ( 48 ) interior ball. This allows a pressure increase in the 60.325 mm (2″⅜) Tubing ( 47 ). Once the Lower Packer ( 46 ) is fixed, pressure continuous being increased until the Shear Out ( 48 ) ball is displaced. This enables the circuit to perform the Lower Formation Injection.
6—Assembly Sequence for the Invention Equipment Installation
[0245] The assembly sequence at the well head is the following:
[0000] I) The Shear Out ( 48 ) ( FIG. 9 ) is assembled, ball included, in the 60.325 mm (2″⅜) (47) tubings.
II) The 60.325 mm (2″⅜) ( 47 ) Tubing is screwed with the Lower Packer ( 46 ).
III) The 60.325 mm (2″⅜) Tubings ( 47 ) required for the separation between the Formations to be injected are screwed to the upper end of the Lower Packer.
IV) The Injector Plug ( 41 ) ( FIG. 8 ) is screwed to the last 60.325 mm (2″⅜) Tubing ( 47 ). The FBHA (D), screwed to the CA (E) ( FIG. 8 ), is delivered already assembled, including the Rupture Disc and the proper torque so that the Workover Equipment screws the Injector Plug ( 41 ) on the 60.325 mm (2″⅜) Tubing upper end ( 47 ), required by the well to comprise the distance of the Upper Formation Perforations ( 49 ).
V) The required quantity of 73.026 mm (2″⅞) Tubings ( 9 ) to reach the surface and screw in the Full Passage Conventional Injection Valve is assembled to the FBHA (D) upper end.
VI) The Lubricator ( 3 ) will be installed on the 73.026 mm (2″⅞) Tubing Full Passage Conventional Injection Valve ( 65 ).
VII) The Mast ( 4 ) can be left assembled in the Lubricator or will be placed whenever a change of the Free Mandrel Assembly (C) is necessary.
[0246] The rest of the SA (A) is assembled as indicated in FIG. 2 .
7—Description of the Equipment Operation
[0247] Once the different components of the invention embodiment have been determined and developed to explain their nature, the description is herein complemented with a summary of what has already been described about the functional and operative relationship of its parts and the outcome they provide.
Installation:
[0248] According to the previous paragraphs and, in other words, for the operational description of the invention device, the following are the operations needed for its installation in a specific well:
1::1 Complete Verification of the Tubing String Water Tightness
[0249] As the complete Tubing string is assembled, water tightness tests are performed using the Full Blind Plug Not illustrated.
[0250] Once the 73.026 mm (2″⅞) Tubing ( 9 ) (i) has been assembled up to surface, its water tightness is tested. The Well Head pressure is increased up to 3000 psi; the valve is closed and, for 20 minutes, it is necessary to verify that it keeps constant.
[0251] Once tubing water tightness testing has been satisfactory, the Full Blind Plug is removed.
1 :: 2 Lower Packer ( 46 ) Fixing
[0252] The FMA (C) is lowered with the Blind Middle Plug, that is to say, the fluid pumped by the Workover Equipment is only injected through the Lower Mandrel. It pressurizes the Telescopic Union ( 37 and 39 ), the Injection Tube ( 40 ), the 60.325 mm (2″⅜) Tubings ( 47 ) and the Shear Out ( 48 ). (This circuit is closed). As the pressure is slowly increased, the Lower Packer ( 46 ) is fixed by cutting the pins. This is perceived by the impact of Jaws against the Casing ( 10 ). The proper fixing is verified according to the Packer supplier specifications.
[0253] After that, the pressure is increased until the Shear Out ( 48 ) ball enables the Lower Formation Injection. Meanwhile, Formation admission tests are made according to the established program. Pressures and volumes are also checked. During this operation, the pressure in the circuit to fix the Upper Packer ( 44 ) is null (white space).
1::3 Upper Packer ( 44 ) Fixing
[0254] The FMA (C) is removed with the Blind Middle Plug, and the Middle Plug ( 17 ) is placed. The Lower Plug is changed by a Blind Lower Plug. In this case, when the fluid is pumped through the 73.026 mm (2″⅞) Tubing ( 9 ), it is all directed to the Upper Formation Injection Circuit. This is blocked in the Injector Plug ( 41 ) by the Rupture Disc ( 42 ).
[0255] When pressure is increased by the Workover Equipment Pump, the required pressure is reached by the rupture of the Upper Packer ( 44 ) pins and the Upper Packer is fixed. Its proper position is checked according to what has been recommended by the manufacturer. Thereon, the pressure continues to be increased until the Rupture Disc bursts and this enables the circuit to inject in the Upper Formation.
[0256] Admission tests are performed at different pressures according to the defined program.
[0000] 1::4 Downstroke or FMA (C) insertion
[0257] Open Valves ( 6 1 ) and ( 6 5 ). Keep all the other valves closed. The FMA (C) is normally assembled for simultaneous injection with the Middle Plug ( 17 ), the Lower Plug ( 22 ) and corresponding regulated Injection Valves according to the injection program. The Formation Selective Injection begins automatically when the FMA (C) arrives and inserts into the FBHA (D).
[0258] After assembling the Well Head ( 8 ), the FMA (C) can be installed with the Workover Equipment Pump or with the Plant Injection Fluid.
[0259] During the downstroke, fluid is injected in both formations without any type of control. In both cases, the fluid pushes the FMA (C) with the Upper and Lower Formation Injector Valves regulated according to the well Injection program until the FMA (C) inserts into the FBHA (D). At this moment, Selective Injection is automatically started in both formations according to what has been programmed. Once the downstroke has begun, the Operator does not need to wait for the FMA (C) to reach and insert into the FBHA (D) as it will be done in 20 or 25 minutes and Selective Injection will begin automatically.
[0260] 1::5 Upstroke to recover the FMA (C) on the surface
[0261] Close ( 6 1 ) Valve ( FIG. 2 ) and partially open Valve ( 6 2 ) and completely open Valve ( 6 3 ). This allows Injection Fluid to flow into the Impeller ( 5 ). This component drives it through the Annular (e 1 ), opens the Casing Protective Valve ( 36 ), goes into the FBHA (D) lower chamber and drives the FMA (C) to the surface until it is hooked in the Catcher ( 2 ). The well is depressurized. The FMA (C) together with the TA (B) are removed by turning round the Catcher ( 2 ) and then, they are hoisted by the Mast ( 4 ).
[0262] If the well is not depressurized, the Catcher ( 2 ) can not be turned round. For safety reasons, it is designed to block itself, even if there is low pressure. In this case, the Operator can leave and perform other activities. When the operator comes back, he will find the FMA (C) in the Catcher ( 2 ) and the Formations already pressurized.
[0263] At the Well Head, the following components can be replaced:
a) The Injector Valves by removing the used ones and placing new controlled units. b) The FMA (C) with the valves already installed.
[0266] In both cases the task will be performed by the operator. Obviously, FMA (C) replacement is faster with the valves already controlled.
1::6 Selective Injection Operation in Both Formations
[0267] The Injection Fluid (+) reaches the Surface Assembly (A) along a Pipeline ( 1 ) fed from the Water Plant and enters the System through ( 6 1 ) Valve completely open. Valves ( 6 2 ), ( 6 3 ) and ( 6 4 ), shown in FIGS. 1 and 2 , must be closed.
[0268] The 73.026 mm (2″⅞) Injection full passage Conventional Valve ( 6 5 ) has to be open to allow the FMA (C) to get through. The injection fluid, which enters the well through Valve ( 6 1 ), fills the Lubricator ( 3 ) (+) ( FIG. 2 ) and the fluid flows through 73.026 (2″⅞) Tubing ( 9 ) (i) (+), goes through the TA (B) (+) and enters the Upper Mandrel (+).
[0269] In the Upper Mandrel, the Upper Formation Injection Valve ( 18 ) ( FIGS. 4 , 5 , 7 A, 7 B, 8 and 9 ) takes the (+) fluid and regulates the flow (#) that must be injected in that Formation by guiding it through the Middle Plug ( 17 ) passage ( 19 ).
[0270] This regulated fluid (#) fills the chamber limited in the upper end by the Seal Ring ( 16 ) that blocks the Upper Packer Collar ( 25 ). In the lower part, it is limited by the Seal Ring ( 20 ) with the Lower Packer Collar ( 32 ).
[0271] The already regulated fluid is compelled to go through the Annular (e 6 ) to the FBHA (D) inner side passage (C 2 ) ( FIGS. 7A , 7 B and 8 ) through which it successively discharges into the Annulars (e 9 ), (e 10 ) and (e 11 ). On the outside, they remain limited with the On Off ( 43 ) interior and the Upper Packer ( 44 ). On the inside, it is limited by the Telescopic Union exterior ( 37 and 39 ) and the Injection Tube ( 40 ). In the lower end, the limit is the Injector Plug. ( 41 ). The fluid goes out through the Rupture Disc passages ( 42 ) ( FIGS. 8 and 9 ).
[0272] The fluid, which is regulated (#) by the Upper Injector Valve ( 18 ) ( FIG. 4 ), is oriented through the Injector Plug ( 41 ) Rupture Disc passage ( 42 ) ( FIGS. 8 and 9 ) to the chamber limited by:
[0000] I) The Upper Packer ( 44 ) lower side in the upper end ( FIG. 9 )
II) The Well Casing ( 10 ) on the outside ( FIG. 9 )
III) The Telescopic Union ( 37 and 39 ) and the Injector Tube ( 40 ) in the inside ( FIG. 9 )
IV) The Lower Packer ( 46 ) upper side in the lower end ( FIG. 9 )
[0273] The Fluid (#) regulated by the Upper Formation Injection Valve ( 18 ) ( FIG. 4 ) is then pushed to inject in the Upper Formation through the Casing Upper Perforations ( 49 ) ( FIGS. 9 and 13 ).
[0274] This is the course taken by the regulated fluid to go into the Upper Formation ( FIG. 16 ). The Injection fluid (+) takes up the Upper Formation Injection Valve outer chamber (e 7 ) in the Upper Mandrel. The fluid flows through the Middle Plug ( 17 ) vertical passages (C 1 ) ( FIGS. 4 , 7 B, 8 and 9 ). These passages run into a chamber and the fluid (+) is taken by the upper part of the Lower Formation Injection Valve ( 21 ) ( FIGS. 4 , 7 B and 11 ), which regulates the flow (*) to be injected in the Lower Formation. This already regulated fluid (*) to be injected in the Lower Formation is conducted through the Middle Plug inner part ( 22 ), Telescopic Union ( 37 and 39 ) inner part, Injection Tube ( 40 ), Injector Plug inner part ( 41 ), 60.325 mm (2″⅜) Tubings ( 47 ) and Lower Packer ( 46 ), and finally unloaded through the Shear Out ( 48 ) ( FIGS. 1 , 9 , 11 and 13 ) into the chamber limited by:
[0000] I) Lower Packer ( 46 ) lower side in the Upper end ( FIGS. 9 , 11 and 13 )
II) The Well Casing ( 10 ) on the outside ( FIGS. 9 , 11 and 13 )
III) The bottom hole in the lower end
[0275] The Lower Formation regulated fluid (*) is introduced through the Casing Lower Perforations ( 50 ) in the above-mentioned Formation ( FIGS. 11 , 13 and 17 ).
[0276] This is the course taken by the regulated fluid (*) to go into the Lower Formation.
[0277] FIGS. 7A and 7B show two sections of the Transport Assembly (B) screwed in the upper end of the FMA (C) inserted into the FBHA (D) and injecting selectively in both formations. Both sections show the circuits that drive fluids to every formation. The Plant Fluid (+) is taken to be regulated by the Upper Formation Injection Valve ( 18 ) for the Upper Formation (#) and the Lower formation Fluid (*) is taken to be regulated by the Lower Formation Injection Valve ( 21 ).
[0278] In FIG. 7A , section is parallel to the Middle Plug ( 17 ) Injection Passage ( 19 ).
[0279] In FIG. 7B , section is perpendicular to the Middle Plug ( 17 ) Injection passage ( 19 ).
[0280] FIG. 4 shows the fluid that has been regulated for the Upper Formation required conditions.
[0281] According to the previous detailed explanations and in order to reinforce the invention operational comprehension, here follows a summary of the fluid operative paths. This fluid is injected through the component parts of the invention structure in two formations: Upper and Lower Formations in the simplified model adopted as an example to perform one of the possible applications of the invention.
[0282] Starting from the Surface Assembly (A), the symbol (+) is used to represent the fluid provided by the Plant through the pipeline ( 1 ), Valve ( 6 1 ). The fluid already regulated by the Valve ( 18 ) and to be injected in the Upper Formation is represented by (#) symbol. The fluid regulated by Valve ( 21 ) and to be injected in the Lower Formation is represented by the (*) symbol.
[0283] The fluid that comes from the Plant goes into the Tubing ( 9 ) (i) (+) through the 2″⅞ conventional full passage Injection Valve ( 6 5 ). To make this operation possible, the Valve ( 6 1 ) must be open and the ( 6 2 ), ( 6 3 ), and ( 6 4 ) valves shut until the fluid reaches the Free Mandrel Assembly (C) ( FIG. 4 ) through the Transport Assembly (B) ( FIG. 3 ). Selective Injection is then performed in the two formations (#) and (*).
[0284] In a downward description, it can be observed that two watertight chambers have been formed. They make it possible to direct the fluid to be injected:
[0000] 1—An upper chamber ( FIGS. 7A , 7 B, 8 , 9 , 11 and 13 ) limited by the closure produced between the upper Seal Ring ( 16 ) that packs in the Upper Packer Collar ( 25 ), and the Plant pressure (+) contained in the Tubing string up to this location.
2—At the same time, an Upper Mandrel chamber will also be determined. This is contained between said closure produced by the upper Seal Ring ( 16 ) with the Upper Packer Collar ( 25 ) and the closure produced between the Middle Plug ( 17 ) Seal Ring ( 20 ) with the Lower Packer Collar ( 32 ). This chamber contains the fluid to be injected (#) in the Upper Formation with pressure regulated by Injection Valve ( 18 ) and channeled through the Middle Plug ( 17 ) passage ( 19 ). Both the Plant pressure (+) in the annular (e 7 ) and in the (C 1 ) passage and the Injection Pressure (#) in the Upper formation coexist in this chamber ( FIGS. 7A , 7 B and 8 ).
[0285] The Free Mandrel Assembly (C) ( FIG. 4 ) lodges the upper Injection Valve ( 18 ) that regulates the Upper Formation Injection (#) and is screwed in the Middle Plug ( 17 ) in its lower part. The circuit that drives this already regulated fluid is identified by the symbol (#). It is driven ( FIGS. 7A , 7 B and 8 ) through the Middle Plug ( 17 ) passage ( 19 ), Annular (e 6 ), FBHA (D) vertical passages (C 2 ) to Annulars (e 9 ), (e 10 ) and (e 11 ), Injector Plug ( 41 ) through Rupture Disc ( 42 ) passage to Annular limited by:
[0000] I The Upper Packer lower part ( 44 ) ( FIGS. 8 , 9 and 13 )
II The Lower Packer upper part ( 46 ) ( FIGS. 8 , 9 and 13 )
III On the outside by the Casing ( 10 ) ( FIGS. 8 , 9 and 13 )
[0286] The fluid to be injected goes through the Casing Perforations ( 49 ) and enters the Upper Formation.
[0287] 3—The Lower chamber ( FIG. 11 ) is determined by the closure of the Lower Packer Collar ( 32 ) and Middle Plug ( 17 ) Seal Ring ( 20 ) and Lower Plug ( 22 ) Seal Rings ( 23 ) with seat ( 34 ). The Lower Formation Injection Valve ( 21 ) admits the Plant Fluid (+) by its upper end and regulates it to be injected (*) in the Lower formation according to the established conditions.
[0288] Between the Upper Mandrel Jacket ( 15 ) and the outside of the Upper Regulation valve ( 18 ), in the Annular (e 7 ), the Plant (+) fluid feeds the Lower Regulation Valve ( 21 ) through the Middle Plug ( 17 ) passages (C 1 ). Said Valve ( 21 ) transforms the pressure and the volume as requested for Lower Formation Injection.
[0289] FIGS. 7A , 7 B and 8 show, in the FBHA (D), the circuit that drives this regulated flow, identified by the symbol (*), to the Lower Formation. It must go through the Lower Plug ( 22 ), Telescopic Union ( 37 and 39 ), Injector Tube ( 40 ) through Injector Plug ( 41 ) central passage ( FIGS. 8 , 11 and 13 ). In its end, the 60.325 mm (2″⅜) Tubings ( 47 ) are screwed. These tubings connect the Lower Plug ( 41 ) with the Lower Packer ( 46 ). The 60.325 mm (2″⅜) Tubings ( 47 ) and the Shear Out ( 48 ) are screwed to the Lower Packer lower end; the fluid (*) flows through the Casing ( 10 ) Lower Formation Perforations ( 50 ) ( FIGS. 1 , 11 , 13 and 17 ).
[0000] 4—Free Mandrel Assembly Recovery Chamber (x) ( FIG. 18 ) is the chamber limited by the outside of the Injection Valve Jacket ( 21 ) and the FBHA (D) inner diameter, Annular (e 8 ) ( FIGS. 7A , 7 B and 8 ). The chamber is closed by the Casing Protective Valve ( 36 ). The fluid that fills it is at the pressure of the column that contains the Annular.
[0290] In order to make the Free Mandrel Assembly (C) return to the surface, low pressure fluid is injected (x) through the Annular (e 1 ) and 73.026 mm (2″⅞) Tubing 9 (Direct) is depressurized.
[0291] The Casing Protective Valve ( 36 ) opens and lets the fluid in. This fluid drives the Free Mandrel Assembly (C) until it is caught in the Catcher ( 2 ). To remove the Free Mandrel Assembly (C) together with the Transport Assembly (B), it is only necessary to operate the Surface Valves in the following way:
1—Close Valve ( 6 1 ).
2—Open Valve ( 6 2 ).
3—Open Valve ( 6 3 ).
[0292] 4 —Keep Valve ( 6 4 ) closed.
[0293] With this configuration, the Plant Water enters through the Impeller ( 5 ) into the annular. This opens the Casing Protecting Valves ( 36 ) allowing the fluid to enter and produce the disconnection of the Free Mandrel Assembly (C) and the Transport Assembly (B) from the FBHA (D). From this moment on, the fluid produces the upward push that makes the Rubber Cups ( 13 ) expand and closes the Transport Assembly Valve ( 12 ) located in the Fishing Neck ( 11 ).
[0294] The upward speed is proportional to the volume of the fluid injected in the Annular (e 1 ). The upstroke ends with the Free Mandrel Assembly (C) and the Transport Assembly (B) hooked together in the Catcher ( 2 ) located in the Lubricator ( 3 ).
[0295] To remove them from the well:
[0000] 1) Turn the Catcher ( 2 ) eye-bolt until it adopts the “Catching” position. In this position, the Catcher cage retains the assemblies when they make an impact in their upstroke.
2) Close all Surface Assembly Valves ( 6 1 , 6 2 , 6 3 , 6 4 ).
[0296] 3) Wait until 73.026 mm (2″⅞) Tubing ( 9 ) (Direct) pressure reaches zero.
4) Turn the Catcher ( 2 ) 90° to remove it from the Lubricator ( 3 ).
5) Raise the Free Mandrel Assembly (A) and the Transport Assembly (B) with the Mast ( 4 ).
6) Lower the assemblies and unhook them for inspection or replacement.
[0297] To install the Free Mandrel Assembly (A) and the Transport Assembly (B), the reverse process has to be performed:
1) All surface Valves must be shut. ( 6 1 to 6 4 ). 2) The two assemblies are hooked together, installed in the hoisting system and then introduced in the Lubricator ( 3 ). 3) The Catcher ( 2 ) is turned 90° to close the Lubricator ( 3 ). 4) The Catcher eye-bolt is turned to the releasing position so that the Free Mandrel Assembly (A) and the Transport Assembly (B) unhook from the Catcher ( 2 ) and start the downward movement. 5) Valve ( 6 1 ) is opened so that the fluid push makes the assemblies descend at a proper speed, according to the injected flow.
[0303] A speed of about 70 to 85 meters/minute is considered reasonable for the downstroke.
[0304] A greater downward speed is also possible. For example, 100 meters/minute (shorter downstroke) and when it is close to the FBHA (D), slow down the speed to 50 meters/minute so that the insertion is adequate. Once the two assemblies are engaged, the pressure begins to rise until it reaches the Pipeline pressure. In this moment, the system begins to inject selectively in the two formations.
[0305] A manufacturing possibility, which leads to materializing this invention, and the way it works has been described. To complete the documents, here follows a synthesis of the invention contained in the claims which come next.
[0306] (There appears a signature followed by a seal that reads “LUIS SALVADOR CUNEO. Industrial Property Agent. Registration Number 1409”.)
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The Invention is to be applied for selective injection of fluids in different formations, keeping the casing isolated from fluid pressure. “Fluid” is used in its widest sense: gases or liquids. It is hydraulically driven by the injection fluid. A single operator must only handle surface standard valves. It consists of five assemblies: Surface, Transport, Free Mandrel, Fixed Bottom Hole and Complementary. The Free Mandrel is the dynamic main device that carries all the Injection valves together, one for each formation, from the Bottom Hole to the Surface in 30′ and viceversa. As this operation is performed many times in the well lifetime, it allows a cumulative time and money saving. Workover equipment is only used for installing the system and for fixing packers. Formation Pressure is kept when the system is installed or when it is pulled up. Changes can be made at any time when they are needed.
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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 to the field of oil and gas exploitation, more specifically to systems and methods for well control, especially for well pressure control in wells with hydrocarbon fluids, as defined in the enclosed independent claims.
BACKGROUND ART
[0002] Drilling for oil and gas in deep waters or drilling through depleted reservoirs is a challenge due to the narrow margin between the pore pressure and fracture pressure. The narrow margin implies frequent installation of casing, and restricts the mud circulation due to pressure drop in the annulus between the wellbore and drill string or in other words the increase in applied or observed pressure in the borehole due to the drilling activity such as circulation of drilling fluid down the drill pipe up the annulus of the well bore. Reducing this effect by reducing the circulating flow rate, will again reduces drilling speed and causes problems with transport of drill cuttings in the borehole.
[0003] Normally, in conventional floating drilling with a marine drilling riser installed, two independent pressure barriers between a formation possibly containing hydrocarbons and the surroundings are required. In conventional subsea drilling operations, normally, the main (primary) pressure barrier is the hydrostatic pressure created by the drilling fluid (mud) column in the borehole and drilling riser up to the drilling installation. The second barrier comprises the Blow-Out Preventer (BOP) connected to the subsea wellhead on seabed.
[0004] A conventional drilling system is shown in FIG. 1 a.
[0005] If a formation is being drilled where the hydrostatic pressure of the drilling fluid is not sufficient to balance the formation pore pressure, an influx of formation fluids that may contain natural gas could enter the wellbore. The primary barrier is now no longer effective in controlling or containing the formation pore pressure. In order to contain this situation, the subsea Blow Out Preventer (BOP) must be closed. In a conventional drilling system the oil and gas industry has developed certain standard operational well control procedures to contain the situation for such an event. These are well established and known procedures and will here only be described in broad general terms.
[0006] FIG. 1 a illustrates a conventional subsea drilling system. If the pressure in the borehole 1 due to the hydrostatic pressure from the drilling fluid is lower than the pore pressure in the formation being drilled, an influx into the well bore might occur. Since the density of the influx is lower (in most cases) than the density of the drilling fluid and now occupy a certain height of the wellbore, the hydrostatic pressure at the influx depth will continue to decrease if the well can not be shut in using the BOP. By shutting in the well by closing one of several elements 15 a, b, c, d , 16 in the subsea BOP stack 3 and trapping a pressure in the well 14 , the influx from the formation can be stopped (see FIG. 1 b ). The procedures of containing this situation and how the influx is circulated out of the well by pumping drilling fluid down the drillstring 8 out of the drillbit 10 and up the annulus of the wellbore 14 is well established. The valves in the choke line 25 is opened on the subsea BOP to the high pressure (HP) choke line 24 and the bottom hole pressure controlled by the adjustable choke 22 on top of the coke line on the drilling vessel above the body of water. Downstream the adjustable choke valve, the well stream is directed to a mud-gas separator 42 . This is a critical operation, particularly in deep water areas as there are very narrow margins as to how high the surface pressure upstream the surface choke can be before the formation strength is exceeded in the open hole section.
[0007] Floating drilling operations are often more critical compared to drilling from bottom supported platforms, since the vessel is moving due to wind, waves and sea currents. This means that the floating drilling vessel and the riser may be disconnected from the subsea BOP and wellbore below. If heavier than seawater drilling fluid is being used, this will result in a hydrostatic pressure drop in the well. Generally, a riser margin is required. A riser margin is defined as the needed density (specific gravity) of the drilling fluid in the borehole to over-balance any formation pore pressure after the drilling riser is disconnected from the top of the subsea BOP near seabed in addition to the seawater pressure at the disconnect point 20 . When disconnecting the marine drilling riser from the subsea BOP, the hydrostatic head of drilling fluid in the bore hole and the hydrostatic head of sea water should be equal or higher than the formation pore pressure (FPP) to achieve a riser margin. Riser margin is difficult to achieve, particular in deep waters. The reason is that there can be substantial pressure difference between the pressure inside the drilling riser due to the heavy drilling fluids and the pressure of seawater outside the disconnect point on the riser. To compensate for the pressure reduction in the open hole falling below the pore pressure when the riser is disconnected, would require drilling with a very high mud weight in the well bore and riser. So when drilling with this heavy mud weight all the way up to the spill point on the rig 5 , normally being between 10 to 50 m above sea level, the bottom hole pressure would be higher than the formation strength is able to support. Hence the formation strength would be exceeded and mud losses would occur. It would no longer be possible to circulate and transport the drill cuttings out of the borehole and the drilling operation would have to stop.
[0008] Riser Less Drilling, Dual Gradient Drilling and drilling with a Low Riser Return System (LRRS), have been introduced to reduce some of the above mentioned problems. The LRRS is described in, e.g., WO2003/023181, WO2004/085788 and WO2009123476, which all belong to the present applicant.
[0009] In dual gradient (DG) drilling systems a high density drilling fluid is used below a certain depth in the borehole, with a lighter fluid (for example sea water or other lighter fluid) above this point. When drilling with a riser, a dual gradient effect could be achieved by diluting the drilling riser contents with a gaseous fluid for example, or another lighter liquid, U.S. Pat. No. 6,536,540 (de Boer). Another method could be to install a pump on the seabed or subsea and keep the riser content full or partially full of seawater instead of mud while the returns from the well bore annulus is pumped from seabed up to the drilling installation in a return path external from the main drilling riser. Hence there are two different density liquids in addition to the atmospheric pressure creating the hydrostatic pressure on the underground formation. References are made to prior art, U.S. Pat. No. 4,813,495 (Leach) and U.S. Pat. No. 6,415,877 (Fincher et. al.).
[0010] Another technology that could create a riser margin is the single mud gradient, Low Riser Return System (LRRS) belonging to the applicant. Here, a pump is placed somewhere between the sea level and sea bed and connected to the drilling riser. The drilling mud level is lowered to a depth considerable below the sea level. Due to the shorter hydrostatic head (height) of the drilling fluid acting on the open hole formation, the density of the drilling mud could be increased without exerting excess pressure acting on the formation. If this heavy drilling mud was carried all the way back to the drilling rig, as the case would be in a conventional drilling operation, the hydrostatic pressure would exceed the formation strengths, and hence mud losses would occur.
[0011] In riserless drilling, there is simply not a riser installed hydraulically connecting the seabed installed BOP to the drilling rig trough a marine drilling riser. Normally, the top of the wellbore (subsea BOP) is kept open to seawater pressure during drilling; hence the hydrostatic wellbore pressure is made up of the seawater pressure acting on the well at seabed, plus the hydrostatic pressure of the drilling fluid in the well below this point, also described in U.S. Pat. No. 4,149,603 (Arnold).
[0012] Several other concepts have been introduced and are in the public domain.
[0013] Other systems have introduced a closing element on top of the subsea BOP that can isolate the seawater pressure at seabed from acting on the borehole annulus (U.S. Pat. No. 6,415,877). Such closing element could be a so called Rotating Control Device (RCD) or a rotating BOP. These are somewhat different from an annular preventer in that it is possible to rotate the drill string while sealing pressure from below or above (seawater). It is not recommended practice to rotate the drillstring while a conventional annular BOP is closed during drilling due to excess wear on the rubber element. If such a system is used in combination with a subsea mudlift pump at seabed or mid sea, the suction pressure of the mud pump below the RCD in addition to the drilling fluid height and dynamic pressure loss in the annulus, directly control the pressure in the borehole.
[0014] Common for all these drilling systems is that the drilling fluid returning from the well cannot be returned through high pressure choke or kill lines in a conventional manner due to limited formation strength when the BOP is closed after an influx has occurred. Due to the heavy mud weight required or used, this mud will be displaced out of the wellbore annulus ahead of the lighter influx, hence the formation strength cannot support to be hydraulically in contact with the surface installation when the annulus of the wellbore and the conduit (kill or/and choke lines) back to surface are filled with the heavy drilling fluid. This effect will restrict the use of earlier systems or will put severe strain and requirement on the equipment and processes in a well control event.
[0015] In dual Gradient Drilling and riserless drilling, many types of Subsea Lift Pumps (SLP) can normally not handle a significant amount of gas from the well, as the case may be in a well control event for a gas kick. There are several reasons for this. In normal operations these pumps must handle a significant amount of drill cuttings and rocks in addition to the fine solid particles of the weight materials used in the drilling mud. If a gas influx is introduced into the wellbore at a considerable depth and pressure, this gas will expand when circulated up the bore hole to the seabed or mid-ocean where the pump is located. If this return path of fluids from the well has to go directly into the pump, it will put severe strain on the pump system.
[0016] Secondly, the bottom hole pressure will be a direct function of the fluid head in the annulus, the dynamic pressure loss in the annulus and the pump suction pressure. It will be extremely difficult to achieve a stable and controllable suction pressure on the pump when you will have slugs of high concentration hydrocarbon gas flowing directly into the pump system. As a consequence it will be a great advantage if the hydrocarbon gas and drilling fluid could be separated from each other subsea, before liquid drilling fluid and solids being diverted and pumped to surface by the subsea pump. This was also envisioned by Gonzales in U.S. Pat. No. 6,276,455.
[0017] Thirdly as the subsea pump in earlier systems is in direct communication with the annulus, the return lines and the pump system must be of the same high pressure rating as the BOP itself. This put severe requirements on the pump system to handle internal pressures.
[0018] Subsea Choke Systems.
[0019] Prior art exists in an attempt to compensate for the excessive pressure in the borehole acting on the well when circulating out a kick in a conventional manner through high pressure small bore choke line and a surface choke on the upper part of this line. U.S. Pat. No. 4,046,191 (Neath) and U.S. Pat. No. 4,210,208 (Shanks) introduced a surface controlled subsea choke where the flow from below a closed Subsea BOP was directed into the main bore of the drilling riser through a subsea choke.
[0020] Neath envisioned a conventional drilling system where the riser was full of conventional weighted drilling fluid. If such a system was used in a situation where dual gradient drilling technology was used, the pressure on the downstream of the adjustable choke could become too high due to the high mud weight used. Also since the riser was initially full of drilling mud, gas introduced into the base of the riser at great water depth could introduce further problems since the riser have limited collapse and internal pressure ratings.
SUMMARY OF THE INVENTION
[0021] In order to overcome challenges with prior art in conducting well control operations during riserless drilling and other dual gradient drilling technology, a method of controlling wellbore pressure in a controlled fashion will be explained.
[0022] Several alternatives for creating a subsea separation system within a subsea BOP will be explained below. Reference numbers refer to the accompanying drawings, as examples only.
[0023] Subsea BOP Gas Separation System
[0024] A riser joint used may be particularly designed to function as a separator where the separated gas is vented to the surface via the riser and the liquid is pumped to the surface via an exterior return path from the main drilling riser ( FIG. 2 and FIG. 3 ). The main difference here with prior art is that the mud/liquid level in the riser is controlled and located at a considerable level below the sea level. In this fashion it is prevented that drilling fluids or liquids will be unloaded from the top of the riser if gas is being released into the base of the riser.
[0025] In another embodiment, a BOP extension joint (BOP-EJ) located between lower and upper annular preventer is so designed that with 2 different BOP elements closed, a chamber or cavity will be formed where gas can be separated from liquids by gravity and the separated gas vented via a conventional choke line or a separate conduit line, or alternatively via a riser to the surface. The liquid is pumped to the surface by the subsea mud pump controlling the liquid level in the cavity.
[0026] Another alternative would be a separate unit for separation where the separated gas is vented via a conventional choke line and the liquid is pumped to the surface through a separate liquid conduit line (not shown here).
[0027] A representation of a new riserless drilling system is shown in FIG. 4 . In this system a subsea mud pump 11 is installed on seabed or some distance above and hydraulically connected to the well so that the drilling fluid and drill cuttings are pumped up to the drilling installation in a separate return flow path 12 . The interphase between the drilling fluid and the seawater is then somewhere in the vicinity of the Subsea BOP.
[0028] BOP-Extension Joint vs. Riser Joint for Mud/Gas Separation
[0029] A conventional subsea BOP is normally equipped with two annular preventers on modern rigs. The lower annular preventer 16 in FIG. 1 a is normally the uppermost closing element in the lower BOP stack 3 which consists of a series of ram type preventers stacked on top of each other 15 a, b, c, d and the said BOP stack 3 installed with a special connector either to a High Pressure Wellhead (HP WH) 52 or a Horizontal Christmas-Tree (HXT) (not shown here). The total height of the lower subsea BOP is in the vicinity of 7 to 10 meter. The height of the HP WH is approximately 1 meter. The HP WH is normally installed on what is defined as the surface casing which normally sticks 2-3 meter above the seabed. The upper annular preventer 19 is normally installed in what is termed the Lower Marine Riser Package (LMRP). However, some rigs may have both annular preventers above the riser BOP disconnect point 20 , FIG. 1 b , in the LMRP. The interface between the lower BOP stack and the LMRP is normally designed a hydraulic remote operated disconnect point between the lower marine riser package (riser) and the lower subsea BOP. Hence the distance between the lower annular preventer on the BOP and the upper annular preventer in the LMRP is normally approximately 1.5-2.5 meters. In order to create a longer distance between the 2 annular preventers an extension joint could be installed to create more space.
[0030] If the mud and gas could be separated in a BOP cavity and/or BOP Extension Joint thereby creating a gas phase in the upper part of the BOP, this would allow a surface choke to control the gas pressure if connected to the cavity between the two closing elements, hydraulically either by flexible or fixed lines (no gas vent through riser).
[0031] BOP-Extension Joint can then be used for fluid-mud/gas separation in drilling with and without the riser.
[0032] If and when using the Low Riser Return System in another embodiment of this invention, the upper annular preventer can be closed during a drill pipe connection to avoid fluid level adjustment in the riser where in this case, the fluid level in the choke line is used to control and regulate the annulus pressure in order to compensate for the equivalent circulating density (ECD) effect (time saving). This is also explained in WO2009/123476, belonging to the applicant. The downside of having the liquid separated from the gas close to seabed as opposed to higher up in the riser is the longer pump suction line needed in deep water and the higher differential pressure capacity of the subsea pump system.
[0033] Another feature of this arrangement is the possibility to control bottom hole pressure while drilling (lower annular open) and when circulation out a well kick (lower annular closed), by controlling the liquid mud level in the choke line (subsea choke fully open) ( FIG. 6 ). In this case the upper annular could be substituted with a rotating BOP (RBOP or RCD) 19 where the mud pressure in the borehole annulus 1 is regulated by the liquid mud level in the choke line 51 ( FIG. 6 ). The pressure in the BOP and or BOP extension is now a function of the liquid level 51 in the choke line and the gas/air pressure above. This gas can either be ventilated to atmospheric pressure or controlled and regulated by the surface choke 22 . This will create a softer and more dynamic process than having the pump suction pressure (only liquid) directly controlling the wellbore pressure. When low compressibility liquid is contained in a closed loop system, it will create a very stiff system. Small changes will affect well bore pressure immediately, while a level control of drilling fluid, mud and/or seawater in the choke line will be a slower and more controllable process.
[0034] While drilling, this could set up a unique method of pressure control. An influx into the borehole between the open hole and drillstring could have a self regulating effect. An influx into the wellbore has a density higher than air in top of the choke line and for the case of example 8½″ hole and 6″ drill collars would have a capacity of minimum 17.8 litre per meter hole section. The capacity of most choke lines (3″-5) is between 4.56 litre per meter to 12.6 litre per meter. An influx of a certain magnitude would increase the level in the smaller capacity choke line to a higher level than the influx constitute in the openhole—drillstring annulus, hence an influx progressing would be stopped just by the higher hydrostatic pressure created by a higher liquid level 51 in the choke line 17 .
BRIEF DESCRIPTION OF DRAWINGS
[0035] FIG. 1 a illustrates a conventional subsea drilling system in normal drilling operations
[0036] FIG. 1 b illustrates conventional subsea drilling system in well control mode
[0037] FIG. 2 illustrates a first embodiment of the present invention, including a riser, in drilling mode.
[0038] FIG. 3 illustrated the embodiment of FIG. 2 in well control mode.
[0039] FIG. 4 illustrates a second riserless embodiment of the present invention in drilling mode.
[0040] FIG. 5 illustrates the embodiment of FIG. 4 in well control mode.
[0041] FIG. 6 illustrates the system of FIGS. 4 and 5 performing an alternative method for well control.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIG. 2 illustrates a first embodiment of the subsea drilling system of the invention. It comprises a well having a well bore 1 . The well bore may be partially cased. Above the seabed level 2 is arranged a subsea BOP 3 with a BOP extension joint 3 a which is equipped with several pressure sensors and several inlets and outlets. A riser 4 is connected to the BOP and extends to a vessel 5 above the sea level 6 . The riser 4 has a slip joint 7 to accommodating heave of the vessel 5 and a riser tensioning system 7 a , 7 b . Above the diverter housing and diverter outlet is a low pressure gas stripper installed 53 to prevent low pressure gas escaping to the drill floor of the drilling rig. The diverter line 36 is ventilated to the atmosphere or the mud gas separator (not shown). The flow line valve 35 is closed as the drilling fluid now is returned via the subsea pump 11 and return line 12 .
[0043] Drill string 8 extends from a top drive 9 on the platform 5 and into the well bore 1 . The lower end the drill string 8 is equipped with a drill bit 10 .
[0044] A liquid return line 12 is connected to the BOP extension 3 a at a first side port 13 and extends to the water surface. The liquid return line has a subsea lift pump 11 for aiding mud return to the surface vessel 5 . The liquid return line has a valve 49 in the branch between the first side port 13 and the pump 11 .
[0045] A gas return line 17 is also connected to the BOP 3 or BOP extension 3 a by a second side port 18 . The gas return line 17 extends to the water surface and drilling vessel 5 . The gas return line has a first valve 21 close to the second side port 18 and a choke valve 22 near the water surface 6 or on the drilling unit. Both the liquid return line 12 and the gas return line 17 are at their upper ends connected to a collection tank 23 via a mud gas separator 42 on the drilling rig.
[0046] The BOP has a main bore 14 through witch the drill string 8 extends. A plurality of safety valves 15 , rams 15 a , 15 b , 15 c , are adapted to close the main bore 14 around the drilling tubular or to seal the wellbore completely 15 d , to prevent a blow-out.
[0047] Above the safety valves 15 and below the first side port 13 the BOP 3 has a lower annular valve 16 , which is adapted to close around the drilling tubulars 8 .
[0048] The BOP has an upper annular valve 19 above the second side port 18 . This annular valve may be a so-called rotating BOP, enabling drilling while the valve is closed.
[0049] A by-pass line 24 extends from the lower BOP (here two side ports 25 and 26 are shown) below the lower annular valve 16 to a third side port 27 between the first and the second side ports 13 and 18 . The by-pass also has a branch 29 connecting to the gas return line 17 here defined as the gas line or choke line. The bypass line 24 has lower valves 28 to close off the lower part of the by-pass line 24 , a first upper valve 30 to close off the branch 29 and a second upper valve 31 to close off the connection to the port 27 . In addition, there is a choke valve 32 in this bypass line.
[0050] The system also has a kill line 33 , which is also included in a conventional system.
[0051] At the top of the riser is a mudflow line 34 with a flow line valve 35 and a overboard line (diverter) 36 with a valve 37 , which are also according to a conventional system.
[0052] As also according to a conventional system, there are several mud pumps 38 pumping mud from the collection tank 23 to the top drive 9 through a line 39 . A valve 40 is included in the line 39 close to the top drive.
[0053] In addition, there is a booster line 41 extending from a mud pump 38 to a fourth side port 42 in the Lower Marine Riser Package or a circulating line connected below the first side port 13 . The line 41 is equipped with at least 1 valve 50 close to the side port 42 . This can be a backpressure valve and or a 2 way shut-off valve. This line may also be used to inject low density fluid or gas into the return path downstream the subsea choke valve installed close to the subsea BOP.
[0054] The system as described above in connection with FIG. 2 is basically the same for all the embodiments described hereinafter. In the following only the items deviating from the arrangement in FIG. 2 will be described in detail.
[0055] The system of FIG. 2 can be used for drilling with and without marine drilling riser. FIG. 4 shows a system without a riser. Except for the lack of a riser, the system is identical with the system described in FIG. 2 .
[0056] The operation of the system according to the invention will now be described:
[0057] FIG. 2 illustrates normal drilling mode of the system. During normal drilling with a riser, both the lower and upper annular valves 16 , 19 in the BOP 3 are open. The mud level 45 in the BOP or BOP extension or riser is controlled using the subsea mud lift pump 11 , which is hydraulically connected to the lower part of the BOP extension joint or riser. Any drill gas or background gas is vented off through the marine drilling riser, i.e. through the gas vent line 36 . Suspended and small gas bubbles may for the most case follow the liquid mud phase into the pump system 11 and be pumped to the surface. At surface the returns can be directed to the shale shakers 43 directly or via a valve 47 to the mud gas separator 42 . The system allows the mud level 45 to be adjusted for control of the bottom hole pressure. The fluid above the mud in the riser can be any type of liquid or gas, including air.
[0058] FIG. 3 shows the system in a well control event. The drill string rotation is stopped and the lower and upper annular valves 16 , 19 are closed. This creates a cavity 46 between the lower and upper annular valves 16 , 19 . The well fluid is diverted from below the lower annular valve 16 to below the upper annular valve 19 , i.e. to within the cavity 46 , through the bypass line 24 containing the choke valve 32 . Separation of the fluids in the cavity 46 in the BOP extension joint will take place due to gravity. The outlet 13 to the subsea lift pump 11 is arranged below the inlet level 27 for the well fluid, and the gas is vented off to the surface through the choke or gas return line 17 connected to the outlet 18 located above the fluid inlet 27 from the well. Normally, the gas/liquid interface level 45 will be located below the level for the gas line 17 . A surface choke 22 is used to control the pressure of the gas phase. The level 45 in the BOP cavity can be measured either by pressure transducers, gamma densitometries, sound, or other methods.
[0059] In this circulation and well pressure control method the surface drill pipe pressure can be regulated by regulating the subsea choke 32 , the subsea pump 11 can be used to regulate the liquid level 45 in the BOP cavity and the pressure in the cavity can be regulated by the pressure in the surface choke 22 , pressure in the BOP cavity, or the liquid level 51 in FIG. 6 (or combination of the two).
[0060] FIGS. 4 and 5 show riserless drilling, and well control mode in riserless drilling, respectively.
[0061] During riserless drilling, the annular valves 16 , 19 in the BOP 3 are open as illustrated in FIG. 4 . The mud/sea water level 45 in the BOP 3 is controlled using the subsea mud lift pump 11 and pressure sensors in the extension joint 3 a between the two annulars 16 , 19 . Any small amount of drill gas or background gas may escape to sea from the open top of the BOP extension. However, most of the drill gas will follow the return liquids through the pump system 11 . In a well control event, the drill string 8 rotation is stopped and the lower and upper annular valves 16 , 19 are closed, as illustrated in FIG. 5 . The well fluid is diverted from below the lower annular 16 to below the upper annular valve 19 through the bypass line 24 containing the choke valve 32 . The choke valve 32 will now control the bottom hole pressure and the pressure downstream the choke 32 will be much lower than the upstream pressure. This will improve the separation process.
[0062] Separation of the fluids in the BOP extension joint 3 a will take place due to gravity. An outlet 13 to the subsea lift pump 11 is arranged below the inlet level 27 for well fluid, and any free gas is vented off to surface through the flexible or fixed choke line 17 to above the water surface. Normally, the gas/fluid level 45 will be located below the outlet level 18 for the vent line 17 . A surface choke 22 is used to control the pressure of the gas phase.
[0063] FIG. 6 illustrates the subsea separator in an alternative mode. Here the subsea choke 32 is used to control bottom-hole pressure (BHP). The separator with the vent line 17 is used to remove the gas from the liquid before entering the subsea lift pump. However, the liquid is allowed to enter the vent line 17 and establish a liquid/gas interface 51 in the vent line 17 . The head of this liquid column and any pressure above the liquid/gas interface defines the pressure in the separator cavity 46 . By regulating the pressure above the fluid level and the level of the interface 51 , the pressure in the cavity 46 can be adjusted as illustrated in FIG. 6 .
[0064] The pressure in the cavity 46 can be increased by pumping mud from the surface through the boost line 41 . This will quickly raise the interface 51 and hence increase the pressure in the cavity 46 . The pressure in the cavity 46 can be lowered by increasing the pump rate of the subsea return pump 11 . This will quickly reduce the level of the interface 51 and hence the pressure in the cavity 46 . This provides a means for rapidly adjusting the pressure in the cavity 46 and hence the back pressure against the well fluid entering the cavity 46 from the by-pass line 24 if the choke is fully open.
[0065] In the case of a subsea pump failure or as an option, a low density fluid or gas may be injected into the return lines or choke line, downstream of the subsea choke valve, so as to keep the pressure immediately downstream the subsea choke valve 32 substantially lower than the pressure upstream the subsea choke valve. In this manner the well pressure can be controlled accurately by the subsea choke.
[0066] Means to Reduce Pressure Fluctuations:
[0067] In order to avoid slug flow and large pressure variations, a choke valve 32 can be used to control the flow of fluids into the separator 48 and avoid or reduce the pressure fluctuations. Pressure fluctuation downstream of the subsea choke valve 32 could also affect the upstream pressure of the subsea choke (well pressure). However, keeping the gas/fluid level within the separator allows large gas flow rates to the handled.
[0068] Increasing the diameter of the choke line (6-8 inches) allows the liquid to enter the vent line 17 and separate from the gas without excessive pressure fluctuation in the BOP cavity. Since a subsea choke valve reduces the pressure, a low pressure choke line may be used.
[0069] In an effective riserless subsea separation system, the liquid/gas interface level may be kept within the separator and a surface choke valve to control the separator pressure may be introduced.
[0070] When keeping the pressure in the separator equal to or just below the ambient seawater pressure, the normal drilling operations can be conducted without major adjustments to the separator pressure. With only gas in the choke line, the size can be reduced (2-3 inches). This system will also reduce the gas separated from the liquid before entering the subsea lift pump. The pressure will reduce the subsea pump differential pressure needed to bring the return fluid back to the drilling vessel. Gas bleed off may take place at high rates.
[0071] This means that the remaining gas still contained in the liquids has to be separated at surface. So, the gas from the choke line, and the mud and gas from the subsea lift pump can be diverted through the mud gas separator/Poor Boy degasser 42 and vented off through the vent line in the derrick.
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A subsea mud pump can be used to return heavy drilling fluid to the surface. In order to provide a less stringent requirement for such a pump and to better manage the bottom hole pressure in the case of a gas kick or well control event, the gas should be separated from the drilling fluid before the drilling fluid enters the subsea mud pump and the pressure within the separating chamber. The mud pump suction should be controlled and kept equal or lower than the ambient seawater pressure. This can be achieved within the cavities of the subsea BOP by a system arrangement and methods explained. This function can be used with or without a drilling riser connecting the subsea BOP to a drilling unit above the body of water.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to suspended ceiling grid construction and, in particular, to a bracket for supporting peripheral ceiling grid runners from adjacent wall structure.
PRIOR ART
Geographic regions prone to or predicted to experience seismic events can benefit with construction elements that reduce the effects of these occurrences. In this context, suspended ceiling grids have been provided with various expedients to accommodate a sudden structural shift or series of shifts of limited amplitude and maintain sufficient integrity to keep ceiling panels carried on the grid from falling. There remains a need for a simple, quick, and effective way of supporting grid runners at the perimeter of a suspended ceiling apart from the standard wall angle. Often, the plenum above the ceiling adjacent its perimeter is occupied by utilities such as air ducts, electrical raceways and the like. These utilities and other objects can make it difficult to support the ends of grid runners or tees at these locations with suspension wire from above, for example.
SUMMARY OF THE INVENTION
The invention provides a novel bracket particularly useful in higher seismic category geographic zones where suspended ceiling grid tees or runners are to be supported in close proximity to a wall other than by a conventional wall angle. Brackets of the invention, sometimes referred to as braces, can eliminate the need for suspension wires at the perimeter of a ceiling. Such wires can be difficult to install and, therefore, expensive for lack of conveniently accessible superstructure.
The inventive bracket, capable of being produced with various profiles, is preferably formed as a sheet metal stamping. The bracket can be marketed in a substantially two dimensional configuration and be bent as it is installed to suit the geometry of the grid and wall intersections. In general, the bracket body includes a saddle-like portion that extends horizontally over a grid runner and a vertically extending portion above the plane of the grid runner adapted to be fastened to a wall.
Ideally, the bracket optionally provides limited horizontal movement of the grid runner or a rigid connection of the grid runner to the wall. Horizontal movement is achieved with a slot in the bracket body that lies alongside a part of the grid runner and receives a fastener extending through the grid runner. Alternatively, the horizontal movement is accommodated by a depending pivotal arm integral with the bracket body. One part of the vertically extending portion is anchored flat against a surface of the wall at the boundary of the ceiling and another part of the vertically extending portion serves as a web between the wall anchored part and the horizontally extending portion of the bracket. The two parts of the vertically extending portion can be connected at a bend line defined by a zone weakened with a series of aligned apertures or slots in the sheet metal body. This construction permits the bracket to be bulk shipped in a “flat” configuration to occupy relatively small volume and be custom bent at the installation site by the installer to fit the intersection geometry of the ceiling grid and the wall especially if it is other than 90°.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a perimeter area of a suspended ceiling grid illustrating a first embodiment of the invention;
FIG. 2 is a perspective view of a bracket of the first embodiment of the invention;
FIG. 3 is an end view of the bracket of FIGS. 1 and 2 ;
FIG. 4 is an elevational view of the bracket of FIGS. 1 and 2 ;
FIG. 5 is a perspective view of a bracket of a second embodiment of the invention;
FIG. 6 is an end view of the bracket of FIG. 5 ;
FIG. 7 is an elevational view of the bracket of FIG. 5 ;
FIG. 8 is a perspective view of a bracket of a third embodiment of the invention;
FIG. 9 is an end view of the bracket of FIG. 8 ;
FIG. 10 is an elevational view of the bracket of FIG. 8 ;
FIG. 11 is a perspective view of a bracket of a fourth embodiment of the invention;
FIG. 12 is an end view of the bracket of FIG. 11 ;
FIG. 13 is an elevational view of the bracket of FIG. 11 ;
FIG. 14 is a perspective view of a bracket of a fifth embodiment of the invention;
FIG. 15 is an end view of the bracket of FIG. 14 ;
FIG. 16 is an elevational view of the bracket of FIG. 14 ;
FIG. 17 is perspective view of a bracket of a sixth embodiment of the invention;
FIG. 18 is an end view of the bracket of FIG. 17 ; and
FIG. 19 is an elevational view of the bracket of FIG. 17 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, in particular, to FIGS. 1-4 , there is illustrated a vertical rigid wall 10 on which a conventional suspended ceiling wall angle 11 is mounted by suitable fasteners such as screws. The wall angle 11 , conventionally roll-formed of sheet metal, lies at the perimeter and plane of a suspended ceiling grid represented by a grid runner or tee 12 of conventional construction. The grid runner 12 , ordinarily of roll-formed sheet metal, has the general cross-section of an inverted T with a lower horizontal flange 13 , vertical central web 14 , and an upper polygonal hollow reinforcing bulb 15 .
Typically, the wall angle 11 in several pieces is placed end-to-end to run along each wall surrounding the ceiling grid. Grid runners 12 are ordinarily spaced apart on two or four foot centers (or metric equivalent). In some categories of seismic rated geographic areas, it can be desired to support the peripheral grid runners 12 within 8″ of a wall 10 . Often, the plenum above the plane of the ceiling is crowded with utilities in spaces adjacent the walls 10 making it difficult and time-consuming and, therefore expensive if not impractical to use conventional hanger wires in these spaces.
The invention provides a bracket or brace 18 adapted to support the end of a grid runner 12 adjacent a wall 10 or similar structure at the edge or periphery of the ceiling. While FIG. 1 illustrates only one grid runner or tee 12 , it will be understood that it is representative of numerous tees uniformly spaced from one another along the wall 10 and a separate bracket 18 is provided for each tee. The bracket 18 , and other versions depicted in FIGS. 5-18 to be described, are preferably sheet metal stampings of, for example, 0.024″ gauge steel. The bracket 18 includes a horizontally extending portion shown generally at 21 and a vertically extending portion shown generally at 22 which can be considered to overlap where they merge. The horizontally extending portion (sometimes simply “horizontal portion”) 21 includes an inverted channel or saddle 23 giving the bracket 18 an inverted J-shaped cross-section shown in FIG. 3 . A lower edge of the horizontal portion 21 has a small lengthwise extending flange 24 . Opposite sidewalls 27 , 28 are spaced apart to slip over the grid tee bulb 15 . Typically, the bulb is ¼″ wide (or metric equivalent). One of the channel sidewalls 28 extends vertically substantially below the opposite wall 27 such that when the bracket 18 is installed on a grid runner 12 , it lies alongside the grid runner web 14 . Both walls 27 , 28 forming the channel 23 have holes 29 and a horizontally elongated slot 31 for receiving a screw or other fastener 32 . The extended wall 28 has a second set of holes 33 and a horizontally elongated slot 34 below the first mentioned holes 29 and slot 31 .
The vertically extending portion (sometimes simply “vertical portion”) 22 of the bracket 18 has two sections or parts 36 , 37 separated by a bend line made by a series of vertical aligned slots or apertures 38 . The presence of the apertures 38 leaves small spaced land areas 39 which are relatively weak along the line of the apertures in resistance to bending the plane of one section 37 relative to the other 36 . As a result, a low force, preferably even without hand tools applied by the installer is all that is required to locate the section 37 in a plane perpendicular or otherwise relative to the other section 36 . Preferably, the bracket 18 is manufactured with both sections 36 , 37 of the vertical portion 22 coplanar so that the bracket occupies a minimum space when packed and shipped with identical brackets 18 . Weakening at the bend line allows the installer to ordinarily bend the section 37 to an angle corresponding to that at which the grid runner to which it is to be attached intersects the wall 10 . While this angle is most often a right angle, it can be essentially any other angle.
With reference to FIG. 3 , it will be understood that the inverted channel 23 is dimensioned to seat on the sides and upper face as well as to support under one side of the bulb of a grid runner bulb 15 of a standard duty grid runner 12 . The bracket 18 can be fixed to a grid runner 12 by assembling a screw 32 through the slot 31 (or the holes 29 ) and into the sidewall of the bulb 15 . When the slot 31 is used, a limited longitudinal movement of the grid runner 12 relative to the bracket is accommodated. The lower flange 24 is proportioned to engage the grid runner web 14 and thereby assist in aligning and stabilizing the grid runner 12 to the bracket 18 . A standard duty grid runner or tee 12 will measure nominally 1½″ in height from the lower flange 13 to the top of the bulb 15 . The lower holes 33 and slot 34 of the bracket 18 can be used, for instance, where the grid runner height is relatively short such as with a cross runner or cross tee. While a grid runner end rests on a wall angle 11 , the bracket 18 can be installed by slipping the inverted channel 23 on the horizontal portion 21 down over the end of the grid runner so that the bulb 15 is received in the inverted channel 23 . The bracket 18 is fastened to the wall 10 with screws or nails or other fasteners 41 assembled through holes 42 in the distal section 37 of the vertical portion 22 . A lower area 43 of the distal section 37 can be slipped behind the vertical leg of the wall angle 11 or can be simply overlayed on this vertical leg.
In the variants of the bracket of the invention shown in FIGS. 5-19 , equivalent or analogous elements of the version described with reference to FIGS. 1-4 are identified with the same numerals. Generally, like the first-described bracket 18 , each of the other brackets shown in the subsequent figures are stamped of a suitable gauge of sheet steel. In FIGS. 5-7 , the horizontal portion 21 of a bracket 46 is extended to enable a grid runner or tee 12 to be supported by the bracket at a greater distance from a wall 10 than that obtained by the bracket of FIGS. 1-4 . The bracket 46 includes a second saddle-like inverted channel 47 aligned with and rearward of the channel 23 . The channels 23 and 47 are each adapted to closely fit over three faces of a conventional grid runner bulb 15 . In this version of the bracket 46 , the vertical portion 22 has a height that is about ⅔ of the length of the horizontal portion 21 measured from the bend line formed by the slots 38 .
Referring to FIGS. 8-10 , a bracket 51 , like the bracket 18 , has an L-shape in elevational view. The length and height of the bracket 51 are increased from that of the first-described bracket 18 . By way of example, the horizontal portion 21 , measured from the line of the slots 38 to the distal end can be about 8″ and the vertical portion can be about 7½″ high.
FIGS. 11-13 illustrate a bracket 56 having a horizontal portion 21 with a depending pivotal leg 57 . An elongated embossment 58 in the horizontal portion 21 stiffens the bracket 56 . The leg 57 supports a tee for limited longitudinal motion as a substitute for the slot 31 found in other bracket versions. Either one of two holes 59 in an L-shaped tab 61 accepts a self-drilling screw that is driven into the bulb 15 of a grid runner or tee 12 . The leg 57 can pivot either to the right, as shown in phantom in FIG. 13 or, similarly, to the left. When the grid runner 12 is displaced longitudinally, the tab 61 pivots on the screw fixing it to the bulb 15 . In applications where the grid runner 12 is to be rigidly fixed relative to a wall, a screw is inserted in one or more of the holes 29 and driven into the bulb.
FIGS. 14-16 depict a bracket where a gusset-like area 67 extends between the horizontal portion 21 and the vertical portion 22 . The gusset-area 67 can have a polygonal embossment 68 generally following and inset from the profile of the bracket. Sheet material used to form the inverted channel 23 leaves a rectangular aperture 69 in the horizontal portion 21 . A lower part 70 of the horizontal portion 21 , which includes holes 33 and slot 34 is offset towards the center of the channel 23 to allow it to abut the web 14 of a grid runner 12 .
FIGS. 17-19 show a bracket 71 with a right angle profile and in which the horizontal portion 21 has a lower section 72 offset towards the center of the inverted channel 23 . This geometry, like that of the bracket 66 allows the lower section 72 to abut the web 14 of a grid runner 12 to align and stabilize the bracket and grid runner.
All of the disclosed brackets are characterized by a plate-like structure that fits closely against a grid runner and embossments or offsets of the same extend into the space above or below the reinforcing bulb of a grid runner so that lay-in ceiling panels can be installed and lifted for access without undue interference. Additionally, the various disclosed brackets are characterized by a vertically extending portion that rises above a standard 1½″ grid runner or tee by more than 1½ times this height thereby allowing the bracket to sustain adequate levels of vertical force at the distal end of the horizontally extending portion.
While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention.
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A seismic bracket for supporting ends of suspended ceiling grid runners from a wall comprising a stamped sheet metal body, the body having a horizontally extending portion and a vertically extending portion, the vertically extending portion, in its installed position, rising above the top of a standard grid runner a distance at least 1½ times the height of such standard grid runner, the vertically extending portion having two sections generally coextensive in the vertical direction, a first section being integral with the horizontally extending portion and a second section arranged to be in a vertical plane that intersects a vertical plane occupied by the horizontally extending portion, the horizontally extending portion being arranged to support a grid runner to move longitudinally a limited distance, the second section of the vertically extending portion having an aperture for securing the bracket to the wall at a location substantially above the grid tee.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
PRIOR ART
It has been proposed to place water in the walls of safes for the purpose of protecting the contents of these structures against fire damage. Such disclosures are set forth in U.S. Pat. Nos. 67,929, 79,808 and 2,829,608. U.S. Pat. No. 131,842 discloses a portable safe protector in the form of a double walled case adapted to be fitted around the outside of a safe, the space between the walls being filled with water for fire protection. With each of these known structures, the water chambers are accessible for filling and emptying from outside the casing.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the principles of this invention a normally portable or mobile safe or the like is rendered relatively non-portable or immobile, after it has been located in a desired spot, by adding excess weight to the interior of the safe in sufficient amount to make the safe too heavy for transport manually or by ordinary means. In a preferred embodiment, the walls of the casing forming the safe are provided with a chamber means adapted to be filled with a mass such as a liquid or small steel balls. The chamber means may include a single chamber, a plurality of separate chambers or a plurality of chambers interconnected with one another. Access to the chamber means for filling and emptying is available only when the door of the safe is open. After the safe is located where needed, and the chamber means has been filled with liquid, the safe is so heavy that it is relatively immovable, and yet when it must subsequently be moved, the liquid can be drained after opening the door of the safe so that the weight of the safe is reduced to render it easily transportable to another location. Access to the excess weight only when the door is open prevents unauthorized removal of the excess weight.
IN THE DRAWINGS
The FIGURE shows a perspective view of a preferred form of a safe or storage box that embodies this invention.
DETAILED DESCRIPTION
The safe or storage box 10 includes relatively impenetrable walls which completely surround an internal storage space, the walls including side walls 12, a back wall 13, a top wall 14, a bottom wall and a front wall 16. The front wall is provided with a secure door 18 hinged to the inside of a side wall so that the hinge means 20 is concealed when the door is closed to completely seal the contents within the storage space. The door may be provided with any suitable combination lock or other locking device for safely sealing the contents within the safe. The casing walls, top, bottom, and door means are all made and assembled from known steels or other material that is substantially tamperproof, as is known in the art. While such a casing may be well adapted to protect the contents of the safe against theft, relatively small sized casings, even though locked, may be sufficiently light to be transported by a thief to a location where forced entry into the safe can be made without fear of detection.
In accordance with the preferred form of this invention, in order to render the safe or strong box 10 less portable, most or all of the inside walls of the casing are constructed to have chamber means 22 integral therewith adapted for liquid storage. The chamber means forming an integral part of the inside walls of the casing may be formed as a single unit or a plurality of individual but interconnected chambers may be provided. The chamber or chambers are designed to be filled and emptied via a suitable access means. In the illustrated embodiment the chamber or chambers may be filled through an inlet 24 and may be drained of liquid through an outlet 26. The inlet and outlet are provided with suitable seals to hold the liquid sealed in the chamber means so as to add the weight of the liquid to the safe to make it relatively immovable and to allow the liquid to be removed by permitting the liquid to be drained when the safe is to be moved.
The access means is accessible only when the safe door is open. In the illustrated embodiment the inlet 24 and outlet 26 are located on the top and bottom sides of the front wall directly behind the door in positions that are entirely concealed within the safe when the door 18 is closed. The inlet 24 and outlet 26 are thus disposed so that they can be reached only when the door 18 is open. After the safe has been transported to its destination and after the chamber means 22 has been filled with the liquid, the safe remains relatively immovably positioned in that spot until the door 18 is opened and the chamber means is drained to lighten the safe and permit its removal to another location.
As indicated above, the liquid containing chamber means 22 may be made up of several separate interconnected chambers for convenience, that are attached to and are supported by the inside walls of the casing. When a plurality of chambers are assembled together within the casing, suitable piping interconnections can be made whereby to easily fill and drain all of the separate chambers through the common inlet 24 and outlet 26. Any available liquid may be filled into the chamber means to add weight to the safe. Water is the most conveniently available liquid but other liquids especially those denser than water can be used if available.
In place of chamber means 22, the inside walls of the chamber can be provided with suitable rack supporting means for receiving separable lead or other conveniently handled weight means. As many weights can be positioned on such racks as may be deemed desirable. It is apparent that such added weights positioned within the casing body and seated on racks attached to the inside walls of the casing, cannot be removed until door 18 is opened. Once the casing has been transported to its destination, it can easily be made immovable by simply adding more or less weights to the racks positioned within the body of the casing. Once loaded with the portable weights, the safe can be made portable again only by someone having knowledge of the combination lock or key to the door 18 of the strong box.
As an example of the preferred form of the structure, a 30" by 30" by 30" casing with a 3" thick hollow liquid retaining chamber means on the inside of 5 of the sides of the casing, will hold approximately 45 gallons of water. Thus, 360 pounds can be added to the weight of the safe by simply filling this chamber means 22 with water and sealing the concealed inlet and outlet ports. The casing on the other hand can be easily lightened for transport by draining the water from chamber means 22. But it is to be noted that the chamber means cannot be drained until door 18 is opened to expose inlet 24 and outlet 26 so that once in position and after the chamber means 22 is filled, the safe is rendered substantially immovable until prepared for transport by being drained by one having access through the unlocked door of the safe. Likewise as stated above, any weights stored on racks within the casing, inhibit the portability of the safe until these weights are removed after the door has been opened.
It is, of course, desirable to provide a pressure relief valve to permit any water or other liquid that may become vaporized to escape from the chamber storage means should the liquid tend to boil away under pressure as might happen during a fire. On the other hand, the use of water in a chamber so protected, tends to protect the contents of the safe from destruction as taught in the prior art. Any relief valve or vent means can be constructed and placed in such a position to prevent an unauthorized person from tampering with such a protective device to drain the chamber means.
The above description covers the preferred form of this invention. It is possible that modifications thereof may occur to those skilled in the art that will fall within the scope of the following claims.
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A storage container, such as a safe, is provided with internal removable excess mass which renders the container relatively immobile until the mass is removed. The mass may be, for example, water stored between inner and outer walls of the container or lead shot, steel balls or anti freeze. Normal access to the mass for removal thereof, in order to render the container relatively mobile, is available only after the door of the container has been opened.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to United States patent application Ser. No 08/523,712, filed on Sep. 5, 1995 under Docket Number 2462-SL-VD by the inventors herein and assigned to the assignee of the present invention.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to United States patent application Ser. No 08/523,712, filed on Sep. 5, 1995 under Docket Number 2462-SL-VD by the inventors herein and assigned to the assignee of the present invention.
BACKGROUND OF THE INVENTION
This invention relates generally to door handle assemblies for use with panic exit devices and more particularly to modular door handle assemblies which have redundant dual-action handle return springs which also have a lock detent function.
Currently available door handle assemblies with internal locking require relatively complex locking and unlocking mechanisms with separate springs for handle return and locking functions. They consist of several parts and are spring loaded so that repairs required because of damage due to vandalism or routine wear and tear are often difficult to accomplish without losing or damaging some parts. This increases down time, repair time, and thus the cost of maintenance and repair for buildings employing such locks.
The foregoing illustrates limitations known to exist in present door handle assemblies, and it would be advantageous to provide an alternative directed to overcoming one or more of those limitations. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, a door handle assembly is provided including a door handle on a rotatable handle shaft; a housing having a face with a bore for receiving the handle shaft and having means for mounting the door handle assembly to a door; means, mounted in the housing, for operating a door latch in response to rotation of the door handle; means for returning the handle to a parked position upon release of the handle from rotating force; and means for releasably locking the door handle assembly to prevent operation of the door latch.
The foregoing and other aspects of the invention will become apparent from the following detailed description, when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic front perspective view illustrating a modular door handle assembly;
FIG. 2 is a schematic rear perspective view of the door handle assembly shown in FIG. 1;
FIG. 3 is a schematic view of the assembly in FIG. 2, with the cover plate removed to show the operating mechanism of the invention in the parked position;
FIG. 4 is a view as in FIG. 3 showing the handle assembly in the latch-retracted position;
FIG. 5 is another view as in FIG. 3 showing the operating mechanism in the parked and locked position; and
FIG. 6 is a sectional view illustrating the bearings and other features of the housing as well as construction details of the modular handle assembly.
DETAILED DESCRIPTION
FIG. 1 shows the environment of the invention. A modular door handle assembly 100 has a housing 10, a lock 120, and a handle 30. In this view, mounting studs 5 and tailpiece 50 are seen extending rearwardly from the back of the housing. This type of handle assembly is usually used with panic exit devices opposite the push bar. Note that a lever is shown here, since levers are most commonly used in commercial buildings where panic exit devices are provided; but any type of handle including push-pull handles, thumb lever handles, or knobs may be used.
The invention is best described by reference to all six figures; because not all features are visible in every figure and, for the sake of clarity, not every feature is numbered in every figure. Modularity of the assembly is best illustrated in FIGS. 1 & 2, while structure and operation are best illustrated by referring to FIGS. 3-6.
FIGS. 2-6 show that assembly 100 has a housing 10, in which are mounted the handle shaft 35, cam 20, slider 60, lock bar 80, locking lugs 85, springs 90, dogs 95, and input cam 70; all of which, except for cam 20 are mounted behind cover plate 15. The cover plate 15 is secured to housing 10 by studs 5, which also serve as fasteners for mounting the modular door handle assembly to a door. These dual-function studs each have a skirt "k" which retains the cover plate 15 against the housing 10 whether the assembly 100 is attached to a door or not. For fire door installations, the studs are designed to remain in place, even after door lock trim components have melted away, and to maintain attachment of the door lock mechanism. A ledge 11 of the housing 10 surrounds most of the lower portion of the housing and act as a stand-off support for cover 15, a guide for slide 60, and a retainer and guide for dogs 95. Thus, the cover does not interfere with movement of the slide, cam, dogs, lock bar, or input cam; but it does maintain the parts in alignment for smooth operation.
Handle shaft 35 extends from lever 30 through housing 10 and protrudes far enough for mounting the cam 20 and its retaining ring 24. A transverse through-drilled bore "b" is provided in lever shaft 35 for driving the cam 20 when it is installed on the shaft. A shear pin 22 of a length L greater than the diameter D of lever shaft 35 (preferred L is equal to approximately 1.5×D) is installed in bore "b" of the lever shaft. Cam 20 has a bore with a diameter which is a slip fit on lever shaft 35 and also preferably has symmetric opposed lobes 25 to coact with the slider 60 for either left or right handing of levers. It has a recess or slot "a" extending radially from the bore of cam 20. This slot does not extend completely through cam 20 and, when the cam 20 is installed the slot "a" aligns with the transverse bore "b" through lever shaft 35 and receives the protruding portion of shear pin 22. Thus, when shear pin 22 is installed in bore "b" of lever shaft 35 and cam 20 is slipped onto the shaft, the shear pin 22, which has a slip fit in the bore "b", nests in the slot or recess "a" and is retained in the shaft by the cam. This transmits torque between the lever shaft 35 and cam 20 so that, when the lever 30 is moved, the cam responds; and, conversely, when the cam 20 is moved by the return mechanism described below the shaft 35 also turns and returns the lever 30 to its parked position.
The shear pin 22 also provides protection for the door handle assembly 100 against vandalism and over-torquing in general. If excessive torque is applied, the shear pin 22 fails and the handle 30 turns freely, thereby avoiding damage to other parts of the assembly. Because the cam 20 and shear pin 22 have slip fits with the lever shaft, they are easily removed for replacement. The cam 20 is secured on shaft 35 by retaining ring 24. Thus, the retaining ring 24, retains cam 20, which has a slip fit on shaft 35, on the shaft; and the cam 20 retains shear pin 22, which has a slip fit in transverse bore "b" and protrudes into the slot "a" of the cam 20, to ensure co-rotation of shaft 35 and cam 20 under normal operating conditions.
FIGS. 3-5, in which the cover plate 15 has been removed, illustrate further details of the invention, in which, when cam 20 is symmetrical lobes 25 are identical and have the same driving effect on the slider 60 regardless of the direction in which the handle 30 and handle shaft 35 rotate. When the handle 30 is rotated, shaft 35 and cam 20 also rotate. Cam lobes 25 push against slider 60 to move the slider and to thereby move the lever arm 75 of cam 70 which is positioned in the lateral branch "L" of the branched slot "S" of the slider. This causes rotary motion of the cam 70 which is transferred by input cam shaft 40 to tailpiece 50 and thence to the door latch spindle (not shown). Preferably, pin 45 retains tailpiece 50 in shaft 40 of cam 70 by extending through a transverse bore in the shaft 40, the bore being aligned with a hole (not numbered) in the tailpiece 50.
When the door handle 30 is operated, handle shaft 35 turns and causes cam 20 to turn. Cam lobes 25 push against the slider 60 and drive it upward against the springs 90. As the slide moves upward, the lateral branch L of the branched slot S drives cam lever 75 causing cam 70 to rotate. This drives cam shaft 40 and tailpiece 50 to operate a door latch spindle (not shown) and unlatch the door.
FIG. 3 shows the operating sequence before it has begun, and FIG. 4 shows the sequence at its end. It can be seen that springs 90 are compressed in FIG. 4 by the upward displacement of the slide 60 caused by operation of the door handle 30. FIG. 4 also shows the lock bar 80 and the locking lugs 85 which are interdigitated with similar projections 65 of slide 60 when the lock bar is in the unlocked position. Upon release of the handle 30 from the rotating force imposed upon it to operate the latch, springs 90 return to their extended position seen in FIG. 3, and in doing so, drive slide 60 downward, thereby returning input cam 70, cam lever 75, cam 20, handle shaft 35, and handle 30 to their parked positions. The compression springs 90 are very strong and durable, and because of the redundancy provided by the invention structure, are doubly so in this application.
The locked position of lock bar 80 is shown in FIG. 5. Notice that locking lugs 85 are aligned with the projections 65 of the slide 60 and prevent upward movement of the slide. A lock bar arm 88 extends from the lock bar 80 and is usually operated by a thumb turn (not shown) from the inside of the door and by a key lock 120 and cam 121 from the outside. In its leftward position, the lock bar 80 and locking lugs 85 are clear of the path of the projections 65 of the slide 60, and the slide is free to move. In the rightward position shown in FIG. 5, lugs 85 are aligned with the projections 65, and the mechanism is locked.
There are two detents 87 in the lower edge of lock bar 80 which are spaced so that one of the detents is always aligned with one of two co-acting spring-loaded dogs 95 to retain the lock bar 80 in either the locked or unlocked position. The dogs 95 project slightly above the portion of housing ledge 11 in which they are supported, such that their tapered ends are in continuous contact with the surface of lock bar 80. When the lock bar is in the unlocked position, the left dog and left detent are engaged. When the lock bar is in the locked position, the right dog and the right detent are engaged. The ends of the lock bar 80 have a taper corresponding to half of the detent so that, when either dog 95 is engaged, the other rests against the tapered end of the lock bar and reinforces the retaining action. The dogs 95 are spring-loaded by the dual-acting springs that also return the slide and handle to the parked position when the handle is released. The retaining action is, therefore, very positive and distinct.
The integrally formed thrust and rotation bearings for the door handle 30, door handle shaft 35, and input cam shaft 40 are illustrated by reference to FIGS. 1 and 6. When forming the housing 10, by casting, pressing and sintering, machining, molding, or welding, cores or inserts are placed so that bearing surfaces are provided at appropriate locations. Boss 104 on housing 10 provides a sufficient mass to accommodate the integral bearing function. As shown, there is an insert 105 which has the actual rotation bearing surface for the handle shaft 35. End face 107 of the boss 104 provides the thrust bearing against which shoulder 37 of handle 30 bears. Using the insert or not, it is usually required to do some final grinding, honing, or polishing to get the best bearing surfaces. For the input cam shaft 40, bore wall 115 and bore end 116 act as the rotation and thrust bearing surfaces, respectively. Use of integrally formed bearings speeds and simplifies assembly by eliminating the need for installing and aligning of loose bearings.
The mounting studs 5 are used for mounting the modular door handle assembly to the door and also for holding the assembly together in the housing. Except for the lock 120 and the cam 20, virtually all the parts of the assembly 100, according to the invention, are held in the housing 10 by the cover plate 15, which is fastened in place by the four (preferably) studs 5 after the other components are installed. This simplifies and speeds manufacturing the modular handle assemblies by minimizing the number of parts and also the number of operations which require use of tools.
This invention provides modular door handle assemblies for installation primarily in doors with panic exit devices. Installation is simplified, and durability of the assembly in service is assured by the minimal number of parts required and by the redundancies of the design. The locking mechanism is simple, but it is ruggedly made, as are all working parts of the lock.
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A modular door handle assembly has a door handle on a rotatable handle shaft mounted on a housing having a face with a bore for receiving the handle shaft. Dual-function studs retain a cover on the housing and have provision for mounting the door handle assembly to a door. Other provisions, within the housing, provide for operating a door latch in response to rotation of the door handle together with a mechanism for returning the handle to a parked position upon release of the handle from rotating force and a locking feature for releasably locking the door handle assembly to prevent operation of the door latch. The handle return and locking features are both driven by a pair of dual acting springs. The modular design simplifies repair and replacement of the assembly.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
A memorabilia storage device incorporated in a burial monument and a method for modifying an existing monument to provide such a device is disclosed herein.
BACKGROUND OF THE INVENTION
The desire to keep sentimental items close to the burial site of a person is well known, and a number of devices have been provided in the prior art for storing memorabilia in or near a tomb or grave site. The provision for memorabilia storage near a tomb or grave site is meaningful, because it gives many people peace of mind prior to death by knowing that they will still be in close proximity to objects that have sentimental value. Providing a memorabilia storage compartment that is accessible to visitors of a grave site is also important because it provides the visitors a sense of staying in touch with the decedent by changing or adding memorabilia stored therein. In this way, survivors can share major events with the deceased by placing pictures and other memorabilia in the storage compartment.
A number of prior art devices provide a memorabilia storage compartment as part of a casket in which the deceased will be buried or, in the case of a cremation, as part of the urn or urn storage device in which the ashes are stored. U.S. Pat. Nos. 5,727,291; 5,678,289; and 5,675,876 all provide caskets having compartments therein for storage of memorabilia and artifacts that have sentimental meaning to the deceased. It is a significant disadvantage of the casket incorporated memorabilia storage compartments, though, that they are not accessible after the casket is buried. Thus, they afford no opportunity to the family and friends of the deceased to “stay in touch” with the deceased through additions or changes to the memorabilia stored in the compartment.
A number of other devices in the prior art disclose memorabilia storage compartments that can be viewed by visitors to the grave site. U.S. Pat. Nos. 4,227,325 discloses a grave marker including a cylindrical chamber that rests on top of the marker in which memorabilia is stored and displayed to those who visit the grave site through a small opening in the cylinder. The storage cylinder is not incorporated into the grave marker, but rather is supported thereon by dual supports.
U.S. Pat. No. 5,553,426 discloses a gasketed lock-box for storage of memorabilia that is anchored into the ground near the burial site. The '426 patent comprises a hollow box and is not incorporated with or into a traditional stone, granite or marble monument. A significant disadvantage of the '426 patent is that it would be subject to collapse under heavy weight, such as a lawnmower and would be subjected to expansion and contraction with temperature changes, disadvantageous compared to a stone, granite or marble monument of solid construction.
U.S. Pat. No. 5,729,921 discloses a burial marker having an air and water tight container therein that is accessible to visitors of the grave site. It also includes a cylindrical container in which memorabilia is retained. The marker 12 of the '921 patent is a box that is interred in the ground, like a headstone, but the box 112 is not a traditional headstone comprising stone, granite, marble or any other rigid material. Rather, the box 12 is constructed from material such as plastic that is very light and easy to mold. It is a significant disadvantage of the '921 marker that it is so constructed because such an embodiment lacks the strength and rigidity to withstand the shifts and temperature changes in the surrounding ground or heavy weight placed upon it, such as a lawnmower.
None of the prior art devices disclose a memorabilia storage device or compartment that is formed as part of a heavy, rigid monument with closure means affixed to the monument. While it is well known that burial monuments may be raised out of the ground or buried to be flush with the ground, there is no device or method in the prior art whereby a memorabilia storage compartment can be formed in the monument itself and accessed either through the top of the marker, for those monuments that are flush with the ground, or the front, back or side of the marker for those that are raised above the ground. In addition, none of the prior art devices disclose a memorabilia storage compartment that solely comprises materials such as brass, porcelain, marble and granite that are generally accepted in cemeteries because of their resistance to weather. Many cemeteries have restrictions as to what materials may be included in burial monuments, and specifically preclude plastics and similar materials that are prone to weathering and breakage.
OBJECTION OF THE INVENTION
It is an object of the present invention to provide a burial monument having a compartment accessible to visitors to a grave site wherein memorabilia can be stored.
It is another object of the present invention to provide a burial monument having a memorabilia storage compartment incorporated into the monument itself.
It is yet another object of the present invention to provide a method for modifying an existing burial monument to provide a memorabilia storage compartment therein.
It is a further object of the present invention to provide a memorabilia storage device as part of a burial monument utilizing only brass, porcelain, marble and other weather resistant materials.
It is a further object of the present invention to provide a burial monument having a waterproof and weatherproof memorabilia storage compartment.
It is yet another object of the present invention to provide a flush mounted burial marker having a memorabilia storage compartment formed therein that is accessible to visitors to the grave site through the top face.
It is another object of the present invention to provide a raised monument or bench monument having a memorabilia storage compartment formed therein that is accessible to visitors to the grave site through a front, side or rear face.
It is a further object of the present invention to provide a burial marker having a generally rectangular memorabilia storage compartment formed therein.
These and other objects and advantages of the present invention will be apparent from a review of the following specification and accompanying drawings.
SUMMARY OF THE INVENTION
The burial marker of the present invention comprises a weather resistant monument of solid construction wherein a memorabilia storage compartment is formed. A means for closing the memorabilia storage compartment is also provided which protects the interior of the compartment and memorabilia stored therein from water and weather. In the most preferred embodiment of the present invention, the memorabilia storage compartment comprises a cylindrical boring in the weather resistant monument and the closing means comprises a removable cap providing access to the storage compartment. A recessed ring is received within an annular cut out of larger diameter than the cylindrical boring comprising the storage compartment, the ring being affixed to the monument through the use of adhesive. The recessed ring has an interior thread which corresponds to an external thread of a downwardly depending shaft of a removable cap. A gasket surrounds the downwardly depending shaft and is affixed to the cap such that, when the cap is positioned so that the exterior thread engages the interior thread of the recessed ring, rotating of the cap tightens down the cap onto the monument until the gasket is compressed to form a seal between the cap and monument. This preferred embodiment of the present invention is particularly advantageous because the memorabilia storage compartment may be formed in the top, front, or back of a monument, and so is adaptable for upright, slant, bevel, flush, bench or mausoleum monuments. The removable cap is the only element of the memorabilia storage device that is exposed so that memorabilia stored therein is not subjected to rain or weather, but rather is protected from the elements.
In another preferred embodiment of the present invention, the closing means related to the memorabilia storage compartment is provided by a cover that is permanently affixed to the monument by a hinge. The cover is positioned on the monument such that it completely covers the memorabilia storage compartment when closed. The hinge is spring loaded to bias the cover against a flat surface of the monument. A gasket affixed to the underside of the hinged cover provides a seal between the cover and the monument.
In another embodiment of the present invention, the memorabilia storage compartment formed in a burial monument is generally rectangularly shaped and the hinged cover is correspondingly generally rectangularly shaped. The gasket affixed to the hinged cover is also generally rectangularly shaped and engages a face of the monument at a flat surface. The flat surface is advantageous in that the seal formed by the gasket is improved for a machined flat surface.
A method for storing memorabilia in close proximity to a burial site incorporating the principles of the present invention is also provided. Memorabilia is stored by first providing a weather resistant monument of solid construction. This method can be applied for new or existing monuments. A cylindrical cavity is bored into the weather resistant monument, followed by a boring of the monument on the same center as the cylindrical cavity to provide a larger diameter annular cut out. A ring having an interior thread is then positioned and affixed to a shelf formed by the larger diameter annular cut out. A cap is then provided which has a downwardly depending shaft with an exterior thread thereon that corresponds to the interior thread of the recessed ring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a flush mount burial monument with a memorabilia storage compartment accessible on the top.
FIG. 2 is a perspective view of a raised burial monument having a memorabilia storage compartment accessible on the side of the monument.
FIG. 3 is the detailed section view of the memorabilia storage compartment.
FIG. 4 is the detailed section view of the memorabilia storage compartment with a hinged and gasketed cover.
FIG. 5 is a partial perspective view of a burial marker having a generally rectangularly shaped memorabilia storage compartment therein.
FIG. 6 is a perspective view of a bench monument having a memorabilia storage compartment formed therein.
DETAILED DESCRIPTION OF THE INVENTION
The present invention comprises a burial marker 10 comprising a monument 11 of solid construction positioned near a grave site, the monument 11 having therein a memorabilia storage compartment 18 . The burial marker 10 of the present invention embodying the principles of the present invention may be an upright, slant, bevel, flush bench or mausoleum marker. The memorabilia storage compartment 18 may be formed in a front, side or back face of the monument 11 to provide maximum accessibility to visitors to the burial site. The principles of the present invention are particularly well suited to provide memorabilia storage compartments in new burial markers or in existing burial markers through a modification embodied by the method of the present invention.
In the most preferred embodiment of the present invention, the memorabilia storage compartment 18 is formed in the flush mount monument 11 so as to be accessible at the upper surface 12 of monument 11 . As shown in FIG. 1, the cap 16 over the memorabilia storage compartment 18 is provided on the upper surface 12 alongside, and may be incorporated with, the monument inscription 14 . As shown in FIG. 1, the memorabilia storage compartment of the present invention comprises a cylindrical boring 18 into the monument 11 which, because of the rigidity and stability of the monument 11 , constructed from granite, stone or marble, comprises a sturdy protective cavity for the enclosure of memorabilia 20 provided by the deceased or visitors to the grave site.
In another embodiment of the present invention, a raised monument 30 is depicted in FIG. 2 as having an inscription 32 on its front face 34 . To enhance the aesthetic qualities of the monument 30 and to avoid interference between the memorabilia storage compartment cap 36 and the inscription 32 , the cylindrical boring 38 providing the memorabilia storage compartment 38 is made accessible at a side face 39 of the monument 30 . By providing the cap 36 to seal the memorabilia storage compartment 38 , the memorabilia 40 stored therein is protected from the weather in a stable and sturdy compartment 38 formed within the monument 30 itself.
In another embodiment, a memorabilia storage compartment 24 is formed in an upright portion of a memorial bench 22 . A cap 26 allows the memorabilia storage compartment 24 to be maintained airtight and watertight to protect memorabilia stored therein.
A more detailed view of a memorabilia storage compartment 42 embodying the principles of the present invention is provided at the sectional view of FIG. 3. A cylindrical boring 42 in which memorabilia may be stored is shown, the boring 42 having been removed from a monument 44 of solid construction. To accommodate the inclusion of a means for closing and sealing the storage compartment 42 , a larger diameter annular cutout 46 is also made in the monument 44 near the upper face 45 of the monument 44 to provide an upper shelf 48 . The closing means 50 comprises a recessed ring 52 having an interior thread 54 . The recessed ring 52 is positioned on the upper shelf 48 and permanently affixed to the monument 44 through the use of a bonding agent, such as adhesive 56 .
To make the storage compartment 42 of the preferred embodiment of the invention watertight and airtight, a gasket ring 58 is provided which is positioned between the recessed ring 52 and the cap 60 . The cap 60 has a downwardly extending shaft 62 having an exterior thread 64 and a larger diameter head 66 .
Closure and sealing of the storage compartment 42 is effected when the cap 60 is positioned near the monument 44 so that the interior thread 54 of the recessed ring 52 is engaged by the exterior thread 64 of the downwardly extending shaft 62 affixed to the cap 60 . Rotation of the cap 60 results in a screwing down of the cap 60 toward the face 45 of the monument 44 . The cap 60 is screwed down sufficiently that the gasket 58 is compressed between the face 45 and the underside 65 of the cap 60 . When sufficiently compressed, the gasket 58 forms an airtight and watertight seal to prevent any contaminants from invading the storage compartment 42 , thereby protecting the memorabilia stored therein.
In another preferred embodiment of the present invention, a memorabilia storage compartment 80 is provided comprising a cylindrical cutout 80 formed in a monument 82 of solid construction. A closing means for the compartment 80 is provided comprising a cap 84 that is permanently affixed to the monument 82 at a hinge 88 . Attached to the underside of the cap 84 is a gasket 86 which, when the cap is rotated into engagement with the face 90 of the monument 82 , forms an airtight and watertight seal preventing contamination of the storage compartment 80 or memorabilia stored therein. The hinge 88 is spring loaded to maintain the cap 84 in a closed position so that accessing the memorabilia storage compartment 80 requires rotation of the cap 84 about the hinge 88 as shown in FIG. 4 .
Another embodiment of the present invention, shown in FIG. 5, is a burial monument 100 having a generally rectangularly shaped memorabilia storage compartment 102 formed therein. A generally rectangularly shaped cover 104 is provided, permanently affixed to the monument 100 at hinge 106 . The hinge 106 is spring biased to maintain the cover 104 in a closed position against the monument 100 so that the gasket 108 , affixed to the cover 104 , forms an airtight and watertight seal. To further enhance the seal formed by the gasket 108 , that portion of the side face 110 engaged by the gasket 108 is machined flat.
It is contemplated by the principles of the present invention that any of the memorabilia storage compartments disclosed herein may be provided with locking mechanisms without disclosing from the principles of the present invention. Specifically, a key/latch locking mechanism may be incorporated in any of the caps 16 , 26 , 36 , 60 , 84 , 104 to provide a secure memorabilia storage compartment.
A method for storing memorabilia in close proximity to a burial site is also embodied by the principles of the present invention which provides for storage of memorabilia not only with new monuments, but also with existing monuments through steps of modification. The first step in providing for memorabilia storage in close proximity to a burial site is to provide a weather resistant monument 11 of solid construction. Next, a cylindrical cavity 18 is formed in the monument 11 of sufficient diameter to hold memorabilia such as cards and letters that have sentimental value to the deceased or visitors to the grave site. Next, a larger diameter annular cut out is formed in the monument 11 on the same center as the cylindrical cavity 18 , an interior shelf 48 being formed near the face 45 of the monument 44 (FIG. 3 ). A ring 52 having an interior thread 54 is then affixed to the shelf 48 and a cap 60 having a downwardly extending shaft 62 with an exterior thread 64 is provided. The interior thread 54 is then engaged by the exterior thread 64 and the cap 60 is rotated to effect closure of the memorabilia storage compartment 42 .
The foregoing description of a preferred embodiment 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. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best 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.
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A burial monument having a memorabilia storage compartment incorporated therein. A monument is solid construction has a cylindrical boring removed to provide a compartment within the solid monument. The compartment is closed to form an airtight and watertight chamber by providing a cap with a gasket affixed thereto. The cap engages a threaded inner ring or is hinge mounted to the monument in alternative embodiments. A method for modifying burial monuments to provide a memorabilia storage compartment is also disclosed.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
Oil being pumped from deep wells is quite warm and often contains wax compositions and various gases intermixed with the crude oil. As the oil is being pumped from deep in the ground to the surface, the oil is cooled by evolution and expansion of dissolved gases so that the waxes are cooled enough to deposit out onto the inner surface of the production tube through which the oil is exiting. The wax deposits on the inner surface of the oil well production tube in a reasonably well-defined zone. Deposition of the waxes ends at the point where sufficient gas has evolved to permit the wax deposition rate to drop below the value required to resist the scouring action of the flowing oil. Thus the process of wax deposition and build-up is reasonably stable. This waxing problem can be so serious as to substantially plug the production tube requiring shut down of the well, pulling of the pump plunger and physically removing the wax by mechanical brushing. Obviously, this is very expensive and output is reduced.
Oil wells have an inner pipe, or production tube, generally of steel, through which the oil exits and oil wells generally have a casing, or "oil string", surrounding the production tube, which is generally made of steel and which generally reaches down to the oil-bearing earth structure. There is thus provided annular space between the production tube through which the oil exits and the oil string casing.
It is the purpose of the invention to use the existing annulus, described above, thermal gradients along the length of the well, and a selected working fluid to prevent the deposition of wax on a continuous, self-controlled, basis.
PRIOR ART
The problem of wax deposition in oil wells has been recognized for a long time. Generally, means have been suggested to heat the exiting crude oil in order to keep the wax liquified. One such process is discussed in U.S. Pat. No. 3,908,763 which discloses a method of maintaining the flow of paraffin-containing crude oil by maintaining the temperature above the melting temperature of the paraffin so that the paraffin is dissolved and re-absorbed in the crude oil and carried in a fluid state in the crude oil as it flows from the well. Heating is accomplished by conducting a heating oil through a conducting loop line extending from the top of the well to the bottom of the well then back to the top of the well to form a loop whereby essentially the entire well structure is maintained at a temperature below the fracturing temperature of the oil and the paraffin and above the oil chill temperature where the paraffin separates from the oil. The apparatus used to heat the heating oil is a closed loop steam system wherein the heating oil is heated in a tank by steam generated by a heater. The disadvantages of this system derive from the requirement for heating large amounts of crude oil. Contrasted to this, the present invention provides a system whereby only a very small energy input is required to heat the thin layer of wax near the inner surface of the production tube and therafter letting the exiting oil physically remove the wax deposits. Moreover, the heat to operate the thermal syphon is provided by the oil approaching and entering the production tube at its base. Temperatures at this depth are many degrees warmer than those characterizing the wax deposit zone of the production tube. Oil entering this tube conveys heat from the surrounding rock to the production tube, heating the thermal syphon working medium in the lower regions of the annulus, thus vaporizing liquid which has previously condensed in the wax deposit zone, giving up heat and melting the wax at the steel-wax interface.
OBJECTS OF THE INVENTION
It is an object of this invention to maintain the flow of wax-containing crude oils in a well structure by heating the outer surface of the production tube to melt a thin layer of deposited wax in order that the wax deposits may be physically removed by the exiting crude oil.
It is another object of this invention to provide an oil well structure having an inner well tube and an outer well casing with an annular space in between which is plugged at or near the lower extremity and at a point above which wax ceases to be deposited out of the exiting oil.
It is a further object of this invention to use the known physical characteristics of a fluid working medium which is maintained at such a pressure that it will volatilize at temperatures associated with the section of oil production tube exterior below the wax deposit zone and condense at temperatures characterizing the exterior surface of the production tube in the wax deposit zone. Thus, with no addition of energy for pumping or heat, this working medium will transfer heat from the deep rocks to the wax deposit zone, preventing the wax from adhering to the inner production tube surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectioned elevational view of the invention in an oil well.
FIG. 2 is a top view of FIG. 1 taken along section line 2--2.
BRIEF DESCRIPTION OF THE INVENTION
This invention uses a thermal syphon to control the deposition of wax on the inner surface of the production tube through which crude oil exits by warming the outer surface of the tube sufficiently throughout the length of the defined zone where the wax deposition normally occurs to create a liquid film immediately adjacent to the inner surface of the production tube which results either in formed wax deposits being removed by the flow of oil from the well or prevention of adherent deposit formations of wax.
More specifically, a ring plug, or "packer", can be inserted in the annular space between the production tube and the oil string casing just above the oil extraction zone. Another ring plug, or "packer", can be installed in the annular space further up in the well beyond the region where the deposition of the wax onto the inner surface of the production tube normally ceases. A fluid of favorable liquifaction and vaporization temperatures at convenient pressures can be introduced into the space between the ring plugs in the annular space between the production tube and the oil string casing at such a pressure that at the higher temperatures at the base of the well the fluid vaporizes and rises convectively to the wax deposition zone where it condenses and drops back with the normal heat of condensation being used to warm the exterior surface of the production tube. The outer surface of the production tube acts as a condenser in areas where wax build-up has occurred since such deposits form and persist creating areas slightly cooler than uncoated regions of the tube. Thus, such areas will selectively receive heat from condensation of the working medium which will, therefore, provide heat when it is required to melt the wax at the tube interface while minimizing loss of heat elsewhere. Since the amount of heat necessary to melt an interface layer of wax is limited, it is possible to extract these few BTU's needed from the surfaces of the production tube and casing at depths where sufficient temperatures exists to prevent deposition of wax in such deposition zone.
The working medium used in the thermal syphon system of this invention may be any of the well-known materials having temperatures of vaporization from about 100° F. to about 400° F. over the pressure range of about 0.10 to 10 atmospheres. Moreover, such a medium must be compatible with steel, concrete and oil field sealing materials. Also, the medium must be inexpensive, possess long-term stability, present few problems of toxicity, and must be inactive in the presence of petroleum products. Suitable materials for the working medium include inorganic materials such as ammonia and substituted amines; alcohols such as methyl alcohol, ethyl alcohol and other lower alcohols; ketones, such as acetone; aldehydes such as formaldehyde and acetaldehyde; saturated hydrocarbons such as propane, pentane, heptane, hexane, and octane; halogenated hydrocarbons such as dichlorodifluoromethane (freon); cyclic ring compounds such as cyclobutane, cyclopentane, cycloheptane and cyclohexane; and ring compounds such as benzenes, xylenes and naphthalenes. The listed working medium materials may be substituted as long as the working medium remains within the indicated working parameters. Also, mixtures of one or more of the indicated working medium materials may be used if desired. Pentane is a preferred working medium because the temperature and pressure requirements needed for heating the outer surface of the inner well casing are easy to handle, it is compatible with oil well materials, it is cheap and stable, and its heat transfer properties and density are adequate.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to FIG. 1, earth formations 10 are penetrated by a borehole leading from the surface of the earth to an oil-producing formation. The borehole is lined by steel casing 12 which is cemented into place by cement 14. It will be understood by those skilled in the art that several layers of steel casing and cement may be concentrically around the borehole at the surface depending upon the depth of the well and the drilling procedure used.
Concentric within the steel casing 12 is a production tube 16 which extends from the surface of the earth to the oil-producing formation. Oil produced by the well enters the production tube 16 from the oil-producing formation and is allowed to flow or is pumped to the surface through the central bore through the production tube 16 as is known in the art.
An upper plug or packer 18 and a lower plug or packer 20 is provided in the annulus between casing 12 and production tube 16 to isolate a portion 26 of the annulus.
A working fluid pipe 22 and a clean-out pipe 24 are provided through the upper packer 18 and extend from the surface through the packer 18 into the annulus portion 26. The working fluid pipe 22 extends to just below the upper packer 18, while the clean-out pipe 24 extends into the annulus portion 26 to a point just above the lower packer 20.
Annulus portion 26 is divided into a lower, evaporation region 28 and an upper, condensation region 30. Upper packer 18 is positioned to be just above the area 32 from which wax is to be removed. It can thus be seen that region 32 to be cleaned is on the opposite wall of the production tube 16 from the condensation region 30 of the annulus portion 26.
In operation, when a new well or a reconditioned well is ready to be put into production, a production string with upper packer 18 and lower packer 20 appropriately positioned is lowered into place. It will be understood that the packers 18 and 20 may be any of the known production type packers or wire line set packers such as are known in the art. The location of the upper packer 18 will be controlled by the location of the area 32 from which the formation of wax is to be prevented. This location may be determined from prior experience with the subject well or from theoretical calculations. The length of annulus region 26 may then be determined by the temperature gradient of the well and the temperature of the working fluid needed to provide adequate evaporation and condensation to transfer heat from the evaporation region 28 to the condensation region 30 of annulus portion 26. Based on these criteria, the location of lower packer 20 is determined.
After the production string including packers 18 and 20, production tube 16, and pipes 22 and 24 is in place, the working fluid is then transferred from the surface through working fluid pipe 22 to annulus region 26.
It is a common practice to fill the annulus between the production tube 16 and the casing 12 with a liquid such as sea water, salt water, fresh water, drilling fluid or in some cases a hydrocarbon. It will thus be understood that any liquid present in the well between the production tube 16 and the well casing 12 will likewise be trapped between packers 18 and 20. This fluid is circulated out of annulus portion 26 by introducing an inert gas such as nitrogen through working fluid pipe 22 until all unwanted fluid in the annulus portion 26 has been expelled through clean-out pipe 24. The annulus is then evacuated and a working fluid such as pentane or other fluid disclosed herein may then be placed in annulus portion 26 through either pipe 22 or 24. After the correct volume of working fluid has been placed in annulus portion 26, clean-out pipe 24 is closed in. The pressure in the annulus portion 26 is then either increased or decreased until the critical pressure is reached for the temperature to cause boiling at region 32 and condensation in region 30 to release heat to tubing 16.
Working fluid pipe 32 is then closed in. The working fluid in evaporation region 28 will evaporate or boil due to the heat present in the borehole at the lower elevation. The vapor from the working fluid due to this evaporation will rise to condensation region 30. The pressure in region 30 is monitored through working fluid pipe 22 such as by pressure gage 34 for maintaining conditions in condensation region 30 at the dew point for the working fluid used so that the working fluid condenses on the walls of the production tube 16 thereby releasing heat. The condensed working fluid then runs down the walls of tubing 16 and casing 12 to evaporation region 28. The heat released due to the condensation of working fluid on the walls of production tubing 16 is sufficient to raise the temperature at region 32 to prevent the formation of wax, or if it has formed, to melt the interface between the wax and the inner walls of production tubing 16. Crude oil being produced through production tubing 16 will then flush out and scour wax from tubing 16.
FIG. 2 is a top view of the well showing well casing 12 cemented into place by cement 14 in an earth formation 10.
In some installations, much of the heat transferred by the vapor of the working medium may be deposited on the inner surface of casing 12 and still assist in heating region 32 because heat transfer from casing 12 to the surrounding ground is restricted by cement, earth, rock, or other insulation. As a result the inner surface of casing 12 in region 30 is heated, raising its temperature, and thus further limiting temperature drop of the production tube surface 32 in region 30 by reducing radiation and convection.
Again, it will be understood that the well casing 12 and cement 14 may actually be a series of concentric layers of casing and cement depending upon the physical configuration of the well in which the invention is used. Production tube 16 is shown concentrically located within casing 12. Working fluid pipe 22 and clean-out pipe 24 are located in the annulus between production tube 16 and well casing 12. In addition to the configuration shown in FIGS. 1 and 2, pipes 22 and 24 may be connected to an appropriate by-pass sub comprising concentric tubing for by-passing upper packer 18 allowing a conventional packer to be used.
EXAMPLE
The preferred working fluid of the present invention is pentane or heptane. The most preferred working fluid is pentane because of its vapor specific volume at the temperature encountered in oil wells for which the invention is intended. Also, at these temperatures, the saturation pressures to be maintained in condensation region 30 are most advantageous.
In Van der Waals equation of state:
(P+(n.sup.2 a)/v.sup.2)(v-nb)=nRT
where:
P=saturation pressure in atmosphere,
n=moles,
v=volume in liters,
T=saturation temperatures in degrees absolute,
R=0.08205 liter atmosphere per degree per mole,
a=a constant in liter atmosphere per mole, (19.01 for pentane), and
b=a constant in liters per mole (0.1460 for pentane).
Thus, knowing the temperature range of interest, the saturation pressures can be determined. Table I is a tabulation of the temperature, pressure and latent heat at selected temperatures for pentane.
TABLE I______________________________________ Saturation LatentTemp. Temp. Pressure HeatC.° F.° PSIA BTU/lb______________________________________20 68 11.02 157.8140 104 22.04 152.9160 140 33.06 147.2380 176 56.41 141.55100 212 104.26 128.19______________________________________
In a typical well, the steel casing 12 has a 7 inch inner diameter; the production tube 16 has a 2 inch inner diameter and a wall thickness of 0.25 inches. The cross sectional area of the annulus portion 26 between the casing 12 and the production tube 16 is 0.233 square feet. The thickness of the concrete for the present example is 2 inches.
For the present example, the temperature of the oil flowing in production tube 16 through the evaporation region 28 is 145° F., the temperature of the earth just below the deposit zone 32 is 80° F., the initial temperature of the working fluid in annulus portion 26 is 143° F., and the temperature of solidified wax on the walls of production tube 16 in zone 32 is 140° F. The packers 18 and 20 are spaced 1000 feet apart to make the length of the thermal siphon 1000 feet. The heat siphon of the invention supplies enough heat to melt 10 pounds of wax per hour along the interface of the wax and the steel of the production tube 16 in zone 32. The latent heat of fusion of wax is 100 BTU per pound, making a total of 1000 BTU's per hour that the heat siphon of the invention must supply. Table II is a tabulation of the temperature saturation pressure, vapor specific volume and liquid density of pentane in the temperature range of the well of the example.
TABLE II______________________________________ Saturation Vapor Specific LiquidTemp. Pressure Volume Density°F. PSIA ft..sup.3 /lb lb/ft.sup.3______________________________________135 31 2.62 36.8138 32 2.55140 33 2.49 36.6142 34 2.42145 35.5 2.35 36.4148 37 2.23150 38.4 2.20 36.1152 40 2.13155 42 2.06______________________________________
The heat distribution per unit of pipe surface in the condensation region 30 is:
______________________________________heat-to-earth = (T.sub.i - T.sub.e) (K.sub.c)/t.sub.c= (143 - 80)(5)/2 = 157.5 BTU per hour,______________________________________
where:
T i =initial temperature of the working fluid
T e =temperature of the earth
K c =conductivity of concrete (5 BTU inch per hour per °F. per square feet), and
t c =thickness of concrete 14 to the earth 10.
______________________________________Heat-to-wax = (T.sub.i - T.sub.w)(K.sub.s)/t.sub.s= (143 - 140)(360)/0.25= 4320 BTU per hour______________________________________
where:
T i =initial temperature of the working fluid
T w =temperature of solidified wax in deposit zone 32.
K s =conductivity of steel (360 BTU inches per hour per °F. per square foot) and,
t s =thickness of steel production tube 16.
The ratio of heat-to-wax over heat-to-earth is 4320/157.5 or 27.4 which means that about 27 times the heat released to the earth 10 is released to the production tube 16. This means that the heat loss to the earth surrounding the thermal siphon is not excessive, but rather is low enough to maintain the inner surface of the casing 12 at a favorable temperature with relatively negligible heat loss.
The length of condensation region 30 needed to supply 1000 BTU's per hour is calculated by:
BTU.sub.w =(K.sub.s /t.sub.s)(A.sub.c)(T.sub.i -T.sub.w)
where:
BTU w =BTU's needed to melt 10 lbs. of wax per hour (1000),
K s =conductivity of steel (360 BTU inches per hour per °F. per square foot),
t s =thickness of production tube 16,
______________________________________A.sub.c = area of condensation region 30 for transferring heat,= πdL = 0.5236L, where d and L are in feet,______________________________________
T i =initial temperature of the working fluid, and
T w =temperature of the solidified wax. then:
______________________________________1000 = (360/.25)(0.5236L)(143 - 140), orL = (1000)/((360/.25)(0.5236)(3))= 0.442 feet.______________________________________
The length of the evaporation region 28 needed to transfer heat from the oil at the hotter depths of the well to the working fluid can be calculated by:
BTU.sub.w =(K.sub.s /t.sub.s)(A.sub.c)(T.sub.o -T.sub.i)
where:
BTU w =BTU's needed to melt 10 lbs. of wax per hour (1000),
K s =conductivity of steel (360 BTU inches per hour per °F. per square foot),
t s =thickness of production tube 16,
A c =area of evaporation region 28 for transferring heat, =πdL=0.5236L, where d and L are in feet,
T o =the temperature of the oil at the depth of the evaporation region 28, and
T i =initial temperature of the working fluid. thus:
______________________________________1000 = (360/.25)(0.5236L)(145 - 143), orL = (1000)/((360/.25)(0.5236)(2))= 0.663 feet.______________________________________
It can thus be seen that to melt 10 pounds of wax per hour at the temperature indicated, the evaporation region 28 must be at least 0.663 feet long and the condensation region 30 must be at least 0.442 feet long. Since the total length of the siphon is 1000 feet these requirements are easily met.
It is known that the critical flux for pentane nucleate boiling is 72,900 BTU per square foot per hour ±50%. If the flux is higher than this amount, film boiling occurs and the heat transfer characteristics of the pentane is seriously affected. A length of 20 feet for the evaporation region 28 results in the heat transfer area being equals to 0.5236×20 or 10.47 square feet. The specific heat flux to melt 10 pounds of wax per hour is 1000 BTU per hour transferred through the 10.47 square feet of the evaporation region 28. This equals 1000 BTU per hour/10.47 ft 2 or 95 BTU per square foot per hour. This is far below the point at which pentane changes from nucleate boiling to film boiling. To achieve a critical flux of 72,900 BTU per square foot per hour, the evaporator would have to be less than 0.026 feet long. This can be calculated by:
______________________________________(72,900)/(1) = (1000)/(0.5236L), orL = 1000/(72,900 × 0.5236)= 0.026 feet.______________________________________
This is less than the evaporation region length of 0.664 ft for the temperatures of the example. Thus, the evaporation region length is well over the critical length needed to maintain nucleate boiling of the pentane.
Referring to Table I, the latent heat of pentane at 140° F. is 147.23 BTU per lb. This requires the vaporization of 1000/147.23 or 6.79 lbs of pentane per hour. Also shown in Table II, the specific volume of pentane vapor at 140° F. is 2.49 cubic feet per lb. This requires a mass flow of (6.79 lbs/hr)×(2.488 ft 3 /lbs) or 16.89 ft 3 /hr. The cross sectional area of the annulus portion 26 is 0.233 ft 2 . Thus, the velocity of the pentane is (16.89 ft 3 /hr)/(0.233 ft 2 ) or 72.49 ft/hr or 0.02 ft/sec. All of these values are within reasonable ranges.
The mass of pentane required for an assumed siphon length of 1000 ft and an evaporation region length of L feet is shown in Table III.
TABLE III______________________________________Evaporator EvaporatorLength L Volume At 140° F. Pentane Charge in lbsFt. Cubic Ft. Liquid Vapor Total______________________________________10 2.33 85.28 92.64 177.9220 4.66 170.56 91.70 262.2640 9.32 341.11 89.83 430.9480 18.64 682.22 86.09 768.31______________________________________
Thus, in the present example 262.26 pounds of pentane is placed into annulus portion 26 and the pressure is maintained at 33 PSIA through working tube 22. Then pentane would reach equilibrium having an evaporation region length of 20 ft with 170.56 pounds of liquid and 91.70 pounds of vapor in the heat siphon of the invention.
With the lowest 100 ft. of the annulus portion 26 occupied by liquid, a liquid volume of 22.3 cubic feet is provided. The upper 900 feet are occupied by vapor having a volume of 200.7 cubic feet. For this configuration, the thermal siphon of the invention requires 816.18 pounds of liquid and 80.60 pounds of vapor for a total of 869.78 pounds at 140° F. If the temperature rises in the annulus from an initial value of 140° F. to 150° F., the vapor pressure, remaining saturated, will rise from 33 to 38.4 PSIA and the vapor specific volume will drop from 2.49 to 2.20 cubic feet per pound (see Table II).
It will be understood that small temperature increases will cause a rise of pressure in the annulus portion 26 and an increase in liquid level which causes an increase in the evaporation region heat transfer surface slightly increasing vapor generation. This will be balanced by a reduction in condenser action with the rise in temperature. If the excursion is in the reverse direction and the temperature drops, the liquid level will drop. The drop will be counter-balanced by more effective condenser action of this heat siphon of the invention. In most cases condensation action can be maintained as desired by changing the pressure in the annulus portion 26 responsive to temperature sensed through working fluid pipe 22.
In the event of substantial temperature excursions which cannot be compensated for by pressure changes to the annulus portion 26, system equilibrium is maintained by a closed loop control system. This involves connection of a pressurized pure pentane container 40 to one of the clean out pipe 24 or working fluid pipe 22 through control a valve 42 and pump 44 capable of admitting or removing a measured amount of pentane from the annulus portion 26 responsive to temperature of pressure sensed as through a probe 46 in the annulus portion 26 through working fluid pipe 22 whose measurements are transmitted over a transmitting means 48 to the surface of the earth.
Thus, there has been shown and described novel means for controlling wax formation in oil wells using a thermal syphon system. It will be apparent to those skilled in the art, however, that many changes, modifications, variations, and other uses and applications for the subject means are possible and contemplated, and all such changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.
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This invention relates to a system for controlling wax formation in oil wells using a thermal syphon wherein a confined annular space between the production tube and the oil string casing is provided by means of a plug, or "packer", installed at a point well below the level at which solid waxes begin to deposit out of the exiting crude oil and a plug, or "packer", installed above the point at which waxes would otherwise stop depositing out of the exiting crude oil and thereafter filling the confined annulus with a fluid working medium. The quantity and properties of the fluid working medium are arranged such that the medium is vaporized at the lower extremeties of the confined annulus and condensed on the surfaces of the upper regions of the confined annulus, particularly in the zone of wax deposition. The condensation process warms the production tube sufficiently to prevent formation of adhesive wax deposits or, alternatively, reliquifies a thin film of deposited wax which enables the flowing crude oil to remove the deposited wax. The condensed working medium flows by gravity to the lower part of the confined annulus where it again becomes available for vaporization and subsequent condensation. No external power is used for this circulation which is caused solely by temperature differences between lower and higher levels of the annulus.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims benefit of U.S. Provisional Patent Application No. 61/930,401, filed Jan. 22, 2014, which is hereby incorporated by reference in its entirety.
BACKGROUND
This invention pertains to construction and more particularly to expansion of existing houses and the like.
Many houses constructed during the post-World War II housing boom are single story dwellings. While the ‘ranch style’ house was popular then, now, with the price of land at a premium and consumers desiring larger, more spacious houses, multi-story dwellings are becoming the standard. Multi-story houses benefit not only the inhabitants but owners as well. The additional stories increase the size and the value of the house commensurately.
Financially it often is impractical to buy an existing single story house, demolish it and rebuild a new multi-story dwelling; rather, it would be ideal if the existing structure could be modified to increase its size. If the land size is large enough, it would be a simple matter to just build the house out farther but, many times, the house is already at a maximum size allowed per regulated footprint and setbacks for the land on which it resides.
Therefore, the only way to keep the existing structure and increase the size of the dwelling is to add additional levels. Converting a single story structure to a two-story effectively doubles the size of the living space and markedly increases the value of the structure. Traditionally, the addition of levels to an existing structure is an expensive and time consuming process that often yields minimum returns on investment. A new system and method for adding levels to an existing structure at a minimal cost and time would be most beneficial.
Currently, the process of adding an additional level to an existing structure requires the complete removal and destruction of the roof. The roof must be removed to allow the new level to be constructed and to allow access for the reinforcement of the existing structure. Reinforcement of the existing structure must often be done since the initial construction was not done in a manner to support the non-existent additional level(s). Once reinforced, the additional level(s) could be constructed on top of the existing structure. Finally, a new roof structure can be formed to complete the remodeling process. The removal and reconstruction of the roof structure adds additional time and cost to the process of adding the new level(s).
The invention enables a method for raising a structure with a jacking system for installation of a building element, which comprises one or more of vertical jack assemblies and a system to control the rate at which the structure can be elevated by the jack assemblies independently of each other jack assembly.
An object of this invention is to reduce the time and cost associated with the addition of new level(s) to an existing structure. The invention preserves the existing roof structure, creates a new system to rapidly construct the new level on the existing structure and utilizes pre-manufactured components to further decrease the cost and improve efficiency.
SUMMARY OF THE INVENTION
The invention is a system and method capable of lifting an entire structure, the roof of a structure or some portion of a structure. The invention uses a system of frames about the periphery of the structure to which jack members are mounted. The jack members extend to raise the desired structure or portion thereof. A control system is also provided to manage the lifting process; the control system monitors the lifting process and controls the rate of the extension of the jack members.
The lifting system and method disclosed has many advantages over the previous systems and methods. The invention does not require the use of specialized lifting beams to lift the structure or parts thereof. Additionally, since the installation of the system is within the footprint of the structure, there is minimal clearance required about the structure to be lifted.
When used on a roof structure, the system and method preserves the existing roof by lifting the roof vertically to install an additional story in the structure below. The vertical lifting also minimizes the potential for damage to the roof structure during the construction process since the roof is not moved laterally which can shift or damage the roof structure. Typically when a roof is removed to install an additional level in the structure, the roof requires reinforcement before the lifting process can begin, with the invention, the roof does not require such strengthening.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1-8 are conceptual drawings showing in perspective view the steps of enlarging a building structure such as a single-story house by raising the roof structure, adding floor structure and installing walls for a second story under the raised roof, using a jacking system according to an embodiment of the invention.
FIG. 9 is a side elevation view of the wall jacking installation as initially installed on a side of a building structure and coupled to the roof structure.
FIG. 10 is a side elevation view of the wall jacking system of FIG. 9 following an initial lift of the roof structure and placement of lateral bracing.
FIG. 11 is a side elevation view of the wall jacking system of FIG. 10 following a final lift of the roof structure, extension of the lateral bracing and installation of new second story floor framing.
FIG. 12A is a cross-sectional view through the building wall of FIG. 9 showing details of connection of the jacking system to the sill plate and the roof structure.
FIG. 12B is an enlarged view of the connection of FIG. 12A to the roof structure.
FIG. 13 is a cross-sectional view through the building wall of FIG. 10 showing details of connection of the upper portion of the jacking system and lateral bracing to the upper portion of the existing wall and to the roof structure.
FIG. 14 is a top plan view of the drive element 1400 used on the bottom rail for driving one of the wall jacks in FIGS. 9-13 .
FIG. 15 is a side elevation view of the drive element 1400 of FIG. 14 .
FIG. 16 is a cross-sectional view of the drive element 1400 of FIG. 15 .
FIGS. 17A-17C are side views of non-metallic slider blocks in the vertical lifting elements 230 .
FIGS. 18A-18D are cross sectional views of non-metallic slider blocks in the vertical lifting elements 230 of FIGS. 17A-17C .
FIG. 19A is a perspective view of the non-metallic lifting block 241 . FIG. 19B is a side elevation view of the lifting block 241 . FIG. 19C is a top plan view of the lifting block 241 .
FIG. 20A is a side view of the diagonal cross-brace outer tube and ‘lock pin block’ of FIGS. 11 and 13 .
FIG. 20B is a top view of the diagonal cross-brace outer tube and ‘lock pin block’ of FIGS. 11 and 13 .
FIGS. 21 and 22 are conceptual drawings showing in perspective view the steps of raising an entire building with a jacking system for repair or replacement of sill plates, supporting walls, and or footings, using a jacking system according to an embodiment of the invention.
FIG. 23 is an enlarged side elevation view of the drive element 1400 located between the floor joists for lifting an entire building.
FIG. 24 is a cross-sectional view of the drive element 1400 of FIG. 23 .
FIG. 25A is a side elevation view of the jacking system showing upper and bottom horizontal rails in preparation of securing diagonal bracing and lifting an entire building; FIG. 25B is a plan view of the bottom rail; and FIG. 25C is an enlarged view of FIG. 25B showing the interconnection to the vertical lifting element.
FIG. 26 is a side elevation view of the jacking system showing diagonal bracing secured to upper and bottom horizontal rails in preparation of and lifting an entire building.
FIG. 27 is a side elevation view showing placement of diagonal bracing to provide lateral stability of lifted structure while at same time providing sufficient space to excavate, prep and pour new footings and foundation walls.
FIG. 28 is a cross sectional view showing general location of threaded rod support blocks for the jacking system when raising either a roof structure or raising an entire building.
FIG. 29 is side elevation view showing general location of threaded rod support blocks for the jacking system when raising either a roof structure or a complete structure as shown in FIG. 25A .
FIGS. 30A-30D are cross sectional views of a vertical lifting jack assembly showing the threaded rod support blocks at various sections in FIG. 29 .
FIGS. 31A-31B show transverse sectional views of the tubing section in its normal location to keep the threaded rod support blocks in place.
FIGS. 32A-32B show transverse sectional views of the tubing section in its raised position to either install or replace the threaded rod support blocks.
DETAILED DESCRIPTION
FIG. 1 shows a single story structure 100 to which an additional level(s) will be added. The roof 102 sits atop the main section 104 which is supported by the foundation sill plate 106 .
FIG. 2 shows the structure of FIG. 1 with the lifting rails 200 , 210 , and 220 installed around the periphery of the structure 100 . The bottom lifting rail 200 is fastened to the sill plate 106 of the structure 100 and will serve as the base of the lifting system. The middle lifting rail 210 is attached about the upper periphery of the structure 100 and below the roof structure 102 . Middle rail 210 is attached through the sides of the house and into the vertical studs of the main section 104 . The upper lifting rail 220 is installed about the lower periphery of the roof 102 of the structure 100 . The rail 220 is attached to the sill of the roof and/or attached to the ends of the rafters of the roof 102 .
FIG. 3 shows the rails 200 , 210 and 220 installed on the structure 100 and roof 102 . The rails are interconnected by vertical lifting elements 230 . The vertical lifting elements 230 will exert an upward force on upper rail 220 that will cause the roof structure 102 to lift up and away from the structure 100 . In addition to the vertical lifting elements 230 , extendible cross-braces 240 are installed between rails 210 and 220 . The bottoms of cross-braces 240 are anchored to brackets affixed to the middle rail 210 , the extendible end of the cross-braces 240 are attached to the rail 220 by a bracket, the upper and lower connection points allowing the end of the cross-brace to rotate about the connection points in the vertical plane of the structure.
FIG. 4 illustrates the initial phase of the lifting process. The roof 102 is attached to the upper rail 220 that has been raised via the vertical lifting elements 230 to a first position an initial distance above the structure 100 . As the roof structure 102 is raised, the ends of the cross-braces 240 extend and the ends rotate about their respective pin joints thereby providing lateral stability to the roof structure that has been separated from the perimeter walls of the house. The cross-braces 240 are allowed to automatically extend as the structure 102 is raised, but are prevented from retracting by an internal retaining element. The internal retaining element is a feature that allows the cross-braces to act as compression only members that will provide lateral stability of the existing roof and wall structure during lateral loads from construction, wind or seismic loads. The cross-braces are retractable by a user actuating a release mechanism that releases the internal retaining element thus allowing the cross-braces to retract automatically or by the user.
FIG. 5 shows the installation of the additional floor 502 atop the main section 104 , which formerly supported the roof 102 . The roof 102 is still at the initial position as lifted to in FIG. 4 . This initial position is at a minimum height necessary to allow the installation of the floor 502 .
FIG. 6 illustrates the second phase of the lifting process. The roof 102 , attached to rail 220 , has been lifted higher than the final height of the new walls. Extendible cross-braces 240 have extended further to continue to provide lateral stability of the roof structure 102 and the existing walls 104 .
FIG. 7 shows the installation of the new walls 504 , framing the periphery of the new level atop floor 502 . Once the walls 504 are completed, the roof structure 102 is lowered down upon the new walls and reattached atop the new walls 504 to complete the two-story structure.
FIG. 8 shows the completed two-story structure with the lifting system and equipment removed from the building. The structure now has an additional story added to the pre-existing structure at minimal cost and time spent.
FIG. 9 is a schematic showing details of the lifting system attached to the structure 100 . The bottom lifting rail 200 is attached to the sill plate 106 . The bottom lifting rail 200 has holes 202 spaced regularly along the length of the rail 200 . Multiple bottom rail elements 200 are interconnected to encircle the perimeter of the sill plate 106 . The rail elements 200 are connected to one another using a butt joint 910 . The rails 200 have holes 202 A at each end. The butt joint 910 is inserted inside the end of a rail 200 and is locked in place by inserting retaining pins in the end holes 202 A and through the holes on the butt joint. The end holes 202 A are spaced to ensure that the spacing of the holes 202 is maintained across the interconnection at the butt joint 910 . The interlocked elements of the lower rail 200 form a rigid framework that encircles the sill plate 106 and will act as the lower structure of the lifting system.
The top lifting rail 220 is attached to the roof structure 102 . The top rail 220 is attached to the structure 102 via the ends of the roof rafters. Rail 220 encircles the roof structure 102 and will support the structure during the lifting process. The roof normally provides structural integrity to the structure 100 . It acts as a diaphragm and holds the wall together and, in turn, the walls provide the rigid base on which the roof 102 sits. If separated from the structure 100 , the roof structure 102 has a tendency to splay out and deform from the original shape, when this occurs, the roof is typically beyond salvage and must be rebuilt. Using this method and system, the rail 220 will maintain the form and size of the roof structure 102 when it is separated from the structure 100 . This will ensure that the roof 102 can be reattached to the new walls once they are installed atop the main section of the existing structure. The reuse of the existing roof structure 102 is more cost and time efficient than the previously existing method in which the majority of the structure would have to be rebuilt or time consumingly reshaped to fit.
The middle lifting rail 210 is attached around the upper periphery of the main portion 104 of the structure 100 . The middle rail 210 is attached to the studs of the house. Depending on the strength of the existing structure, the middle rail 210 can be attached to every stud or at some other regular or irregular interval. As with the bottom rail 200 , middle rail 210 is made of individual elements that are interconnected using butt joints 910 . Rails 210 also have the same hole pattern as that of rail 200 and 220 , in this manner, the rail combination has spaced set of vertically arrayed hole patterns. Similar to the top rail 220 , the middle rail 210 will maintain the dimensions of the main section 104 during the lifting process. With the roof removed, the walls are not braced for out of plane loads and would have a tendency to warp and move out of position, if not properly restrained in their position. This would necessitate a laborious process of “truing” or straightening the walls back to their original positions before the roof could be attached. The retention of the original dimensions and shape of the main section 104 during the lifting process allows the quick installation of a second story floor and additional walls atop and then the reattachment of the roof with minimal time and cost.
The vertical lifting elements 230 are attached at regular or irregular intervals around each side of the house and interconnect the rails 200 , 210 and 220 . Elements 230 are affixed to each rail using the holes 202 disposed on each rail. The system of holes on each rail allows for the quick attachment and removal of the lifting elements 230 , additionally, the vertically-aligned pattern of holes makes it easy for someone installing the lifting elements 230 to space them properly and position them vertically around the periphery.
FIG. 10 shows the roof lifted to the initial position. The extendible, diagonal cross-braces 240 have been installed. The upper ends of the diagonal cross-braces may be attached at a common root point 1002 or at separate locations on the top lifting rail 220 . The common root point 1002 may be a single bracket or separate brackets attached to the top rail 220 , the cross brace ends are attached to the bracket(s) by pin joints 1004 . The lower ends of the cross-braces 240 are affixed to the middle lifting rail 210 at points 1006 spaced equidistant from the root point 1002 . The connection points 1006 are brackets similar to or the same as bracket 1002 , and attach the lower end of the cross-brace 240 to the middle rail 210 . The lower end of the cross-brace 240 attaches to the bracket 1006 at a pin joint 1008 . The use of the pin joints allows the cross braces to rotate about the joint as the angle between the cross-brace 240 and middle rail 210 changes due to the lifting of the roof 102 . As the roof is lifted, the cross-braces 240 will automatically extend and lock in position. In this manner, they provide lateral stability to the roof structure 102 . The cross-braces 240 can utilize a ratcheting mechanism that allows them to be extended but will not allow them to be shortened until an external operation releases the ratchet mechanism and allows the extension pieces of the cross-braces to retract back into the main body tube of the cross-braces 240 . The locking extension action can also be achieved by shaped frictional rings that allow for free extension but are locked into position upon application of back pressure. There exists many ways to achieve the locking extension mechanism and are well known to those skilled in the art. Each face of the structure would have at least one set of the cross braces installed.
As can be seen in FIG. 11 , the vertical lifting elements 230 are telescoping. The main body 232 of the lifting element 230 is affixed at its top end to the middle lifting bar 210 , while the bottom end is affixed to the lower lifting bar 200 . The extension portion 234 is moveable within the main body 232 and connects to the top rail 220 and exerts the upward lifting force and motion to raise the roof structure 102 above the main structure 104 . The extension portion 234 may be a single telescoping piece that moves within the main body 232 , or may contain multiple telescoping pieces that nest within each other. Also seen in FIG. 11 are the extension elements 242 of the cross-braces 240 . These are one-way extendible, meaning the extension elements will extend from the cross-braces 240 as the roof structure 102 is raised by the lifting elements 230 , but will not automatically retract back within the cross-brace 240 unless an external manipulation is performed to release them. This provides lateral stability to the roof structure 102 and the existing walls 104 .
FIG. 12A is a detailed schematic view of the vertical lifting element 230 attached to the top, middle and bottom lifting rails 220 , 210 and 200 . The bottom lifting rail is attached to the sill plate via brackets 204 that are mounted to the sill plate 106 via mechanical fasteners. Before adding the additional level(s) to the structure, a study must be carried out to determine if the existing foundation and sill plate 106 is adequate to support the additional load. If the foundation and sill plate is found to not be adequate, it must be retrofitted or reinforced before the lifting system can be installed and used. The bracket used to mount the lower lifting rail to the sill plate can be integrated into the bracket that holds the vertical lifting element to the lower lifting bar 200 or it may be a separate piece. It is advantageous to use an integrated bracket that performs both functions as the added strength due to mounting of the bracket to the sill plate will help support the loads exerted on the vertical lifting element 230 as the roof load is elevated. The top of the lifting element main tube is attached to the middle rail 210 . The middle rail 210 is attached to the studs of the structure 100 by a bracket 214 affixed by mechanical fasteners like the foundation bracket. Like the foundation bracket 204 , the middle rail bracket 214 can be similar, attaching both the rail to the stud and the vertical lifting element to the rail. The top of the extension portion 234 of the vertical lifting element 230 is attached to the existing rafters or trusses with a bracket 222 attached to the top rail 220 and the perimeter roof structure 102 as better shown in FIG. 12B . At gable ends, the top rail 220 attaches to the end rafter or truss top chord just below the roof sheathing similar to the method that the mid rail 210 is attached to the exiting walls 104 .
FIG. 13 is a detailed schematic view of a wall cross-section showing the detail of the diagonal cross-brace element 240 . The bottom end of the element 240 is attached to the middle rail by a bracket 244 . Extending from the bracket is a reinforced strap 248 that is further screwed to a wall stud of the building to provide a more secure and unmoving mounting point for the cross-brace 240 . The upper end of the cross-brace 240 is attached to the top rail via a bracket 246 .
FIG. 14 is a top view detailing the mounting of the vertical lifting element drive motor. The drive element 1400 is attached to the lower mounting rail and lower mounting rail bracket. A transformer supplying power to the drive element can be mounted on the lower rail at a nearby position using a set of the pre-drilled holes 202 .
FIG. 15 shows a detailed side view of the drive element 1400 and bracket 107 A and FIG. 16 shows a detailed top view of the drive element 1400 showing lifting rod 1406 in cross-section. The drive element 1400 has a drive motor 1402 that is attached to the drive gear box 1404 that drives a self-locking Acme threaded lifting rod 1406 . Each vertical lifting element 230 has a drive block attached to the threaded lifting rod 1406 that elevates the extending portion 234 as the threaded lifting rod 1406 is rotated. The extending portion 234 is driven a pre-determined height and then pinned at that height via a cotter pin that slides through the main tube and extending portion. For lifting elements that have multiple extending portions, each telescoping portion is pinned through the surrounding tubes to hold them in their extended positions. The internal lifting element is driven upwards by a drive block which engages the thread of the threaded lifting rod 1406 . Once the internal drive block has reached the top of the threaded lifting rod 1406 , the extending portions of the vertical lifting elements 230 are pinned at that height and the internal drive block is lowered as the threaded lifting rod 1406 is reversed and lowers back to the bottom of the lifting element 230 . There a different and second drive block reengages the threaded lifting rod 1406 and is again driven upward, repeating the lifting process. By having equal lengths of internal lifting element(s) in each vertical lifting element 230 , ensures that all the vertical lifting elements 230 extend to an equal height with each lifting process. Thus the roof structure 102 does not get warped or broken and the weight stays evenly distributed across each of the vertical lifting elements. Each drive element 1400 is attached to a central driving control panel that ensures each drive element 1400 is driven the amount required to maintain the roof structure level and a controlled lift. There exist other lifting options available that can be used in this system, such as hydraulic pistons or jacks.
FIGS. 17A-17C is an exploded side view of non-metallic slider blocks 241 in the vertical lifting element 230 . The vertical lifting element 230 is composed of an inner element 230 A, a middle element 230 B and a main element 230 C. The non-metallic slider blocks 241 are secured in place by a projection that engages holes in the members of the telescoping vertical lifting element 230 . The engagement holes on the various elements 230 A, 230 B and 230 C are of two differing sizes to accommodate two differently sized non-metallic slider blocks 241 A and 241 B. The nonmetallic slider block 241 A has a sliding surface diameter nearly the width of a face of the inner element 230 A. The same slider block 241 A is also disposed at an end of the element 230 B that inner element 230 A extends outwards from an opposite end of the element 230 B, slider block 241 B is disposed, having a diameter nearly the width of the face of the middle element 230 B. Main element 230 C has a slider block 241 B disposed at an end. The non-metallic slider blocks align the elements 230 A, 230 B and 230 C of the lifting element 230 , which prevents the various elements from rubbing or twisting inside of each other during the lifting process. The outer shape of the non-metallic slider blocks 241 can be round, square, rectangular or a profile not here described. The shape of the projection on the non-metallic slider blocks 241 can be round, square, rectangular or a profile not here described. The non-metallic slider blocks are ideally made of a high molecular weight plastic having a low friction coefficient, but sufficient material strength to resist compression.
FIGS. 18A-18D is a cross sectional view of the non-metallic slider blocks 241 in the nested vertical lifting elements 230 . The projections on the non-metallic slider blocks 241 are shown engaging holes in the members of the vertical lifting elements 230 .
FIG. 19A is a perspective view of a circular example of the non-metallic lifting block 241 . The block has a large diameter 243 and a small diameter 245 . The flat face of the large diameter 243 is the friction face that contacts a portion of the lifting element 230 as it slides. The small diameter 245 sits in holes in the lifting elements 230 and provides restraint to hold the nonmetallic slider block 241 in place on the lifting element. FIG. 19B is a side elevation view of the non-metallic slider block 241 . FIG. 19C is a plan view of the non-metallic slider block 241 .
FIG. 20A is a side view and FIG. 20B is a top view of the diagonal cross-brace outer tube and a separate ‘lock pin block’ item 258 . The diagonal cross-braces 240 can utilize an internal ratcheting mechanism here defined as a ‘lock pin block’ item 258 . The ‘lock pin block’ item 258 engages with the corresponding indentations of the inner tube of the diagonal cross-braces 240 , as shown in section G-G. This allows the diagonal cross-braces 240 to be extended but does not allow the diagonal cross-braces 240 to be shortened until an external operation releases the ratchet mechanism or ‘lock pin block’ item 258 . The release of the ‘lock pin block’ item 258 enables the inner tubes of the cross-brace to retract back into the outer body tube of the cross-brace 240 . The spring loaded index plunger, as shown in FIG. 20A , is an example device that may be used to index and restrain an object, in this case, the removable ‘lock pin block’ 258 .
FIG. 21 shows a complete structure 100 which may be lifted for repair or replacement of sill plates, supporting walls, footings and other structural features. Additionally, the building may be lifted to add an additional level(s) to the structure. In a further embodiment, the structure may be lifted and the roof structure may be, simultaneously or separately, lifted to accomplish the desired construction tasks.
FIG. 22 shows the structure of FIG. 21 raised with the telescoping wall jacks 230 , with diagonal braces 240 , installed to avoid wracking.
FIG. 23 shows a detailed side view of the drive element 1400 and bracket 107 A. FIG. 24 shows a detailed top view of the drive element 1400 of FIG. 23 . The drive element 1400 has a drive motor 1402 that is attached to the drive gear box 1404 that drives a self-locking Acme threaded rod 1406 . Each vertical lifting element 230 has a drive block attached to the threaded rod 1406 that lowers the extending portion 234 as the threaded lifting rod 1406 is rotated. The extending portion 234 is driven a pre-determined length by an internal drive block and then pinned via a cotter pin that slides through the main tube and extending portion. For lifting elements that have multiple extending portions, each telescoping portion is pinned through the surrounding tubes to hold them in their extended positions. The internal lifting element is driven downwards by a drive block which engages with the threads of the threaded rod 1406 . Once the internal drive block has reached the end of the threaded lifting rod 1406 , the extending portions of the vertical lifting elements 230 are pinned. The internal drive block is returned to an initial position as the threaded rod 1406 is reversed. Once the drive block is returned, a different and second drive block is inserted and reengages the threaded rod 1406 . The new drive block is driven downward, repeating the lifting process. Having equal lengths of internal lifting element(s) in each vertical lifting element 230 ensures that all the vertical lifting elements 230 extend an equal length with each lifting process. In doing so, the building structure 100 does not get warped or damaged since the weight stays evenly distributed across each of the vertical lifting elements. There exist other lifting options available that can be used in this system, such as hydraulic pistons or jacks.
Each drive element 1400 is attached to a central driving control panel that ensures each drive element 1400 is driven, either independently or in unison, such that structure remains level and lift is controlled. An example control means could include monitoring of the amperage drawn by each drive element 1400 . A method of monitoring the amperage drawn by each of the drive elements 140 can be an ammeter attached to each drive element. The amperage drawn by each drive element 1400 is correlated to the amount of torque each drive element 1400 is exerting to lift the structure. Should the amount of amperage drawn by a drive element 1400 spike, it can be indicative of unequal loading which could mean that the load is now unbalanced or proceeding at unequal rates. The controller can vary the amount of power and lift rate of each of the drive elements 1400 to rebalance and relevel the structure.
Alternative control and measurement systems can be used, such as load cells on each drive element, voltage monitoring of the drive elements 1400 and/or the system as a whole or others, level and/or alignment sensors on the jacks and/or structure, or some combination thereof. An example alignment sensor system is a system of sensors that relay the relative position and/or extension length of a wall jack member in relation to the other wall jack members. Aligning the lifting of each of the wall jack members lifts the structure in a stable and balanced state as desired.
FIG. 25A is a schematic side elevation showing details of the lifting system attached to the structure 100 . The top lifting rail 220 is attached to the structure 100 at the underside of the floor joists as also previously shown in FIG. 23 . The bottom lifting rail 200 has holes 202 spaced regularly along the length of the rail 200 . Section A-A is identified to further define method of attachment of the bottom rail 200 .
FIG. 25B is a schematic top view of the lifting system and identifies that both top lifting rail 230 and bottom rail 200 are attached to the same side of the outer element 230 C of the vertical lifting elements 230 .
FIG. 25C shows cross Section A-A identifying bracket 247 has an integral locating pin 248 that engages in a hole in the outer element 230 C of the vertical lifting elements 230 . Hardware connects bracket 247 to the bottom rail 200 through holes 202 A, thereby rigidly linking the vertical lifting elements 230 together with top rail 220 . Multiple bottom rail elements 200 are interconnected to form a rigid framework that links together predetermined vertical lifting element assemblies 230 and acts as the lower structure of the lifting system. The bottom rail elements 200 are connected to one another using a butt joint 910 . The rails 200 have holes 202 A at each end. The butt joint 910 is inserted inside the end of a rail 200 and is locked in place by inserting retaining pins in the end holes 202 A and through the holes on the butt joint. The end holes 202 A are spaced to ensure that the spacing of the holes 202 is maintained across the interconnection at the butt joint 910 .
FIG. 26 shows a detailed method of applying extendible cross-braces 240 between ‘pairs’ of wall jacks 230 to provide lateral stability of lifted structure. The spacing of the wall jacks 230 and cross-braces 240 provides sufficient space to accomplish the desired construction steps. With the structure raised, workers can excavate, prep and pour new footings and foundation walls and or add an additional level(s) under the original level. The ‘lock pin block’ item 242 is shown on each extendible cross-braces 240 .
FIG. 27 shows a detailed method of applying extendible cross-braces 240 between predetermined ‘pairs’ of wall jacks 230 to provide lateral stability of lifted structure while providing access required to excavate, prep and pour new footings and foundation walls.
The vertical lifting elements 230 are attached at regular or irregular intervals around each side of the house, and other predetermined locations to interconnect the rails 200 , and 220 . Elements 230 are affixed to each rail using the holes 202 disposed on each rail. The system of holes on each rail allows for the quick attachment and removal of the lifting elements 230 . Additionally, the vertically-aligned pattern of holes makes it easy for someone installing the lifting elements 230 to space them properly and position them vertically around the periphery or other predetermined locations.
FIG. 28 shows a detailed schematic view of a wall cross-section showing the detail of the method using the tube 230 D to provide and retain replaceable threaded rod supports 249 thereby limiting deflection due to the applied vertical load when lifting either a roof structure or an entire building.
FIG. 29 shows a detailed schematic side view of a structure with Section B-B and Section D-D identified to show the detail of the method to provide and retain replaceable threaded rod supports 249 using the tube 230 D.
FIG. 30A shows a detailed cross Section C-C of outer element 230 C of lifting element 230 showing detail of the method to provide replaceable threaded rod supports 249 . Location where cross Section C-C is taken is shown in FIG. 32B . Location where cross Section C-C is taken is shown in FIG. 32B with the middle element in the raised position when lifting a roof structure, and the middle element in the lowered position when lifting an entire structure.
FIG. 30B shows a detailed cross Section B-B of outer element 230 C of lifting element 230 showing the detail of the method to provide and retain replaceable threaded rod supports 249 . Location where cross Section B-B is taken is shown in FIG. 29 .
FIG. 30C shows a detailed cross Section C 1 -C 1 of outer element 230 C and middle element 230 B of lifting element 230 showing detail of the method to provide replaceable threaded rod supports 249 . Location where cross Section C 1 -C 1 is taken is shown in FIG. 32B with the middle element in the lowered position when lifting a roof structure, and in the middle element in the raised position when lifting an entire structure.
FIG. 30D shows a detailed cross Section D-D of middle element 230 B of lifting element 230 showing detail of the method to provide replaceable threaded rod supports 249 . Location where cross Section D-D is taken is shown in FIG. 29 with the middle element 230 B in the raised position when lifting a roof structure, and the middle element 230 B in the lowered position when lifting an entire structure.
A drive block attached is to the threaded lifting rod 1406 that elevates the extending portion 234 B when raising a roof structure or pushes downward extending portion 234 B when raising an entire structure as the threaded lifting rod 1406 is rotated. The extending portion 234 B is driven a pre-determined distance and then pinned at that location via a cotter pin that slides through the main tube and extending portion. After the inner extending portion 234 B is pinned, replaceable threaded rod supports 249 are installed through holes in outer tube 230 C of lifting element assembly 230 . A length of tubing 230 D is utilized to secure and retain replaceable threaded rod supports 249 . One or more than one set of replaceable threaded rod supports 249 and section of tube 240 D may be used per lifting element assembly 230 .
FIG. 31A shows detailed cross Section E-E of lifting element assembly 230 showing the detail of the method to retain the replaceable threaded rod supports 249 with section of tubing 230 D in its normal position. Two differently sized non-metallic slider blocks 241 A and 241 B are inserted in holes in tube section 240 D, and make contact with replaceable threaded rod supports 249 , thereby serving as a ‘stop’ and limits the vertical travel of tube section 240 D. FIG. 31B is a detailed cross section of lifting element assembly 230 showing the detail of the method to retain the replaceable threaded rod supports 249 with section of tubing 230 D in its normal position. FIG. 31B identifies where Section E-E is taken.
FIG. 32A shows detailed cross Section F-F of lifting element assembly 230 with section of tubing 230 D in its raised position to install or replace replaceable threaded rod supports 249 . FIG. 32B identifies where Section F-F is taken.
The various elements of this apparatus can be made of steel or other suitable materials. These can include aluminum and other metals. Selection of materials is based on the likely loads each element would encounter during the lifting process. In this manner, certain materials can be chosen for their compressive or tensile strength and weight. Composite materials can also be used; the lightweight and high strength of these materials may be optimal, but must be weighed against the cost of manufacturing the various elements. Additionally, each element of this apparatus is reusable, making this system easy to install and remove on multiple building sites. Due to the modular nature of this system, it can be expanded to fit a building of many sizes.
Having described and illustrated the principles of the disclosed technology in a preferred embodiment thereof, it should be apparent that the disclosed technology can be modified in arrangement and detail without departing from such principles. We claim all modifications and variations coming within the spirit and scope of the following claims
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A system and method for raising a structure, or part thereof, the system comprising vertical jack members connected and disposed about a rail system attached about the periphery of the structure. The vertical jack members comprise an outer sleeve and a slidable inner portion that is driven vertically by a jack screw and drive block. Extensible diagonal cross-braces stabilize the jack members and structure being raised.
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BACKGROUND
[0001] Conventional systems for treatment of earth formations, such as acidizing, in downhole industries typically employ coiled tubing. Coiled tubing is run into a borehole and treatment is performed on one zone of the formation at a time. After treatment of a zone is completed the coiled tubing is moved to align with the next zone and the process is repeated until all desired zones have been treated. This process is time consuming because of the serial nature. Additionally, coiled tubing is unable to reach the toe of wells with long horizontal or highly deviated sections. The maximum flow rate through the coiled tubing is limited because of the flow area available. As such, industry is receptive to new systems and methods that alleviate any of the foregoing concerns.
BRIEF DESCRIPTION
[0002] Disclosed herein is a method of treating a formation. The method includes, running a first string having at least one first port into a completion string having a plurality of second ports, flowing treating fluid through the first string, and flowing treating fluid through the at least one first port and through at least one of the plurality of second ports and into the formation.
[0003] Further disclosed herein is a treatment and completion system. The system includes, a completion string positioned within a borehole in an earth formation, a first string runnable within the completion string, having a plurality of first ports distributed along the first string that are configured to be in fluidic communication with a plurality of second ports along the completion string. The plurality of first ports are independently settable to a different flow restriction, and a plurality of seals distributed along the first string or the completion string are configured to seal to the other of the first string and the completion string to isolate the plurality of first ports from one another such that treating fluid can be pumped through the first string and through the plurality of first ports and through the plurality of second ports to treat a plurality of zones of a formation simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0005] FIG. 1 depicts a schematic of a treating system disclosed herein; and
[0006] FIG. 2 depicts a schematic of an alternate treating system disclosed herein.
DETAILED DESCRIPTION
[0007] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0008] Referring to FIG. 1 , an embodiment of a treating system disclosed herein is illustrated at 10 . The treating system 10 includes a first string 14 referred to herein is a treating string that is runnable within a completion string 18 . The treating string 14 includes a plurality of first ports 22 referred to herein as treating ports that are distributed along the treating string 14 . The treating ports 22 are configured to be in fluidic communication with second ports 26 that are distributed along the completion string 18 . Each of the plurality of treating ports 22 is independently settable to a different flow restriction level. The ports 22 and 26 can be simply openings of selected sizes and shapes including perforations, slots and round holes, for example. The ports 22 can also include flow control devices that include restrictors such as annular tortuous flow paths like mazes and helical flow paths, for example. They can also include movable portions such as sleeves to alter restriction of flow therethrough including completely closing flow through one or more of the ports 22 , 26 . A plurality of seals 30 are distributed along the treating string 14 or the completion string 18 and are configured to seal to the completion string 18 . Sealing of the seals 30 isolates each of the plurality of treating ports 22 from one another within the completion string 18 . Similarly, seals 32 , such as packers, for example, sealingly engage between the completion string 18 and a borehole 50 within an earth formation 38 thereby creating separate zones 34 along the borehole 50 . The seals 38 may be aligned with the seals 30 to allow an operator to control flow of fluid through specific ports 22 and through specific ports 26 and into the formation 38 simultaneously. The foregoing structure allows for greater control of injection flow rates along the borehole 50 than is permitted with conventional systems.
[0009] The treating system 10 allows for customization of flow restriction through each of the treating ports 22 along the treating string 18 . These adjustments can be configured to account for various characteristics and differences between the zones 34 . These differences can be due to variations in permeability between the different zones 34 , for example. They can also be due to where along the completion string 18 (i.e. relative locations along the completion string 18 ) each of the treating ports 22 will be located. Flow restriction of the treating ports 22 near a heal 42 of the completion string 18 will likely need to be set at a higher flow restriction level than the treating ports 22 near a toe 46 of the completion string 18 to balance flow of treating fluid between the zones 34 near the heal 42 with the zones 34 near the toe 46 .
[0010] The treating string 14 , unlike conventional treating systems that employ coiled tubing, uses sections of pipe that are connected together in an end-to-end fashion. As such, the treating string 14 can be run through a full length of the completion string 18 regardless of how highly deviated the completion string 18 may be, including when the deviated portion of the completion string 18 is completely horizontal.
[0011] Additionally, the inner diameter that defines a flow area through the treating string 14 can be significantly larger than conventional coiled tubing treating lines. As such, treating fluids, such as acid for acidizing the formation 38 , for example, can be injected at higher flow rates. These higher flow rates can be beneficial when treating fluid needs to be pumped deep into one or more of the zones 34 including those that have low permeability or are far from the heal. The high flow rates possible allow for treating a plurality of the zones 34 simultaneously, up to and including all the zones 34 along the borehole 50 .
[0012] In addition to the treating ports 22 being independently customized for flow restriction to the specific desired needs of the zones 34 that will be treated via the treating ports 22 , the treating ports 22 can work together in pairs with the second ports 26 . Knowing specific distinctive features about second ports 26 allows an operator to customize the treating ports 22 to work in concert with the second-ports 26 . This is helpful since some or all of the second ports 26 may be simply slotted openings in a base pipe (as in the present embodiment). In a hydrocarbon recovery application, for example, after injecting a treating fluid, the treating string 14 may be left in place during production of hydrocarbons. In this embodiment employing inflow control devices as the ports 22 can allow for more complete emptying of hydrocarbon from all of the zones 34 than would occur without the inflow control devices 22 being present. Additionally, the inflow control devices delay water breakthrough in highly permeable zones 34 that would likely produce water much earlier if the inflow control devices 22 were not present. Alternately the treating string 14 can be removed from the completion string 18 and hydrocarbons produced through the completion string 18 alone. In yet another embodiment a third string (not shown) could be run into the completion string 18 and production carried out through both the completion string 18 and the third string.
[0013] In one embodiment of the treating system 10 the flow restriction levels of the treating ports 22 are adjustable after being run into the completion string 18 . Control lines 54 in operable communication with actuators 58 at each of the treating ports 22 can adjust the flow restriction of each of the treating ports 22 as desired in real time. This real time adjustment can include completely closing of the treating ports 22 to thereby allow operators to alter flow rates as well as the total amount of treating fluid supplied to the particular zones 34 .
[0014] Referring to FIG. 2 , an alternate embodiment of a treating system disclosed herein is illustrated at 110 . The treating system 110 differs from the system 10 in that instead of treating all of the zones 34 simultaneously, only a subset of the full number of the zones 34 is treated at one time. In the embodiment illustrated three of the zones 34 are treated at one time, although any number of the zones 34 could be included in a subset in an alternate embodiment. As illustrated, the first three zones 34 being treated are those nearest the toe 46 . After this first treatment is completed a treating string 114 employed within the completion string 18 is moved toward the heal 42 to align three treating ports 122 thereon with the next three second ports 26 and treating fluid is supplied therethrough. This is repeated until all of the zones 34 have been treated.
[0015] The system 110 uses just two seals 130 , one on either side of the two outer-most treating ports 122 . Although embodiments can use one of the seals 130 between any of the treating ports 122 as each application dictates.
[0016] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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A method of treating a formation includes, running a first string having at least one first port into a completion string having a plurality of second ports, flowing treating fluid through the first string, and flowing treating fluid through the at least one first port and through at least one of the plurality of second ports and into the formation
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[0001] This application is a Continuation-In-Part of: (a) Great Britain Application No. 1314731.9, filed on Aug. 16, 2013; and (b) International Application No. PCT/GB2013/050371, filed on Feb. 15, 2013, which claims the priority of Great Britain Application No. 1202743.9, filed on Feb. 17, 2012.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of treating aqueous fluid comprising a water miscible polymer and in particular but not exclusively to a method of treating aqueous fluid comprising a Kinetic Hydrate Inhibitor (KHI). The present invention further relates to aqueous fluid treatment apparatus which is configured to treat aqueous fluid comprising a water miscible polymer.
BACKGROUND TO THE INVENTION
[0003] Gas hydrates (or clathrate hydrates) are crystalline water-based solids which physically resemble ice and in which small non-polar molecules, partially polar molecules or polar molecules with large hydrophobic moieties, such as methane and carbon dioxide, are trapped inside cage-like structures of hydrogen bonded water molecules. The molecules trapped in the cage-like structures lend support to the lattice structure of the gas hydrate through van der Waals interactions; without such support the lattice structure is liable to collapse into a conventional ice crystal structure or liquid water. Gas hydrates typically form under elevated pressure and low temperature conditions. Such gas hydrate formation favouring conditions often arise in oil/gas pipelines and may result in agglomerations of clathrate crystals which are liable to obstruct the flow line, limit or stop production and/or damage equipment, such as pipelines, valves and instrumentation, and thereby pose significant economic and safety concerns. The formation of gas hydrates in oil and gas production operations therefore presents a significant economic problem and safety risk.
[0004] It is known to use Low Dosage Hydrate Inhibitors (LDHIs) to prevent gas hydrate caused flow line blocking and equipment fouling problems. There are two types of LDHIs: Kinetic Hydrate Inhibitors (KHIs); and Anti-Agglomerants (AAs). KHIs inhibit the nucleation and/or growth of gas hydrate crystals in produced water whereas AAs prevent the agglomeration of hydrate crystals into problematic plugs.
[0005] The active part of most commercially available KHI formulations is a synthetic polymer. The most commonly used synthetic polymer is a water miscible poly-n-vinylamide such as polyvinylcaprolactam (PVCap). The active polymer typically makes up less than half of a KHI formulation with the remainder being water miscible polymer solvent such as a low molecular weight alcohol, e.g. methanol, ethanol or propanol, a glycol, e.g. monoethylene glycol (MEG) or a glycol ether, e.g. ethylene glycol monobutyl ether (EGBE) or 2-butoxyethanol. Dispersion of the solid polymer in the liquid solvent provides for ease of distribution of the KHI, for example by pumping of the KHI through pipelines to the inhibitor injection points. Furthermore the solvent acts as a synergist by enhancing the hydrate formation inhibiting properties of the polymer. The polymer is by far the most expensive part of KHI formulations.
[0006] KHIs offer many advantages over traditional approaches to hydrate inhibition. Nevertheless there are a number of problems associated with the use of KHIs including the following specific examples. In view of the non-biodegradable nature of many KHI polymers the disposal of KHI containing reservoir produced water is normally a significant issue where there is no reinjection of the produced water into the reservoir, e.g. where reinjection is impossible. Where produced water is treated KHI polymers are liable to foul treatment apparatus, such as MEG or methanol regeneration units. Where there is reinjection of produced water high reservoir temperatures can give rise to KHI polymer precipitation which is liable to block well perforations and rock pores and thereby reduce injection efficiency.
[0007] The present invention has been devised in the light of the inventors' appreciation of problems associated with the use of KHIs, including the problems mentioned above. It is therefore an object for the present invention to provide a method of treating aqueous fluid comprising a water miscible polymer, such as at least one Kinetic Hydrate Inhibitor (KHI). It is a further object for the present invention to provide aqueous fluid treatment apparatus which is configured to treat aqueous fluid comprising a water miscible polymer, such as at least one Kinetic Hydrate Inhibitor (KHI).
STATEMENT OF INVENTION
[0008] According to a first aspect of the present invention there is provided a method of treating aqueous fluid, the method comprising adding an organic compound to a mass of aqueous fluid comprising at least one Kinetic Hydrate Inhibitor (KHI), the organic compound comprising a hydrophobic tail and a hydrophilic head, the hydrophobic tail comprising at least one C—H bond and the hydrophilic head comprising at least one of: a hydroxyl (—OH) group; and a carboxyl (—COOH) group.
[0009] In use the mass of aqueous fluid, which may be aqueous fluid present in an oil or gas production operation, is treated by addition of the organic compound. The organic compound may be added, for example, at an oil or gas production processing facility, such as a facility configured to handle produced water. The mass of aqueous fluid may therefore comprise aqueous liquid, such as produced water which may comprise at least one of formation and condensed water. The addition of the organic compound to the mass of aqueous fluid may cause separation of at least a part of the KHI from the aqueous fluid. More specifically the organic compound may cause separation from the aqueous fluid of a water miscible polymeric KHI, such as a water miscible synthetic polymer, comprised, for example, in a KHI formulation. The organic compound may be configured to have, at the most, limited solubility in water. The organic compound, e.g. pentanol or heptanoic acid, may have a miscibility with water (by mass) of less than 10%, 8%, 6%, 4%, 2%, 1%, 0.5%, 0.3%, 0.2%, 0.1% or 0.05%. Where an organic compound is of limited solubility in water less of the organic compound may be lost to the aqueous fluid. This means the aqueous fluid may be contaminated by the organic compound to a reduced extent. In addition an organic compound of limited solubility in water may be more liable to form a liquid phase apart from the aqueous fluid; as described below such phase separation may aid removal of the KHI. The aqueous fluid may be a substantially polar phase. The liquid phase comprising the organic compound may be a substantially non-polar phase and may be substantially non-aqueous.
[0010] The organic compound comprises a hydrophobic tail and a hydrophilic head, the hydrophobic tail comprising at least one C—H bond and the hydrophilic head comprising at least one of: a hydroxyl (—OH) group; and a carboxyl (—COOH) group. The hydrophilic head may comprise one and perhaps solely one of: a hydroxyl (—OH) group; and a carboxyl (—COOH) group.
[0011] The organic compound is understood to displace water dissolved KHI and thereby cause separation of the KHI from the aqueous fluid. More specifically at least a part of the KHI may transfer from the aqueous fluid to the organic compound. The structure of the organic compound, i.e. with regards to its C—H bond comprising hydrophobic tail and hydroxyl or carboxyl group comprising hydrophilic head, may be similar to the structure of the KHI. Thus the organic compound may interact with water in a similar fashion to the KHI such as to favour displacement of the KHI from the aqueous fluid to the organic compound. The organic compound, e.g. pentanol or heptanoic acid, may be operative to remove more than 80%, 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% of KHI, such as PVCap, present in aqueous fluid from the aqueous fluid.
[0012] The method may further comprise the step of removing at least a part of the KHI from the mass of aqueous fluid. The step of removing at least a part of the KHI may be carried out after the step of adding the organic compound to the mass of aqueous fluid. Where the KHI is comprised at least in part in a second liquid phase (i.e. a phase apart from the aqueous fluid), the removal step may comprise at least one of: gravity separation; liquid-liquid coalescing separation; and centrifugal separation. The removal step may therefore be a physical rather than chemical removal step involving physical separation of at least a part of the KHI from the aqueous fluid. On account of a difference in density between the first, aqueous phase and the second KHI comprising phase, the two phases can be expected to be readily separable from each other. The thus treated mass of aqueous fluid may now be used with the risk of adverse consequences arising from the presence of KHI being at least reduced. For example and where the mass of aqueous fluid is subject thereafter to known treatment approaches, such as MEG or methanol regeneration, such known treatment approaches can be followed with a reduced risk of KHI fouling the treatment apparatus. Where the mass of aqueous fluid is thereafter introduced to a geological formation, such as in the form of reinjection of produced water into a reservoir, removal of KHI reduces the risk of blockages occurring. Furthermore where the mass of aqueous fluid is thereafter disposed of, e.g. overboard, the risk of environmental damage arising from KHI is reduced.
[0013] Thereafter the removed KHI may be disposed of by known means, such as incineration. Disposal of the KHI after its removal from the mass of aqueous fluid may be more readily and cost effectively accomplished than disposal of a mass of aqueous fluid, such as produced water, comprising the KHI.
[0014] According to another approach the method may be used to determine the concentration of KHI in the mass of aqueous fluid. It may, for example, be important to know the concentration of KHI to ensure that KHI is being applied in an effective fashion or to ensure that KHI has been removed, e.g., from produced water ahead of disposal of the produced water. Furthermore accurate determination of KHI concentration may be required of laboratory tests. The method according to the invention may therefore further comprise determining a concentration of KHI in a mass of material, such as in a mass of the second, liquid phase. The step of determining the concentration of the KHI may therefore be carried out after the step of removing the KHI from the mass of aqueous fluid. Determining the concentration of KHI may be accomplished by a known method, such as analysis by InfraRed (IR) spectrometry, UltraViolet (UV) spectrometry or visual spectrometry. Alternatively the organic compound may be removed from the separate phase comprising the KHI, e.g. by heating the separate phase or perhaps heating the separate phase at reduced pressure, such in a partial vacuum, to drive off the organic compound and leave the KHI behind. The remaining KHI may then be weighed and the concentration of the KHI in the mass of aqueous fluid may be determined on the basis of material balance. Alternatively or in addition the method may comprise removing a small portion of the mass of aqueous fluid comprising the KHI and adding the organic component to the small portion. More specifically the method may further comprise removing the KHI from the small portion, e.g., by gravity or centrifugal separation. The step of determining the concentration of the KHI may be carried out after the step of removing the KHI from the small portion. Thus the analysis may be carried out on a sample of small volume taken from a large volume of aqueous fluid comprising the KHI. The concentration of KHI in the mass of aqueous fluid may be determined by inference based on the analysis of the small portion of aqueous fluid.
[0015] KHIs are normally present in low concentrations, such as less than 0.5 mass percent, in the like of reservoir produced water. Known approaches to determining the concentration of KHIs in such circumstances tend to be problematic. For example such known approaches are often complex, specific to one form of KHI and inaccurate at low concentrations, such as the concentration levels seen in produced water. The approach to concentration determination according to the present invention may be simpler, more accurate and more reliable than known approaches, in particular where the concentration levels are low. The approach according to the present invention may provide for concentration determination at lower levels of concentration, such as below 0.25 mass percent.
[0016] The organic compound may comprise a long hydrophobic tail and a short hydrophilic head. The organic compound may thus be of comparatively low miscibility with water on account of the presence of the short hydrophilic head and long hydrophobic tail. As mentioned above, the organic compound may have a structure such that its behaviour mimics the behaviour of the KHI to be displaced from the mass of aqueous fluid. The hydrophobic tail may comprise at least four, five or six carbon atoms with each carbon atom forming a C—H bond. The organic compound may comprise no more than one hydroxyl group. The organic compound may comprise no more than one carboxyl group. The hydroxyl or carboxyl group may be terminal to the organic compound.
[0017] In one form the organic compound may be an alcohol. The organic compound may therefore have the general formula R—OH, where R has the formula C n H m . More specifically the R group may comprise at least one of: an alkyl group (in the form of single bonded straight chain and branched isomers); an allyl group; a cyclic group (i.e. comprising cyclic single bonded carbon atoms); and a benzyl group. Higher molecular weight alcohols, such as butanol and higher, have been found to be effective at displacing KHI. Generally KHI displacement has been found to improve as the carbon number increases. A significant improvement in displacement has been observed with a carbon number of five and above. Furthermore an increase in carbon number may provide for a decrease in volatility and reduced solubility in the aqueous fluid; such properties are desirable for utility of the present invention. The carbon number of the alcohol may be at least four, five, six, seven or eight. Alternatively or in addition the carbon number of the alcohol may be no more than 12, 11 or 10. Alcohols with a carbon number of 6, 7 or 8 may have very low miscibility with water or be almost immiscible with water, e.g. less than about 2% miscibility by mass. In addition alcohols with a carbon number of 6, 7 or 8 may displace more than 90% of a KHI such as PVCap from the aqueous fluid. Alcohols with yet higher carbon numbers, e.g. with a carbon number of nine or more, may be used. However use of such higher carbon number alcohols may be less favoured when the alcohols are solid under standard conditions. The carbon number of the alcohol may therefore be no more than eleven, ten, nine or eight.
[0018] In another form the organic compound may be a carboxylic acid. The organic compound may therefore have the general formula R—COOH, where R is a monovalent functional group. More specifically the R group may comprise at least one of: an alkyl group (in the form of single bonded straight chain and branched isomers); an allyl group; a cyclic group (i.e. comprising cyclic single bonded carbon atoms); and a benzyl group. The organic compound may be a fatty acid and more specifically a saturated or an unsaturated fatty acid. Higher molecular weight carboxylic acids, such as pentanoic acid and higher, have been found to be effective at displacing KHI. Generally KHI displacement has been found to improve as the carbon number increases. A significant improvement in displacement has been observed with a carbon number of five and above. Furthermore an increase in carbon number may provide for a decrease in volatility and reduced solubility in the aqueous fluid; such properties are desirable for utility of the present invention. The carbon number of the carboxylic acid may be at least five, six, seven or eight. Alternatively or in addition the carbon number of the carboxylic acid may be no more than 13, 12, 11 or 10. Carboxylic acids with a carbon number of 5, 6, 7, 8, 9 or 10 may have very low miscibility with water or be almost immiscible with water, e.g. less than about 5% miscibility by mass. In addition carboxylic acids with a carbon number of 5, 6, 7, 8, 9 or 10 may displace more than 70% of a KHI such as PVCap from the aqueous fluid. Carboxylic acids with higher carbon numbers, e.g. with a carbon number of ten or more, may be used. However use of such higher carbon number carboxylic acids may be less favoured when the carboxylic acids are solid, such as under standard conditions. The carbon number of the carboxylic acid may therefore be no more than twelve, eleven, ten or nine.
[0019] In another form the organic compound may be a glycol ether. The organic compound may thus comprise: at least one pair of hydrocarbon groups bonded to each other by way of an oxygen atom; and one hydrocarbon group comprising a single hydroxyl (OH) group. The hydroxyl group may be terminal. A hydrocarbon group comprised in the glycol ether may be one of: an alkyl group; an allyl group; a cyclic group (i.e. comprising cyclic single bonded carbon atoms); a benzyl group; and a phenol group.
[0020] The method may further comprise adding a second organic compound to the mass of aqueous fluid, the second organic compound being of lower density than the first organic compound (i.e. the organic compound discussed hereinabove). Adding a second organic compound of lower density than the first organic compound may aid separation into two phases and with substantially no reduction in movement of KHI from the phase constituted by the mass of aqueous fluid to the phase constituted by the first organic compound. For example gravity separation into two separate phases may be quicker when the second organic compound is present. The second organic compound may be miscible with the first organic compound. After addition to the mass of aqueous fluid the first and second organic compounds may therefore together form a separate phase with thus formed phase being of lower density than a phase formed by the first organic compound alone. The second organic compound may be substantially hydrophobic. The KHI may be substantially immiscible in the second organic compound. The second organic compound may be a hydrocarbon. The second organic compound may have a carbon number no more than a carbon number of the first organic compound. A carbon number of the second organic compound may be greater than four and less than eleven. The second organic compound may comprise an alkane, such as heptane. The second organic compound may comprise a plurality, i.e. a mixture, of different organic compounds of the form presently described.
[0021] The density of the second organic compound may be at least substantially 0.5, 0.6 or 0.7 grams per millilitre. Alternatively or in addition the density of the second organic compound may be no more than substantially 0.9, 0.8 or 0.7 grams per millilitre. A density of the second organic compound between substantially 0.6 grams per millilitre and substantially 0.8 grams per millilitre has been found advantageous in certain circumstances such as where a density of the first organic compound is between substantially 0.8 grams per millilitre and substantially 0.9 grams per millilitre when it comprises a hydroxyl group. The density of the first organic compound may be at least substantially 0.7 or 0.8 grams per millilitre when it comprises a hydroxyl group. Alternatively or in addition the density of the first organic compound may be no more than substantially 1.0 or 0.9 grams per millilitre when it comprises a hydroxyl group. Alternatively a density of the second organic compound between substantially 0.6 grams per millilitre and substantially 0.8 grams per millilitre has been found advantageous in certain circumstances such as where a density of the first organic compound is between substantially 0.8 grams per millilitre and substantially 1.0 gram per millilitre when it comprises a carboxyl group. The density of the first organic compound may be at least substantially 0.8 or 0.9 grams per millilitre when it comprises a carboxyl group. Alternatively or in addition the density of the first organic compound may be no more than substantially 1.05 or 0.95 grams per millilitre when it comprises a carboxyl group.
[0022] The treatment fluid may comprise no more than substantially 99% volume, 95% volume, 90% volume, 85% volume, 80% volume, 75% volume, 70% volume, 60% volume, 50% volume, 40% volume, 30% volume, 20% volume, 10% volume, 5% volume or 1% volume of the second organic compound. The treatment fluid may comprise at least substantially 1% volume, 5% volume, 10% volume, 20% volume, 30% volume, 40% volume, 50% volume, 60% volume, 70% volume, 75% volume, 80% volume, 85% volume, 90% volume or 99% volume of the second organic compound. A treatment fluid comprising the first organic compound to at least substantially 20% volume and the second organic compound up to substantially 80% volume has been found under certain circumstances to provide for effective movement of KHI from the phase constituted by the mass of aqueous fluid to the phase constituted by the first organic compound. Concentrations of the first organic compound below substantially 20% volume have been found under certain circumstances to be less effective at moving KHI from the phase constituted by the mass of aqueous fluid. This may be because the KHI dissolves less readily in such a smaller volume of the first organic compound.
[0023] The second organic compound may be added to the mass of aqueous fluid at substantially a same time and perhaps along with the first organic compound. The first and second organic compounds may therefore be mixed and stored as a mixture before being added to the mass of aqueous fluid. Alternatively or in addition the second organic compound may be added following addition of the first organic compound and where the first organic compound either comprises the second organic compound or lacks the first organic compound. More specifically the second organic compound may be added to the phase constituted by the mass of aqueous fluid following separation into two phases after addition of the first organic compound. Furthermore the second organic compound may be added to the phase constituted by the mass of aqueous fluid after physical separation of the two phases as described elsewhere herein. The subsequent addition of the second organic compound may provide for removal of at least one of remaining KHI and remaining first organic compound, such as a cloudy micro-droplet suspension of KHI and the first organic compound. The method may further comprise a second removal step after addition of the second organic compound. Such a second removal step may comprise physical separation as described above with reference to the first removal step.
[0024] The mass of aqueous fluid before treatment may comprise a KHI formulation. A KHI formulation may comprise at least one KHI compound, such as a polymeric KHI and at least one further compound which enhances the performance or solubility of the KHI compound. The performance enhancing compounds may comprise at least one organic salt, such as a quaternary ammonium salt. Alternatively or in addition the KHI formulation may comprise a water miscible polymer solvent such as a low molecular weight alcohol, e.g. methanol, ethanol or propanol, a glycol, e.g. monoethylene glycol (MEG) or a glycol ether, e.g. ethylene glycol monobutyl ether (EGBE) or 2-butoxyethanol.
[0025] The at least one KHI may comprise a polymeric KHI. As will be familiar to the notionally skilled person a KHI prevents or at least limits the nucleation and/or growth of gas hydrate crystals. The at least one KHI may, typically, be water miscible. The at least one KHI may be organic. Alternatively or in addition the at least one KHI may comprise a compound selected from the group consisting of poly(vinylcaprolactam) (PVCap), polyvinylpyrrolidone, poly(vinylvalerolactam), poly(vinylazacyclooctanone), co-polymers of vinylpyrrolidone and vinylcaprolactam, poly(N-methyl-N-vinylacetamide), co-polymers of N-methyl-N-vinylacetamide and acryloyl piperidine, co-polymers of N-methyl-N-vinylacetamide and isopropyl methacrylamide, co-polymers of N-methyl-N-vinylacetamide and methacryloyl pyrrolidine, and combinations thereof. Alternatively or in addition the at least one KHI may comprise a compound selected from the group consisting of copolymers of acryloyl pyrrolidine and N-methyl-N-vinylacetamide, derivatives and mixtures thereof.
[0026] Alternatively or in addition the at least one KHI may comprise acrylamide/maleimide co-polymers such as dimethylacrylamide (DMAM) co-polymerized with, for example, maleimide (ME), ethyl maleimide (EME), propyl maleimide (PME), and butyl maleimide (BME). Alternatively or in addition the at least one KHI may comprise acrylamide/maleimide co-polymers such as DMAM/methyl maleimide (DMAM/MME), and DMAM/cyclohexyl maleimide (DMAM/CHME), N-vinyl amide/maleimide co-polymers such as N-methyl-N-vinylacetamide/ethyl maleimide (VIMA/EME), and lactam maleimide co-polymers such as vinylcaprolactam ethylmaleimide (VCap/EME). Alternatively or in addition the at least one KHI may comprise polymers such as polyvinyl alcohols and derivatives thereof, polyamines and derivatives thereof, polycaprolactams and derivatives thereof, polymers and co-polymers of maleimides, acrylamides and mixtures thereof.
[0027] The mass of aqueous fluid may further comprise at least one thermodynamic hydrate inhibitor (THI), such as MEG. Such a THI may be comprised in the mass of aqueous fluid further to the like of MEG used as a KHI polymer solvent. THIs and KHIs may both be employed to address the problem of gas hydrate formation. Depending on circumstances as much THI as produced water or perhaps even more THI may be used in oil production processes. The use of such significant volumes of THI imposes a considerable capital expenditure and operational expenditure burden with regards to both introduction of THI to the process and separation of THI from the produced oil. A comparatively small amount of KHI may provide for a significant reduction in the amount of a THI, such as MEG, required to provide a desired hydrate formation inhibition effect. For example it has been found that as little as 1% KHI can provide for a 20 to 40 weight percent reduction in MEG used. However and as mentioned above the use of KHI in addition to THI presents problems with regards to, for example, the adverse impact of the KHI on: the environment; processing equipment, such as MEG regeneration units; and downhole formations where there is reinjection of produced water. The present invention addresses such problems by removing KHI and may thereby provide for the use of KHI in combination with THI to reduce significantly the volume of THI used in oil or gas production processes.
[0028] The method according to the present invention may form part of an oil or gas production or exploration process. Therefore according to a second aspect of the present invention there is provided an oil or gas production or exploration method comprising the method according to the first aspect of the present invention.
[0029] More specifically the method may further comprise introducing at least one KHI to a conduit, such as a flow line comprised in an oil or gas production or exploration facility which is susceptible to gas hydrate formation. The at least one KHI may disperse in a mass of aqueous fluid, such as produced water, present in the oil or gas production or exploration facility. The method may further comprise introducing the organic compound at processing apparatus comprised in the oil or gas production or exploration facility. The processing apparatus may, for example, comprise a separator and the organic compound may be introduced upstream or preferably downstream of the separator.
[0030] The oil or gas production or exploration method may further comprise a KHI removal step as described with reference to the first aspect of the present invention. The KHI removal step may be performed by a separation process, which may be performed upstream of a regeneration process described further below. Oil or gas production or exploration facilities normally comprise a separator which is operative to separate well fluids into gaseous and liquid components. Two phase separators are often employed in gas recovery and three phase separators are often employed in oil recovery. More specifically the separator is normally operative to separate gaseous components and liquid components in gas recovery and to separate gaseous components, oil and water in oil recovery. The liquid component in two phase separation and the water component in three phase separation may comprise two phases, namely a first aqueous phase and a second liquid phase comprising the organic compound and the KHI. The KHI removal step may be performed in a primary separator, e.g. a two or three phase separator, configured to further separate the first and second liquid phases from each other. Alternatively or in addition the KHI removal step may be performed in a KHI separator operative downstream of the primary separator. Furthermore the organic compound may be introduced to the mass of aqueous fluid, e.g. the liquid component or water component, after primary separation.
[0031] The oil or gas production or exploration method may yet further comprise disposal of the first aqueous phase after the KHI removal step. Disposal might, for example, comprise dumping the first aqueous phase overboard. Alternatively or in addition the oil or gas production or exploration method may yet further comprise reinjection of the first aqueous phase after the KHI removal step. Disposal normally requires higher purity of the first aqueous phase than reinjection. In methods comprising such further steps KHI may be substantially the only hydrate inhibitor employed. In methods comprising the latter step, i.e. reinjection, the aqueous fluid may comprise condensed water and perhaps also formation water. Alternatively or in addition the first aqueous phase after separation from the second KHI comprising phase may be subject to a THI regeneration process where a THI has been introduced to the oil or gas production or exploration facility. After primary separation the THI is normally comprised in the liquid component in two phase separation and in the water component in three phase separation. After the KHI removal step the THI is normally comprised in the first aqueous phase. The oil or gas production or exploration facility may therefore comprise THI regeneration apparatus, such as a MEG regeneration unit, which is operative on the first aqueous phase. As will be familiar to the notionally skilled reader, THI regeneration apparatus is operative to transform rich, i.e. contaminated, THI to lean, i.e. clean, THI. Rich THI comprises water which is driven off by the regeneration apparatus heating the rich THI. The regeneration apparatus may further provide for removal of salt comprised in the rich THI. Salt laden THI is normally more problematic in oil production than gas production on account of the former involving recovery of salt laden produced water along with the oil. Rich THI may also comprise small amounts of hydrocarbons present on account of partial or incomplete separation. The regeneration apparatus may therefore further comprise hydrocarbon removal apparatus which is operative to remove hydrocarbons, e.g. in the form of vapour or liquid, from the rich THI. The hydrocarbon removal apparatus may be operative on rich THI before heating of the rich THI to drive off the water. The hydrocarbon removal apparatus may, for example, be a flash vessel. The oil or gas production or exploration method may therefore further comprise a THI regeneration process which is operative to transform used THI. In summary THI regeneration may be carried out with a reduced risk of fouling of regeneration apparatus on account of prior removal of KHI.
[0032] The aforegoing description is concerned primarily with oil or gas production. Nevertheless the present invention may also be applicable in exploration operations and in particular in well testing operations. The oil or gas production or exploration method may therefore comprise a well testing method. As will be familiar to the notionally skilled reader, well testing involves extracting hydrocarbon fluids from test wells to help determine the characteristics of a reservoir and thereby determine prospects for hydrocarbon recovery from the reservoir. Normally well testing facilities comprise a mobile two or three phase separator which is operative on produced well fluids. Water separated by the separator is normally disposed overboard because there is no or limited facility for reinjection, treatment or storage. A THI, which is typically methanol, is normally used to address hydrate formation. Environmental considerations impose limits on the amount of methanol that can be used. Likewise environmental considerations normally preclude or limit the use of KHIs. However the capability of the present invention to remove KHI provides for the use of KHI in combination with methanol to reduce significantly the volume of methanol used during well testing. The well testing method may therefore comprise the method of treating aqueous fluid and the step of removing KHI from the treated aqueous fluid as described above with reference to the first aspect of the present invention. More specifically the well testing method may comprise producing oil or gas from a test well, adding the organic compound to at least one of formation and condensed water from the test well and removing a second KHI comprising phase from a first aqueous phase after addition of the organic compound. The first aqueous phase may comprise THI, e.g. methanol, of a volume lower than that required had no KHI been present. The well testing method may further comprise disposing of the first aqueous phase, e.g. by disposal overboard.
[0033] Further embodiments of the second aspect of the present invention may comprise one or more features of the first aspect of the present invention.
[0034] According to a third aspect of the present invention there is provided apparatus for treating aqueous fluid, the apparatus comprising a vessel, such as a flow line comprised in an oil or gas production or exploration facility, containing a mass of aqueous fluid comprising at least one Kinetic Hydrate Inhibitor (KHI), and an arrangement configured to introduce an organic compound to the mass of aqueous fluid contained in the vessel, the organic compound comprising a hydrophobic tail and a hydrophilic head, the hydrophobic tail comprising at least one C—H bond and the hydrophilic head comprising at least one of: a hydroxyl (—OH) group; and a carboxyl (—COOH) group.
[0035] The apparatus for treating aqueous fluid may further comprise a separator, such as a two or three phase separator as described above. Alternatively or in addition the apparatus for treating aqueous fluid may further comprise THI regeneration apparatus as described above. Furthermore the THI regeneration apparatus may be configured to add the organic compound to the mass of aqueous fluid, e.g. to the liquid component from a two phase separator or to the water component from a three phase separator, before the aqueous fluid is subject to regeneration of THI, e.g. by heating to drive off water. THI regeneration apparatus may further comprise a KHI separator which is operative after addition of the organic compound to separate a first aqueous phase and a second liquid phase from each other, the second liquid phase comprising the organic compound and the KHI.
[0036] The apparatus may further comprise a second KHI separator which is operative after addition of a second organic compound of a form described elsewhere herein to separate a first aqueous phase and a second liquid phase from each other, the second liquid phase comprising the KHI. The second organic compound may therefore be operative to remove KHI remaining after a primary removal and separation process involving addition of the first organic compound with the second KHI separator providing for physical separation of the two phases formed following addition of the second organic compound.
[0037] Further embodiments of the third aspect of the present invention may comprise one or more features of the first or second aspect of the present invention.
[0038] According to a fourth aspect of the present invention there is provided THI regeneration apparatus comprising apparatus for treating aqueous fluid according to the third aspect of the present invention. Embodiments of the fourth aspect of the present invention may comprise one or more features of any previous aspect of the present invention.
[0039] According to a further aspect of the present invention there is provided a method of treating aqueous fluid, the method comprising adding an organic compound to a mass of aqueous fluid comprising a water miscible polymer, such as a water miscible synthetic polymer, the organic compound comprising a hydrophobic tail and a hydrophilic head, the hydrophobic tail comprising at least one C—H bond and the hydrophilic head comprising at least one of: a hydroxyl (—OH) group; and a carboxyl (—COOH) group. Embodiments of the further aspect of the present invention may comprise one or more features of any previous aspect of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0040] The present invention will now be described by way of example only with reference to the following drawings, of which:
[0041] FIG. 1 shows an oil or gas production facility comprising apparatus according to the present invention;
[0042] FIG. 2 is a graph showing plots of alcohol carbon number versus a) miscibility in water by mass and b) effectiveness of removal of PVCap from water;
[0043] FIG. 3 is a graph showing plots of carboxylic acid carbon number versus a) miscibility in water by mass and b) effectiveness of removal of PVCap from water; and
[0044] FIG. 4 shows a separator arrangement and a MEG regeneration unit comprised in apparatus according to the present invention.
DESCRIPTION OF EMBODIMENTS
[0045] An oil or gas production facility 10 is shown in FIG. 1 . The oil or gas production facility 10 comprises a reservoir 12 containing reserves of oil and/or gas which is located below the seabed 14 , an offshore platform 16 which is present above the sea surface 18 and well bores 20 which provide for fluid communication between the reservoir 12 and the platform 16 . The oil or gas production facility 10 further comprises an onshore processing facility 22 which is in fluid communication with the platform 16 by way of a main pipeline 24 . In practice the main pipeline is normally located on or in the seabed 14 . However to provide for clarity of illustration the main pipeline 24 is shown above the sea surface 18 . The oil or gas production facility 10 also comprises a KHI storage tank 26 on the offshore platform 16 . The KHI storage tank 26 is in fluid communication with the platform end of the main pipeline 24 by way of a control valve and pumping apparatus. In addition the oil or gas production facility 10 comprises a treatment fluid storage tank 28 , which is in fluid communication with the onshore processing facility 22 , and a used KHI polymer storage tank 30 , which is in fluid communication with the onshore processing facility 22 .
[0046] A method according to a first embodiment of the present invention will now be described with reference to FIG. 1 . A vendor delivers a KHI formulation to the operator of the oil or gas production facility 10 . The KHI formulation is of known form. For example the KHI formulation comprises a water miscible polymer such as polyvinylcaprolactam (PVCap) and a water miscible polymer solvent such as a low molecular weight alcohol, a glycol or a glycol ether. The water miscible polymer makes up less than half of the KHI formulation with the remainder comprising the polymer solvent. The operator puts the KHI formulation in the KHI storage tank 26 on the offshore platform 16 . The KHI formulation is introduced to the main pipeline 24 by way of operation of the control valve and pumping apparatus. Alternatively the KHI formulation is injected at the wellhead or downhole. The volume and rate of introduction of KHI formulation are determined in dependence on the extent of gas hydrate formation risk in the main pipeline and the onshore processing facility 22 . A treatment fluid (which constitutes an organic compound) is stored in the treatment fluid storage tank 28 . Further details of the treatment fluid are provided below. When treatment of produced water is required to remove KHI polymer present in produced water, treatment fluid is introduced from the treatment fluid storage tank 28 and added to a mass of produced water (which constitutes a mass of aqueous fluid) contained in the onshore processing facility 22 . The treatment fluid forms a second, substantially non-polar phase apart from the first, substantially polar phase comprising the produced water and as it does the structure of the treatment fluid is such as to cause the transfer of the KHI polymer from the polar phase to the non-polar phase formed by the treatment fluid. The two phases separate from each other on account of their different densities. Then the second, substantially non-polar phase is removed from the first, substantially polar phase by gravity separation, liquid to liquid coalescing separation or centrifugal separation and stored in the used KHI polymer storage tank 30 . The second phase contained in the used KHI polymer storage tank 30 is then disposed of, e.g. by incineration. The now treated produced water may then be used or further processed as described below with reference to FIG. 4 .
[0047] The treatment fluid will now be described in more detail. In one form the treatment fluid is an alcohol having the general formula R—OH, where R has the formula C n H m . Higher molecular weight alcohols, such as butanol and higher and more particularly alcohols with a carbon number of five or more, have been found to be effective at displacing KHI polymer from produced water. This is because low molecular weight alcohols do not form a separate phase. Pentanol has a low degree of miscibility with water, i.e. about 2% by mass. Excess pentanol results in separation into a pentanol rich phase and a water rich phase. Furthermore excess pentanol results in KHI polymer displacement from the water rich phase to the pentanol phase. Pentanol has been found to displace more than 90% of PVCap in water. Generally KHI polymer displacement has been found to improve as the carbon number increases. Furthermore an increase in carbon number provides for an increase in miscibility with KHI polymers, a decrease in volatility and a decrease in its solubility in the aqueous phase which provide for improved performance. Octanol, which is almost immiscible with water at a solubility of substantially 30 mg of octanol per litre of water, has been found to completely displace KHI polymer from aqueous solution. Alcohols with yet higher carbon numbers can be used to displace KHI polymers. However alcohols with a carbon number of more than eleven are solid under standard conditions and therefore less readily usable. Tests have demonstrated that the presence of other water soluble organic compounds, such as MEG and ethanol, and inorganic salts, such as sodium chloride, have little or no appreciable effect on the displacement of KHI polymer from produced water.
[0048] A graph showing plots of alcohol carbon number versus a) miscibility in water by mass and b) effectiveness of removal of PVCap from water can be seen in FIG. 2 . A first plot shows miscibility in water by mass with alcohols with a carbon number of three or less being completely or nearly completely miscible with water. The first plot shows the miscibility to drop to about 2% for pentanol and to drop yet further to about 0.5% for hexanol. A second plot shows the percentage of PVCap removed from water with an alcohol carbon number of three or less providing for minimal or no removal of PVCap. Higher alcohol carbon numbers provide for an increase in removal with a carbon number of 5, i.e. pentanol, providing for a significant improvement at over 90% removal of PVCap. Alcohols with a carbon number of six or seven demonstrate yet further improvement. Hexanol removes 0.5 wt % PVCap for at least 0.5 wt % of hexanol added.
[0049] In another form the treatment fluid is a glycol ether. Thus the treatment fluid comprises: at least one pair of hydrocarbon groups bonded to each other by way of an oxygen atom; and one hydrocarbon group comprising a single hydroxyl (OH) group. Example glycol ethers include: ethylene glycol monoethyl ether; ethylene glycol monopropyl ether; ethylene glycol monobutyl ether; ethylene glycol monophenyl ether; ethylene glycol monobenzyl ether; diethylene glycol monomethyl ether; diethylene glycol monoethyl ether; and diethylene glycol mono-n-butyl ether. Glycol ethers having a carbon number of at least six have been found to be effective at displacing KHI polymers. It is believed that a higher carbon number is required of glycol ethers than alcohols on account of the presence of the oxygen atom in the glycol ether between hydrocarbon groups which is operative to increase the miscibility of the hydrophobic tail of the glycol ether; a longer hydrophobic tail is therefore required to compensate for the increase in miscibility.
[0050] In another form the treatment fluid is a carboxylic acid having the general formula R—COOH, where R is a monovalent functional group. Higher molecular weight carboxylic acids, such as pentanoic acid and higher, i.e. carboxylic acids with a carbon number of five or more, have been found to be effective at displacing KHI polymer from produced water. This is because low molecular weight carboxylic acids do not form a separate phase. Pentanoic acid has a low degree of miscibility with water, i.e. about 5% by mass. Excess pentanoic acid results in separation into a pentanoic acid rich phase and a water rich phase. Furthermore excess pentanoic acid results in KHI polymer displacement from the water rich phase to the pentanoic acid phase. Pentanoic acid has been found to displace about 90% of PVCap in water. Generally KHI polymer displacement has been found to improve as the carbon number increases. Furthermore an increase in carbon number provides for an increase in miscibility with KHI polymers, a decrease in volatility and a decrease in its solubility in the aqueous phase which provide for improved performance. Octanoic acid, which is almost immiscible with water at a solubility of substantially 0.68 g of octanoic acid per litre of water, has been found to substantially displace KHI polymer from aqueous solution. Carboxylic acids with yet higher carbon numbers can be used to displace KHI polymers. However carboxylic acids with a carbon number of more than nine are solid under standard conditions and therefore less readily usable. Tests have demonstrated that the presence of other water soluble organic compounds, such as MEG and ethanol, and inorganic salts, such as sodium chloride, have little or no appreciable effect on the displacement of KHI polymer from produced water.
[0051] A graph showing plots of carboxylic acid carbon number versus a) miscibility in water by mass and b) effectiveness of removal of PVCap from water can be seen in FIG. 3 . A first plot shows miscibility in water by mass with the miscibility dropping to about 5% for pentanoic acid and dropping yet further to about 0.25% for heptanoic acid. A second plot shows the percentage of PVCap removed from water with an carboxylic acid carbon number of four or less providing for minimal or no removal of PVCap. Higher carboxylic acid carbon numbers provide for an increase in removal with a carbon number of five, i.e. pentanoic acid, providing for a significant improvement at about 90% removal of PVCap. Carboxylic acids with a carbon number of six or seven demonstrate yet further improvement. Heptanoic removes more than 99% of PVCap.
[0052] According to yet another form the treatment fluid comprises a second organic compound of lower density than the first organic compound (i.e. the alcohol, glycol ether or carboxylic acid described above). In one approach and where the first organic compound is heptanol or heptanoic acid, the treatment fluid comprises a substantially equivalent volume of heptane. The presence of heptane in the treatment fluid has been found to aid separation into two phases and with substantially no reduction in movement of KHI from the phase constituted by the mass of aqueous fluid to the phase constituted by the first organic compound. Aiding separation by way of the second organic compound provides for ease of physical separation as described above with reference to FIG. 1 and which takes place in the KHI separator 44 which is described below with reference to FIG. 4 . According to another approach the treatment fluid comprises 80% volume of heptane and 20% volume of heptanol. According to yet another approach the treatment fluid comprises no more than 50% volume of heptane with the balance being heptanoic acid. Movement of KHI from the phase constituted by the mass of aqueous has been found to be substantially unaffected by the reduction in the percentage volume of heptanol or heptanoic acid. Furthermore a second organic compound such as heptane is normally of lower cost than a first organic compound such as heptanol or heptanoic acid. Increasing the percentage volume of the second organic compound therefore provides a cost benefit. According to yet another approach the treatment fluid comprises plural second organic compounds, such as a mixture of hexane and heptane. The first and second organic compounds are mixed with each other and added together. Alternatively a further volume of the second organic compound is added after addition of the mixture of the first and second organic compounds and after physical separation of the two phases formed following addition of the mixture of the first and second organic compounds. The addition of the further volume of the second organic compound provides for removal of whatever KHI and first organic compound remains, e.g. in the form of a cloudy suspension. Alternatively the second organic compound is not mixed with the first organic compound with the first organic compound being added alone as part of a first KHI removal stage and the second organic compound being added subsequently as part of a second KHI removal stage. Subsequent addition of the second organic compound provides for removal of KHI and first organic compound remaining, for example, in the form of a cloudy suspension.
[0053] A method according to a second embodiment of the present invention will now be described with reference to FIG. 1 . The second embodiment involves determining the concentration of KHI polymer in the produced water. The method according to the second embodiment is as follows. A small sample, e.g. 1000 g, of produced water is removed at the onshore processing facility 22 . Where the small sample of produced water contains about 0.1 mass percent of KHI polymer, the addition of 5.0 g of octanol or heptanoic acid to the sample displaces substantially all of the KHI polymer to an octanol or heptanoic acid rich phase and yields a KHI polymer concentrated octanol or heptanoic acid phase of substantially 17 mass percent of KHI polymer. The concentration of KHI polymer in the octanol or heptanoic acid rich phase is then determined accurately by a known method, such as by InfraRed (IR) spectrometry, UltraViolet (UV) spectrometry or visual spectrometry. Alternatively the octanol or heptanoic acid is removed from the respective octanol or heptanoic acid rich phase, e.g. by heating the octanol or heptanoic acid rich phase to drive off the octanol or heptanoic acid, to leave the KHI polymer behind. The remaining KHI polymer is then weighed. The concentration of the KHI polymer in the octanol or heptanoic acid phase makes accurate determination of the mass fraction straightforward whereby the concentration of KHI polymer in the produced water is calculated readily on the basis of simple mass balance.
[0054] An example separator arrangement and a MEG regeneration unit, which are comprised in apparatus according to the present invention, are shown in FIG. 4 . In a first form the apparatus of FIG. 4 is comprised in the onshore processing facility 22 of FIG. 1 . In a second form suited for a well testing process part of the apparatus of FIG. 4 is comprised in or adjacent the offshore platform 16 .
[0055] Considering the first form of the apparatus of FIG. 4 further, FIG. 4 shows a conventional separator 40 , which is either a two phase separator used in gas production or a three phase separator used in oil production. The two phase separator is operative to receive produced fluid and to separate the fluid into a gaseous component and a liquid component. The liquid component which comprises mainly condensed water is then received in a treatment fluid receiving chamber 42 . The gaseous component is conveyed away from the separator 40 for further processing. The three phase separator is operative to receive produced fluid and to separate the fluid into a gaseous component, an oil component and a water comprising component. The gaseous component is either conveyed away from the separator 40 for flaring or subsequent processing and the oil component is conveyed away from the separator 40 for further processing. The water comprising component, which is normally salt laden on account of the produced water comprised in this component, is conveyed away from the separator 40 to the treatment fluid receiving chamber 42 . Treatment chemical or fluid is introduced to the treatment fluid receiving chamber 42 from the treatment fluid storage tank 28 as described above with reference to FIG. 1 . The contents of the treatment fluid receiving chamber 42 are then conveyed to a KHI separator 44 . The KHI separator 44 is operative to remove the second, substantially non-polar phase, which comprises the KHI polymer, from the first, substantially polar aqueous phase. As described above with reference to FIG. 1 , the KHI separator 44 is operative by one or more of gravity separation, liquid to liquid coalescing separation and centrifugal separation. Where gravity separation is used, the process can be assisted by introducing gas bubbles to lighten the hydrocarbon phase or by adjusting the temperature. Such separation techniques will be familiar to the person skilled in the art. The second, substantially non-polar phase is then conveyed from the KHI separator 44 to the used KHI polymer storage tank 30 . The first, substantially polar aqueous phase is conveyed from the KHI separator 44 and then used or further processed depending on the application to hand. Where the process comprises the addition of a second organic compound subsequent to the addition of the first organic compound, the apparatus of FIG. 4 further comprises a second treatment fluid receiving chamber (not shown) immediately after and in fluid communication with the KHI separator 44 and which is fed from a second treatment fluid storage tank (not shown). In addition the apparatus of FIG. 4 further comprises a second KHI separator (not shown) immediately after and in fluid communication with the second treatment fluid receiving chamber. The second treatment fluid storage tank is filled with the second organic compound which is then fed therefrom into the second treatment fluid receiving chamber where it mixes with fluid received from the first KHI separator 44 . Two phases are thus formed and are separated from each other in the second KHI separator, with the remaining KHI and first organic compound containing phase being conveyed to the used KHI polymer storage tank 30 . The other phase, i.e. the now further treated first, substantially polar aqueous phase, is conveyed from the second KHI separator and then used or further processed depending on the application to hand. According to a first application the first, substantially polar aqueous phase is re-injected 46 into the reservoir formation. The first application is of particular utility where the aqueous fluid comprises condensed water and perhaps also formation water. According to a second application the first, substantially polar aqueous phase is disposed overboard 48 . In a third application in which the first, substantially polar aqueous phase comprises THI and perhaps a significant proportion of THI, the first, substantially polar aqueous phase is conveyed from the KHI separator 44 to a THI regeneration unit 50 . The THI regeneration unit 50 is operative in accordance with known practice to transform rich THI to lean THI by driving off water from the first, substantially polar aqueous phase. The lean THI is then re-used subject, if necessary, to further processing to remove hydrocarbons present. The driven off water is then either disposed of, e.g. overboard, or used for re-injection. Considering FIG. 4 yet further apparatus according to an embodiment of the present invention is constituted by the treatment fluid receiving chamber 42 , the KHI separator 44 and the THI regeneration unit 50 , which together constitute improved THI regeneration apparatus.
[0056] Considering the second form of the apparatus of FIG. 4 further, a mixture of KHI and THI (e.g., in the form of methanol) are introduced to well fluids present in a well testing process to reduce the likelihood of hydrate formation, with the KHI affording a reduction in the volume of methanol employed. After use the well fluids are conveyed to the separator 40 which is constituted as a mobile unit present on or adjacent the offshore platform 16 . After separation the aqueous component is conveyed to the treatment fluid receiving chamber 42 and treated with treatment fluid as described above before being conveyed to the KHI separator 44 for removal of the first, substantially polar aqueous phase and second, substantially non-polar phase from each other. This second form of the apparatus lacks the THI regeneration unit 50 with the first, substantially polar aqueous phase, which comprises methanol albeit a reduced volume of methanol on account of the previously present KHI, being disposed of overboard 48 and the second, substantially non-polar phase, which comprises the KHI, being collected in the used KHI polymer storage tank 30 . According to an alternative approach where operating conditions allow, inhibition is provided by way of KHI alone, i.e. no THI such as methanol is used. Otherwise the process is as described above with the KHI being separated following treatment with treatment fluid.
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The present invention relates to a method of treating aqueous fluid and apparatus therefor. The method comprises adding an organic compound to a mass of aqueous fluid comprising at least one Kinetic Hydrate Inhibitor (KHI). The organic compound comprises a hydrophobic tail and a hydrophilic head. The hydrophobic tail comprises at least one C—H bond and the hydrophilic head comprises at least one of: a hydroxyl (—OH) group; and a carboxyl (—COOH) group.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/198,129 filed Aug. 26, 2008 and entitled “DETECTING GAS COMPOUNDS FOR DOWNHOLE FLUID ANALYSIS,” which is hereby incorporated in its entirety by this reference.
FIELD OF THE INVENTION
[0002] The invention is generally related to downhole fluid analysis, and more particularly to in situ detection of gaseous compounds in a borehole fluid.
BACKGROUND OF THE INVENTION
[0003] Phase behavior and chemical composition of borehole fluids are used to help estimate the viability of some hydrocarbon reservoirs. For example, the concentration of gaseous components such as carbon dioxide, hydrogen sulfide and methane in borehole fluids are indicators of the economic viability of a hydrocarbon reservoir. The concentrations of various different gasses may be of interest for different reasons. For example, CO 2 corrosion and H 2 S stress cracking are leading causes of mechanical failure of production equipment. CH 4 is of interest as an indicator of the calorific value of a gas well. It is therefore desireable to be able to perform fluid analysis quickly, accurately, reliably, and at low cost.
[0004] A variety of techniques and equipment are available for performing fluid analysis in a laboratory. However, retreiving samples for laboratory analysis are time consuming. Further, some characteristics of borehole fluids change when brought to the surface due to the difference in environmental conditions between a borehole and the surface and other factors. For example, because hydrogen sulfide gas readily forms non-volatile and insoluble metal sulfides by reaction with many metals and metal oxides, analysis of a fluid sample retreived with a metallic container can result in an inaccurate estimate of sulfide content. This presents a technological problem because known fluid analysis techniques that can be used at the surface are impractical in the borehole environment due to size limitations, extreme temperature, extreme pressure, presence of water, and other factors. Another technological problem is isolation of gases, and particular species of gas, from the borehole fluid.
[0005] The technological problems associated with detection of gas in fluids have been studied in this and other fields of research. For example, US20040045350A1, US20030206026A1, US20020121370A1, GB2415047A, GB2363809A, GB2359631A, US6995360B2, US6939717B2, W02005066618A1, W02005017514A1, W02005121779A1, US20050269499A1, and US20030134426A1 describe an electrochemical method for H2S detection using membrane separation. US20040045350A1, GB2415047A, and GB2371621A describe detecting gas compounds by combining infrared spectrophotometry and a membrane separation process. US20060008913 A1 describes the use of a perfluoro-based polymer for oil-water separation in microfluidic system.
SUMMARY OF THE INVENTION
[0006] In accordance with an embodiment of the invention, apparatus for performing in situ analysis of borehole fluid includes a gas separation system and a gas detection system. The gas separation system may include a membrane. The gas separated from the fluid by the membrane may be detected by techniques such as reaction with another material or spectroscopy. When spectroscopy is employed, a test chamber is used to hold the gas undergoing test. Various techniques may be employed to protect the gas separation system from damage due to pressure differential. For example, a separation membrane may be integrated with layers that provide strength and rigidity. The integrated separation membrane may include one or more of a water impermeable layer, gas selective layer, inorganic base layer and metal support layer. The gas selective layer itself can also function as a water impermeable layer. The metal support layer enhances resistance to differential pressure. Alternatively, the test chamber may be filled with a liquid or solid material.
[0007] In accordance with another embodiment of the invention, a method for downhole fluid analysis comprises: sampling a downhole fluid; taking a gas from the downhole fluid by using a gas separation module; and sensing the gas.
[0008] One of the advantages of the invention is that borehole fluid can be analyzed in situ. In particular, gas is separated from the fluid and detected within the borehole. Consequently, time consuming fluid retrieval and errors caused by changes to fluid samples due to changes in conditions between the borehole and the environment are at least mitigated.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 illustrates a logging tool for gas separation and detection in a borehole.
[0010] FIG. 2 illustrates an embodiment of the tool for gas separation and detection in greater detail.
[0011] FIG. 3 illustrates an embodiment of the gas separation and detection tool of FIG. 2 having a gas separation membrane and spectroscopy sensor.
[0012] FIG. 4 illustrates alternative embodiments of the gas separation and detection tool, both with and without sampling chamber.
[0013] FIG. 5 illustrates embodiments of the gas separation and detection tool with different integrated membranes.
[0014] FIG. 6 illustrates embodiments of the integrated membrane in greater detail.
[0015] FIG. 7 illustrates another alternative embodiment of the gas separation and detection tool with an integrated membrane.
[0016] FIG. 8 illustrates an embodiment of the gas separation and detection tool with a fluidic buffer.
[0017] FIG. 9 illustrates a solid state embodiment of the gas separation and detection tool.
[0018] FIG. 10 illustrates an alternative embodiment of the gas separation and detection tool.
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 , a wireline logging tool ( 106 ) is suspended from an armored cable ( 108 ), and may have optional centralizers (not shown). The cable ( 108 ) extends from the borehole ( 104 ) over a sheave wheel ( 110 ) on a derrick ( 112 ) to a winch forming part of surface equipment, which may include an analyzer unit ( 114 ). Well known depth gauging equipment (not shown) may be provided to measure cable displacement over the sheave wheel ( 110 ). The tool ( 106 ) may include any of many well known devices to produce a signal indicating tool orientation. Processing and interface circuitry within the tool ( 106 ) amplifies samples and digitizes the tool's information signals for transmission and communicates them to the analyzer unit ( 114 ) via the cable ( 108 ). Electrical power and control signals for coordinating operation of the tool ( 106 ) may be generated by the analyzer unit ( 114 ) or some other device, and communicated via the cable ( 108 ) to circuitry provided within the tool ( 106 ). The surface equipment includes a processor subsystem ( 116 ) (which may include a microprocessor, memory, clock and timing, and input/output functions—not separately shown), standard peripheral equipment (not separately shown), and a recorder ( 118 ). The logging tool ( 106 ) is representative of any logging device that may be used in accordance with principles described herein. It will be understood by those of skill in the art having the benefit of this disclosure that the gas separation and detection tool described in detail below can be implemented as a wireline, MWD, LWD, or other type of tool, including but not limited to tools mounted in the formation or mounted in a completion of the borehole to perform ongoing measurements over time.
[0020] Referring to FIG. 2 , an embodiment of the gas separation and detection tool includes a separation module ( 200 ) and a detection module ( 202 ). A test chamber ( 204 ) may also be defined between the separation module and detection module. Gas that is present in a borehole fluid in a flowline ( 206 ) enters the chamber via the separation module, i.e., the gas is separated from the fluid in the flowline. Differential pressure between the flow line and the chamber may facilitate gas separation. The detection module subjects the separated gas in the chamber to a testing regime which results in production of an indicator signal ( 208 ). The indicator signal is provided to interpretation circuitry ( 210 ) which characterizes the gas sample, e.g., in terms of type and concentration.
[0021] Referring to FIGS. 2 and 3 , the separation module may include a membrane ( 300 ). The membrane has characteristics that inhibit traversal by all but one or more selected compounds. One embodiment of the membrane ( 300 ) is an inorganic, gas-selective, molecular separation membrane having alumina as its base structure, e.g., a DDR type zeolite membrane. Nanoporous zeolite material is grown on the top of the base material. Examples of such membranes are described in US20050229779A1, US6953493B2 and US20040173094A1. The membrane has a pore size of about 0.3-0.7 nm, resulting in a strong affinity towards specific gas compounds such as CO2. Further enhancement of separation and selectivity characteristics of the membrane can be accomplished by modifying the surface structure. For example, a water-impermeable layer such as a perfluoro-based polymer (e.g. Teflon AF or its variations), polydimethyl siloxane based polymer, polyimide-based polymer, polysulfone-based polymer or polyester-based polymer may be applied to inhibit water permeation through the membrane. Other variations of the separation membrane operate as either molecular sieves or adsoption-phase separation. These variations can formed of inorganic compounds, inorganic sol-gel, inorganic-organic hybrid compounds, inorganic base material with organic base compound impregnated inside the matrix, and any organic materials that satisfy requirements.
[0022] The chamber ( 204 ), if present, is defined by a rigid housing ( 302 ). The membrane ( 300 ) occupies an opening formed in the housing ( 302 ). The housing and membrane isolate the chamber from the fluid in the flowline, except with respect to compounds that can traverse the membrane. As already mentioned, when partial pressure of gas compounds is greater in the flowline than in the chamber, differential pressure drives gas from the flowline into the chamber. When the partial pressure is greater in the chamber than in the flowline, differential pressure drives gas from the chamber into the flowline. In this manner the chamber can be cleared in preparation for subsequent tests.
[0023] Operation of the detector module ( 202 ) may be based on techniques including but not limited to infrared (IR) absorption spectroscopy. An IR absorption detector module may include an infrared (IR) light source ( 304 ), a monitor photodetector (PD) ( 306 ), an IR detector ( 308 ), and an optical filter ( 310 ). The IR source ( 304 ) is disposed relative to the optical filter ( 310 ) and IR detector ( 308 ) such that light from the IR source that traverses the chamber ( 204 ), then traverses the filter (unless filtered), and then reaches the IR detector. The module may be tuned to the 4.3 micrometer wavelength region, or some other suitable wavelength. The monitor PD ( 306 ) detects the light source power directly, i.e., without first traversing the chamber, for temperature calibration. If multi-wavelength spectroscopy is used, e.g., for multi-gas detection or baseline measurement, several LEDs or LDs can be provided as light sources and a modulation technique can be employed to discriminate between detector signals corresponding to the different wavelengths. Further, spectroscopy with NIR and MIR wavelengths may alternatively be employed. In each of these variant embodiments the absorbed wavelength is used to identify the gas and the absorption coefficient is used to estimate gas concentration.
[0024] FIG. 4 illustrates embodiments of the invention both with and without a test chamber. These embodiments may operate on the principle of measuring electromotive force generated when the gas reacts with a detecting compound, i.e., the gas sensor module ( 202 ) includes a compound that reacts with the target gas. Because the electromotive force resulting from the reaction is proportional to the gas concentration, i.e., gas partial pressure inside the system, gas concentration in the flowline can be estimated from the measured electromotive force. Alternatively, these embodiments may operate on the principle of measuring resistivity change when the gas reacts with the detecting compound. Because the resistivity change is proportional to the gas concentration, i.e., gas partial pressure inside the system, gas concentration in the flowline can be estimated from the measured resistivity change.
[0025] Other features which enhance operation may also be utilized. For example, a water absorbent material ( 400 ) may be provided to absorb water vapor that might be produced from either permeation through the membrane or as a by product of the reaction of the gas with a detecting compound. Examples of water absorbant material include, but are not limited to, hygroscopic materials (silica gel, calcium sulfate, calcium chloride, montmorillonite clay, and molecular sieves), sulfonated aromatic hydrocarbons and Nafion composites. Another such feature is a metal mesh ( 402 ) which functions as a flame trap to help mitigate damage that might be caused when gas concentration changes greatly over a short span of time. Another such feature is an O-ring seal ( 404 ) disposed between the housing and the flowline to help protect detection and interpretation electronics ( 406 ). Materials suitable for construction of components of the gas sensor module include SnO2, doped with copper or tungsten, gold epoxy, gold, conductive and non-conductive polymer, glass, carbon compounds and carbon nanotube compounds for the purpose of proper sealing, maintaining good electrical connection, increasing sensitivity and obtaining stable measurements. The housing may be made of high performance thermoplastics, PEEK, Glass-PEEK, or metal alloys (Ni).
[0026] Referring to FIGS. 5 and 6 , various features may be employed to help protect the membrane from damage, e.g., due to the force caused by the pressure differential where the chamber contains only gas. One such feature is an integrated molecular separation membrane. The integrated membrane can include a water impermeable protective layer ( 500 ), a gas selective layer ( 502 ), an inorganic base layer ( 504 ) and a metal support layer ( 506 ). The metal support layer increases the mechanical strength of the membrane at high-pressure differentials. Gas permeates through the molecular separation layer and goes into the system via small holes in the metal support. In another embodiment the integrated molecular separation membrane includes a molecular separation membrane/layer bonded to a metal support layer and sealed with epoxy ( 508 ) or any other sealant. The epoxy can be a high temperature-resistant, non-conductive type of epoxy or other polymeric substances. The molecular separation layer can act as a water/oil separation membrane. Gas permeates through the molecular separation layer and goes into the system via small holes in the metal support. In another embodiment the integrated separation membrane includes a molecular separation membrane/layer bonded to a metal support layer and sealed with epoxy. The metal support is designed to accommodate insertion of the molecular separation membrane. The epoxy or sealant can be a high temperature, non-conductive type of epoxy or other polymeric substances. Gas permeates through the molecular separation layer and goes into the system via small holes in the metal support.
[0027] Referring to FIG. 7 , in an alternative embodiment the integrated membrane includes a molecular separation membrane/layer ( 700 ) bonded between porous metal plates ( 702 , 704 ). In addition to integrating the gas separation and pressure balancing functions into one mechanical assembly, this alternative embodiment provides support for the membrane both at a pressure differential where flowline pressure is greater than chamber pressure and at a pressure differential where chamber pressure is greater than flowline pressure.
[0028] Referring to FIG. 8 , an alternative embodiment utilizes an incompressible liquid buffer ( 800 ) to help prevent membrane damage due to pressure differential. The liquid buffer may be implemented with a liquid material that does not absorb the target gas. Because the liquid buffer is incompressible, buckling of the membrane due to the force caused by higher pressure in the flowline than in the chamber is inhibited when the chamber is filled with liquid buffer. A bellows can be provided to compensate for small changes in compressibility within the chamber due to, for example, introduction or discharge of the target gas. FIG. 8 illustrates a membrane and a spectrometer module, to which the above embodiments of FIGS. 2-7 can be applied either alone or in combination.
[0029] FIG. 9 illustrates an alternative embodiment that is different from the above embodiments of FIGS. 2-7 in utilizing a solid state chamber ( 900 ). The solid state chamber is formed by filling the cavity defined by the housing with a nanoporous solid material. Suitable materials include, but are not limited to, TiO 2 , which is transparent in the NIR and MIR range. The target gas which traverses the membrane enters the nanospace of the solid material. Since the chamber is solid state, buckling of the membrane due to higher pressure in the flowline than in the chamber is inhibited. However, because the chamber is porous, gas can be accommodated.
[0030] FIG. 10 illustrates another alternative embodiment of the gas separation and detection tool. The tool includes a non H2S-scavenging body ( 1000 ) with a gas separation module ( 200 ) which may include a membrane unit ( 1002 ) as illustrated in FIGS. 2-9 . The separated gas enters a test chamber defined by the body and membrane unit due to differential pressure. Optical fibre is used to facilitate gas detection. In particular, light from a lamp source ( 1004 ) is inputted to an optical fibre ( 1006 ), which is routed to one side of the chamber. A corresponding optical fibre ( 1008 ) is routed to the opposite side of the chamber, and transports received light to a receiver ( 1010 ). A microfluidic channel fibre alignment feature ( 1012 ) maintains alignment between the corresponding fibres ( 1006 , 1008 ). The arrangement may be utilized for any of various gas detection techniques based on spectroscopy, including but not limited to infrared (IR) absorption spectroscopy, NIR and MIR. In each of these variant embodiments the absorbed wavelength is used to identify the gas and the absorption coefficient is used to estimate gas concentration.
[0031] While the invention is described through the above exemplary embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Moreover, while the preferred embodiments are described in connection with various illustrative structures, one skilled in the art will recognize that the system may be embodied using a variety of specific structures. Accordingly, the invention should not be viewed as limited except by the scope and spirit of the appended claims.
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A gas separation and detection tool for performing in situ analysis of borehole fluid is described. The tool comprises a sampling chamber for a downhole fluid. The sample chamber comprises a detector cell with an opening. The tool also comprises a gas separation module for taking a gas from the downhole fluid. The gas separation module comprises a membrane located in the opening, a support for holding the membrane, and a sealant applied between the housing and the membrane or support. Moreover, the tool comprises a gas detector for sensing the gas.
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CROSS REFERENCE TO RELATED APPLICATIONS
This patent application is a divisional application of commonly-owned U.S. patent application Ser. No. 10/788,211 entitled “Ladder Support Apparatus and Methods” filed on Feb. 26, 2004 now U.S. Pat. No. 7,073,629, which application is incorporated herein by reference.
FIELD OF THE INVENTION
The present disclosure relates to ladder support apparatus, and more specifically, to support assemblies for ladders operating on a plurality of support members.
BACKGROUND OF THE INVENTION
Ladders are ubiquitous devices used in a wide variety of commercial and residential circumstances. In some applications, such as during the intermediate stages of construction of structures (e.g. houses, buildings, aircraft, etc.) it may be desirable for ladders to be used prior to the installation of a uniform floor surface. This may present a challenge because most ladders are not designed to operate in the absence of a uniform floor surface.
For example, certain painting and sealing operations on aircraft sections often involve working over open floor beams at heights requiring ladders. Due to the nature of the paint and seal process, the installation of temporary flooring may not be practical. In order to resolve this problem, step ladders have been equipped with elongated rails that have been bolted or nailed to the bottoms of the legs and which extend between and beyond the front and rear legs to serve as supports for the ladders over the open floor beams.
Although desirable results have been achieved using such prior art methods, there is room for improvement. For example, it is undesirable to permanently modify the ladder by bolting or nailing the elongated rails onto the legs for various reasons, including, for example, because the ladder is thereafter rendered unable to fold up for storage. The resulting ladder assembly thereafter requires additional storage space than unaltered ladders, and may be unsuitable for other applications in which ladders are required, such as in relatively small spaces. The transport of such ladder assemblies from one work area to another typically requires more effort than the transport of unaltered ladders. Therefore, ladder support apparatus and methods that at least partially mitigate these effects would be useful.
SUMMARY OF THE INVENTION
The present invention is directed to support assemblies for ladders operating on a plurality of support members. Apparatus and methods in accordance with the present invention may advantageously provide desired support for a ladder during operations over non-uniform surfaces (e.g. a plurality of floor beams) without permanent modification of the ladder, thereby allowing the ladder to be easily converted back to its original configuration for normal use, for transport, and for storage. These and other advantages may be achieved using embodiments of ladder support assemblies in accordance with the present invention.
In one embodiment, a method of operating a ladder, comprising: positioning a ladder having first and second pairs of legs in an operating position suitable for supporting a user; providing a ladder support assembly clampably coupled to the ladder, the ladder support assembly including at least one elongated member extending between a respective one of the first and second pairs of legs of the ladder, the elongated member being clampably coupled to the respective one of the first and second pairs of legs of the ladder by first and second coupling assemblies positioned at spaced-apart positions on the elongated member; and supporting the ladder with the ladder support assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention are described in detail below with reference to the following drawings.
FIG. 1 is an isometric view of a ladder assembly in accordance with an embodiment of the present invention;
FIG. 2 is an enlarged isometric view of a left front coupling assembly of the ladder support assembly of FIG. 1 ;
FIG. 3 is an enlarged isometric view of a left rear coupling assembly of the ladder support assembly of FIG. 1 ;
FIG. 4 is a first partially-exploded isometric view of the left front and left rear coupling assemblies of the ladder support assembly of FIG. 1 ;
FIG. 5 is a second partially-exploded isometric view of the left front and left rear coupling assemblies of the ladder support assembly of FIG. 1 ;
FIG. 6 is a third partially-exploded isometric view of the left front and left rear coupling assemblies of the ladder support assembly of FIG. 1 ;
FIG. 7 is a fourth partially-exploded isometric view of the left front and left rear coupling assemblies of the ladder support assembly of FIG. 1 ;
FIG. 8 is an enlarged isometric view of a channel end cap of the ladder support assembly of FIG. 1 ;
FIG. 9 is an isometric view of a ladder assembly in accordance with an alternate embodiment of the present invention;
FIG. 10 is an enlarged first isometric view of a clamping assembly of the ladder support assembly of FIG. 9 ;
FIG. 11 is an enlarged second isometric view of the clamping assembly of the ladder support assembly of FIG. 9 ;
FIG. 12 is an exploded view, a partially-exploded view, and an assembled view of one of the front coupling assemblies of FIG. 9 ;
FIG. 13 is an exploded view and an assembled view of a strut assembly of the ladder support assembly of FIG. 9 ;
FIG. 14 is an enlarged elevational view of a side brace assembly of the ladder support assembly 220 of FIG. 9 ;
FIG. 15 is an enlarged isometric view of a lower brace coupling assembly of the side brace assembly of FIG. 14 ; and
FIGS. 16 and 17 are exploded and assembled views of the lower and upper brace coupling assemblies of FIG. 15 .
DETAILED DESCRIPTION
The present invention relates to support assemblies for ladders operating on a plurality of support members. Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 1-17 to provide a thorough understanding of such embodiments. One skilled in the art, however, will understand that the present invention may have additional embodiments, or that the present invention may be practiced without several of the details described in the following description.
In general, ladder support assemblies in accordance with the present invention may be removably coupled to the ladder to provide a “floor” wherever it is needed, without altering the ladder itself in any way. Thus, the ladder support assembly may be coupled to the ladder when needed, such as while performing operations over open floor beams, and may be uncoupled from the ladder so that the ladder may be easily folded for transport and storage.
For example, FIG. 1 is an isometric view of a ladder assembly 100 in accordance with an embodiment of the present invention. In this embodiment, the ladder assembly 100 includes a ladder 102 having left and right front legs 104 , 106 , and left and right rear legs 108 , 110 . A ladder support assembly 120 includes a left elongated member 122 and a right elongated member 124 . Left and right front coupling assemblies 130 a , 130 b couple the left and right front legs 104 , 106 with the left and right elongated members 122 , 124 , and left and right rear coupling assemblies 140 a , 140 b couple the left and right rear legs 108 , 110 with the left and right elongated members 122 , 124 . The left and right elongated members 122 , 124 are engaged over a plurality of floor beams 126 . The bottoms of the elongated members 122 , 124 may coated with a layer 125 of a non-skid material, such as, for example, a spray-on polyurethane.
In the particular embodiment shown in FIG. 1 , the ladder 102 is “facing” in a direction that is approximately parallel with an interior wall 103 of an aircraft during an intermediate stage of assembly. It will be appreciated that the elongated members 122 , 124 are adapted to extend at least between the respective legs of the ladder 102 , and preferably, to extend between and beyond the respective legs of the ladder 102 in order to span a suitable number of floor beams 126 to provide stability to the ladder 102 . Thus, a user may use the ladder assembly 100 to perform certain manufacturing operations (e.g. painting and sealing operations) on the aircraft prior to the installation of temporary flooring on the floor beams 126 within the aircraft. It will be appreciated that the elongated members 122 , 124 may be any type of suitable elongated members, and that the invention is not limited to the particular embodiment shown in FIG. 1 . Thus, although the elongated members 122 , 124 shown in FIG. 1 are formed using an aluminum channel, in alternate embodiments, the elongated members could be formed from other members and other material types, including, for example, aluminum box section extrusion, steel members, or any other suitable members.
FIGS. 2 and 3 are enlarged isometric views of the left front and left rear coupling assemblies 130 a , 140 a of the ladder support assembly 120 of FIG. 1 . FIGS. 4-7 are partially-exploded isometric views of the left front and left rear coupling assemblies 130 a , 140 a of the ladder support assembly 120 of FIG. 1 . In this embodiment, the left front coupling assembly 130 a includes a slotted base 132 adapted to slideably engage into a channel 123 of the left elongated member 122 ( FIG. 2 ). An arm member 134 is slideably coupled to the base 132 , and a locking member 136 is coupled to the arm member 134 ( FIG. 7 ). In this embodiment, the locking member 136 projects transversely at an approximately right angle away from the arm member 134 .
As best shown in FIGS. 6 and 7 , a side rail 135 projects outwardly from the base 132 along the length of the channel 123 . A top rail 137 is engaged over an upper portion of the base 132 and laterally beyond the channel 123 to approximately the outer edges of the elongated member 122 ( FIG. 2 ). The arm member 134 is positioned on the top rail 137 , and a threaded member 138 is threadedly engaged through the arm member 134 and the top rail 137 to secure the arm member 134 and the top rail 137 in position on the base 132 ( FIGS. 2 and 7 ).
In operation, the left front coupling assembly 130 a is engaged with the left front leg 104 of the ladder 102 by positioning the base 132 into the channel 123 of the left elongated member 122 . The left front leg 104 is also placed in the channel 123 and is engaged against the base 132 . The locking member 136 and the side rail 135 are engaged against the left front leg 104 , and the threaded member 138 is tightened, thereby clamping the left front coupling assembly 130 a to the channel 123 and securing the left front leg 104 into position in the channel 123 . More specifically, the side rail 135 is engaged against the left front leg 104 , clamping the leg 104 against the side of the channel 123 and preventing lateral movement of the leg 104 within the channel 123 . The locking member 134 is engaged with the leg 104 , preventing the leg from lifting out of the channel 123 . The base 132 , the arm member 134 , and the locking member 136 cooperate to prevent the leg 104 from moving longitudinally along the length of the channel 123 .
Similarly, the left rear coupling assembly 140 a includes a slotted base 142 adapted to slideably engage into the channel 123 ( FIG. 3 ), and an arm member 144 slideably coupled to the base 142 . A locking member 146 is coupled to the arm member 144 and projects outwardly therefrom ( FIG. 6 ). A side rail 145 projects outwardly from the base 142 along the length of the channel 123 . A top rail 147 is engaged over the base 142 and extends laterally beyond the channel 123 to approximately the outer edges of the elongated member 122 ( FIG. 3 ). A threaded member 148 secures the arm member 144 and the top rail 147 in position on the base 142 ( FIGS. 2 and 7 ).
The operation of the rear coupling assembly 140 a is similar to the operation of the front coupling assembly 130 a described above. In brief, the left rear leg 108 is positioned in the channel 123 , and the base 142 is engaged into the channel 123 and abutted against the left rear leg 108 . The side rail 145 is engaged against the left rear leg 108 , clamping the leg 108 against the side of the channel 123 and preventing lateral movement of the leg 108 within the channel 123 . The locking member 144 is engaged with the left rear leg 108 , preventing the leg from lifting out of the channel 123 . The base 142 , the arm member 144 , and the locking member 146 cooperate to prevent the leg 108 from moving longitudinally along the length of the channel 123 of the elongated members 122 , 124 ( FIGS. 1 and 2 ).
FIG. 8 is an enlarged isometric view of a channel end cap 150 of the ladder support assembly 120 of FIG. 1 . After the front and rear leg coupling assemblies 130 , 140 are installed into the channel 123 of the first and second elongated members 122 , 124 , the channel end cap 150 is secured at each end of the elongated members 122 , 124 (two visible in FIG. 1 ).
With the ladder support assembly 120 coupled to the ladder 102 , the ladder 102 may be utilized on a variety of non-uniform support surfaces. For example, as shown in FIG. 1 , because the ladder 102 is supported by the elongated members 122 , 124 , the ladder 102 may be used over a plurality of floor beams 126 . Of course, it will be appreciated that the ladder support assembly 120 provides a stable support that enables the ladder 102 to be utilized on a variety of non-uniform support surfaces, and is not limited to the specific floor-beam example shown in FIG. 1 .
Embodiments of ladder support assemblies in accordance with the present invention may provide significant advantages over the prior art. For example, since the support assembly is clampably coupled to the ladder using the front and rear coupling assemblies 130 , 140 , there is no need to permanently modify the ladder to utilize the advantages of the ladder support assembly. Also, the support assembly may be easily coupled to, and uncoupled from, the ladder as needed. Because the support assembly may be easily removed from the ladder, the ladder may be easily converted back for normal use, and may be folded up readily in the usual fashion for storage. These and other advantages may be achieved using embodiments of ladder support assemblies in accordance with the present invention.
FIG. 9 is an isometric view of a ladder assembly 200 in accordance with an alternate embodiment of the present invention. In this embodiment, the ladder assembly 200 includes a ladder 202 and a ladder support assembly 220 . The ladder support assembly 220 includes front and rear transverse members 222 , 224 that span transversely between and beyond the left and right front legs 204 , 206 , and between and beyond the left and right rear legs 208 , 210 , respectively. The front transverse member 222 is coupled to the front legs 204 , 206 using front coupling assemblies 230 a , 230 b . Similarly, the rear transverse member 224 is coupled to the rear legs 208 , 210 using rear coupling assemblies 240 a , 240 b . Side brace assemblies 260 brace the outer portions of the front and rear transverse members 222 , 224
FIGS. 10 and 11 are enlarged isometric views of front and rear coupling assemblies 230 b , 240 a of the ladder support assembly 220 of FIG. 9 . FIG. 12 is an exploded view 261 , a partially-exploded view 263 , and an assembled view 264 of the front coupling assembly 230 b of FIG. 9 . In this embodiment, the front coupling assembly 230 b includes a slotted base 232 adapted to slideably engage into a channel 223 of the front transverse member 222 , a support plate 234 coupled to the slotted base 232 , and a locking member 236 coupled to the support plate 234 .
As shown in FIGS. 10 and 12 , in operation, the slotted base 232 is engaged into the channel 223 , and the support plate 234 is coupled to the slotted base 232 and positioned on an upper portion of the front transverse member 222 , spanning across the channel 223 . Finally, the locking member 236 is coupled to the support plate 234 and engaged with the front leg 206 of the ladder 202 ( FIG. 10 ). Thus, the locking member 236 of the front coupling assembly 230 b securely engages the front leg 206 , thereby coupling the ladder 202 to the front transverse member 222 . Similarly, as best shown in FIG. 11 , the rear coupling assembly 240 a includes a slotted base 242 (not visible), a support plate 244 , and a locking member 246 . The components of the rear coupling assembly 240 a are assembled in the same manner as the components of the front coupling assembly 230 b , and securely engage the rear leg 208 of the ladder 202 with the rear transverse member 224 .
FIG. 13 is an exploded view 251 and an assembled view 253 of one end of a strut assembly 250 . The strut assembly is part of the side brace assembly 260 of FIG. 9 . In this embodiment, the strut assembly 250 includes a strut member 262 , a joint base 252 (two required per strut member) that slidably engages into a strut channel 225 , and a top plate 254 that engages with the joint base 252 . In the assembled position 253 , the upper portion of the strut member 262 is clamped between the top plate 254 and the joint base 252 . A complete assembly 253 is positioned on each end of the strut member 262 . A channel stop block 256 is coupled to each end portion of a strut member 262 . In this embodiment two strut assemblies 250 are employed per transverse members 222 , 224 ( FIG. 9 ).
FIG. 14 is an enlarged elevational view of a side brace assembly 260 of the ladder support assembly 220 of FIG. 9 . FIG. 15 is an enlarged isometric view of a lower brace coupling assembly 270 of the side brace assembly 260 of FIG. 14 . FIGS. 16 and 17 are exploded and assembled views of the lower and upper brace coupling assemblies 270 , 280 of FIG. 15 . As best shown in FIG. 14 , in this embodiment, the side brace assembly 260 includes a strut member 262 that is coupled to the rear transverse member 224 by the lower brace coupling assembly 270 , and to the left rear leg 208 of the ladder 202 by the upper brace coupling assembly 280 . As shown in FIG. 9 , the ladder support assembly 220 may include four side brace assemblies 260 . One skilled in the art will appreciate that the side braces shown in FIG. 9 protect the cantilevered portions of the transverse members 222 , 224 from bending under load. Transverse members of heavier cross section might not require side braces, but at the cost of increased weight.
Referring to FIGS. 15 and 16 , the lower brace coupling assembly 270 includes a slotted base 272 that engages into the channel of the transverse member 224 . A coupling tab 274 is hingeably coupled to a clamp plate 276 which, in turn, is coupled to the slotted base 272 . In operation, the clamp plate 276 and the slotted base 272 cooperate to clampably secure the lower brace coupling assembly 270 to the transverse member 224 . The coupling tab 274 is coupled to a strut top plate of the strut member 262 . In one particular embodiment, the strut member 262 is coupled to the coupling tab 274 such that it may rotate with respect to the coupling tab 274 and provide an additional degree of freedom to account for the compound angle at which the strut typically meets the transverse member.
The construction of the upper brace assembly 280 is similar to the lower brace assembly 270 . As shown in FIG. 17 , the upper brace assembly 280 includes a slotted base 282 that is engaged with the rear leg 208 of the ladder 202 ( FIG. 14 ). A coupling tab 284 is hingeably coupled to a clamp plate 286 . In operation, the clamp plate 286 and the slotted base 282 cooperate to clampably secure the upper brace coupling assembly 280 to the rear leg 208 , and the coupling tab 284 is coupled to a strut top plate of the strut member 262 . Again, in one embodiment, the brace member 262 is rotatably coupled to the coupling tab 284 to provide an additional degree of freedom to account for the compound angle at which the strut typically meets the ladder.
It will be appreciated that the ladder support assembly 220 described above with reference to FIGS. 9-17 advantageously expands the manner in which the ladder 202 may be used over non-uniform surfaces. For example, because the front and rear transverse members 222 , 224 extend between and beyond the front and rear legs, respectively, the ladder 202 may be used in a different direction over the plurality of floor beams 126 shown in FIG. 1 . More specifically, the ladder support assembly 220 enables the ladder 202 to be used with the ladder “facing” the interior wall 103 of the aircraft. This allows a user to perform necessary operations on the interior wall 103 without twisting the user's body or requiring the user to stand “sideways” on the ladder 202 . Thus, the above-noted advantages of ladder support assemblies in accordance with the present invention may be achieved in an alternate embodiment that permits the ladder 202 to be utilized in a direction that faces along or approximately parallel with the plurality of floor beams 126 , thereby improving the versatility of the ladder 202 .
While preferred and alternate embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of these preferred and alternate embodiments. Instead, the invention should be determined entirely by reference to the claims that follow.
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Ladder support apparatus and methods are disclosed. In one embodiment, a method includes positioning a ladder having first and second pairs of legs in an operating position suitable for supporting a user. A ladder support assembly clampably coupled to the ladder, the ladder support assembly including at least one elongated member extending between a respective one of the first and second pairs of legs of the ladder, the elongated member being clampably coupled to the respective one of the first and second pairs of legs of the ladder by first and second coupling assemblies positioned at spaced-apart positions on the elongated member. The ladder is supported with the ladder support assembly on, for example, a non-uniform surface.
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FIELD OF TECHNOLOGY
[0001] The present application relates generally to rotary tools used for drilling subterranean material. More particularly, the present application is directed to a method of manufacturing and repairing rotary tools for drilling subterranean material having cutting control structures releasably secured to the tool body.
BACKGROUND
[0002] Fixed-cutter drag-type rotary drill bits having natural and synthetic diamond cutting elements affixed to a distal crown of the bit body have been employed in subterranean drilling for many decades. Rotary drag-type drill bits are typically comprised of a bit body having a shank for connection to a drill string and encompassing an inner channel for supplying drilling fluid to the face of the bit through nozzles or other apertures. Drag bits may be cast and/or machined from metal, typically steel, or may be formed from wear-resistant metal particles (typically tungsten carbide (WC)) infiltrated at high temperatures with a liquefied (typically copper-based) binder material to form a matrix. Such bits may also be formed with layered-manufacturing technology, as disclosed in U.S. Pat. No. 5,433,280 incorporated herein by reference.
[0003] Drag bits herein disclosed include polycrystalline diamond compact (PDC) cutters typically comprised of a large diamond table (usually of circular, semi circular or tombstone shape) which presents a generally planar cutting face. A cutting edge (sometimes chamfered or beveled) is formed on one side of the cutting face which, during boring, is at least partially embedded into the formation so that the formation is received against at least a portion of the cutting face. As the bit rotates, the cutting face moves against the formation and shavings of formation material (cuttings) are sheared off and are forced up the surface of the cutter face. In brittle materials at atmospheric pressure the formation cuttings easily separate from the cutter face and break down into small particles that are transported out of the bore hole via circulating drilling fluid. Another cutting then begins to form in the vicinity of the cutting edge, is forced up the face of the cutting surface, and breaks off in a similar fashion. Such action occurring at each cutting element on the bit removes formation material over the entire face of the bit, and so causes the bore hole to become progressively deeper.
[0004] However, for ductile formations under pressure that exhibit plastic properties, such as highly pressurized deep shales, mudstones, and siltstones, the formation cuttings have a marked tendency to stay intact and adhere to the cutting face of the cutting element. If the cutting is not broken into smaller pieces or removed from the cutting face, the cuttings collect as a mass of cuttings ahead of the PDC cutting elements and eventually clog the junk slots with drilled-up material. Once this phenomenon, termed bit balling, occurs the bit ceases to drill effectively.
[0005] U.S. Pat. No. 6,328,117 to Berzas et al. discloses apparatus for the prevention of bit balling that includes a chip breaker affixed upon fixed-cutter, rotary-type drill bits used in drilling subterranean formations. The chip breaker includes a knife-like protrusion positioned proximate a cutting element and adjacent a fluid course defined by the bit body. As formation cuttings are generated during drilling, the cuttings move over the protrusion and are split or scribed by the protrusion.
[0006] Even in view of such improvements disclosed in the aforementioned prior art, rotary tools are still susceptible to bit balling during drilling of subterranean material. Operating rotary tools at an excessively high great depth of cut (DOC) may generate more formation cuttings than can be consistently broken or cleared from the bit face and back up the bore hole via the junk slots on the face of the bit. Furthermore, chip breakers disclosed in the prior art are exposed to extremely large loads that can cause the chip breaker to either be eroded or entirely removed from the bit body.
[0007] It is therefore necessary to provide the industry with an apparatus and method for breaking down and dispersing formation cuttings that collect on the body of fixed-cutter drag-type rotary tools regardless of the size, shape or composition of the cutting and regardless of the type of subterranean material encountered by the rotary tool. Fixed-cutter drag-type rotary tools such as rotary drill bits, casing bits, reamers, bi-center rotary drill bits, reamer wings, down-hole milling tools, bi-center drill bits, or other drilling tools known in the art for utilizing cutting elements may benefit from the present disclosure and, as used herein, the term “rotary drill bit” encompasses any and all such apparatuses.
SUMMARY
[0008] The application herein provides apparatus and methods for releasably securing cutting control structures to a tool body of a rotary tool for drilling subterranean material. The rotary tool includes a tool body having a distal crown end comprising a circumferential series of raised cutting blades with recessed junk slots therebetween. Cutting elements are located proximate a leading peripheral edge of one of said raised cutting blades and cutting control structures are located interiorly of said cutting elements at a leading surface of an adjacent junk slot. The cutting control structures provide a means for splitting, breaking, twisting and/or diverting cuttings, chips or shavings that collect on the cutting face of a cutting element during drilling of subterranean material. The cutting control structures are releasably secured to the tool body in an adjacent junk slot whereby a used rotary tool is refurbishable by removing and replacing worn cutting control structures without degradation to the tool body. The embodiments disclosed herein permit rapid removal and replacement of cutting control structures that become worn or removed during drilling of subterranean material. The embodiments disclosed herein also enable easy modification of the location of cutting control structures in field operations thereby optimizing the position of cutting control structures depending on the drilling conditions. Furthermore, a variety of cutting control structures such as splitters, breakers, diverters and wedges can be configured on a single tool body for optimal break-up and dispersion of cuttings during drilling operations.
[0009] The foregoing and other objects, features and advantages of the disclosure will become more readily apparent from the following detailed description of the preferred embodiments as disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments of the present application will now be described, by way of example only, with reference to the attached Figures, wherein:
[0011] FIG. 1 is a perspective side view of a first embodiment rotary-type drill bit in accordance with the present disclosure;
[0012] FIG. 2 is a partial sectional view of a second embodiment of a rotary-type drill bit illustrating cutting control structures mounted on a carrier releasably secured to the bit body;
[0013] FIG. 3 is a partial sectional view of a formation chip being modified by a cutting control structure on a drill bit in accordance with the present disclosure;
[0014] FIG. 4 is a perspective view of the cutting control structures mounted to a carrier on a cutting blade of a rotary-type drill bit;
[0015] FIG. 5 is another perspective view of the cutting control structures mounted to a carrier on a cutting blade of rotary-type drill bit;
[0016] FIG. 6 is a perspective view of a carrier having cutting control structures mounted thereon;
[0017] FIGS. 7A-7C are examples of single cutting control structures releasably securable to a bit body;
[0018] FIG. 8 is an example of a removable cutting control structure according to the present disclosure with a press fit engagement to the bit body;
[0019] FIG. 9 is a second example of a removable cutting control structure according to the present disclosure with a press fit engagement to the bit body;
[0020] FIG. 10 is an example of a removable cutting control structure according to the present disclosure with a screw engagement to the bit body; and
[0021] FIG. 11 is a partial sectional view of a removable cutting control structure that is welded, brazed, press fit or shrink fit into a recess in the bit body according to the present disclosure.
DETAILED DESCRIPTION
[0022] It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the example embodiments described herein. However, it will be understood by those of ordinary skill in the art that the example embodiments described herein may be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Also, the description is not to be considered as limiting the scope of the embodiments described herein.
[0023] Referring to FIG. 1 , a drill bit 10 in accordance with the present disclosure comprises a body 12 having a threaded connection 14 at a proximal end 16 thereof and a crown 18 at a distal end 20 thereof. The crown 18 includes a plurality of longitudinally extending blades 22 that define a plurality of fluid courses 23 with adjacent junk slots 24 thereinbetween. Along each blade 22 , proximate the distal end 20 of the body 12 , is a plurality of cutting elements 25 attached to the leading peripheral edge 27 of the blades 22 and oriented to cut into a subterranean formation upon rotation of the bit 10 .
[0024] The drill bit 10 as illustrated in FIG. 1 is of a drag bit that can include polycrystalline diamond compact (PDC) cutters typically comprised of a large diamond table usually of circular, semi-circular or other shape) which presents a generally planar cutting face. While this type of drill bit is illustrated, the disclosure as contained herein can be equally applied to other types of tools used in drilling or otherwise modifying a subterranean material. These subterranean materials can include man-made material such as concrete and steel among other materials. Other examples of tools to which this disclosure could apply have been indicated in the background.
[0025] As illustrated, the fluid courses 23 and adjacent junk slots 24 are defined by the following surfaces: a first, leading side wall 26 , a second, trailing side wall 28 and a bottom surface 30 . The leading side wall 26 provides a surface adjacent the cutting face 29 of the cutting elements 25 . A plurality of cutting control structures 31 are each releasably secured to the leading side wall 26 interiorly of a cutting element 25 . In addition, each cutting control structure 31 preferably has a longitudinal axis L that is in substantial alignment with the center C of the adjacent cutting face 29 so that, as formation cuttings are generated during drilling, the cutting control structure 31 modifies the size, shape or directional path of the cutting that comes in contact with the cutting control structure 31 . It is noted that the orientation or 65 alignment of the longitudinal axis L relative to the cutting face 29 may be engineered based on the location of the cutting element 25 on the bit 10 and the predicted direction of formation cutting generation over the cutting face 29 . Accordingly, as formation cuttings, also referred to herein as shavings or formation chips, are cut by the cutting elements 25 , the cuttings slide over the cutting face 29 and across the leading side wall 26 adjacent the cutting elements 25 , are modified by the cutting control structures 31 , and are carried away by drilling fluid flowing through the fluid course 23 .
[0026] In hard drilling applications that involve drilling hard subterranean material, the cutting control structures 31 may be formed from at least one of the group comprising polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), carbide and ceramics. In soft drilling applications that involve drilling relatively softer material, the cutting control structures 31 may be formed from at least one of the group comprising copper, aluminum and plastic. Furthermore, cutting control structures 31 include splitters, breakers, diverters and/or wedges. A chip breaker 31 or splitter 31 includes a knife-like protrusion positioned proximate a cutting element 25 . As formation chips, shavings or cuttings are generated during drilling, the cuttings move over the protrusion and are split or scribed by the protrusion. Chip diverters and wedges include a blunt protrusion that is generally wedge-shaped and positioned proximate a cutting element 25 . As formation chips, shavings or cuttings are generated during drilling, the cuttings move over the protrusion and are deflected or dispersed from the cutting face 29 . Other suitable geometries for splitters, breaker, diverters and wedges will be discussed in further detail below.
[0027] The cutting control structures are especially useful in ductile formations under pressure, such as pressurized shales, mudstones, and siltstones; the cuttings of those materials have a marked tendency to stay intact and adhere to the cutting face of the cutting element. If the cutting is not broken into smaller pieces or removed from the cutting face, the cuttings collect and build up as a mass of cuttings ahead of the cutting elements and eventually clog the junk slots with material. As described herein, the cutting control structures encourage at least one of breaking apart, splitting, and divergence of the cutting from the cutting surfaces.
[0028] In a second embodiment shown in FIG. 2 , cutting control structures 31 are fixably mounted to a carrier 50 at an upper surface 52 of an exposed end 51 of the carrier 50 . The cutting control structures 31 are fixably mounted to the carrier 50 and positioned relative to a cutting element 25 such that the cutting control structures 31 lie in a potential flow path of cuttings generated by the operating cutting element 25 . The carrier 50 is releasably secured to the leading side wall 26 such that the upper surface 52 of the carrier 50 is elevated above the leading side wall 26 . As a result, at least a portion of the cutting control structures 31 lie in an elevated plane relative to the cutting element 25 and can be configured to project over the cutting face 29 of the cutting element 25 to enhance the dispersion of cuttings from the cutting face 29 . While in the illustrated embodiment the carrier 50 has a top surface 52 that is raised relative to the face of the leading side wall 26 , the carrier 50 can be mounted approximately flush with the leading side wall 26 and a portion of the cutting control structure 31 that lies above the cutting element can be configured to project over the cutting face 29 of the cutting element 25 .
[0029] In another embodiment, the carrier 50 is releasably secured to the leading side wall 26 such that the upper surface 52 of the carrier 50 is flush-oriented with the leading side wall 26 of the adjacent junk slot 24 . Additionally, the cutting control structures 31 can be configured such that they do not project over the cutting face 29 of the cutting element 25 , thereby easing disengagement and replacement of worn cutting control structures 31 .
[0030] FIG. 3 illustrates a means for releasably securing the cutting control structure 31 to the leading side wall 26 . A carrier 50 comprises an exposed end 51 having an upper surface 52 and anchoring end 55 having a top anchoring portion 54 and a releasable anchorage 56 . The cutting control structure 31 is fixably mounted to the carrier 50 at the upper surface 52 of the exposed end 51 of the carrier 50 . The releasable anchorage 56 includes a substantially cylindrical portion 57 for releasably securing the carrier 50 to a retention recess 82 within the leading side wall 26 . The retention recess 82 can be formed by boring a threaded cylindrical passage into the leading side wall 26 . The substantially cylindrical portion 57 of the releasable anchorage 56 is threaded to releasably secure the carrier 50 to the retention recess 82 by screwing the substantially cylindrical portion 57 into the retention recess 82 . Additionally, a top anchoring portion 54 of the anchoring end 55 of the carrier 50 can have a larger cross-sectional area compared to the cylindrical portion 57 or other portions of the releasable anchorage 56 . The top anchoring portion 54 is configured to fit within a top portion recess 80 that accommodates the top anchoring portion 54 . Increasing the cross-sectional area of the top anchoring portion 54 increases the surface area contacting the leading side wall 26 , thereby distributing the stresses and loads exerted on the carrier 50 during drilling.
[0031] In another embodiment, to further secure the carrier 50 to the leading side wall 26 , the retention recess 82 can be formed by boring a threaded cylindrical passage through the leading side wall 24 and through a rear surface of the cutting blade. The carrier 50 is releasably secured to the retention recess 82 by screwing the substantially cylindrical portion 57 into the retention recess 82 . In at least one embodiment the distal end 58 of releasable anchorage 56 can also be fastened with a nut to the rear surface of the cutting blade (not shown).
[0032] In other embodiments, the carrier 50 can be releasably secured to the bit body 12 by welding, brazing, bonding, using studs, shrink fitting a portion of the carrier 50 to the bit body 12 and/or friction fitting a portion of the carrier 50 to the bit body 12 . For example, the upper surface 52 of the exposed end 51 of the carrier 50 could be welded, brazed and/or bonded around its perimeter. In another embodiment, it is also possible to braze the top anchoring portion 54 of the cutting control structure 31 within the retention recess 82 . Other mechanisms that secure the releasable anchorage 56 of the cutting control structure include the implementation of threaded engagements, locking mechanisms, studs, friction fitting, press fitting and the like.
[0033] As illustrated in FIG. 3 , formation cutting 40 may be both split and lifted or split, lifted and twisted and/or dispersed from leading side wall 26 by cutting control structure 31 relative to cutting face 29 of cutting element 25 and leading side wall 26 . By splitting and lifting the cutting 40 away from leading side wall 26 , the unsupported portion 44 of the cutting 40 that is exposed to the flow of drilling fluid is weakened by drilling fluid penetrating into cracks and pores and can be relatively easily broken away from the rest of the cutting 40 by the force of drilling fluid flowing through the fluid course. Segments 42 of cutting 40 , one of which is viewable in FIG. 3 with the other directly therebehind, will typically have two additional sides 41 exposed to the action of the drilling fluid for further break-up of segments 42 away from the rest of the cutting 40 . The cutting control structure 31 can further deflect and/or disperse the cutting from the cutting face 29 into an adjacent junk slot 24 (not shown). Therefore, the cutting control structures 31 of this embodiment may modify the shape, size or directional path of the cuttings generated while drilling.
[0034] FIGS. 4 and 5 illustrate an embodiment with cutting control structures 31 fixably mounted to a carrier 50 at an upper surface 52 the exposed end 51 of the carrier 50 . FIG. 4 provides a perspective view of the cutting face 29 of the cutting elements 25 . FIG. 5 provides a side perspective view of the cutting elements 20 along with cutting control structures 31 . The carrier 50 is releasably secured to the leading side wall 26 . In the illustrated embodiment, the adjacent cutting control structures 31 are spaced apart on the carrier 50 at distance-X that is not equivalent to the spacing distance-Y between adjacent cutting elements 25 . The spacing between adjacent cutting control structures 31 relative to the spacing between adjacent cutting elements 25 may vary in order to optimized the contact between cutting control structures 31 and cuttings based on the directional path (such as line A) that cuttings follow during drilling of subterranean material. The spacing between adjacent cutting control structures 31 relative to the spacing between adjacent cutting elements 25 may be maintained such that the angle between the directional of path of two flow patterns of cuttings across a pair of adjacent cutters is constant across the pair of adjacent cutters 25 and a pair of corresponding adjacent cutting control structures 31 . In another embodiment, the adjacent cutting control structures are spaced apart on the carrier 50 at distance-X substantially equal to a spacing distance-Y between cutting elements 25 on the raised cutting blade. Maintaining an equivalent distance between adjacent cutting control structures 31 relative to the distance between adjacent cutting elements 25 is useful if adjacent cutting elements 25 are arranged substantially linearly and/or produce a flow pattern of cuttings in a substantially linear directional path.
[0035] While the embodiments shown in FIGS. 2 , 4 , and 5 have three cutting control structures mounted on the top surface 52 of the carrier 50 , other arrangements of the cutting control structures are considered within the scope of this disclosure. For instance, a pair of cutting control structures 31 can be affixed to the carrier 50 . Additionally, the cutting control structures 31 can be arranged such that more than three are provided on the carrier. As will be described below, the cutting control structures 31 can also be individually releasably secured to the tool body.
[0036] FIG. 6 illustrates another embodiment of a carrier 50 with a plurality of cutting control structures 31 fixably mounted to the carrier 50 . The carrier 50 comprises an exposed end 51 having an upper surface 52 and anchoring end 55 having a top anchoring portion 54 and a releasable anchorage 56 . The cutting control structures 31 are fixably mounted to the carrier 50 at the upper surface 52 of the carrier 50 . The releasable anchorage 56 comprises a substantially cylindrical and threaded portion 62 for releasably securing the carrier 50 to the bit body 12 . In accordance with this embodiment, the carrier 50 may be secured to the bit body by screwing the substantially cylindrical and threaded portion 62 into a threaded recess in the bit body. The carrier 50 may be unscrewed and replaced with another carrier 50 when one or a plurality of cutting control structures 31 become worn or broken from use in drilling subterranean material, thereby making a drill bit 10 refurbishable.
[0037] FIGS. 7A-7C illustrate several other embodiments of cutting control structures 31 in accordance with the present disclosure. In FIG. 7A , the cutting control structure 31 is illustrated as having a cone-shaped protrusion or protuberance 30 . The cutting control structure 31 includes an exposed end 51 having an upper surface 52 and an anchoring end 55 having a top anchoring portion 54 and a releasable anchorage 56 . The releasable anchorage 56 comprises a substantially cylindrical and threaded portion 62 for releasably securing the cutting control structure 31 to the bit body 12 . In accordance with this embodiment, the cutting control structure 31 can be secured to the bit body 12 by screwing the substantially cylindrical and threaded portion 62 into a threaded recess in the bit body 12 . The cutting control structure 31 can be unscrewed and replaced with another cutting control structure 31 when the cutting control structure 31 becomes worn or broken from use in drilling subterranean material, thereby making a drill bit 10 refurbishable. Although the cutting control structure 31 is not mounted to a carrier in this embodiment, one or more cutting control structures 31 illustrated in this embodiment can be mounted to a carrier that is releasably secured to the bit body in any number of ways herein disclosed.
[0038] In FIG. 7B , the cutting control structure 31 ′ is illustrated as having an elliptical-shaped protrusion or protuberance 30 ′. The cutting control structure 31 ′ includes an exposed end 51 having an upper surface 72 and an anchoring end 55 having a top anchoring portion 74 and a releasable anchorage 76 . The releasable anchorage 76 comprises a substantially cylindrical and threaded portion 78 for releasably securing the cutting control structure 31 ′ to the bit body 12 . In accordance with this embodiment, the cutting control structure 31 ′ can be secured to the bit body 12 by screwing the substantially cylindrical and threaded portion 78 into a threaded recess in the bit body 12 . The cutting control structure 31 ′ can be unscrewed and replaced with another cutting control structure 31 ′ when the cutting control structure 31 ′ becomes worn or broken from use in drilling subterranean material, thereby making a drill bit 10 refurbishable. Although the cutting control structure 31 ′ is not mounted to a carrier in this embodiment, one or more cutting control structures 31 ′ illustrated in this embodiment can be mounted to a carrier that is releasably secured to the bit body in any number of ways herein disclosed.
[0039] In FIG. 7C , the cutting control structure 31 ″ is illustrated as a semi-cylindrical shaped protrusion or protuberance 30 ″. The cutting control structure 31 ″ includes an exposed end 51 having an upper surface 72 and an anchoring end 55 having a top anchoring portion 74 and a releasable anchorage 76 . The releasable anchorage 76 includes a substantially cylindrical and threaded portion 78 for releasably securing the cutting control structure 31 ″ to the bit body 12 . In accordance with this embodiment, the cutting control structure 31 ″ can be secured to the bit body 12 by screwing the substantially cylindrical and threaded portion 78 into a threaded recess in the bit body 12 . The cutting control structure 31 ″ can be unscrewed and replaced with another cutting control structure 31 ″ when the cutting control structure 31 ″ becomes worn or broken from use in drilling subterranean material, thereby making a drill bit 10 refurbishable. Although the cutting control structure 31 ″ is not mounted to a carrier in this embodiment, one or more cutting control structures 31 ″ illustrated in this embodiment can be mounted to a carrier that is releasably secured to the bit body in any number of ways herein disclosed.
[0040] In other embodiments the cutting control structures 31 may have substantially rectangular-shaped, diamond-shaped, knifelike protrusions and/or any other shape of protrusion that would be understood by one of ordinary skill in the art as effective in modifying the shape, size or directional path of cuttings formed during drilling of subterranean material.
[0041] FIG. 8 illustrates another means for releasably securing a cutting control structure 31 to the bit body. In accordance with FIG. 8 , a cutting control structure 31 includes a protrusion 30 , an exposed end 51 having upper surface 52 and an anchoring end 55 having a top anchoring portion 54 and a releasable anchorage 56 . The releasable anchorage 56 is of generally smaller diameter than the top anchoring portion 54 . The releasable anchorage 56 has a locking surface 107 , which has formed thereon a series of sharp edged radial projections 112 such as circular ridges or barbs comprised of a hard material. A retention recess 109 is preformed or drilled in the bit body 12 forming a cavity or socket for insertion of the releasable anchorage 56 . An annular sleeve element 105 of metal or other suitable material may be placed in the retention recess 109 and is shown extending into the retention recess 109 to form a shoulder 114 . The sleeve element 105 has a hardness value less than that of the sharp edged radial projections 112 so that the releasable anchorage 56 may be inserted with force into the sleeve element 105 and retained by friction within the sleeve element 105 by the sharp ridges or barbs 112 . The cutting control structure 31 may be forcibly removed and replaced with another control structure 31 when the cutting control structure 31 becomes worn or broken from use in drilling subterranean material, thereby making a drill bit 10 refurbishable.
[0042] As shown in FIG. 8 , the sleeve element 105 does not cover the center bottom region 111 of the retention recess 109 . While in FIG. 9 , the sleeve element 105 is constructed such that the center bottom region 111 of the retention recess 109 is covered by sleeve element 105 . The shape, size and degree of overlay of the sleeve element 105 in the retention recess 109 can be varied depending upon the degree of support needed in the retention recess 109 and depending on the material used for constructing the sleeve 105 and the locking surface 107 .
[0043] FIG. 10 illustrates another means for releasably securing a cutting control structure 31 to the bit body 12 . The cutting control structure 31 includes a protrusion 30 fixed to an upper surface 52 of an exposed end 51 . The cutting control structure 31 further includes an anchoring end 55 having a top anchoring portion 54 and a releasable anchorage 56 . The releasable anchorage 56 includes a substantially cylindrical and threaded portion 108 for releasably securing the cutting control structure 31 to the bit body 12 . A sleeve 115 is mounted within a cavity 106 formed in the bit body 12 . The sleeve 115 accommodates the top anchoring portion 54 of the cutting control structure 31 and is also shaped to accommodate the corresponding substantially cylindrical and threaded portion 108 of the releasable anchorage 56 . A distal end 110 of the substantially cylindrical and threaded portion 108 of the releasable anchorage 56 passes through the sleeve 115 and is threadably engaged with the bit body 12 . The threaded engagement of the releasable anchorage 56 to the bit body 12 fixes the sleeve 115 to the bit body 12 and allows the sleeve 115 and the cutting control structure 31 to be removed and replaced.
[0044] In other embodiments, the cutting control structure 31 can be releasably secured to the bit body 12 by welding, brazing, bonding, using studs, shrink fitting a portion of the cutting control structure 31 to the bit body 12 and/or friction fitting a portion of the cutting control structure 31 to the bit body 12 . For example, the upper surface 52 of the exposed end 51 of the cutting control structure 31 could be welded, brazed and/or bonded around its perimeter. In another embodiment, it is also possible to braze the top anchoring portion 54 of the cutting control structure 31 within the recess 109 as illustrated in FIG. 8 and FIG. 11 . Other mechanisms that secure the releasable anchorage 56 of the cutting control structure 31 shown in FIG. 8 include the implementation of threaded engagements, locking mechanisms, studs, friction fitting, shrink fitting and the like.
[0045] The methods and systems herein disclosed of releasably securing a cutting control structure 31 are not limited to fixed-cutter rotary drill-bits. The methods and systems herein disclosed can be extended to releasably securing cutting control structures 31 to any down-hole tool that generates cuttings during operation including but not limited to fixed-cutter drag-type rotary tools such as rotary drill bits, casing bits, reamers, bi-center rotary drill bits, reamer wings, down-hole milling tools and bi-center drill bits. Furthermore, the systems and methods herein disclosed are not limited to drilling subterranean formations. The methods and systems herein disclosed can be extended to drilling or cutting any subterranean structure, composition of matter or formation that generates cuttings during downhole operations.
[0046] The embodiments disclosed herein exhibit significant advantages over the prior art. The embodiments disclosed herein permit rapid removal and replacement of cutting control structures that become worn or broken during drilling of subterranean material without degradation to the tool body. The embodiments disclosed herein also enable easy modification of the location of cutting control structures during field operations thereby optimizing the position of cutting control structures depending on the drilling conditions and conditions of the wellbore. Furthermore, a variety of cutting control structures such as splitters, breakers, diverters and wedges can be configured on a single tool body for optimal break-up and dispersion of cuttings during drilling operations, thereby optimizing rate of penetration of the drill bit and alleviating bit balling.
[0047] Example embodiments have been described hereinabove regarding a method and apparatus for repairing or refurbishing fixed-cutter drag-type rotary tools for drilling subterranean material and having cutting control structures releasably secured to the tool body. Various modifications to and departures from the disclosed example embodiments will occur to those having skill in the art. The subject matter that is intended to be within the spirit of this disclosure is set forth in the following claims.
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A rotary tool for drilling subterranean material is disclosed. The rotary tool includes a tool body having a distal crown end comprising a circumferential series of raised cutting blades with recessed junk slots therebetween. Cutting elements are located proximate a leading peripheral edge of the raised cutting blades and cutting control structures are located interiorly of the cutting elements at a leading surface of an adjacent junk slot. Cutting control structures are releasably secured to the tool body in the adjacent junk slot whereby a used rotary tool is refurbishable by removing worn cutting control structures without degradation to the tool body and replacing the worn cutting control structures by installing new cutting control structures in the worn cutting control structures' locations.
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[0001] This application claims the priority of German application 102 23 902.9, filed May 29, 2002, the disclosure of which is expressly incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to a lock mechanism for securing a door kinematics system of an airplane door.
[0003] Over the last few years the number of incidents in which unauthorized passengers have tried to get outside a plane during flight and to open a door of the airplane has risen. If such a passenger should succeed in opening a door, this would have catastrophic consequences because the deploying evacuation slide on the airplane could cause it to crash or the sudden drop in cabin pressure could hurl the staff and passengers out of the airplane.
[0004] In this respect the necessity exists for a lock mechanism so as to secure doors of the airplane against unauthorized opening.
[0005] It is, therefore, an object of the present invention to make a lock mechanism for securing a door kinematics system of an airplane door available, which with a simple design and simple, inexpensive production can safely lock an airplane door and if required, particularly in case of an emergency, can release the locked state of the door.
[0006] This object is achieved with a lock mechanism comprising a control unit, an actuator for actuating a locking system and an automatic reset device. The lock mechanism is furthermore designed in such a way that the control unit actuates the actuator as a function of the existence of a predetermined signal in order to bring the locking system into the locked position. When required, especially in case of an emergency, the automatic reset device returns the locking system autonomously into a released state so that the airplane door can be opened from the inside. Furthermore, the automatic reset device ensures that, for example upon failure of an individual component of the lock mechanism, the lock mechanism is also returned into the unlocked state so as to allow actuation of the door kinematics system for opening the door.
[0007] Beneficially the lock mechanism comprises a rotatory actuator. The use of a rotatory actuator hereby offers a high level of operational reliability while requiring little space, especially when it comes to locking a door during flight. A brushless DC motor is preferably used as the rotatory actuator. Such a motor is compact, requires only a little space and has a low weight. Furthermore, such motors are largely maintenance-free and exhibit a high level of reliability. Another possibility for a rotatory actuator is the use of a driving mechanism with a solenoid, with which an inexpensive driving mechanism can be made available; however, this rotary actuator has a higher weight and greater space requirement than a DC motor.
[0008] In a particularly preferred design, the predetermined signal, as a function of which the control unit actuates the actuator, is a “flight” signal of the airplane. In this way, it can be ensured that the lock mechanism always automatically locks the door kinematics system during flight.
[0009] Another preferred possibility for making the predetermined signal available is to equip the system with a switch, for example in the cockpit, wherein the predetermined signal is generated upon actuation of the switch and the lock mechanism locks the door kinematics system. Such a switch can for example also be used for maintenance purposes or for checking the function of the lock mechanism on the ground.
[0010] So as to enable a reduction in the input speed of the actuator, the lock mechanism furthermore preferably contains a transmission, especially a planetary gear system.
[0011] The automatic reset device preferably contains a spring element, which allows a particularly inexpensive lock mechanism to be made available. In an even more preferred design the automatic reset device comprises at least two spring elements, which each are able individually to reset the locking system from the locked position into the released position. In this way, a redundancy of the reset device is enabled, compensating even for the failure of a spring element, and even greater safety is achieved for cases where the locking system has to be reset in cases of emergency. The spring elements are preferably prestressed by bringing the locking system in the locked position. In this way, the reset device is always automatically transferred into its tensioned state when the door kinematics system becomes locked.
[0012] The spring resistance of the spring element is preferably selected in such a way that the spring element is in a position to bring the locking system into the released position from the locking position within just a few seconds.
[0013] Furthermore, it is preferred that the rotatory actuator is designed in such a way that it, when switched current-less, also acts as a brake when the locking system is returned from the locked position into the released position. This enables a damped resetting of the locking system.
[0014] The locking system beneficially comprises a hook and a brace element with a recess, in which the hook engages in the locked state and thus blocks the door kinematics system. In order to prevent mechanical stress from being applied on the locking system during the locked state, a separate stop element is preferably provided, which establishes a starting and/or ending position without applying stress on the hook itself.
[0015] The control unit preferably selects the actuator such that the speed is reduced when approaching the stop in order to achieve gentler stopping.
[0016] Pursuant to another preferred design of the present invention, the control unit selects the actuator such that with a suitable signal the locking system is actively pushed in the release direction.
[0017] The invented lock mechanism is suitable especially also for retrofitting airplanes that are already being used with appropriate modifications. Since the invented lock mechanism has a very light and compact design, it can generally be installed without difficulty between doorframe segments of the door.
[0018] The following is a description of the present invention based on a preferred exemplary design shown in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a diagrammatic perspective view of a lock mechanism pursuant to an embodiment of the invention in the locked state,
[0020] [0020]FIG. 2 is a diagrammatic perspective view of the locking system in the locked state from the side opposite to that of FIG. 1,
[0021] [0021]FIG. 3 is a diagrammatic perspective view of the lock mechanism in the unlocked state,
[0022] [0022]FIG. 4 a diagrammatic perspective view of the locking system in the unlocked state from the side opposite to that of FIG. 3, and
[0023] [0023]FIG. 5 is a diagrammatic depiction of an opening process of the lock mechanism.
DETAILED DESCRIPTION OF THE INVENTION
[0024] [0024]FIGS. 1 through 5 depict a lock mechanism pursuant to an exemplary design of the present invention. FIGS. 1 and 2 show the locked state of the lock mechanism, and FIGS. 3 and 4 show the released state of the lock mechanism.
[0025] As can be seen particularly in FIG. 1, the lock mechanism pursuant to the invention comprises a control unit 10 , which is connected with an actuator 1 via a cable 14 . The actuator 1 is a rotatory actuator, comprising a brushless DC motor 2 , which drives an output shaft 17 . The DC motor 2 is connected via a reducing planetary gear 3 with a locking system or a locking kinematics system 18 , comprising an actuator lever 5 , a connecting element 6 , a hook 7 , two springs 8 a , 8 b and a brace 9 (see in particular FIGS. 2 and 4). In the locked state, the hook 7 engages in a recess 16 incorporated in the brace 9 with undercut (see FIG. 1). The brace 9 is hereby attached on an interior door lever 15 (indicated only diagrammatically), which can be actuated manually via a handle roller 12 in order to open the airplane door in the familiar fashion.
[0026] The lock mechanism furthermore comprises a stop mechanism, having a first stop 11 a , a second stop 11 b and a lever 4 (see FIG. 3). The lever 4 is connected with the output shaft 17 of the transmission 3 and thus limits the path of motion of the hook 7 . The stop mechanism prevents the hook 7 from being pushed against the brace 9 under load and possibly being damaged.
[0027] Two spiral springs 8 a and 8 b , provided as the automatic reset device, are tensioned into the locked position with the movement of the locking system. This state is shown in FIG. 2. In the released state, the springs 8 a , 8 b are also released to their specified pre-stress. The restoring force of the springs 8 a and 8 b is such that they individually are in a position to reset the locking system autonomously from any position into the released state. Thus, a redundant automatic reset device is provided.
[0028] As can be seen particularly in FIG. 1, the lock mechanism pursuant to the invention can be mounted between two doorframe segments 13 of the airplane door.
[0029] A function of the invented lock mechanism of the design is as follows. When the airplane lifts off the ground, automatically, a so-called “flight” signal is generated, which indicates the flying state of the airplane. This signal is supplied to the control unit 10 , which controls the lock mechanism 1 . Based on the “flight” signal, the control device 10 controls the actuator 1 by means of electric signals via the line 14 in such a manner that the DC motor 2 drives the output shaft in a controlled fashion by limiting its tension range. The speed of the output shaft is reduced in the planetary gear 3 . The output shaft 17 of the planetary gear is connected with the actuator lever 5 by means of a toothed area. The hook 7 , proceeding from the position shown in FIGS. 3 and 4, is thus moved upward in the direction of the recess 16 via the actuator lever 5 and the connecting element 6 . As FIG. 3 shows, in the starting position of the lock mechanism, the lever 4 rests against the second stop 1 b . The hook is turned upward until the lever 4 stops against the first stop 11 a (FIG. 1). This arranges the hook 7 in the recess 16 of the brace 9 , without creating a contact between the hook 7 and the brace 9 . The lock mechanism is hereby brought into its locked position.
[0030] If a passenger should now try to pull the interior door lever 15 by means of the handle roller 12 , the hook 7 prevents the unlocking and unlatching of the door kinematics system.
[0031] It shall be noted that when the hook 7 arrives in its final position (i.e. the lever 4 rests against the first stop 11 a ), the control unit 10 shuts off the electronic commutation required for turning the actuator through the detection of a current impulse and introduces constant current into the motor. This prevents the motor from overheating at the limit stop, and the requirement for electric energy for maintaining the position of the hook 7 in the locked state is minimized. Furthermore, the detection of the current impulse enables an automatic adjustment of the actuator's path of motion on the stop to be achieved. In this way, a limit position sensor can be foregone.
[0032] When the “flight” signal is not detected, for example, when the airplane is on the ground or in case of a power failure in an emergency situation, the motor 2 is switched currentless and the hook 7 is set back into its starting position through the restoring force of the two springs 8 a , 8 b so that the interior door lever 15 is released and can be actuated to open the door. In this way, it is possible to actuate the interior door lever 15 in the direction of the arrow in FIG. 4.
[0033] The motor 2 functions as a brake by short-circuiting the motor coils via a brake resistance and thus prevents a hard stop.
[0034] As shown in the detailed, diagrammatic depiction of FIG. 5, the geometry of the contact surfaces between hook 7 and recess 16 are designed through a tapered tangent such that, in the currentless case, an opening torque onto the hook 7 is generated through manual forces on the handle roller 12 even in the case of a sluggishness of the locking system 18 . When current is applied, this opening torque is overcompensated by the holding torque of the actuator.
[0035] The lock mechanism pursuant to the invention is, therefore, designed in such a way that, even in the case of failure of one of the components of the lock mechanism (e.g. failure of the motor, mechanical breakage of a component), the reset device can release the lock mechanism autonomously so that the possibility of opening the door manually in an emergency is always guaranteed. By selecting the rotatory actuator 1 , a safe state (released state) can be achieved with a high level of reliability even when an individual element of the lock mechanism fails. Furthermore, the electromechanical lock mechanism exhibits great reliability, even when maintaining the locked position, while having a low weight and low manufacturing and assembly costs. Due to the compact design, it is also easily possible to retrofit the invented lock mechanism for airplanes that are already being used.
[0036] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
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A device for locking a door kinematics system of the door of an airplane includes a control unit, an actuator for actuating a locking system and an automatic reset device. The control unit actuates the actuator as a function of the existence of a predetermined signal so that the actuator brings the locking system in a locking position. The reset device, if required, brings the locking system autonomously into a release position.
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