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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 the art of earth boring and, more particularly, to a riase bit for boring large diameter raise holes by enlarging a pilot hole into the larger diameter hole.
BACKGROUND OF THE INVENTION
It is well known in the earth boring art to produce relatively large diameter holes between a first location and a second location in a mine or other underground works by operations commonly referred to as raise drilling. A raise drilling operation begins by drilling a small diameter pilot hole through the earth from a first location to an opening at a second location using a small diameter pilot bit. After the pilot hole is completed, the pilot bit is removed from the drill string and a large diameter raise bit is attached. The raise bit is rotated and drawn along the pilot hole thereby enlarging the pilot hole to the desired size.
Many strict requirements are imposed upon drill bits used in boring large diameter holes. The drill bit must be a balanced, high-performance apparatus that is rugged and will perform for a long period of time. Replaceable rolling cutters are located and spaced so that upon rotation of the drill bit every portion of the hole being drilled will be acted upon by one or more of the cutters in order to disintegrate the formations and form the desired large diameter hole. This insures that almost the entire wear in drilling takes place on the cutters rather than on the main bit body. The cutters are readily replaceable thereby allowing the life of the drill bit to be extended by replacing the individual cutters.
DESCRIPTION OF PRIOR ART
United States Department of the Interior, Bureau of Mines, Technical Report on Foster-Miller Associates, Inc., Contract H0210044, "Design, Fabricate And Test A Conical Borer" described a conical borer system.
In U.S. Pat. No. 3,633,691 to Milton L. Talbert, patented Jan. 11, 1972, a bit for drilling large diameter holes is shown. Cutters are arranged in a staged configuration around the central shaft. The innermost cutters are the same large cutters used at other locations on the bit allowing complete interchangeability. The innermost cutters are turned inward. This reduces the uncut bottom next to the pilot hole and provides a stronger bit because the central shaft has not been weakened by milling or other operations.
In U.S. Pat. No. 3,638,740 to Dan B. Justman, patented Feb. 1, 1972, a rotary drill for producing a raise bore including a body having roller cutter assemblies arranged to cut the working face of an earth formation so that the plane of an inner portion of the working face inclines downwardly and inwardly towards a pilot hole, and the plane of an outer portion of the working face inclines downwardly and outwardly towards the gage of the raise bore, and the plane of an intermediate portion of the working face extends between the inner and outer inclined portions is shown.
In U.S. Pat. No. 3,750,767 to Rudolf Carl Otto Pessier, patented Aug. 7, 1973, a reaming type rock boring drill having an innermost cutter, rotatably supported as a beam is shown. A sleeve or other support member disposed close to, but spaced apart from, the drill stem that forms a portion of the bit body serves as a trunnion or journal for the inner end of the load pin of the cutter bearing assembly. Drilling with such an assembly results in an uncontacted kerf of rock contiguous with the pilot hole. This kerf is disintegrated by mounting the innermost cutter so that the forces applied to the borehole bottom by this cutter act along a line directed into the formation and inwardly toward the pilot hole. As a result, a much higher cutting efficiency is achieved, when contrasted with earlier dispositions in which the innermost cutter acted directly on the bottom of the borehole immediately adjacent the pilot hole.
In U.S. Pat. No. 4,007,799 to Robert L. Dixon and Robert E. Allison, patented Feb. 15, 1977, a raise type of earth boring drill in which the cutter assembly is detachably secured to the drive stem to permit replacement of the stem is shown. The stem slidably engages a central opening in the cutter assembly, the cutter assembly engaging a shoulder on the stem which carries axial loads in the drill. The cutter assembly is detachably anchored by a plurality of bolts to a torque plate attached to the end of the stem for transmitting torque load to the cutter assembly, the bolts clamping the cutter assembly against the shoulder.
SUMMARY OF THE INVENTION
The present invention provides a raise bit for enlarging a pilot hole into a larger diameter hole by disintegrating the earth formations that surround the pilot hole. The bit includes a cutterhead with a multiplicity of rolling cutters for contacting and disintegrating the formations that surround the pilot hole. The cutterhead comprises a series of rolling cutters mounted so that the cutter face profile extends in a uniform manner to the edge of the pilot hole. The face profile of the cutters forms a conical shape. The included angle of the cone face profile is in the range of 134° to 60°. The above and other features and advantages of the present invention will become apparent from a consideration of the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view partially in section of a raise bit constructed in accordance with the present invention.
FIG. 2 is an illustration of the cutter face profile of prior art raise bits.
FIG. 3 is an illustration of the cutter face profile of the raise bit shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and, in particular, to FIG. 1, a raise bit constructed in accordance with the present invention is illustrated. The bit is generally designated by the reference number 10. A series of main plates 11 form the basic framework of the bit 10. A central drive stem 12 projects from the main plate 11. A central passage 17 in drive stem 12 allows drilling fluid (air) to be circulated through the bit 10. The upper portion 13 of the drive stem 12 is threaded to allow the bit 10 to be easily connected to, and disconnected from, a rotary drill string (not shown). A multiplicity of saddles 16 are mounted on the main plates 11 containing a corresponding multiplicity of rolling cutters 15. The rolling cutters 15 contact and disintegrate the formations surrounding the pilot hole during the raise drilling operation.
Drive stem 12 presents no interference to the center cutters because it attaches to the cutterhead body at points between the cutters after they have been placed in their most effective operating positions. The cutters can be placed as close together radially as their saddles will allow. The lower portion of the drive stem 12 includes extensions that reach over or "bridge" the inner legs of the center saddles 16 and extend into the available vacant areas between the saddles for attachment, for example by being welded or bolted, to the main plates 11. An archway 14 is thereby provided for the inner cutters. The saddles supporting the inner cutters fit into the archway and bring the cutting surfaces of the cutters to the pilot hole thereby eliminating uncut bottom. The drive stem 12 is attached to the cutterhead body without interfering in any way with the most effective operating position of the rolling cutters adjacent the stem. This cutter placement results in continuation of the same straight cutting profile that is produced by the other cutters. This eliminates profile changes which would result in premature wear. This reduces uncut bottom at the stem while maintaining the same profile.
The present invention provides a raise bit that incorporates a more effective cutter arrangement for improved drilling performance. Prior art raise bits used continuous angle bottom configurations utilizing included cone angles that ranged from approximately 180° (true flat bottom) to approximately 134°. This is illustrated in FIG. 2. Simple equations of statics show that as the included cone angle decreases, the total force Q normal to the cutting face increases in indirect proportion to the cosine of A half the included angle. However, the cone side, or the area being cut, is increased by the same factor. Thus the unit load, or pressure, remains constant. Therefore, the penetration rate is increased because a greater area of rock is being attacked at the same unit load per revolution. Thus, the efficiency of the raise boring operation is greatly increased. Other prior art raise bits used multiple profile angles or multiple cutter stages.
Referring now to FIG. 3, the cutter face profile of the bit 10 shown in FIG. 1 is illustrated. The present invention provides a raise bit that incorporates a more effective cutter arrangement for improved drilling performance. The raise bit body is so designed to accommodate a number of rolling cutting elements arranged in a manner such that the face of the cutting elements form a conical shape, the included angle of which is in the range of 134° to 60°. The present invention provides a raise bit which generates sufficient stabilization from the cutting elements to eliminate the need for additional stabilizing elements. The included angle of raise bit 10 is substantially 100°.
Simple equations of statics show that as the included cone angle decreases, the total force Q normal to the cutting face increases in indirect proportion to the cosine of half B the included angle. However, the cone side, or the area being cut, is increased by the same factor. Thus the unit load, or pressure, remains constant. Therefore, the penetration rate is increased because a greater area of rock is being attacked at the same unit load per revolution. Thus, the efficiency of the raise boring operation is greatly increased. Further, assuming that the load per unit area can be decreased and still overcome the threshold strength of the formation being cut, and assuming that present penetration rates are acceptable, lower horsepower raise drilling machines may be utilized to achieve the same raise geometry as the present higher powered machines at an attendant cost savings. Or, under the same assumptions as above, raise geometry may be increased utilizing existing machines. In addition, the side loads on the cutters, or the loads normal to the axis of rotation, increase in direct proportion to the tangent of half B the included angle. These side loads are the loads which supply the centralization or stabilization of the raise head. Thus as the included angle decreases, the stabilizing forces increase, thereby improving the smooth running characteristics of the raise head and greatly increasing the life of the cutters, raise head stem, and associated drill string members.
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A raise bit for enlarging a pilot hole into a larger diameter hole by disintegrating the earth formations that surround the pilot hole is provided with a cutter arrangement that provides a continuous angle bottom configuration in the range of 134° to 60°.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to a mechanical, multistory storing structure capable of individually storing many cargoes including vehicles in a limited space and, more specifically, relates to a multistory multicolumn storing installation capable of storing a plurality of pallets loaded with cargoes on storing platforms disposed respectively in multistory storing divisions.
BACKGROUND OF THE INVENTION
Conventional multistory storing installations are classified generally into those of a tower type having two columns provided with a plurality of multistory storing shelves, and disposed respectively on the opposite sides of a lift, and those of a traveling lift type having two storing blocks each consisting of multistory storing divisions arranged in a multistory, multicolumn arrangement, and a traveling crane or traveling forklift truck that travels in a space between the two storing blocks.
The multistory storing installation of a tower type is subject to limitations on its capacity and it is difficult to increase the storing shelves. The multistory storing installation of a traveling lift type needs a space for the traveling crane or the forklift truck in addition to the space for installing the multistory storing structure. These conventional multistory storing installations are unable to operate efficiently for storing cargoes and sending out cargoes. It is an object of the present invention to provide a multistory multicolumn storing installation capable of efficiently operating for storing and sending out large cargoes, such as vehicles and containers, and of readily accepting an increase in the number of columns.
SUMMARY OF THE INVENTION
To achieve the object, the present invention provides a multistory multicolumn storing installation comprising: a first block comprising two unpartitioned, parallel, storing columns, a lifting mechanism installed in one of the two storing columns, laterally movable platforms provided in the two storing columns in a vertical, multilayer arrangement so as to form storing divisions of the same height, each division being provided with a transporting unit and a driving unit for laterally moving each laterally movable platform provided in each storing division of each column; a second block of a construction similar to that of the first block, except that one of the columns is not provided with the laterally movable platforms, and disposed adjacent to the first block; and wherein each laterally movable platform carries thereon a pallet adapted to be separated from the platform to be transported vertically by the lifting mechanism.
In the multistory multicolumn storing installation of the present invention, each movable platform serves as the floor of each storing division, and a pallet loaded with a cargo can be supported on each movable platform. Each storing division of the storing column having the lifting mechanism respectively is provided with a transporting unit and a driving unit for laterally moving the movable platform. Since one od the columns of the second block equipped with the lifting mechanism does not have any movable platforms, it only defines an empty space. Consequently, the movable platforms in the storing divisions of the adjacent columns can be transferred into the empty space of the second block equipped with the lifting mechanism. Thus, when all the movable platforms in the storing divisions of the column of the first block adjacent to the column of the second block having the lifting mechanism have been transferred to the empty space of the column of the second block equipped with the lifting mechanism, the construction of the first block changes into the original construction of the second block, and the construction of the second block changes into the original construction of the first block.
Accordingly, the movable platform is evacuated temporarily to the empty space of the storing column of the second block having the lifting mechanism to make way for the movable platform loaded with a cargo to be unloaded, and then cargoes stored in the storing divisions can be sequentially transferred to the adjacent storing divisions. Thus, the movable platform loaded with a cargo to be unloaded or transported can be transferred into the empty space of the column having the lifting mechanism, and the pallet loaded with the cargo is separated from the movable platform and it can be moved vertically by the lifting mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
A multistory multicolumn storing installation in a preferred embodiment of the present invention as applied to a multistory parking garage will be described hereinafter with reference to the accompanying drawings in which:
FIG. 1 is a front view of a multistory multicolumn storing installation of the present invention;
FIG. 2 is a sectional side elevation taken along the line II--II in FIG. 1;
FIG. 3 is a perspective view showing the relationship between a movable platform, a driving unit, a transporting unit, a pallet and lifting frames of the multistory multicolumn storing installation of the present invention;
FIGS. 4A-4D are diagrammatically explaining the operation of the multistory multicolumn storing installation of the present invention, in which FIGS. 4A and 4B illustrate the operation by using a lifting mechanism of a second block, and FIGS. 4C and 4D illustrate the operation by using a lifting mechanism of a first block; and
FIGS. 5A and 5B are diagrammatic views illustrating the difference in increasing the storing capacity between the multistory multicolumn storing installation of the present invention and a conventional tower type multistory storing installation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, a frame structure 1 is constructed to form storing columns A, B, C and D, and tiers 1F, 2F, 3F and 4F. As shown in FIG. 1, the left-hand storing columns A and B constitute a first block, and the right-hand storing columns C and D constitute a second block. Although there are no partition(s) between the adjacent storing columns, each storing division is designated by the names of the corresponding storing column and the corresponding floor; for example, the storing division on the third floor 3F in the storing column A is designated by "A3".
Vehicles are received or sent out from the first floor 1F. The storing columns A and D have storing divisions A1 to A4 and D1 to D4, exclusively for storing vehicles, with storing divisions A2 to A4 and D2 to D4. Namely, the second floor 2F up to the fourth floor 4F of columns A and D are provided with movable platforms indicated at 12, 13, 14, 42, 43 and 44, respectively, which are designated generally by T. Four lifting carriages 6 are disposed for vertical movement in the storing column B. The front and back lifting carriages 6, 6 on each side of the storing column B are connected by a lifting frame 7. A lifting mechanism 5 is disposed in the upper portion of the fourth floor 4F to suspend the lifting frames 7, 7 by wire ropes 9 to move the lifting frames 7, 7 vertically. Movable platforms indicated at 22, 23 and 24, which are designated generally by T, define storing divisions in the storing column B on the second floor 2F, the third floor 3F and the fourth floor 4F. The construction of the storing column C is similar to that of the storing column B. The storing column C is provided with front and back lifting carriages 16 on each side thereof, lifting frames 17 extended between the front and back lifting carriages 16, and a lifting mechanism 15 in the upper portion of the fourth floor 4F to suspend the lifting frames 17, 17 by wire ropes 19 to move the lifting frames 17, 17 vertically. The storing column C is not provided with any movable platform T.
A pallet P to be loaded with a cargo, for example, a vehicle K, is placed on each movable platform T. Pallets P placed on the movable platforms 12, 13, 14, 22, 23, 24, 42, 43 and 44 are designated by 12p, 13p, 14p, 22p, 23p, 24p, 42p, 43p and 44p, respectively. All the movable platforms T are identical in shape and dimensions, and all the pallets P are identical in shape and dimension. Referring to FIG. 3, the front and back frame members 25 of the movable platform T are provided with projections 26, respectively, and the pallet P has its front and back edges with bifurcate projections 27, respectively. When the pallet P is put in place on the movable platform T, the projections 26 enter into and engage with grooves 28 of the corresponding bifurcate projections 27 to restrain the lateral displacement of the pallet P on the movable platform T. The front and back frame members 25 of the movable platform T restrain the pallet P from back-and-forth displacement.
The lifting mechanisms 5 and 15 are of identical construction and hence the corresponding parts thereof will be designated by the same reference numerals. The lifting mechanism 5 (15) is adapted to rotate the winding drums 34, 34, being directly connected with a shaft 33 of a sprocket 32 in the normal or the reverse direction through a chain 31 by means of a braked geared motor 30. As a result, wire ropes 9 (19) are wound around or drawn out from winding drums 34, 34. As shown in FIG. 3, the carriage 6 (16) is guided by rollers 52 on rails 51 provided on the frame structure 1. Each wire rope 9 (19) is extended along a guide plate 53 provided on the lifting carriage 6 (16), and the free end of the wire rope 9 (19) is connected to a stay 54 formed integrally with the lifting frame 7 (17) fixed to the lifting carriage 6 (16) by a connecting member 55. The tightness of the wire rope 9 (19) is adjusted by a turnbuckle 56. The other end of each wire rope 9 (19) is extended via guide pulleys 61, 62, 63 and a tension pulley 64 to the corresponding winding drum 34 and is fastened to the circumference of the winding drum 34. The braked geared motor 30 of the lifting mechanism 5 (15) thus constructed is controlled by a separately provided controller (not shown) to move the lifting frames 7 (17) upward or downward or to stop the lifting frames 7 (17) at a desired position.
The pair of lifting frames 7 (17) are moved vertically at the same speed in the storing column B (C) by the lifting mechanism 5 (15) provided in the storing column B (C). The span between the lifting frames 7 and 7 (17 and 17) is equal to the distance between the centers of downwardly opening channels 65 forming the opposite side edges of the pallet P. When the lifting frames 7 (17) are moved upwardly, they engage the channels 65 supported on the upper movable platform T and lift up the pallet P from the movable platform T.
A driving unit 71 for laterally moving the movable platform T and a transporting unit 72 are provided on each of a front beam 70f and a rear beam 70r of the frame structure 1 on each of the floors 2F, 3F and 4F of each of the storing columns A and B of the first block and the storing columns C and D of the second block. Each driving unit 71 has a braked geared motor 73 controlled by signals from a separately provided controller (not shown) for rotating a driving sprocket 74 in the normal or the reverse direction, or stopping its rotation. The driving sprocket 74 transmits the rotating motion to an intermediate sprocket 76 through a chain 75, and coupled sprockets 79 are all driven through chains 78, 78 by a driven sprocket 77 coaxial with the intermediate sprocket 76.
As shown in FIG. 3, the transporting unit 72 provided on the front beam 70f of the frame structure 1 has V-grooved rollers 80f arranged in a line. In FIG. 3, only one transporting unit 72 is shown as an example. The transporting unit 72 provided on the rear beam 70r has flat rollers 80r. As shown in FIG. 3, each of the sprockets 79 and each of the rollers 80f are fixedly mounted coaxially on a rotary shaft 81, so that the sprockets 79 and the rollers 80f rotate simultaneously in the same direction. Each rotary shaft 81 is supported in bearings 82 and 83 fixed to the front beam 70f of the frame structure 1. All the driving units 71 are identical in structure and all the transporting units 72 are identical in structure, and they are mounted on the front beams 70f and the rear beams 70r on all the floors of 2F to 4F of all the storing columns.
The rollers 80f supported on the front beam 70f and the rollers 80r supported on the rear beam 70r are rotated in the same direction at the same rotating speed to move the movable platform T supported on the rollers 80f and 80r. A rail 90 having a V-shaped cross section and attached to and projected from the lower surface of the frame member 25 of the movable platform T engages the V-grooved rollers 80f and movable platform T is moved laterally by the rotation of the rollers 80f, preventing back-and-forth displacement of the moving platform T. On the other hand, the flat lower surface of the frame member 25 of the movable platform T which is in contact with the flat rollers 80r assures smooth lateral movement of the movable platform T. Thus, the movable platform T is supported for lateral movement in a horizontal position on the rollers 80f supported on the front beam 70f of the frame structure 1 and on the rollers 80r supported on the rear beam 70r of the same.
The operation of the multistory multicolumn storing installation of the present invention will be described by referring to FIG. 4, specifically to FIGS. 4A and 4B, with respect to transferring the cargoes (vehicles) in the directions of the arrows a and b as indicated in FIG. 1. Referring to FIG. 4A, the rollers 80f and 80r of the transporting units 72 of the storing divisions B4 and C4 are rotated simultaneously in the normal direction (an arrow mark c), thereupon the pallet 24p loaded with the cargo and stored in the storing division B4 is transferred, together with the movable platform 24, to the storing division C4 as indicated by an arrow mark g1. Then, in FIG. 4B, the lifting frames 17 are elevated as indicated by an arrow mark g2 to lift the pallet 24p alone from the movable platform 24 to a level where the pallet 24p does not interfere with the lateral movement of the movable platform 24. Then, the transporting units 72 of the storing divisions B4 and C4 are rotated simultaneously in the reverse direction (an arrow mark d) to return the movable platform 24 alone to the storing division B4 as indicated by an arrow g3. The lifting frames 17 of the column C are moved downwardly therethrough as indicated by an arrow g4 to the first floor 1F, since the space below the 4F in the column C is empty. Then, the cargo (vehicle) is sent out from the multistory multicolumn storing installation.
In storing a cargo (vehicle) in the storing division B4 or in returning the empty pallet 24p to the storing division B4, the foregoing procedure is reversed. Referring to FIG. 4B, the lifting frames 17 supporting the pallet 24p is moved upward through the storing column C as indicated by an arrow b1 to a level where the pallet 24p does not interfere with the lateral movement of the movable platform 24. Then, the transporting units 72 of the storing divisions B4 and C4 are rotated simultaneously in the normal direction (the arrow c) to move the movable platform 24 to directly under the pallet 24p supported on the lifting frames 17, whereupon the lifting frames 17 are lowered to place the pallet 24p on the movable platform 24. As shown in FIG. 4A, the lifting frames 17 are lowered further as indicated by an arrow b3 to a position where the lifting frames 17 may not interfere with the lateral movement of the movable platform 24. Subsequently, the transporting units 72 of the storing divisions B4 and C4 are rotated simultaneously in the reverse direction (the arrow d) to return the movable platform 24 mounted with the pallet 24p to the storing division B4 as indicated by an arrow b4.
FIGS. 4C and 4D illustrate the procedures of sending out the cargo (vehicle) stored in the storing division A4. Referring to FIG. 4C, all the transporting units 72 of the storing division A4 of the storing column A, the storing divisions B4, B3 and B2 of the storing column B, and the storing divisions C4, C3 and C2 of the storing column C are rotated in the normal direction (arrow c) to transfer the respective movable platforms 24, 23 and 22 of the storing divisions B4, B3 and B2, together with the pallets 24p, 23p and 22p, to the storing divisions C4, C3 and C2, respectively, and to transfer the movable platform 14 of the storing division A4, together with the pallet 14p loaded with the cargo, to the storing division B4 (an arrow s1).
Then, as shown in FIG. 4D, the lifting frames 7 are moved upwardly in the direction of an arrow s2 to lift the pallet 14p alone from the movable platform 14 to a position where the pallet 14p may not interfere with the lateral movement of the movable platform 14. The transporting units 72 of the storing divisions A4 and B4 are rotated simultaneously in the reverse direction (the arrow d) to return the movable platform 14 alone into the storing division A4 as indicated by an arrow s3. The lifting frames 7 are moved downwardly through the storing column B to the first floor 1F as indicated by an arrow s4 to send out the cargo (vehicle).
In storing a cargo (vehicle) in the storing division A4, the foregoing procedure is reversed. Thus, the description of procedure of storing the cargo in the storing division A4 is omitted. Procedures of storing cargoes in the rest of the storing divisions and procedures of sending out cargoes stored in the rest of the storing divisions will be surmised from the foregoing description, and hence the individual description thereof will be omitted. The lateral movement of the movable platforms T and the vertical movement and positioning of the lifting frames 7 and 17 are computer controlled with computer programs made for selecting the most rational moving passages.
Referring to FIG. 5, in adding an additional block N1 of storing columns (shaded storing columns) to a conventional multistory storing installation of a tower type having storing columns 103 installed on both sides of a lifting platform 102 operated by a lifting unit 101 as shown in FIG. 5A, a new lifting platform 104 must be provided between the two additional storing columns 103. Therefore, a ground space corresponding to six storing columns is necessary for the four storing columns. On the other hand, in adding an additional block N2 having two storing columns 107 and 108 to the multistory multicolumn storing installation of the present invention having a first block 105 and a second block 106 as shown in FIG. 5B, the additional storing column 108 having a lifting mechanism 101 can be also used as a storing column. Therefore, with the present invention, the five storing columns can be installed in the same ground space as that needed by the four storing columns of the conventional multistory storing installation of a tower type, as shown in FIG. 5A.
The multistory multicolumn storage installation thus constructed in accordance with the present invention has the driving unit and the transporting unit for laterally moving the movable platform in each of the storing divisions of each of the columns of the first and second blocks. Therefore, one of the columns having the lifting mechanism can be utilized as an empty column for storing or sending out the cargo, and the other column also having the lifting mechanism can be utilized as the storing column, too. Thus, cargoes can systematically be stored and transferred, and both lifting mechanisms of the two columns can be used simultaneously for the efficient reception and delivery of cargoes. Cargoes can be received on or delivered from any of the floors. Furthermore, an additional block comprising two columns, one of which is provided with the lifting mechanism and having the movable platform in all of the storing divisions, except the storing division which is utilized for initially receiving and finally sending out the cargo, may be added to increase the storing capacity. Such additional block or blocks can be added in any desired number.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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This invention is related to a multistory, multicolumn storing installation capable of efficiently storing cargoes. The assembly includes a frame structure that defines four adjacent multistory columns A, B, C and D. Movable pallets P, each of which can be loaded with a cargo such as a vehicle, are normally stored in different layers in three of the columns. The pallets are seated on movable platforms T that shift the platforms laterally between adjacent columns. Lifting mechanisms 5 and 15, each of which is attached to a separate center-located column, B and C, move the pallets and their cargoes between the base level of the structure and the intermediate storage levels. A cargo is transferred between the base level and columns B and D by lifting the pallet through column C to the selected storage level and then laterally transferring it into column, B or D. A cargo is moved between a structure base level and storage column A by initially moving all of the pallets in column B into column C, and then moving the pallet to the selected level and laterally into position in column A.
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CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] The present application is a continuation-in-part claiming priority under 35 U.S.C. §120 to U.S. app. Ser. No. 12/575,024, entitled System and Methods Using Fiber Optics in Coiled Tubing, filed Oct. 7, 2009, and which is a Continuation of 11/135,314 of the same title, filed on May 23, 2005, both of which are incorporated herein by reference in their entireties along with the Provisional Parent of the same title under 35 U.S.C. §119(e), App. Ser. No. 60/575,327, filed on May 28, 2004.
FIELD
[0002] Embodiments described relate to tools and techniques for delivering treatment fluids to downhole well locations. In particular, embodiments of tools and techniques are described for delivering treatment fluids to downhole locations of low pressure bottom hole wells. The tools and techniques are directed at achieving a degree of precision with respect to treatment fluid delivery to such downhole locations.
BACKGROUND
[0003] Exploring, drilling and completing hydrocarbon and other wells are generally complicated, time consuming, and ultimately very expensive endeavors. As a result, over the years, a tremendous amount of added emphasis has been placed on monitoring and maintaining wells throughout their productive lives. Well monitoring and maintenance may be directed at maximizing production as well as extending well life. In the case of well monitoring, logging and other applications may be utilized which provide temperature, pressure and other production related information. In the case of well maintenance, a host of interventional applications may come into play. For example, perforations may be induced in the wall of the well, regions of the well closed off, debris or tools and equipment removed that have become stuck downhole, etc. Additionally, in some cases, locations in the well may be enhanced, repaired or otherwise treated by the introduction of downhole treatment fluids such as those containing acid jetting constituents, flowback control fibers and others.
[0004] With respect to the delivery of downhole treatment fluid, several thousand feet of coiled tubing may be advanced through the well until a treatment location is reached. In man cases a variety of treatment locations may be present in the well, for example, where the well is of multilateral architecture. Regardless, the advancement of the coiled tubing to any of the treatment locations is achieved by appropriate positioning of a coiled tubing reel near the well, for example with a coiled tubing truck and delivery equipment. The coiled tubing may then be driven to the treatment location.
[0005] Once positioned for treatment, a valve assembly at the end of the coiled tubing may be opened and the appropriate treatment fluid delivered. For example, the coiled tubing may be employed to locate and advance to within a given lateral leg of the well for treatment therein. As such, a ball, dart, or other projectile may be dropped within the coiled tubing for ballistic actuation and opening of the valve at the end of the coiled tubing. Thus, the treatment fluid may be delivered to the desired location as indicated. So, by way of example, an acid jetting clean-out application may take place within the targeted location of the lateral leg.
[0006] Unfortunately, once a treatment application through a valve assembly is actuated as noted above, the entire coiled tubing has to be removed from the well to perform a subsequent treatment through the assembly. That is, as a practical matter, in order to re-close the valve until the next treatment location is reached for a subsequent application, the valve should be manually accessible. In other words, such treatments are generally ‘single-shot’ in nature. For example, once a ball is dropped to force open a sleeve or other port actuating feature, the port will remain open until the ball is manually removed and the sleeve re-closed.
[0007] As a result of having to manually access the valve assembly between downhole coiled tubing treatments, a tremendous amount of delay and expense are added to operations wherever multiple coiled tubing treatments are sought. This may be particularly the case where treatments within multilaterals are sought. For example, an acid jetting treatment directed at 3-4 different legs of a multilateral well may involve 6-8 different trips into and out of the well in order to service each leg. That is, a trip in, a valve actuation and clean-out, and a trip out for manual resetting of the valve for each treatment. Given the depths involved, this may add days of delay and tens if not hundreds of thousands of dollars in lost time before complete acid treatment and clean-out to each leg is achieved.
[0008] A variety of efforts have been undertaken to address the costly well trip redundancy involved in coiled tubing fluid treatments as noted above. For example, balls or other projectiles utilized for valve actuation may be constructed of degradable materials. Thus, in theory, the ball may serve to temporarily provide valve actuation, thereby obviating the need to remove the coiled tubing in order to reset or re-close the valve. Unfortunately, this involves reliance on a largely unpredictable and uncontrollable rate of degradation. As such, tight controls over the delivery of the treatment fluids or precisely when the coiled tubing might be moved to the next treatment location are foregone.
[0009] As an alternative to ball-drop type of actuations, a valve assembly may be utilized which is actuated at given pre-determined flow rates. So, for example, when more than 1 barrel per minute (BPM) is driven through the coiled tubing, the valve may be opened. Of course, this narrows the range of flow rate which may be utilized for the given treatment application and reduces the number of flow rates left available for other applications. In a more specific example, this limits the range of flow available for acid jetting at the treatment location and also reduces flow options available for utilizing flow driven coiled tubing tools, as may be the case for milling, mud motors, or locating tools. Thus, as a practical matter, operators are generally left with the more viable but costly manual retrieval between each treatment.
SUMMARY
[0010] A reversible valve assembly is disclosed for coiled tubing deployment into a well from an oilfield surface. The assembly includes a valve disposed within a channel of the assembly for reversibly regulating flow therethrough. A communication mechanism, such as a fiber optic line may be included for governing the regulating of the flow. The valve itself may be of a sleeve, ball and/or adjustable orifice configuration. Further, the valve may be the first of multiple valves governing different passages. Once more, in one embodiment first and second valves may be configured to alternatingly open their respective passages based on input from the communication mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front view of downhole coiled tubing equipment employing an embodiment of a surface controlled reversible coiled tubing valve assembly.
[0012] FIG. 2 is art enlarged cross-sectional view of the reversible coiled tubing valve assembly taken from 2 - 2 of FIG. 1 .
[0013] FIG. 3 is an overview depiction of an oilfield with a multilateral well accommodating the coiled tubing equipment and valve assembly of FIGS. 1 and 2 .
[0014] FIG. 4A is an enlarged view of a locator extension of the coiled tubing equipment signaling access of a leg of the multilateral well of FIG. 3 .
[0015] FIG. 4B is an enlarged view of a jetting tool of the coiled tubing equipment reaching a target location in the leg of FIG. 4A for cleanout.
[0016] FIG. 4C is an enlarged sectional view of the valve assembly of the coded tubing equipment adjusted for a fiber deliver application following the cleanout application of FIG. 4B .
[0017] FIG. 5 is a flow-chart summarizing an embodiment of employing a surface controlled reversible coiled tubing valve assembly in a well.
DETAILED DESCRIPTION
[0018] Embodiments are described with reference to certain downhole applications. For example, in the embodiments depicted herein, downhole cleanout and fiber delivery applications are depicted in detail via coiled tubing delivery. However, a variety of other application types may employ embodiments of a reversible coiled tubing valve assembly for a variety of different types of treatment fluids as described herein. Regardless, the valve assembly embodiments include the unique capacity to regulate fluid pressure and/or delivery for a given downhole application while also being adjustable or reversible for a subsequent application without the need for surface retrieval and manipulation.
[0019] Referring now to FIG. 1 , with added reference to FIG. 3 , a front view of downhole coiled tubing equipment 101 is depicted. The equipment 101 includes a reversible valve assembly 100 which, in conjunction with other downhole tools, may be deployed by coiled tubing 110 at an oilfield 301 . Indeed, the assembly 100 and other tools of the equipment 101 may communicate with, or be controlled by, equipment located at the oilfield 301 as detailed further below. The valve assembly 100 in particular may be utilized in a reversible and/or adjustable manner. That is, it may be fully or partially opened or dosed via telemetric communication with surface equipment.
[0020] A ‘universal’ valve assembly 100 , so to speak, with reversibility, may be employed to reduce trips into and out of a well 380 for fluid based treatments as indicated above. This capacity also lends to easier reverse circulation, that is, flowing fluids into and out of the well 380 . Further, this capacity also allows for utilizing the valve assembly 100 as a backpressure or check valve as needed. Once more, given that the valve assembly 100 operates independent of fluid flow, flow rates through the equipment 101 may be driven as high or as low as needed without being limited by the presence of the assembly 100 .
[0021] Telemetry for such communications and/or control as noted above may be supplied through fiber optic components as detailed in either of application Ser. No. 12/575,024 or 11/135,314, both entitled System and Methods Using Fiber Optics in Coiled Tubing and incorporated herein by reference in their entireties. However, other forms of low profile coiled tubing compatible telemetry may also be employed. For example, encapsulated electrically conductive line of less than about 0.2 inches in outer diameter may be utilized to provide communications between the valve assembly 100 and surface equipment.
[0022] Regardless, the particular mode of telemetry, the power supply for valve assembly 100 maneuvers may be provided through a dedicated downhole source, which addresses any concerns over the inability to transport adequate power over a low profile electrically conductive line and/or fiber optic components. More specifically, in the embodiment shown, an electronics and power housing 120 is shown coupled to the coiled tubing 110 . This housing 120 may accommodate a lithium ion battery or other suitable power source for the valve assembly 100 and any other lower power downhole tools. Electronics for certain downhole computations may also be found in the housing 120 , along with any communicative interfacing between telemetry and downhole tools, as detailed further below.
[0023] The coiled tubing 110 of FIG. 1 is likely to be no more than about 2 inches in outer diameter. Yet, at the same time, hard wired telemetry may be disposed therethrough as indicated above. Thus, the fiber optic or low profile electrically conductive line options for telemetry are many. By the same token, the limited inner diameter of the coiled tubing 110 also places physical limitations on fluid flow options therethrough. That is to say, employing flow rate to actuate downhole tools as detailed further below will be limited, as a practical matter, to flow rates of between about ½ to 2 BPM. Therefore, utilizing structural low profile telemetry for communications with the valve assembly 100 , as opposed to flow control techniques, frees up the limited range of available flow rates for use in operating other tools as detailed further below.
[0024] Continuing with reference to FIG. 1 , the coiled tubing equipment 101 may be outfitted with a locator extension 140 , arm 150 and regulator 130 for use in directing the equipment 101 to a lateral leg 391 of a well 380 as detailed below. As alluded to above, these tools 140 , 150 , 130 may be operate via flow control. More specifically, these tools 140 , 150 , 130 may cooperatively operate together as a pressure pulse locating/communication tool. Similarly, the equipment 101 is also outfitted with a flow operated jetting tool 160 for use in a cleanout application as also detailed below.
[0025] Referring now to FIG. 2 , an enlarged cross-sectional view of the valve assembly 100 taken from 2 - 2 of FIG. 1 is depicted. The assembly 100 includes a central channel 200 . The channel 200 is defined in part by sleeve 225 and ball 250 valves. In the embodiment shown, these valves 225 , 250 are oriented to allow and guide fluid flow through the assembly 100 . More specifically, for the depicted embodiment, any fluid entering the channel 200 from a tool uphole of the assembly 100 (e.g. the noted regulator 130 ) is directly passed through to the tool downhole of the assembly 100 (e.g. the noted locator extension 140 ). With added reference to FIG. 3 , a clean flow of fluid through the assembly 100 in this manner may take place as a matter of providing hydraulic support to the coiled tubing 110 as it is advanced through a well 380 in advance of any interventional applications.
[0026] However, depending on the application stage undertaken via the assembly, these valves 225 , 250 may be in different positions. For example, as depicted in FIG. 4C , the sleeve valve 225 may be shifted open to expose side ports 210 for radial circulation. Similarly, the ball valve 250 may be oriented to a closed position, perhaps further encouraging such circulation, as also shown FIG. 4C .
[0027] Continuing with reference to FIG. 2 , with added reference to FIG. 3 , the particular positioning of the valves 225 , 250 may be determined by a conventional powered communication line 275 . That is, with added reference to FIG. 1 , the line 275 may run from the electronics and power housing 120 . Thus, adequate power for actuating or manipulating the valve 225 or 250 through as solenoid, pump, motor, a piezo-electric stack, a magnetostrictive material, a shape memory material, or other suitable actuating element may be provided.
[0028] At the housing 120 , the line 275 may also be provided with interfaced coupling to the above noted telemetry (of a fiber optic or low profile electrical line). Indeed, in this manner, real-time valve manipulations or adjustment may be directed from an oilfield surface 301 , such as by a control unit 315 . As a result, the entire coiled tubing equipment 101 may be left downhole during and between different fluid flow applications without the need for assembly 100 removal in order to manipulate or adjust valve positions.
[0029] In one embodiment, the assembly 100 may be equipped to provide valve operational feedback to surface over the noted telemetry. For example, the assembly 100 may be outfitted with a solenoid such as that noted above, which is also linked to the communication line 275 to provide pressure monitoring capacity, thereby indicative of valve function.
[0030] It is worth noting that each valve 225 , 250 may be independently operated. So, for example, in contrast to FIG. 2 (or FIG. 4C ) both valves 225 , 250 may also be opened or closed at the same time. Further, a host of additional and/or different types of valves may be incorporated into the assembly 100 . In one embodiment, for example, the ball valve 250 may be modified with a side outlet emerging from its central passage 201 and located at the position of the sleeve valve 225 of FIG. 2 . Thus, the outlet may be aligned with one of the side ports 210 to allow simultaneous flow therethrough in addition to the central channel 200 . Of course, with such a configuration, orientation of the central passage 201 with each port 210 , and the outlet with the channel 200 , may be utilized to restrict flow to the ports 210 alone.
[0031] With specific reference to FIG. 3 , an overview of the noted oilfield 301 is depicted. In this view, the oilfield 301 is shown accommodating a multilateral well 380 which traverses various formation layers 390 , 395 . A different lateral leg 391 , 396 , each with its own production region 392 , 397 is shown running through each layer 390 , 395 . These regions 392 , 397 may include debris 375 for cleanout with a jetting tool 160 or otherwise necessitate fluid based intervention by the coiled tubing equipment 201 . Nevertheless, due to the configuration of the valve assembly 100 , such applications may take place sequentially as detailed herein without the requirement of removing the equipment 201 between applications.
[0032] Continuing with reference to FIG. 3 , the coiled tubing equipment 101 may be deployed with the aid of a host of surface equipment 300 disposed at the oilfield 301 . As shown, the coiled tubing 110 itself may be unwound from a reel 325 and forcibly advanced into the well 380 through a conventional gooseneck injector 345 . The reel 325 itself may be positioned at the oilfield 301 atop a conventional skid 305 or perhaps by more mobile means such as a coiled tubing truck. Additionally, a control unit 315 may be provided to direct coiled tubing operations ranging from the noted deployment to valve assembly 100 adjustments and other downhole application maneuvers.
[0033] In the embodiment shown, the surface equipment 300 also includes a valve and pressure regulating assembly, often referred to as a ‘Christmas Tree’ 355 , through which the coiled tubing 110 may controllably be run. A rig 335 for supportably aligning the injector 345 over the Christmas Tree 355 and well head 365 is also provided. Indeed, the rig 335 may accommodate a host of other tools depending on the nature of operations.
[0034] Referring now to FIGS. 4A-4C , enlarged views of the coiled tubing equipment 101 as it reaches and performs treatments in a lateral leg 391 are shown. More specifically, FIG. 4A depicts a locator extension 140 and arm 150 acquiring access to the leg 391 . Subsequently, FIGS. 48 and 4C respectively reveal fluid cleanout and fiber delivery applications at the production region 392 of the lateral leg 391 .
[0035] With specific reference to FIG. 4A , the locator extension 149 and arm 150 may be employed to gain access to the lateral leg 391 and to signal that such access has been obtained. For example, in an embodiment similar to those detailed in application Ser. No. 12/135,682, Backpressure Valve for Wireless Communication (Xu et al.), the extension 140 and atm 150 may be drawn toward one another about a joint at an angle θ. In advance of reaching the leg 391 , the size of this angle θ may be maintained at a minimum as determined by the diameter of the main bore of the well 380 . However, once the jetting tool 160 and arm 150 gain access to the lateral leg 391 , a reduction in the size of the angle θ may be allowed. As such, a conventional pressure pulse signal 400 may be generated for transmission through a regulator 130 and to surface as detailed in the '682 application and elsewhere.
[0036] With knowledge of gained access to the lateral leg 391 provided to the operator, subsequent applications may be undertaken therein as detailed below. Additionally, it is worth noting that fluid flow through the coiled tubing 110 , the regulator 130 , the extension 140 and the arm 150 is unimpeded by the intervening presence of the valve assembly 100 . That is, to the extent that such flow is needed to avoid collapse of the coiled tubing 110 , to allow for adequate propagation of the pressure pulse signal 400 , or for any other reason, the assembly 100 may be rendered inconsequential. As detailed above, this is due to the fact that any valves 225 , 250 of the assembly 100 are operable independent of the flow through the equipment 101 .
[0037] Continuing now with reference to FIG. 4B , an enlarged view of the noted jetting tool 160 of the coiled tubing equipment 101 is shown. More specifically, this tool 160 is depicted reaching a target location at the production region 392 of the leg 391 for cleanout. Indeed, as shown, debris 375 such as sand, scale or other buildup is depicted obstructing recovery from perforations 393 of the region 392 .
[0038] With added reference to FIGS. 1 and 2 , the ball valve 250 of the assembly 100 may be in an open position for a jetting application directed at the debris 375 . More specifically, 1-2 BPM of an acid based cleanout fluid may be pumped through the coiled tubing 110 and central channel 200 to achieve cleanout via the jetting tool 160 . Again, however, the ball valve 250 being in the open position for the cleanout application is achieved and/or maintained in a manner independent of the fluid flow employed for the cleanout. Rather, low profile telemetry, fiber optic or otherwise, renders operational control of the valve assembly 100 and the valve 250 of negligible consequence or impact on the fluid flow.
[0039] Referring now to FIG. 4C , with added reference to FIG. 2 , an enlarged sectional view of the valve assembly 100 is shown. By way of contrast to the assembly 100 of FIG. 2 , however, the valves 225 , 250 are now adjusted for radial delivery of a fiber 450 following cleanout through the jetting tool 160 of FIG. 4B . Delivery of the fibers 450 through the comparatively larger radial ports 210 in this manner may help avoid clogging elsewhere (e.g. at the jetting tool 160 ). The fibers 450 themselves may be of glass, ceramic, metal or other conventional flowback discouraging material for disposal at the production region 392 to help promote later hydrocarbon recovery.
[0040] Regardless, in order to switch from the cleanout application of FIG. 4B to the fiber delivery of FIG. 4C , the acid flow may be terminated and the ball valve 250 rotated to close off the channel 200 . As noted above, this is achieved without the need to remove the assembly 100 for manual manipulation at the oilfield surface 301 (see FIG. 3 ). A streamlined opening of the sleeve valve 225 to expose radial ports 210 may thus take place in conjunction with providing a fluid flow of a fiber mixture for the radial delivery of the fiber 450 as depicted. Once more, while the fluid flow is affected by the change in orientation of the valves 225 , 250 , the actual manner of changing of the orientation itself is of no particular consequence to the flow. That is, due to the telemetry provided, no particular flow modifications are needed in order to achieve the noted changes in valve orientation.
[0041] Referring now to FIG. 5 , a flow-chart is depicted which summarizes an embodiment of employing a surface controlled reversible coiled tubing valve assembly in a well. Namely, coiled tubing equipment may be deployed into a well and located at a treatment location for performing a treatment application (see 515 , 530 , 545 ). Of particular note, as indicated at 560 , a valve assembly of the equipment may be adjusted at an point along the way with the equipment remaining in the well. Once more, the equipment may (or may not) be moved to yet another treatment location as indicated at 575 before another fluid treatment application is performed as noted at 590 . That is, this subsequent treatment follows adjustment of the valve assembly with the equipment in the well, irrespective of any intervening repositioning of the equipment.
[0042] Embodiments described hereinabove include assemblies and techniques that avoid the need for removal of coiled tubing equipment from a well in order to adjust treatment valve settings. Further, valves of the equipment may be employed or adjusted downhole without reliance on the use of any particular flow rates through the coiled tubing. As a result, trips in the well, as well as overall operation expenses may be substantially reduced where various fluid treatment applications are involved.
[0043] The preceding description has been presented with reference to the disclosed embodiments. Persons skilled in the art and technology to which these embodiments pertain will appreciate that alterations and changes in the described structures and methods of operation may be practiced without meaningfully departing from the principle, and scope of these embodiments. For example, embodiments depicted herein focus on particular cleanout applications and fiber delivery. However, embodiments of tools and techniques as detailed herein may be employed for alternative applications such as cement placement. Additionally, alternative types of circulation may be employed or additional tools such as isolation packers, multicycle circulation valves. Regardless, the foregoing description should not be read as pertaining to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.
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A valve assembly for reversibly governing fluid flow through coiled tubing equipment. Valves of the assembly may be directed by a telemetric line running from an oilfield surface. In this manner, valve adjustment and/or reversibility need not require removal of the assembly from the well in order to attain manual accessibility. Similarly, operation of the valves is not reliant on any particular flow rate or other application limiting means. As such, multiple fluid treatments at a variety of different downhole locations may take place with a reduced number of trips into the well and without compromise to flow rate parameters of the treatments.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority of U.S. provisional patent application Ser. No. 60/644,683, filed 18 Jan. 2005 (but incorrectly indicated as being filed on 19 Jan. 2005), is hereby claimed, and this application is incorporated herein by reference.
[0002] In the US this is a continuation in part of U.S. patent application Ser. No. 10/658,092, filed 9 Sep. 2003, which application claimed priority of U.S. provisional patent application Ser. No. 60/409,177, filed 9 Sep. 2002, both of these applications are incorporated herein by reference, and priority of both is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0004] Not applicable
BACKGROUND
[0005] In top drive rigs, the use of a top drive unit, or top drive power unit is employed to rotate drill pipe, or well string in a well bore. Top drive rigs can include spaced guide rails and a drive frame movable along the guide rails and guiding the top drive power unit. The traveling block supports the drive frame through a hook and swivel, and the driving block is used to lower or raise the drive frame along the guide rails. For rotating the drill or well string, the top drive power unit includes a motor connected by gear means with a rotatable member both of which are supported by the drive frame.
[0006] During drilling operations, when it is desired to “trip” the drill pipe or well string into or out of the well bore, the drive frame can be lowered or raised. Additionally, during servicing operations, the drill string can be moved longitudinally into or out of the well bore.
[0007] The stem of the swivel communicates with the upper end of the rotatable member of the power unit in a manner well known to those skilled in the art for supplying fluid, such as a drilling fluid or mud, through the top drive unit and into the drill or work string. The swivel allows drilling fluid to pass through and be supplied to the drill or well string connected to the lower end of the rotatable member of the top drive power unit as the drill string is rotated and/or moved up and down.
[0008] Top drive rigs also can include elevators are secured to and suspended from the frame, the elevators being employed when it is desired to lower joints of drill string into the well bore, or remove such joints from the well bore.
[0009] At various times top drive operations, beyond drilling fluid, require various substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as the top drive unit is rotating and/or moving the drill or well string up and/or down, but bypassing the top drive's power unit so that the substances do not damage/impair the unit. Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movement by the top drive unit of the drill or well string.
[0010] A need exists for a device facilitating insertion of various substances downhole through the drill or well string, bypassing the top drive unit, while at the same time allowing the top drive unit to rotate and/or move the drill or well string.
[0011] One example includes cementing a string of well bore casing. In some casing operations it is considered good practice to rotate the string of casing when it is being cemented in the wellbore. Such rotation is believed to facilitate better cement distribution and spread inside the annular space between the casing's exterior and interior of the well bore. In such operations the top drive unit can be used to both support and continuously rotate/intermittently reciprocate the string of casing while cement is pumped down the string's interior. During this time it is desirable to by-pass the top drive unit to avoid possible damage to any of its portions or components.
[0012] The following US patents are incorporated herein by reference: U.S. Pat. No. 4,722,389.
[0013] While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”
BRIEF SUMMARY
[0014] The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner. The invention herein broadly relates to an assembly having a top drive arrangement for rotating and longitudinally moving a drill or well string. In one embodiment the present invention includes a swivel apparatus, the swivel generally comprising a mandrel and a sleeve, the swivel being especially useful for top drive rigs.
[0015] The sleeve can be rotatably and sealably connected to the mandrel. The swivel can be incorporated into a drill or well string and enabling string sections both above and below the sleeve to be rotated in relation to the sleeve. Additionally, the swivel provides a flow path between the exterior of the sleeve and interior of the mandrel while the drill string is being moved in a longitudinal direction (up or down) and/or being rotated/reciprocated. The interior of the mandrel can be fluidly connected to the longitudinal bore of casing or drill string thus providing a path from the sleeve to the interior of the casing/drill string.
[0016] In one embodiment an object of the present invention is to provide a method and apparatus for servicing a well wherein a swivel is connected to and below a top drive unit for conveying pumpable substances from an external supply through the swivel for discharge into the well string, but bypassing the top drive unit.
[0017] In another embodiment of the present invention is provided a method of conducting servicing operations in a well bore, such as cementing, comprising the steps of moving a top drive unit longitudinally and/or rotationally to provide longitudinal movement and/or rotation/reciprocation in the well bore of a well string suspended from the top drive unit, rotating the drill or well string and supplying a pumpable substance to the well bore in which the drill or well string is manipulated by introducing the pumpable substance at a point below the top drive power unit and into the well string.
[0018] In other embodiments of the present invention a swivel placed below the top drive unit can be used to perform jobs such as spotting pills, squeeze work, open formation integrity work, kill jobs, fishing tool operations with high pressure pumps, sub-sea stack testing, rotation of casing during side tracking, and gravel pack or frac jobs. In still other embodiments a top drive swivel can be used in a method of pumping loss circulation material (LCM) into a well to plug/seal areas of downhole fluid loss to the formation and in high speed milling jobs using cutting tools to address down hole obstructions. In other embodiments the top drive swivel can be used with free point indicators and shot string or cord to free stuck pipe where pumpable substances are pumped downhole at the same time the downhole string/pipe/free point indicator is being rotated and/or reciprocated. In still other embodiments the top drive swivel can be used for setting hook wall packers and washing sand.
[0019] In still other embodiments the top drive swivel can be used for pumping pumpable substances downhole when repairs/servicing is being done to the top drive unit and rotation of the downhole drill string is being accomplished by the rotary table. Such use for rotation and pumping can prevent sticking/seizing of the drill string downhole. In this application safety valves, such as TIW valves, can be placed above and below the top drive swivel to enable routing of fluid flow and to ensure well control.
[0020] In an alternative embodiment the unit can include double swivel portions. In another alternative embodiment unit can include an insertion tool for inserting a plug or ball into the unit.
[0021] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0023] FIG. 1 is a schematic view showing a top drive rig with one embodiment of a top drive swivel incorporated in the drill string;
[0024] FIG. 2 is a schematic view of one embodiment of a top drive swivel;
[0025] FIG. 3 is a sectional view of a mandrel which can be incorporated in the top drive swivel of FIG. 2 ;
[0026] FIG. 4 is a sectional view of a sleeve which can be incorporated into the top drive swivel of FIG. 2 ;
[0027] FIG. 5 is a right hand side view of the sleeve of FIG. 4 ;
[0028] FIG. 6 is a sectional view of the top drive swivel of FIG. 2 ;
[0029] FIG. 6A is a sectional view of the packing unit shown in FIG. 6 ;
[0030] FIG. 6B is a top view of the packing injection ring shown in FIGS. 6 and 6 A;
[0031] FIG. 6C is a side view section of the packing injection ring shown in FIG. 6B ;
[0032] FIG. 7 is a top view of a clamp which can be incorporated into the top drive swivel of FIG. 2 ;
[0033] FIG. 8 is a side view of the clamp of FIG. 7 ;
[0034] FIG. 9 is a perspective view and partial sectional view of the top drive swivel shown in FIG. 2 ;
[0035] FIG. 10 is a schematic view of an alternative embodiment of a top drive swivel having double swivel portions;
[0036] FIG. 11 is a schematic view of an alternative embodiment of a top drive swivel having double swivel portions;
[0037] FIG. 12 is a schematic view of an alternative valve wherein the valve ball holds a plug or ball;
[0038] FIG. 13 shows a tool for inserting a ball into the top drive swivel or drill string;
DETAILED DESCRIPTION
[0039] Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
[0040] FIG. 1 is a schematic view showing a top drive rig 1 with one embodiment of a top drive swivel 30 incorporated into drill string 20 . FIG. 1 is shows a rig 1 having a top drive unit 10 . Rig 5 comprises supports 16 , 17 ; crown block 2 ; traveling block 4 ; and hook 5 . Draw works 11 uses cable 12 to move up and down traveling block 4 , top drive unit 10 , and drill string 20 . Traveling block 4 supports top drive unit 10 . Top drive unit 10 supports drill string 20 .
[0041] During drilling operations, top drive unit 10 can be used to rotate drill string 20 which enters wellbore 14 . Top drive unit 10 can ride along guide rails 15 as unit 10 is moved up and down. Guide rails 15 prevent top drive unit 10 itself from rotating as top drive unit 10 rotates drill string 20 . During drilling operations drilling fluid can be supplied downhole through drilling fluid line 8 and gooseneck 6 .
[0042] At various times top drive operations, beyond drilling fluid, require substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as top drive unit 10 is rotating and/or moving drill or well string 20 up and/or down and bypassing top drive unit 10 so that the substances do not damage/impair top drive unit 10 . Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movements of drill or well string 20 being moved/rotated by top drive unit 10 . This can be accomplished by using top drive swivel 30 .
[0043] Top drive swivel 30 can be installed between top drive unit 10 and drill string 20 . One or more joints of drill pipe 18 can be placed between top drive unit 10 and swivel 30 . Additionally, a valve can be placed between top drive swivel 30 and top drive unit 10 . Pumpable substances can be pumped through hose 31 , swivel 30 , and into the interior of drill string 20 thereby bypassing top drive unit 10 . Top drive swivel 30 is preferably sized to be connected to drill string 20 such as 4½ inch IF API drill pipe or the size of the drill pipe to which swivel 30 is connected to. However, cross-over subs can also be used between top drive swivel 30 and connections to drill string 20 .
[0044] FIG. 2 is a schematic view of one embodiment of a top drive swivel 30 . Top drive swivel 30 can be comprised of mandrel 40 and sleeve 150 . Sleeve 150 is rotatably and sealably connected to mandrel 40 . Accordingly, when mandrel 40 is rotated, sleeve 150 can remain stationary to an observer insofar as rotation is concerned. As will be discussed later inlet 200 of sleeve 150 is and remains fluidly connected to a the central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 .
[0045] FIG. 3 is a sectional view of mandrel 40 which can be incorporated in the top drive swivel 30 . Mandrel 40 is comprised of upper end 50 and lower end 60 . Central longitudinal passage 90 extends from upper end 50 through lower end 60 . Lower end 60 can include a pin connection or any other conventional connection. Upper end 50 can include box connection 70 or any other conventional connection. Mandrel 40 can in effect become a part of drill string 20 . Sleeve 150 fits over mandrel 40 and becomes rotatably and sealably connected to mandrel 40 . Mandrel 40 can include shoulder 100 to supper sleeve 150 . Mandrel 40 can include one or more radial inlet ports 140 fluidly connecting central longitudinal passage 90 to recessed area 130 . Recessed area 130 preferably forms a circumferential recess along the perimeter of mandrel 40 and between packing support areas 131 , 132 . In such manner recessed area will remain fluidly connected with radial passage 190 and inlet 200 of sleeve 150 (see FIGS. 4, 6 ).
[0046] To reduce friction between mandrel 40 and packing units 305 , 415 ( FIG. 6 ) and increase the life expectancy of packing units 305 , 415 , packing support areas 131 , 132 can be coated and/or sprayed welded with a materials of various compositions, such as hard chrome, nickel/chrome or nickel/aluminum (95 percent nickel and 5 percent aluminum) A material which can be used for coating by spray welding is the chrome alloy TAFA 95MX Ultrahard Wire (Armacor M) manufactured by TAFA Technologies, Inc., 146 Pembroke Road, Concord N.H. TAFA 95 MX is an alloy of the following composition: Chromium 30 percent; Boron 6 percent; Manganese 3 percent; Silicon 3 percent; and Iron balance. The TAFA 95 MX can be combined with a chrome steel. Another material which can be used for coating by spray welding is TAFA BONDARC WIRE—75B manufactured by TAFA Technologies, Inc. TAFA BONDARC WIRE—75B is an alloy containing the following elements: Nickel 94 percent; Aluminum 4.6 percent; Titanium 0.6 percent; Iron 0.4 percent; Manganese 0.3 percent; Cobalt 0.2 percent; Molybdenum 0.1 percent; Copper 0.1 percent; and Chromium 0.1 percent. Another material which can be used for coating by spray welding is the nickel chrome alloy TAFALOY NICKEL-CHROME-MOLY WIRE-71 T manufactured by TAFA Technologies, Inc. TAFALOY NICKEL-CHROME-MOLY WIRE-71T is an alloy containing the following elements: Nickel 61.2 percent; Chromium 22 percent; Iron 3 percent; Molybdenum 9 percent; Tantalum 3 percent; and Cobalt 1 percent. Various combinations of the above alloys can also be used for the coating/spray welding. Packing support areas 131 , 132 can also be coated by a plating method, such as electroplating. The surface of support areas 131 , 132 can be ground/polished/finished to a desired finish to reduce friction and wear between support areas 131 , 132 and packing units 305 , 415 .
[0047] FIG. 4 is a sectional view of sleeve 150 which can be incorporated into top drive swivel 30 . FIG. 5 is a right hand sectional view of sleeve 150 taken along the lines 4 - 4 . Sleeve 150 can include central longitudinal passage 180 extending from upper end 160 through lower end 170 . Sleeve 150 can also include radial passage 190 and inlet 200 . Inlet 200 can be attached by welding or any other conventional type method of fastening such as a threaded connection. If welded the connection is preferably heat treated to remove residual stresses created by the welding procedure. Also shown is protruding section 155 along with upper and lower shoulders 156 , 157 .
[0048] Lubrication port 210 can be included to provide lubrication for interior bearings. Packing ports 220 , 230 can also be included to provide the option of injecting packing material into the packing units 305 , 415 (see FIG. 6 ). A protective cover 240 can be placed around packing port 230 to protect packing injector 235 (see FIG. 6 ). Optionally, a second protective cover can be placed around packing port 220 , however, it is anticipated that protection will be provided by clamp 600 and inlet 200 . Sleeve 150 can include peripheral groove 205 for attachment of clamp 600 . Additionally, key way 206 can be provided for insertion of a key 700 . FIG. 5 illustrates how central longitudinal passage 180 is fluidly connected to inlet 200 through radial passage 190 . It is preferred that welding be performed using Preferred Industries Welding Procedure number T3, 1550REV-A 4140HT (285/311 bhn) RMT to 4140HT (285/311 bhn(RMT) It is also preferred that welds be X-ray tested, magnetic particle tested, and stress relieved.
[0049] FIG. 6 is a sectional view of the assembled top drive swivel 30 of FIG. 2 . As can be seen sleeve 150 slides over mandrel 40 . Bearings 145 , 146 rotatably connect sleeve 150 to mandrel 40 . Bearings 145 , 146 are preferably thrust bearings although many conventionally available bearing will adequately function, including conical and ball bearings. Packing units 305 , 415 sealingly connect sleeve 150 to mandrel 40 . Inlet 200 of sleeve 150 is and remains fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 and protruding section 155 form a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 (arrow 201 ); passing through radial passage 190 (arrow 202 ); passing through recessed area 130 (arrow 202 ); passing through one of the plurality of radial inlet ports 140 (arrow 202 ), passing through central longitudinal passage 90 (arrow 203 ); and exiting mandrel 40 via lower end 60 at pin connection 80 (arrows 204 , 205 ).
[0050] FIG. 6A shows a blown up schematic view of packing unit 305 . Packing unit 305 can comprise packing end 320 ; packing ring 330 , packing ring 340 , packing injection ring 350 , packing end 360 , packing ring 370 , packing ring 380 , packing ring 390 , packing ring 400 , and packing end 410 . Packing unit 305 sealing connects mandrel 40 and sleeve 150 . Packing unit 305 can be encased by packing retainer nut 310 and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 305 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . Packing unit 415 can be constructed substantially similar to packing unit 305 . The materials for packing unit 305 and packing unit 415 can be similar.
[0051] Packing end 320 is preferably a bronze female packing end. Packing ring 330 is preferably a “Vee” packing ring—Teflon such as that supplied by CDI part number 0500700-VS-720 Carbon Reflon (having 2 percent carbon). Packing ring 340 is preferably a “Vee” packing ring—Rubber such as that supplied by CDI part number 0500700-VS-850NBR Aramid. Packing injection ring 350 is described below in the discussion regarding FIGS. 6B and 6C . Packing end 360 preferably a bronze female packing end. Packing ring 370 is preferably a “Vee” packing ring—Teflon such as that supplied by CDI part number 0500700-VS-720 Carbon Reflon (having 2 percent carbon). Packing ring 380 is preferably a “Vee” packing ring—Rubber such as that supplied by CDI part number 0500700-VS-850NBR Aramid. Packing ring 390 is preferably a “Vee” packing ring—Teflon such as that supplied by CDI part number 0500700-VS-720 Carbon Reflon (having 2 percent carbon). Packing ring 400 is preferably a “Vee” packing ring—Rubber such as that supplied by CDI part number 0500700-VS-850NBR Aramid. Packing end 410 is preferably a bronze male packing ring. Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials. Bronze rings preferably meet or exceed an SAE 660 standard.
[0052] A packing injection option can be provided for top drive swivel 30 . Injection fitting 225 can be used to inject additional packing material such as teflon into packing unit 305 . Head 226 for injection fitting 225 can be removed and packing material can then be inserting into fitting 225 . Head 226 can then be screwed back into injection fitting 225 which would push packing material through fitting 225 and into packing port 220 . The material would then be pushed into packing ring 350 . Packing ring 350 can comprise radial port 352 and transverse port 351 . The material would proceed through radial port 352 and exit through transverse port 351 . The material would tend to push out and squeeze packing rings 340 , 330 , 320 and packing rings 360 , 370 , 380 , 390 , 400 tending to create a better seal between packing unit 305 with mandrel 40 and sleeve 150 . The interaction between injection fitting 235 and packing unit 415 can be substantially similar to the interaction between injection fitting 225 and packing unit 305 . A conventionally available material which can be used for packing injection fittings 225 , 235 is DESCO™ 625 Pak part number 6242-12 in the form of a 1 inch by ⅜ inch stick and distributed by Chemola Division of South Coast Products, Inc., Houston, Tex. In FIG. 6 , injection fitting 235 is shown ninety degrees out of phase and, is preferably located as shown in FIG. 9 .
[0053] Injection fittings 225 , 235 have a dual purpose: (a) provide an operator a visual indication whether there has been any leakage past either packing units 305 , 415 and (b) allow the operator to easily inject additional packing material and stop seal leakage without removing top drive swivel 30 from drill string 20 .
[0054] FIGS. 6B and 6C shows top and side views of packing injection ring 350 . Packing injection ring 350 includes a male end 355 at its top and a flat end 356 at its rear. Ring 350 includes peripheral groove 353 around its perimeter. Optionally, ring 350 can include interior groove along its interior. A plurality of transverse ports 351 , 351 ′, 351 ″, 351 ′″, etc. extending from male end 355 to flat end 356 can be included and can be evenly spaced along the circumference of ring 350 . A plurality of radial ports 352 , 352 ′, 352 ″, 352 ′″, etc. can be included extending from peripheral groove 353 and respectively intersecting transverse ports 351 , 351 ′, 351 ″, 351 ′″, etc. Preferably, the radial ports can extend from peripheral groove 353 through interior groove 354 .
[0055] Retainer nut 800 can be used to maintain sleeve 150 on mandrel 40 . Retainer nut 800 can threadably engage mandrel 40 at threaded area 801 . Set screw 890 can be used to lock in place retainer nut 800 and prevent nut 800 from loosening during operation. Set screw 890 threadably engages retainer nut 800 through bore 900 and sets in one of a plurality of receiving portions 910 formed in mandrel 40 . Retaining nut 800 can also include grease injection fitting 880 for lubricating bearing 145 . Wiper ring 271 set in area 270 protects against dirt and other items from entering between the sleeve 150 and mandrel 40 . Grease ring 291 set in area 290 holds in lubricant for bearing 145 .
[0056] Bearing 146 can be lubricated through grease injection fitting 211 and lubrication port 210 . Bearing 145 can be lubricated through grease injection fitting 881 and lubrication port 880 .
[0057] FIG. 7 is a top view of clamp 600 which can be incorporated into top drive swivel 30 . FIG. 8 is a side view of clamp 600 . Clamp 600 comprises first portion 610 and second portion 620 . First and second portions 610 , 620 can be removably attached by fasteners 670 , 680 . Clamp 600 fits in groove 205 / 605 of sleeve 150 ( FIG. 6 ). Key 700 can be included in keyway 690 . A corresponding keyway 691 is included in sleeve 150 of top drive swivel 30 . Keyways 690 , 691 and key 700 prevent clamp 600 from rotating relative to sleeve 150 . A second key 720 can be installed in keyways 710 , 711 . Shackles 650 , 660 can be attached to clamp 600 to facilitate handing top drive swivel 30 when clamp 600 is attached. Torque arms 630 , 640 can be included to allow attachment of clamp 600 (and sleeve 150 ) to a stationary part of top drive rig 1 and prevent sleeve 150 from rotating while drill string 20 is being rotated by top drive 10 (and top drive swivel 30 is installed in drill string 20 ). Torque arms 630 , 640 are provided with holes for attaching restraining shackles. Restrained torque arms 630 , 640 prevent sleeve 150 from rotating while mandrel 40 is being spun. Otherwise, frictional forces between packing units 305 , 415 and packing support areas 131 , 135 of rotating mandrel 40 would tend to also rotate sleeve 150 . Clamp 600 is preferably fabricated from 4140 heat treated steel being machined to fit around sleeve 150 .
[0058] FIG. 9 is an overall perspective view (and partial sectional view) of top drive swivel 30 . Sleeve 150 is shown rotatably connected to mandrel 40 . Bearings 145 , 146 allow sleeve 150 to rotate in relation to mandrel 40 . Packing units 305 , 415 sealingly connect sleeve 150 to mandrel 40 . Retaining nut 800 retains sleeve 150 on mandrel 40 . Inlet 200 of sleeve 150 is fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 and protruding section 155 form a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 ; passing through radial passage 190 ; passing through recessed area 130 ; passing through one of the plurality of radial inlet ports 40 ; passing through central longitudinal passage 90 ; and exiting mandrel 40 through central longitudinal passage 90 at lower end 60 and pin connection 80 . In FIG. 9 , injection fitting 225 is shown ninety degrees out of phase and, for protection, is preferably located between inlet 200 and clamp 600 .
[0059] Mandrel 40 takes substantially all of the structural load from drill string 20 . The overall length of mandrel 40 is preferably 52 and 5/16 inches. Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. NC50 is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Such tool joint designation is equivalent to and interchangeable with 4½ inch IF (Internally Flush), 5 inch XH (Extra Hole) and 5½ inch DSL (Double Stream Line) connections. Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7G for new rotary shouldered tool joint connections having 6⅝ inch outer diameter and a 2¾ inch inner diameter. The Strength and Design Formulas of API 7G-Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 1,477 kpounds tensile load at the minimum yield stress; (b) 62,000 foot-pounds torsion load at the minimum torsional yield stress; and (c) 37,200 foot-pounds recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
[0060] Sleeve 150 is preferably fabricated from 4140 heat treated round mechanical tubing having the following properties: (120,000 psi minimum tensile strength, 100,000 psi minimum yield strength, and 285/311 Brinell Hardness Range). The external diameter of sleeve 150 is preferably about 11 inches. Sleeve 150 preferably resists high internal pressures of fluid passing through inlet 200 . Preferably top drive swivel 30 with sleeve 150 will withstand a hydrostatic pressure test of 12,500 psi. At this pressure the stress induced in sleeve 150 is preferably only about 24.8 percent of its material's yield strength. At a preferable working pressure of 7,500 psi, there is preferably a 6.7:1 structural safety factor for sleeve 150 .
[0061] To minimize flow restrictions through top drive swivel 30 , large open areas are preferred. Preferably each area of interest throughout top drive swivel 30 is larger than the inlet service port area 200 . Inlet 200 is preferably 3 inches having a flow area of 4.19 square inches. The flow area of the annular space between sleeve 150 and mandrel 40 is preferably 20.81 square inches. The flow area through the plurality of radial inlet ports 140 is preferably 7.36 square inches. The flow area through central longitudinal bore 90 is preferably 5.94 square inches.
[0062] FIG. 10 is a schematic view of an alternative embodiment of a top drive swivel 1000 having double swivel portions 1030 , 2030 and intermediate valve 1006 . Each swivel portion 1030 , 2030 can be constructed similar to top drive swivel 30 . Similar to top drive swivel 30 shown in FIG. 1 , top drive swivel 1000 can be connected to top drive unit 10 and drill string 20 . Valve 1006 can be a full opening ball valve. One or more additional valves can be included between swivel portions 1030 , 2030 .
[0063] Stabilizing bracket 1005 can be used to stabilize swivels 1030 and 2030 (and sleeves 1050 and 2050 ). Stabilizing bracket can include arm 1010 which can be connected rigidly, slidingly, or otherwise to rig 1 (shown in FIG. 1 ) or some other fixed member for constraining or restricting movement of sleeves 1050 and 2050 . A sliding connection of arm 1010 allows top drive unit 1 to move drill string 20 up and down at the same time top drive unit 1 rotates drill string 20 . A rigid connection would restrict up and down movement(but not rotation) of drill string 20 . Connecting stabilizing bracket 1010 to rig 1 is preferred to address the tendency of frictional forces (occurring between mandrels 1040 and 2040 and sleeves 1050 and 2050 ) causing sleeves 1050 and 2050 to rotate when mandrels 1040 and 2040 rotate.
[0064] Rotation of top drive unit 1 can cause rotation of swivel mandrel 1040 as shown by arrow 1001 . Rotation of swivel mandrel 1040 in the direction of arrow 1001 causes rotation of valve member 1006 as shown by arrow 1002 . Rotation of valve member 1006 in the direction of arrow 1002 causes rotation of swivel mandrel 2040 as shown by arrow 1003 . Rotation of swivel mandrel 2040 in the direction 1003 causes rotation of drill string 20 . Rotation of top drive unit in the opposite direction as that described above will cause rotation of mandrel 1040 , valve member 1006 , and mandrel in the opposite direction of arrows 1001 , 1002 , and 1003 .
[0065] Line 1300 can be used for fluids or other items which are to be pumped into either or both of swivels 1030 , 2030 . Line 1300 can comprise manifold 1009 , lines 1301 , 1302 along with valve members 1007 and 1008 . Valve members 1007 and 1008 can be any conventionally available valves such as ball or gate valves and can be manually or automatically operated. Valve member 1007 can control flow to/from swivel 1030 . Valve member 1008 can control flow to/from swivel 2030 . Valve member 1006 can control flow between mandrel 1040 and mandrel 2040 . Control valve 2000 can be included in line 1300 to control flow to/from line 1300 .
[0066] With valve 1006 closed (and valves 1007 , 1008 open) fluids can be pumped from top drive unit 10 , into swivel 2050 , into line 1301 , through open valve 1007 , through manifold 1009 , through open valve 1008 , into mandrel 2040 , through lower portion of mandrel 2041 , and into drill string 20 . Control valve 2000 is typically closed for this flow circuit. This flow circuit allows valve 1006 to be circumvented when valve 1006 is closed. During this time period mandrels 1040 , 2040 can be rotated by top drive 10 while sleeves 1050 , 2050 remain stationary.
[0067] A double swivel construction provides the flexibility of allowing an operator to divert the flow of fluids from line 1300 to swivel 1030 or to swivel 2030 (or to both swivel 1030 and swivel 2030 ) while drill string 20 is worked without having to break down drill string 20 or stop operations of top drive unit 10 . For example during cementing operations top drive swivel 1000 can be used to pump cement into drill string 20 which can then be used to cement casing in well bore 14 . With valve 1006 open (and valve 1008 closed) cement can be pumped from line 1300 , through open valve 2000 , through open valve 1007 , into line 1301 , into and into swivel 1050 and mandrel 1040 , through lower portion of mandrel 1041 , through open valve 1006 , into mandrel 2040 , through lower portion of mandrel 2040 , and into drill string 20 . If a plug or ball 2005 (shown in FIG. 11 ) had been placed above valve 1006 , then the pumped cement would be separated from downstream fluid by plug or ball 2005 . With valve 1008 open (and valve 1006 closed), cement can be pumped from line 1300 through open valve 2000 , through open valve 1008 , and into swivel 2050 and mandrel 2040 , through lower portion of mandrel 2041 , and into drill string 20 . With valves 1006 , 1007 , and 1008 , cement can be pumped from line 1300 through open valve 2000 and into both swivels 1030 , 2030 .
[0068] FIG. 11 is a schematic view of an alternative embodiment of a top drive swivel 1000 ′ having double swivel portions. In this embodiment, a valve 2001 is placed between top drive unit 10 and swivel 1000 ′. Valves 1007 , 1008 are placed immediately adjacent swivels 1030 , 2030 . Valve 2001 will prevent any fluid being pumped into swivels 1030 , 2030 from entering top drive unit 10 . Valve 2001 will also prevent any fluid from top drive unit 10 from entering top drive swivel 1000 ′. Shown in FIG. 11 is plug or ball 2005 which can be used to clean the inside of drill string 20 or to separate two sets of fluids being pumped into drill string 20 (e.g., drilling/completion fluid versus cement). Preferably plug or ball 2005 is a 5½ inch rubber ball for 4½ inch IF drill string 20 . Different sized balls can be used for different size drill or work strings 20 . Additionally conventionally available plugs can also be used.
[0069] In another alternative embodiment, valve 2001 can be placed above valve 1006 and between swivels 1050 , 2050 . Plug or ball 2005 can be placed between valves 2001 , 1006 . In this embodiment valves 2001 , 1006 hold plug or ball 2005 until it is to be dropped into drill string 20 . Plug or ball 2005 is dropped by opening valves 2001 , 1006 . Fluid being pumped through mandrel 1040 will force plug or ball 2005 to drop into drill string 20 .
[0070] FIG. 12 shows another embodiment where valve 1006 is a ball valve and plug or ball 2005 is inserted into the through bore 1006 B of valve ball 1006 A of valve 1006 . Valve 1006 is constructed such that through bore 1006 B can accommodate plug or ball 2005 when valve 1006 A is completely in the closed position. In the closed position valve ball 1006 A will trap plug or ball 2005 , but in the open position fluid pressure (schematically illustrated by arrow 1004 ) will force plug or ball 2005 out of valve 1006 and into drill string 20 .
[0071] FIG. 13 shows a tool 2010 for inserting plug or ball 2005 into position in top drive swivel 1000 or valve 1006 . Tool 2010 can comprise three sections: upper section 2011 , middle section 2013 , and lower section 2012 . Upper section 2011 can include a connection for pumping fluid. Upper section 2011 can be removably connected to middle section 2013 by a threaded section 2014 . Middle section 2013 can include an enlarged inner diameter section 2015 and a narrowing diameter section 2016 . Middle section 2013 can also include an o-ring seal 2014 . Lower section 2012 can include threaded section 2018 and an o-ring seal 2019 .
[0072] To insert plug or ball into valve 1006 of top drive swivel 1000 shown in FIG. 10 , lower section 2012 can be threaded into the upper portion of mandrel 1040 . Valve 1006 should be partially closed to prevent plug or ball 2005 from passing. Plug or ball 2005 is inserted into enlarged inner diameter section 2015 of tool 2010 . Upper section 2011 is threaded into enlarged diameter section. A pipe or hose is connected to upper section 2011 and pressurized fluid is pumped through upper section 2011 in the direction of arrow 2020 . The pressurized fluid will force plug or ball 2005 through narrowing section 2016 and out through lower section 2012 and into mandrel 1040 . Plug or ball 2005 will continue downward until stopped by valve 1006 . At this point fluid pressure is cut off and tool 2010 is removed. Valve 1006 is complete closed and top drive swivel 1000 is installed in drill string 20 . When plug or ball 2005 is to be dropped into drill string 20 , valve 1006 is opened and fluid is pumped through mandrel 1040 in the in the direction of arrow 2021 .
[0073] The following will illustrate various methods for using swivels 30 , 1000 .
[0000] Swivel Tool 30 and Swiveling Ball Drop Assembly 1000
[0074] There are many advantages that will lead to successful operations and a reduction in rig time when utilizing Swivel Tool 30 and Swiveling Ball Drop Manifold Assemblies 1000 .
[0075] Cement Plugs set in open hole or in casing can be better distributed along the cement column, especially in directionally drilled wells, as pipe 18 , 20 rotation can be applied while pumping the plugs in place. Swivel Tool 30 will perform efficiently, either in setting a Balanced Plug or using a Plug Catcher.
[0076] When displacing a hole 14 to a reduced mud weight where a high differential pressure may be encountered, the bit can be run to Total Depth and hole 14 displaced in a single step procedure, saving time as to staging in the hole 14 . The pipe 20 can be rotated while the hole 14 is being displaced, which will lead to less contamination of the interface between fluids being displaced and less debris remaining in the hole 14 .
[0077] When the Well 14 is perforated underbalance with a Tubing Conveyed Perforate assembly, the Manifold 1000 assembly can be utilized. A Wireline can be rigged up above the Manifold 1000 and a Correlation Log run, the Tubing Conveyed Perforate moved to be put on depth, lines rigged up and tested, Tubing Conveyed Perforate Packer set, By-Pass 1007 opened, the desired underbalance pumped, By-Pass 1007 closed and the Tubing Conveyed Perforate fired and flow back achieved, By-Pass 1007 opened and the influx reversed out. If the primary detonation of the Tubing Conveyed Perforate is a bar drop, the Full Opening Ball Valve 1006 would be ideal for this purpose.
[0078] The Swivel Manifold 1000 , with the 4½″ IF connections can easily be spaced out with in a stand of drill pipe and stored on the derrick before and after the operation of choice has been performed and easily applied to the Top Drive system 10 .
[0079] The outside torque applied to the Swivel Tool assemblies 1050 , 2050 is a minimum torque value when the pipe 18 , 20 is rotated, however, a Stiff-Arm 1010 assembly can be easily attached and utilized.
[0080] The Swiveling Ball Drop Manifold 1000 can be equipped with 3 inch Low Torque Valves 1007 , 1008 leading to less restriction when pumping fluid through at higher volumes, if desired.
[0000] Open Hole Cement Plug Swivel Tool 30 Only
[0081] (1) Pick up Ported Mule Shoe Sub that has been orange peeled in with a round tapered bottom with one-half inch circular port at the bottom of sub with added one-half inch circular ports staggered on side of sub. The round tapered bottom will help keep the Mule Shoe Sub from setting down in a possible ledge or other downhole obstruction.
[0082] (2) Pick up enough Cement Stingers to cover the height of intended cement plug and 100 feet. Scratchers and Centralizers are optional.
[0083] (3) Trip in hole 14 to casing shoe.
[0084] (4) In a strand of Drill Pipe, pick up the Swivel Tool 30 (with a TIW Valve in the open position on top of the Swivel Tool and a Low Torque Valve in the closed position connected to the side-entry port 200 of the Swivel Tool 30 which is called the pump in sub) and set back on derrick 1 . Rig up Cement Lines on rig 1 floor to be ready for connection to Swivel Tool 30 , once in the hole 14 to cement depth.
[0085] (5) Continue in hole 14 to cement depth.
[0086] (6) Rig up cement lines to Swivel Tool 30 .
[0087] (7) Circulate and condition mud. Rotate the Drill Pipe 18 , 20 while circulating.
[0088] (8) Off-Line operations can be performed while circulating. Cementer can prepare the Spacers and Cement Mix water. The Pre-Job Task Meeting can also be conducted and cement lines tested.
[0089] (9) After the desired circulation time has passed, keep Drill Pipe 18 , 20 rotating, close the TIW Valve above the Swivel Tool 30 , pressure up on top of the TIW to +− 1000 pounds per square inch with the Top Drive 10 and open the Low Torque Valve to inlet 200 .
[0090] (10) Pump Spacer, Cement, Spacer and displace as per Cement Program with pipe 18 , 20 rotating at all times.
[0091] (11) After cement has been spotted, rig down cement line and store Swivel Tool 30 on derrick 1 .
[0092] (12) Pull Drill Pipe 20 out of hole above top of cement. Pump Wiper Ball 2005 to Clean the Drill Pipe 20 if desired.
[0093] (13) Pull out of hole 14 .
[0000] Cement Plug Swivel Tool 1000 /Ball Launch Manifold Plug Catcher
[0094] (1) Pick up Ported Mule Shoe Sub that has been orange peeled in with a round tapered bottom with one-half inch circular port at the bottom of sub with added one-half inch circular ports staggered on side of sub. The round tapered bottom will help keep the Mule Shoe Sub from setting down in a possible ledge.
[0095] (2) Pick up enough Cement Stingers to cover the height of intended cement plug and 100 feet. Scratchers and Centralizers are optional.
[0096] (3) Pick up Plug Catcher.
[0097] (4) Place Cement Stringers in hole to casing shoe.
[0098] (5) In a stand of Drill Pipe, pick up the Swivel Tool and Ball Launch Manifold Assembly 1000 with the Full Opening Ball Valve 1006 in the closed position with proper Wiper Ball or Dart 2005 loaded above the closed Ball Valve 1006 . Place the Low Torque Valve 1008 on the Lower Swivel Pump-in Sub 2030 in open position. Place the Low Torque Valve 1007 to the Upper Swivel Pump-In Sub 1030 in the closed position. Stand the Swivel Tool and Ball Launch Manifold Assembly 1000 on the derrick 1 . Rig up Cement Lines on rig 1 floor to be ready to be connected to the Ball Launch Manifold 1000 and also where the Drill Pipe 14 can be circulated with Rig Pumps and/or from the Cement Pump with necessary valves to isolate either set of pumps.
[0099] (6) Continue in hole 14 to cement depth.
[0100] (7) Rig up cement lines to the Swivel Manifold 1000 .
[0101] (8) Circulate and condition mud with rig pumps. Rotate the Drill Pipe 18 , 20 while circulating.
[0102] (9) Off-Line Operations can be performed while circulating. Cementer can prepare the Spacers and Cement Mix water. The Pre-Job Task Meeting can also be conducted and cement lines tested.
[0103] (10) After the desired circulation time has been completed, keep the Drill Pipe 18 , 20 rotating and isolate the Rig Pumps from the Cement Pump. Set the Cement Pump to pump thru the Lower Swivel Pump-In Sub 2030 . Maintain rotation of Drill Pipe 18 , 20 .
[0104] (11) Pump the first Spacer and Cement. When pumping the second Spacer, pump the calculated volume of the Cement Stinger. Shut down the Cement Pump, close the Low Torque Valve 1008 to the Lower Swivel Pump-In Sub 2030 and open the Low Torque Valve 1007 to the Upper Swivel Pump-In Sub 1030 . Open the Full Opening Ball Valve 1006 , releasing the Wiper Ball or Dart 2005 .
[0105] (12) Displace the Cement. When the Wiper Ball or Dart 2005 lands at the Plug Catcher shut down pumping.
[0106] (13) Store the Swivel Tool and Ball Launch Manifold Assembly 1000 back on the derrick 1 .
[0107] (14) Pull Drill Pipe 20 out of hole 14 , above top of cement.
[0108] (15) Rig up pump line and shear Plug catcher to the Circulation position.
[0109] (16) Pull out of hole 14 .
[0000] Well Clean Out High Differential Displacement Floater Completion Swivel Tool Only
[0110] (1) Pick up Bit plus Scraper and Brush assembly.
[0111] (2) Trip in hole 14 , with Bit half way from Mud Line and Float Collar, pick up second Scraper/Brush assembly.
[0112] (3) Continue to Trip in hole 14 , tag Float Collar.
[0113] (4) Pick up Swivel Tool 30 (but omitting right angle inlet 200 ). Rig up high pressure pump plus rig pumps to the Swivel Tool 30 . Test lines to desired pressure.
[0114] (5) Circulate bottoms up with existing Mud System with rig pumps, rotate drill pipe 20 while circulating.
[0115] (6) Isolate the rig Pumps and test Production Casing with the high pressure pump, if not already tested.
[0116] (7) Displace the Choke, Kill and Booster lines with Seawater.
[0117] (8) Start displacing the existing Mud System with Seawater by pumping down the Drill Pipe 20 with returns up the Annulus with the High Pressure Pump. Once the Seawater has rounded the Bit and the Differential Pressure declines to a safe working pressure, switch to the Rig Pumps and finish the Displacement. (Maintain pipe 20 rotation throughout the displacement to help in removing debris from around the Tool Joints).
[0118] (9) Pull out of hole 14 until the Scraper/Brush assembly is at the Mud Line (boosting the Riser with Seawater)
[0119] (10) Trip in hole 14 , space out Dual Actuated Ball Service Tool and Riser Brush to be one stand above the Dual Actuated Ball Service Tool and the Riser Brush to be at plus or minus 30 feet above the Riser Flex Joint with the Bit at the Float Collar boost riser while Trip in hole 14 ).
[0120] (11) Rotate pipe 20 and circulate bottoms up with seawater.
[0121] (12) Drop ball and open circulating ports in the Dual Actuated Ball Service Tool.
[0122] (13) Jet wash the Well Head and Blow Out Preventers.
[0123] (14) With the Dual Actuated Ball Service Tool above the Blow Out Preventers, function the Annular and the Pipe Rams to have annular blow out preventer attach to Tool.
[0124] (15) Jet wash the Blow Out Preventers. Pull out of hole 14 jet washing the Marine Riser. Put on the side (lay out) the Riser Brush and Dual Actuated Ball Service Tool.
[0125] (16) Trip in hole 14 to the Float Collar.
[0126] (17) Rotate pipe 20 and circulate bottoms up with seawater.
[0127] (18) Align Fail Safe Valves and Choke Manifold to take returns up the Choke and Kill Lines.
[0128] (19) Pump Spacer Trains down the drill pipe 20 with returns up the Riser. When the Spacer Trains are 75 barrels from the Blow Out Preventers, close the Annular and take returns up the Choke and Kill lines. Slow the pumps if necessary, but do not shut down until the Spacer Trains are circulated from the Hole 14 .
[0129] (20) Align The Choke Manifold and Pump Riser Spacer Trains down the Choke, Kill, and Booster lines. Boost Spacer Trains from the Riser at 22 barrels per minute minimum.
[0130] (21) Displace seawater from the Choke, Kill, and Booster Lines with Filtered Completion Fluid.
[0131] (22) Displace seawater from the Hole 14 with Filtered Completion Fluid. Circulate and filter until the National Turbidity Units are at the desired level.
[0132] (23) Pull out of hole 14 .
[0000] Well Clean Out High Differential Displacement Floater Completion
[0133] (1) Pick up Bit plus Scraper and Brush assembly.
[0134] (2) Trip in hole 14 , with Bit halfway from Mud Line and Float Collar, pick up second Scraper/Brush assembly.
[0135] (3) Continue Trip in hole 14 , tag Float Collar.
[0136] (4) Pick up Swivel Tool/Manifold Assembly 1000 with Full Opening Ball Valve 1006 in the closed position. Rig up high pressure pump plus rig pumps to the Manifold Assembly 1000 . Close the lower Low-Torque Valve 1008 and the upper Low-Torque Valve 1007 . Test lines and open the lower Low Torque Valve 1008 .
[0137] (5) Circulate bottoms up with existing Mud System with rig pumps, rotate Drill Pipe 18 , 20 while circulating.
[0138] (6) Isolate the rig Pumps and test Production Casing with the high pressure pump, if not already tested.
[0139] (7) Displace the Choke, Kill, and Booster lines with Seawater.
[0140] (8) Start displacing the existing Mud System with Seawater with the High Pressure Pump. Once the Seawater has rounded the Bit and the Differential Pressure declines to a safe working pressure, switch to the Rig Pumps and finish the displacement. (Maintain Drill Pipe 18 , 20 rotation throughout displacement to help in removing debris from around Tool Joints).
[0141] (9) Pull out of hole 14 until the Scraper/Brush assembly is at the Mud Line (boosting the Riser with Seawater)
[0142] (10) Trip in hole 14 , space out Dual Actuated Ball Service Tool and Riser Brush to be one stand above the Dual Actuated Ball Service Tool and the Riser Brush to be at plus or minus 30 feet above the Riser Flex Joint with the Bit at the Float Collar (boost riser while Trip in hole 14 ).
[0143] (11) Rotate Drill Pipe 18 , 20 and circulate bottoms up with seawater.
[0144] (12) Drop ball 2005 and open circulating ports in the Dual Actuated Ball Service Tool.
[0145] (13) Jet wash the Well Head and Blow Out Preventers.
[0146] (14) With the Dual Actuated Ball Service Tool above the Blow Out Preventers, function the Annular and the Pipe Rams.
[0147] (15) Jet wash the Blow Out Preventers. Pull out of hole jet Washing the Marine Riser. Lay down the Riser Brush and Dual Actuated Ball Service Tool.
[0148] (16) Trip in hole 14 to the Float Collar.
[0149] (17) Rotate pipe 18 , 20 and circulate bottoms up with seawater.
[0150] (18) Align Fail Safe Valves and Choke Manifold to take returns up the Choke and Kill lines.
[0151] (19) Pump Spacer Trains down the Drill Pipe 18 , 20 with returns up the Riser. When the Spacer Trains are 75 barrels from the Blow Out Preventers, close the Annular and take returns up the Choke and Kill Lines. Slow the pumps if necessary, but do not shut down until the Spacer Trains are circulated from the Hole 14 .
[0152] (20) Align The Choke Manifold and Pump Riser Spacer Trains down the Choke, Kill, and Booster Lines. Boost Spacer Trains from the Riser at a minimum of 22 barrels per minute.
[0153] (21) Displace seawater from the Choke, Kill, and Booster lines with Filtered Completion Fluid.
[0154] (22) Displace seawater from the Hole 14 with Filtered Completion Fluid. Circulate and filter until the National Turbidity Units are at the desired level.
[0155] (23) Pull out of hole 14 .
[0156] Tubing Conveyed Perforate Operations with Swivel Tool/Ball Drop Assembly 1000 Well Status: Well Bore has Been Cleaned Up; Filtered Completion Fluid is in Place; No Block Squeeze had to be Performed; Sump Packer has Been set on Depth with Wireline; Operations can be Performed with Omni or IRIS Valve
[0157] (1) Pick up the Tubing Conveyed Perforating Bottom Hole Assembly (pressure activation as primary detonation of Tubing Conveyed Perforate Guns) plus Snap-Latch assembly. Pick up the Omni or IRIS Valve to be in the Well Test Position. Pick up a Radio Active Sub one stand above the Tubing Conveyed Perforate assembly.
[0158] (2) Trip in Hole 14 with the Tubing Conveyed Perforate assembly, limit run in speed from slip to slip at two minutes per stand (94 foot stands). Drift each stand with maximum Outer diameter Drift. Monitor hole 14 on trip tank while Trip in hole 14 for proper fluid back for pipe displacement to confirm Omni/IRIS Valve is in proper position.
[0159] (3) With Snap-Latch one stand above the Sump Packer, obtain pick-up and slack-off weights.
[0160] (4) Sting into Sump Packer. Pick up the Work String to the neutral pipe weight and mark pipe at the Rotary. Snap out, should take 10,000 k to 20,000 k to snap out. (If any doubt of being in the Sump Packer, rig up Wireline and run Gamma-Ray and Collar Log for correct correlation).
[0161] (5) Pick up Swivel Tool/Ball Drop Assembly 1000 and space out as desired to put the Swivel tool 1000 at the desired distance above the Rotary with the Snap-Latch strung into the Sump packer.
[0162] (6) Rig up Choke Manifold on the Rig 1 Floor with lines from the Swivel Tool 1000 to the Manifold and lines from the High Pressure Pump to the Manifold. Rig up lines down stream of the Choke to take returns to the trip tank and to the Mud Pits.
[0163] (7) Sting into the Sump Packer and pick up to the neutral pre-recorded pipe weight. Set the Tubing Conveyed Perforate Packer by rotating the Work String the desired number of turns and slacking off the desired pipe weight onto Tubing Conveyed Perforate packer.
[0164] (8) Open the Upper Low Torque 1007 and Full Opening Ball Valve 1006 to the Work String 20 plus Choke Manifold Valves in the open position back to the Trip Tank. Close the Annular Blow Out Preventer and test the Tubing Conveyed Perforate Packer to the Annulus side to 1,000 pounds per square inch. Monitor for returns at the Trip Tank, no returns should be observed if the Tubing Conveyed Perforate Packer is holding.
[0165] (9) Cycle the Omni Valve to the Reverse Circulating position.
[0166] (10) Break circulation by pumping down the Work String 20 with returns up the Rig Choke or Kill line.
[0167] (11) Test the Pump Lines, Choke Manifold and Swivel Tool 1000 Valve to the desired pressure. Open the top Low Torque Valve 1007 and the Full Opening Ball Valve 1006 .
[0168] (12) Displace the Work String 20 with a lighter fluid, taking returns up the Rig Choke or Kill line until the desired under balance has been achieved.
[0169] (13) Cycle the Omni Valve to the Well Test Position.
[0170] (14) Pressure up the Annulus to 500 psi.
[0171] (15) Fire the Tubing Conveyed Perforate Guns by pressuring up on the Work String to the calculated detonation pressure. Bleed the pressure to 0.
[0172] (16) Monitor firing of the Guns (usually a 5 to 10 minute delay). Obtain Shut in Tubing Pressure. Calculate the difference between the estimated Bottom Hole 14 Pressure and the actual Bottom hole 14 pressure.
[0173] (17) Open the Well 14 thru the desired Positive Choke size and flow back the desired volume.
[0174] (18) Cycle the Omni Valve to the Reverse Circulating Position.
[0175] (19) Reverse out the Influx plus an additional Work String Volume.
[0176] (20) Bleed the pressure on the Annulus to 0.
[0177] (21) Open the Annular Blow Out Preventer.
[0178] (22) Start the Trip Tank Pump circulating on the Annulus. Open the By-Pass on the Tubing Conveyed Perforate Packer by picking up on the Work string. Monitor the fluid loss to the formation. If excessive losses are occurring, close the By-Pass.
[0179] (23) Pump and displace a Loss Circulation Pill of choice. Balance the Loss Circulation Pill by leaving Pill in the Work String above the Omni Valve and with Pill above the Omni Valve on the outside between the Omni and the casing.
[0180] (24) Open the By-Pass and monitor the Hole 14 on the Trip Tank. The Hole 14 should take the calculated volume of fluid from the Omni Valve to the bottom of the perforations and then become static.
[0181] (25) Close the By-Pass and Cycle the Omni Valve to the Well Test Position.
[0182] (26) Open the By-Pass and reverse out Influx that was trapped below the Omni Ball Valve.
[0183] (27) With the By-Pass in the open position, monitor the hole 14 on the Trip Tank while rigging down the Choke Manifold and pump lines.
[0184] (28) Rig down the Swivel Tool and Ball Drop assembly 1000 .
[0185] (29) Make a 5 stand short trip.
[0186] (30) Circulate bottoms up.
[0187] (31) Pull out of hole. Circulate at desired stages while Pull out of hole 14 as to monitor for possible trapped or swabbed Gas.
[0188] Note: If elected, the Choke Manifold that was rigged up on the Rig Floor can be eliminated and the Rig Choke Manifold could be used instead. The flow back could be flowed back to the Trip Tank and timed with the Super Choke adjusted to obtain the desired Barrel of Oil Per Day rate. This could be done to reduce additional expense and save Rig Time.
[0189] If a Bar Drop is elected to be the primary choice of the Tubing Conveyed Perforate detonation, a Pup Joint can be easily added between the Upper Swivel 1050 and the Top Drive 10 . The Full Opening Ball Valve 1006 would be closed and the Ball Valve Wrench taped. The Lower Low Torque Valve 1008 would then be used for circulation activities. Once all operations have been completed and the well is ready to be perforated, the Tape can be removed and the Bar can be dropped when intended. The tape is installed to the Ball Valve 1006 only as a safety factor so that the Bar will not be accidentally dropped prior to the contemplated drop.
[0190] The following is a list of reference numerals:
LIST FOR REFERENCE NUMERALS (Part No.) Reference (Description) Numeral Description 1 rig 2 crown block 3 cable means 4 travelling block 5 hook 6 gooseneck 7 swivel 8 drilling fluid line 10 top drive unit 11 draw works 12 cable 13 rotary table 14 well bore 15 guide rail 16 support 17 support 18 drill pipe 19 drill string 20 drill string or work string 30 swivel 31 hose 40 swivel mandrel 50 upper end 60 lower end 70 box connection 80 pin connection 90 central longitudinal passage 100 shoulder 101 outer surface of shoulder 102 upper surface of shoulder 110 interior surface 120 external surface (mandrel) 130 recessed area 131 packing support area 132 packing support area 140 radial inlet ports (a plurality) 145 bearing (preferably combination 6.875 inch bearing cone, Timken Part number 67786, and 9.75 inch bearing cup bearing cup, Timken part number 67720) 146 bearing (preferably combination 7 inch bearing cone, Timken Part number 67791, and 9.75 inch bearing cup bearing cup, Timken part number 67720) 150 swivel sleeve 155 protruding section 156 shoulder 157 shoulder 158 packing support area 159 packing support area 160 upper end 170 lower end 180 central longitudinal passage 190 radial passage 200 inlet 201 arrow 202 arrow 203 arrow 204 arrow 205 peripheral groove 206 key way 210 lubrication port 211 grease injection fitting (preferably grease zerk (¼-28 td. in. streight, mat.-monel Alemite part number 1966-B) 220 packing port 225 injection fitting(preferably packing injection fitting (10,000 psi) Vesta —PGI Manufacturing part number PF 10N410) (alternatively Pressure ReliefTool for packing injection fitting Vesta —PGI Manufacturing part number PRT —PIF 12-20) 226 head 230 packing port 235 injection fitting (preferably packing injection fitting (10,000 psi) Vesta —PGI Manufacturing part number PF10N410) (alternatively Pressure ReliefTool for packing injection fitting Vesta —PGI Manufacturing part number PRT —PIF 12-20) 240 cover 250 upper shoulder 260 lower shoulder 270 area for wiper ring 271 wiper ring (preferably Parker part number 959-65) 280 area for wiper ring 281 wiper ring (preferably Parker part number 959-65) 290 area for grease ring 291 grease ring (preferably Parker part number 2501000 Standard Polypak) 300 area for grease ring 301 grease ring (preferably Parker part number 2501000 Standard Polypak) 305 packing unit 310 packing retainer nut 314 bore for set screw 315 set screw for packing retainer nut 316 threaded area 317 set screw for receiving area 320 packing end 330 packing ring 340 packing ring 350 packing injection ring 351 transverse port 352 radial port 353 peripheral groove 354 interior groove 355 male end 356 flat end 360 packing end 370 packing ring 380 packing ring 390 packing ring 400 packing ring 410 packing end 415 packing unit 420 packing retainer nut 425 set screw for packing retainer nut 430 packing end 440 packing ring 450 packing ring 460 packing lubrication ring 470 packing end 480 packing ring 490 packing ring 500 packing ring 510 packing ring 520 packing end 600 clamp 605 groove 610 first portion 620 second portion 630 torque arm 640 torque arm 650 shackle 660 shackle 670 fastener 680 fastener 690 keyway 691 keyway 700 key 710 keyway 711 keyway 720 key 730 peripheral groove 800 retaining nut 801 threaded area 810 outer surface 820 inclined portion 830 bore 840 inner surface 850 threaded portion 860 upper surface 870 bottom surface 880 lubrication port 881 grease injection fitting (preferably grease zerk (¼-28 td. in. streight, mat.-monel Alemite part number 1966-B) 890 set screw 900 bore for set screw 910 receiving portion for set screw 1000 top drive swivel 1001 arrow 1002 arrow 1003 arrow 1005 stabilizing bracket 1006 intermediate valve 1006B bore 1006A valve ball 1007 valve member 1008 valve member 1009 manifold 1010 arm 1030 swivel portion 1040 mandrel 1041 lower portion of mandrel 1050 sleeve 1300 line 1301 line 1302 line 2000 valve member 2001 valve 2005 plug or ball 2010 tool 2011 upper section 2012 lower section 2013 middle section 2014 threaded section 2015 enlarged inner diameter section 2016 narrowing diameter section 2018 threaded section 2019 o-ring seal 2020 o-ring seal 2021 arrow 2030 swivel portion 2040 mandrel 2041 lower portion of mandrel 2050 sleeve
[0191] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0192] It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A double swivel for use with a top drive power unit supported for connection with a well string in a well bore to selectively impart longitudinal and/or rotational movement to the well string, a feeder for supplying a pumpable substance such as cement and the like from an external supply source to the interior of the well string in the well bore without first discharging it through the top drive power unit including a mandrel extending through double sleeves which are sealably and rotatably supported thereon for relative rotation between the sleeves and mandrel. The mandrel and sleeves have flow passages for communicating the pumpable substance from an external source to discharge through the sleeve and mandrel and into the interior of the well string below the top drive power unit. The unit can include a packing injection system, clamp, and novel packing configuration. In an alternative embodiment the unit can include a plug or ball insertion tool.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to apparatus for use in driving tunnels, galleries, trenches -- open or otherwise, similar excavations and for convenience referred to hereinafter as "tunnels or the like".
When tunnels or the like are being formed in water-bearing strata by conventional apparatus it is known to utilize ancillary equipment including suction lances to withdraw water from the working. The use of such equipment is complicated, time consuming and costly and adversely affects the efficiency of the overall operation. There is thus a need for an improved form of apparatus and a general object of this invention is to provide such an apparatus.
SUMMARY OF THE INVENTION
In its broadest aspect the invention provides apparatus for use in driving tunnels or the like; said apparatus having an advanceable drive shield provided with devices extendible from the front of the shield to treat the working face. The treatment of the working face contemplated by the invention is primarily, but not exclusively withdrawing water by suction and processes such as ejecting fluid under pressure against the face to assist in breaking up the face. Accordingly in another aspect the invention provides apparatus for use in driving tunnels or the like; said apparatus having an advanceable drive shield provided with hollow devices extendible from the front of the shield to treat the working face by withdrawing water or by conveying fluid under pressure thereto.
Preferably means such as cams or the like are provided for selectively locking the devices in various positions and/or for automatically extending the devices at certain stages during the driving operation. In the case where the drive shield is of continuous cylindrical form, the devices can be distributed around the periphery of the shield and movable therewith. The extension of the devices for operation can then be effected manually or by a suitable mechanism such as an hydraulic unit or units or by spindles or the like.
Where the drive shield is composed of a plurality of elongate drive members mounted side-by-side on a support frame which supports and guides the members for longitudinal displacement the invention can be realized by making at least some of these drive members hollow and by mounting the devices for movement longitudinally of these members. To this end guides can be provided in the hollow members with the devices located in the guides for telescopic movement.
The provision of the devices enables various operations, such as the water removal and other face treatment referred to above to be performed efficiently. Nevertheless, the devices may not be needed in some circumstances and here it is convenient to retract the devices inside the members or the shield and to close off the guides with suitable covers or flaps. It is desirable, however, to provide for removal or insertion of the devices from the rear of the members or the shield by leaving the shield or the members and the guides open at the rear end. Thus where the devices are not needed at all they can be withdrawn from the members or the shield quite easily.
Where the drive shield is composed of drive members supported on a frame, means such as hydraulic rams are usually provided to alternatively move the members, individually or in groups and the frame in the advancing direction towards the working face. It is then desirable to design the apparatus so that the relative movement between the members and the frame extends the devices forwardly. To this end means, such as cams or the like can be arranged between the frame and the devices so as to engage and extend the devices when the frame is shifted up. In one constructional form, a series of projections can be provided on each device which ride over a spring-biased stop carried by the frame in the manner of a ratchet. When the device is moved with its drive member the stop may then engage on one of the projections to prevent the retraction of the device and thereby ensure the device is moved with the frame to extend from the drive member as the frame is shifted. The projections and the associated stop may have interengageable faces designed to engage and to inhibit movement of the device.
Preferably the stops are mounted for swivelling so that the stops can be orientated to allow or inhibit retraction of the devices into the drive members. To avoid interference with the displacement of the drive members, the stops of the frame can be mounted in sleeves which project through slotted apertures in the members. The drive members may also each have a spring-biased stop similar to those of the frame and engageable with the projections of its associated device to permit or inhibit movement of the device relative to the drive member and the guide. Again it is preferable to mount the stops of the drive members for swivelling so that the stops can be orientated to allow or inhibit retraction of the devices into the drive members. As with the stops of the frame, the stops of the drive members can be located in sleeves and slots in the guides can receive the projections.
The provision for swivelling of the stops enables the devices to remain inactive within the drive members whenever desired and the facility for automatic extension of the devices will be rendered inoperative. Nevertheless, the devices can be extended manually or the stops easily re-orientated by a wrench or other suitable tool when the automatic extension facility is again desired. The stops can reliably prevent the devices from retracting under the reactive pressure from the working face but again by re-orientating the stops the devices can be allowed to retract whenever desired.
The characteristic of re-orientating the stops for different actions on the devices can be achieved by providing faces both perpendicular and diametric to the tunnel axis and inclined thereto on the stops and the projections. Thus each projection may have an inclined front face and a perpendicular rear face while each stop may have an inclined rear face and a perpendicular front face when orientated to inhibit retraction of the device. The stop may then be swivelled through 180° to bring its inclined face to the front thereby allowing the passage of a projection or projections and the retraction of the device in question.
As will become apparent hereinafter the invention also provides apparatus for use in driving tunnels or the like and comprising a plurality of elongate drive members arranged side-by-side, a frame supporting the members for longitudinal displacement, means for relatively shifting the members and the frame to effect advancement of the tunnel, devices mounted to move with at least some of the drive members and means for automatically extending said devices from the drive members when the frame is shifted relative to the member to thereby bring the devices into a position for treating the working face in front of the drive members.
The invention may be understood more readily, and various other features of the invention may become apparent, from consideration of the following description.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention will now be described, by way of examples only, with reference to the accompanying drawings, wherein:
FIGS. 1 to 3 are sectional side views of a single drive member of a drive shield of apparatus made in accordance with the invention showing the components thereof in different operating positions; and
FIGS. 4 and 5 are views generally corresponding to FIGS. 1 to 3 and showing a modified extendible device in different operating positions.
DESCRIPTION OF PREFERRED EMBODIMENTS
In general, apparatus constructed in accordance with the invention and as described hereinafter is used in driving tunnels, galleries, trenches or similar excavations especially in water-bearing soil. As shown in the drawings, and as is generally known in the art, the apparatus has a rigid support frame 10 which supports and slidably guides a plurality of elongate drive members 14 also referred to as knives or planks. The members 14 are arranged side-by-side in parallel relationship in contact with the wall of the tunnel or other excavation to form a shield. The members 14 are each individually displaceable in a longitudinal sense in the tunnel driving direction V (FIG. 1). The frame 10 is here composed of two ring structures 11, 12 spaced apart in the driving or advancement direction V and interconnected by means of longitudinal and diagonal frame parts generally designated 13.
To advance the members 14 and the frame 10, means (not shown) such as double-acting hydraulic rams are provided. Such rams would be normally articulated to the frame 10 and to one, or a group, of the members 14. The rams can then advance the members 14 individually or in groups in succession. When the members 14 have been advanced in the direction V by the working stroke of the rams the frame 10 would be shifted up to follow the advanced members 14. In this frame-shifting operation the rams would be operated in unison in a reverse sense with the members 14 lying in frictional contact with the tunnel wall acting as an abutment. The sequence would then be repeated. The foregoing features are well known per se.
When the members 14 are advanced they usually penetrate a working face at the front end of the tunnel. Material can be removed and transported away from the face by any known method. In the case where the material is water bearing and otherwise the features which will now be described are especially useful.
In accordance with the invention and as shown in the drawings, the members 14 are of hollow boxlike cross section having an upper or outer surface and a lower or inner surface. A guide 15, conveniently of tubular form, is provided within some or all of the members 14. The guides 15 can be welded into the members 14. A hollow device 16 used for the purposes described hereinafter and again of tubular form is slidably mounted within each guide 15 so as to be extendible and retractible in a telescopic manner. Each guide 15 extends over the entire length of its associated member 14 and is open at the rear end 14 (FIG. 1) to permit the device 16 thereof to be inserted or withdrawn from the rear. Each device 16 is of such a length to permit the device 16 to be fully retracted and housed within its guide 15. At its front end adjacent the working face, each guide 15 is provided with a flap or cover 17 which is hinged and preferably spring biased to its closed position to permit the guide 15 to be closed off or opened to allow the device 16 to extend out therefrom. FIGS. 1 and 2 show the fully retracted position of the device 16 with the cover 17 closing off the guide 15 whereas FIGS. 3 to 5 show the device 16 extending out from the guide 15 with the cover 17 pivoted to an open position.
Each guide 15 has an elongate slot and the associated device 16 has a set of cams or saw-tooth like projections 18 on its exterior which engage through this slot. The front faces 19 of these projections 18 are inclined as shown whereas the rear faces of the projections 18 are perpendicular or diametric to the tunnel axis. The foremost ring structure 11 of the frame 10 is provided with radial sleeves 21 each slidably guiding a cam follower or complementary stop 20 engageable with the projections 18 of an associated device 16. The sleeves 21 also accommodate springs 22 which resiliently bias the stops 20 outwardly perpendicular to the driving direction V. The stops 20 each have a rear face 23 inclined as shown to correspond with the faces 19 of the associated projections 18 and a front face perpendicular to the tunnel axis. The sleeves 21 project through slots 24 (FIG. 1) in the members 14 provided with the guides 15 so that these members 14 can be displaced in relation to the frame 10 as described hereinbefore without hinderance by the sleeves 21. The members 14 provided with guides 15 are also provided with further sleeves 28 at their central regions. In a similar manner to the sleeves 21, each sleeve 28 slidably guides a further cam follower or complementary stop 25 engageable with the projections 18 of the associates device 16. The sleeves 28 similarly accommodate springs 27 which resiliently bias the stop 25 outwardly perpendicular to the driving direction V. As with the stops 20, the stops 25 each have a rear face 26 which is inclined to correspond with the faces 19 of the projections 18 as well as a front perpendicular face. Engagement between the relatively moving faces 19, 23 or 19, 26 will tend to urge the stops 20, 25 inwards.
However the stops 20, 25 are each capable of being swivelled through 100° about the axis 29 (FIGS. 4 and 5) of the sleeves 21, 28 to thereby bring the inclined faces 23, 26 to the front. In this case engagement between these faces 23, 26 and the relatively moving rear faces of the projections 18 will again tend to move the stops 20, 25 inwards. Preferably detents or the like bias the stops 20, 25 into the two alternative positions. In general, therefore the devices 16 can be extended or retracted as desired. Nevertheless, the arrangement is such as to enable the devices 16 to be extended automatically as the drive shield advances as will now be described.
As shown in FIG. 1, the device 16 depicted therein is completely retracted within the member 14 and the cover 17 closes the front end of the guide 15. The front or first projection 18 is disposed between the stops 20, 25 and the second projection 18 from the front has its rear face closely adjacent the front face of the stop 25. As will be appreciated the following description is related to the single member 14 depicted in the drawings but the same sequence of events occurs with all the members 14 provided with the guides 15 and devices 16.
FIG. 2 shows the components after the member 14, in question has been shifted up in the direction V.
During the advancing of the member 14 the front face 19 of the first projection 18 engages with the rear face 23 of the stop 20 thereby urging the stop 20 inwards to permit the device 16 and the member 14 to shift until the stop 20 is free of the projection 18 whereupon the spring 22 biases the stop 20 outwards again so that the rear face of the projection 18 is closely adjacent the front face of the stop 20 as shown in FIG. 2. The stop 25 maintains its positional relationship with the second projection 18 as also shown. It will be recalled that when the members 14 have all been advanced the frame 10 is shifted up.
FIG. 3 shows the positional relationships when the frame 10 has been shifted up. As can be appreciated from FIGS. 2 and 3 as the frame 10 is displaced the front face of the stop 20 engages on the rear face of the front projection 18 so that the device 16 is extended with the frame 10. The cover 17 is automatically pivoted by the extending device 16 although it is possible to open the cover 17 separately. As the device 16 extends the front face 19 of the third projection 18 from the front engages the rear face 26 of the stop 25 and the stop 25 is urged inwards by the projection 18 against the force of the spring 27 to permit the extension of the device 16. When the device 10 has been advanced with the frame 10 in this manner the first and third projections 18 have their rear faces in abutting relationship with the front faces of the stops 20, 25 thereby preventing inward movement of the device 16 under reactive force from the working face. By swivelling the stops 20, 25 through 180° with a suitable tool the device 16 can be unlocked so that it will be retracted by the reactive pressure of the face or otherwise.
The devices 16 can be connected up to a suction pump in order to withdraw water from the face. Alternatively a source of compressed air or water under pressure can be connected to the devices to assist in breaking up the face. Other forms of treatment are also possible.
If the device 16 is to maintain the extended position shown in FIG. 3 the stop 20 would be swivelled back and forth through 180° so that the device 16 advances with the member 14 but the movement of the frame 10 does not cause further extension of the device 16. It is possible to design the cover 17 so that it permits the passage of the first projection 18 thereby permitting the device 16 to be extended further from the position shown in FIG. 3. Alternatively, as representated in FIGS. 4 and 5, the projections 18 can be positioned closer to the rear of the device 16 as compared with FIGS. 1 to 3. In this case after shifting of the member 14 the device 16 would adopt the position shown in FIG. 4 (c.f. FIG. 2) and when the frame 10 is shifted the device 16 would be further extended by the stop 20 with the third projection 18 riding over the stop 25 to finish up in the position shown in FIG. 5.
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Tunnel-driving apparatus utilizes a plurality of elongate drive or knife members arranged side-by-side and supported and guided for longitudinal movement on a frame. The members and the frame are advanced in succession during the driving process. Some or all of the drive members are hollow and accommodate telescopically extendible and retractible devices, conveniently of tubular form, used for treating the working face, for example, by conveying fluid to or from the face. The devices each have a series of cam-like projections engageable with spring-biased stops supported on the frame and the drive members. These stops serve to lock the devices in various positions and to automatically extend the devices from the members when the frame is shifted.
The stops can be displaced however to generally engage the projections in such manner as to allow or prevent movement of the devices inwardly or outwardly of the drive members.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
A number of U.S. patents relate to variously designed snow removal devices, but these devices are non-related to the improved snow removal device of my present instant invention. These U.S. Pat. Nos. are: 3,309,798 to Devlin; 3,333,354 to Kirshenblat; 3,074,191 to Zierak; and 3,456,368 to Jacques.
SUMMARY OF THE INVENTION
My present invention relates to a unique and novel snow removal device.
An object of my present invention is to provide a portable snow removal device capable of removing snow from the ground, melting the snow and discharging the melted snow into a sewer.
Briefly, my present invention includes a truck unit having a forward cab portion and a rear storage portion. An elongated V-shaped container is disposed in the rear storage portion, wherein the container has a curved base, a pair of upwardly extending end walls and the container is slanted downwardly from a front to a rear of the storage portion. A mechanism is provided for injecting snow and ice into the container. A gate valve is disposed in the rear portion, wherein a connecting pipe communicates between the container and the gate valve. A heating assembly disposed in the storage portion melts the snow and ice in the container which is ejected from the container through the gate valve.
BRIEF DESCRIPTION OF THE DRAWING
The objects and features of the invention may be understood with reference to the following detailed description of an illustrative embodiment of the invention, taken together with the accompanying drawings in which:
FIG. 1 illustrates a side view of a snow removal device;
FIG. 2 illustrates a side cross section view of the device;
FIG. 3 illustrates an end cross sectional view of the device; and
FIG. 4 illustrates a front view of the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1-4 show a snow removal device 10, which generally comprises a truck unit 11 having a forward cab portion 12 and a rear storage portion 14. The cab portion 12 has a base 16, an upwardly extending rear wall 18, a pair of sidewalls 20 and 22, and a top 24. The cab portion has a forward wall 26 with a window 28 therein. The storage portion 14 has a base 34, an upwardly extending forward wall 36 with an opening 38 therethrough, an upwardly extending rear wall 40 with an opening 42 therethrough, a pair of upwardly extending sidewalls 44, 46, and a top 50 with a raised section 52. The forward cab portion 12 and rear storage portion 14 are joined together at their bases 16 and 34, respectively, by a conventional art jackknife base 54, wherein electrical generator unit 57 is mounted on base 54, located between portions 12, 14. The portions 12, 14 are mounted on three axles 56, wherein each axle 56 has pairs of end wheels 58 and 60. An elongated generally V shaped container 62, having a pair of upwardly extending walls 64, 66, and wherein walls 64, 66 are joined to the interior walls of portion 14, and wherein the base portion 68 of container 62 is curved. Supports, for container 62, are used, but not shown, to provide structural support for the container, by resting same on base 34. The container 62 has a pair of end walls 70, 72 wherein the forward end of the container 62 is disposed higher than the rear end of the container 62 such that base 68 is slanted rearwardly downwardly. A gate drainage valve 74 is disposed in opening 42 in rear wall 40, wherein gate valve 74 is joined by a connecting pipe 76 to the chamber 78 of the container 62, wherein pipe 76 extends through end wall 72 of container 62. A pair of heat deflector shields 80, 82 are disposed in portion 14, wherein shield 80 is mounted on the inner surface of wall 36 and extends over the top of end wall 70, thereby providing space 84, between wall 70 and shield 80. The other shield 82 is mounted on the inner surface of wall 40 thereby forming a second space 86 between wall 72 and shield 82. Side shields 152 and 154 extend between deflector shields 80 and 82, on the sides of rear portion 14, in the interior thereof. A plurality of upstanding heating pipes 87 are disposed on the bottom outer surface of container 62, wherein the pipes 87 are joined together in a grid-like connection and have a heated gaseous medium disposed therein. A plurality of rib-like pipes 156 and 158 extend upwardly on the outside of container 62, so as to reside beneath deflector shields 80, 152 and 154 respectively. Fitting 96, shown residing on wall 46, is connected, by a pipe, to blower device 160, which in turn is coupled to all of rib like pipes 156 and 158, by way of pipes 87. Fitting 99 has an air input port, not shown, which permits air to mix with the vapor fuel. Ignition occurs at port 200, such that hot air travels through pipes 156, 158 and 87, exiting at the free ends of pipes 156 and 158, in a manner well known in the art. An external portable tank, not shown, is coupled to fitting 96 which provides gaseous fuel, by way of pump 160, preferably of the blower variety, into pipes 87 and thence pipes 156 and 158. The open ends of pipes 156 and 158 carrying heated air so as to impinge hot air in the uppermost region of container 62. Pipe 92 is coupled to the network of interconnected pipes 87, providing means of coupling the external vaporized fuel source into the network of pipes 87, the fuel being fed into pipe 92 by way of the free end of pipe 92, accessed through port 48. Opening 48 may be employed through which a flexible hose is coupled to the ends of pipe 92.
A first conveyer screw member 98 is disposed longitudinally in the base 68 of container 62, wherein conveyer screw member 98 is rotatably driven by a first covered, waterproof electrical motor 100 and conveys particles of snow and ice towards the rear of the container 62. An elongated open ended chute member 102 extends through opening 38 of wall 36 of portion 14. The upper end 104 of chute member 102 extends into portion 14 through opening 38 of forward wall 36, wherein the upper end 104 is curved shaped. The lower end 106 of chute member 102, extends downwardly toward the ground, wherein a horizontal extension member 108 is joined to lower open end 106 of chute member 102. The member 108 having an open end 110 rides along the ground as truck unit 10 moves forwardly thereby forcing snow into the member 108. A plurality of vanes 112 are disposed in member 108 for cutting the snow as it enters member 108. A second conveyer screw 114 with associated electrical motor 116 is disposed within chute member 102 to heated container 62, heated by pipes 156 and 158. The snow in container 62 melts and drains outwardly through gate valve 74 onto which is removably secured a flexible hose 118 which may be placed into a storm sewer opening in the road, not shown. A hydraulic assembly 120 is disposed on forward portion 12, wherein assembly 120 is powered by hydraulic generator unit 57. The hydraulic assembly 120 is joined to chute member 102. Chute 102 is pivotally mounted onto portion 12, thereby permitting chute member 102 to be tilted such that member 108 is raised off of the ground, when it is not in use, as shown by dotted lines 108a and 102a. The upper end of chute member 102 extends into the raised section 52 of top 50, such section 52 being openable, using hinge 180 therefor.
Thus, there is disclosed in the above description and in the drawings, an embodiment of the invention which fully and effectively accomplishes the objects thereof. However, it will become apparent to those skilled in the art, how to make variations and modifications to the instant invention. Therefore, this invention is to be limited not by the specific disclosure herein, but only by the appending claims.
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A snow removal device includes a truck unit having a forward cab portion and a rear storage portion. An elongated V-shaped container is disposed in the rear storage portion, wherein the container has a curved base, a pair of upwardly extending end walls, and the container is pitched downwardly from a front to a rear of the storage unit. A mechanism is included for injecting the snow and ice into the container as well as a heating assembly disposed in the storage portion for melting the snow and ice for discharge through the gate valve.
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BACKGROUND OF THE INVENTION
[0001] A. Field of the Invention
[0002] The invention broadly relates to a ladder that has a sound system integrated into it. The sound system includes, but is not limited to, a radio, DVD or CD player, MP3 player. iPod or similar device, battery or other power source, amplifiers and speaker(s).
[0003] B. Prior Art
[0004] Many types of ladders have been provided in the prior art, For example, Brown (U.S. Pat. No. 5,971,102) discloses a ladder that includes a storage compartment and/or toolbox positioned adjacent to the work area, including a storage cabinet and a device for retaining a tool easily accessible to the user.
[0005] Smith (U.S. Pat. No. 5,603,405) discloses a ladder top storage rack that includes a rigid tool box securable to a ladder top. Smith also discloses a pair of side pouches secured to the walls of the tool box.
[0006] Joseph (U.S. Pat. No. 5,603,405) discloses an apparatus that attaches to the top platform of a stepladder. The apparatus includes a plate mounted to the stepladder, and a bucket receptacle disposed on top of the plate. The bucket receptacle is used to hold items such as paint cans, nails or cleaning implements therein.
[0007] While these devices fulfill their respective objectives and requirements, the aforementioned patents do not describe a ladder that incorporates a sound system.
[0008] In this respect, the ladder with incorporated sound system substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus that allows the user to listen to and control music or other media while working on or near the ladder without having to use a separate sound system, and without the need to climb or descend the ladder to do so. Therefore, it can be appreciated that there exists a continuing need for a ladder with an incorporated or integrated sound system that allows the user to listen to the music or other media while working on or near the ladder. In this regard, the present invention substantially fulfills this need.
[0009] As used herein, the term “ladder” refers to an apparatus having at least two substantially parallel legs connected by a plurality of rungs or steps spanning the space between the legs, and providing means for a person to climb the ladder from the bottom step or rung, to the top. The term is also intended to encompass self supporting ladders, e.g. step ladders, and extension ladders.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention comprises an improved ladder that includes an integrated sound system. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved ladder that incorporates a sound system into its structure that may include a radio, DVD or CD player, MP3 player, iPod, or other digital source, battery, solar, or other power source, an amplifier, and one or more speakers.
[0011] Ladders come in many forms. The various forms include simple ladders, step ladders, and extension ladders. Simple ladders comprise a pair of generally parallel legs connected by a plurality of rungs, or steps. Step ladders normally comprise two sets of parallel legs, hinged, or connected at the top so that the ladder is self supporting when the second set of legs is extended outward. Extension ladders comprise a pair of individual ladders slideably positioned with respect to another, so that the overall length of the extension ladder can be expanded by a distance substantially equivalent to the length on one of the individual ladders.
[0012] Conventional ladders range from 6 to 15 feet in length, and extension ladders can extend over 30 feet in length. Thus ascending and descending a ladder can be dangerous, inconvenient, and time consuming. A ladder with an incorporated sound system at or near the top would allow a user to access a radio, DVD or CD player, MP3, or iPod device while staying at work on the ladder. This would minimize the number of times a worker climbs up and down the ladder during the day, or work period. Preferably, the ladder and the incorporated sound system device will be durable and resistant to damage from the elements, as well as the rigors of use in rough conditions.
[0013] The present invention, therefore, is an apparatus comprising a ladder and an incorporated sound system mounted near the top thereof. The sound system includes one or more media sources such as a radio, tape or DVD or CD player, iPod and/or MP3 player, a sound amplifier, one or more speakers, and a power source such as a battery or solar device. Preferably, although not a necessary element of the invention, the controls to the sound system will be accessible via a touch pad on or near the top step of the ladder. During typical use, the user does not stand on the top step (for safety reasons). Therefore, the top step is the most convenient location to access the sound system controls.
[0014] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1A is a perspective view of the of the ladder of the invention showing the sound system component thereof mounted below the top step of the ladder spanning the two legs.
[0016] FIG. 1B is an enlarged view of section 1 B of FIG. 1A .
[0017] FIG. 2 is a perspective view of an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] One embodiment of the ladder of this invention is seen in FIG. 1A . The ladder 10 comprises a pair of parallel legs 12 and 14 connected by a plurality of steps or rungs 16 which extend there between.
[0019] As shown, the legs 12 and 14 comprise elongated U-shaped channels, but other configurations can be used. The steps 16 can be spaced apart any desired distance, but, conventionally will be about 8 inches apart which is the normal rise in a step. Situated at or near the top of the ladder 10 is the sound system component 18 of the invention. FIGS. 1A and 1B show the sound system component 18 comprising an elongated box 20 having speakers 22 mounted at each end. In the middle of the box 20 is situated a sound generating media device 24 which can be a AM/FM radio, a satellite radio, a DVD or CD player, an MP3 player, or any other device capable of generating sound such as an I-pod, or even a combination telephone—sound generator. The media device contains knobs 26 for adjusting the volume, and/or selecting a station if the device is a radio. It can also have a touch pad controller 28 for adjusting the sound, etc., if desired.
[0020] As used herein, the term MP3 player refers to a digital device capable of receiving wireless transmitted signals from the ether, or digital signals from a computer, and converting them into sound. MP3 players are well known in the art, and are made by a number of manufacturers. The term iPod refers to a brand of portable media players designed and manufactured by the Apple Corporation, Cupertino, Calif.,
[0021] The MP3 or I-POD devices can be inserted into a slot 29 in the box 20 , and connected to an amplifier (not shown) and speakers 22 in the box 20 .
[0022] The sound system 18 is powered by a battery, not shown. A solar panel for generating power can also positioned on the top plate of step of the ladder to supplement the battery.
[0023] In use, a workman or user of the ladder 10 places the ladder against a wall or other support, climbs the ladder 10 and then turns the sound system component 18 on, selecting the desired station if the media device is a radio, or selecting music from a CD, or downloaded music if it is an MP3 player, an I-pod, or the like.
[0024] The legs 12 , 14 , and steps 16 of the ladder 10 of the invention can be made of any convention material, such as aluminum, or wood. What is required is that the structural material be strong enough to support the weight of a user or person who climbs the ladder for any reason.
[0025] Also, while the ladder shown in FIG. 1A is a conventional straight ladder, with parallel legs, other types can be used. Ladders with legs that are spaced apart further at the bottom than at the top are also suitable for use. Thus, ladders with substantially parallel legs are included within the purview of this invention.
[0026] Whatever form the ladder takes, the sound system is incorporated into it at or near the top step or rung for ease of use. The box 20 containing the speakers 22 , amplifier, battery, and sound generator 24 , can be attached to the legs 12 , 14 , by appropriate screws.
[0027] Another embodiment of the invention is a step ladder with the sound system incorporated therein. This embodiment is shown in FIG. 2 , wherein the step ladder 30 comprises a first pair of legs 32 , 34 hinged at the top to a second pair of legs 36 , 38 . The first pair of legs 32 , 34 are connected by steps 40 spanning the space between the legs 32 , 34 . A foldable hinged strut 42 connects opposing sets of legs to supply support. The sound system component 44 of this embodiment of the invention is positioned at or near the top step 40 spanning the legs 32 , 34 . The sound system component 44 is essentially the same as that shown and described in connection with FIGS. 1A , and 1 B.
[0028] It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the above description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0029] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0030] Further, the purpose of the abstract set forth herein is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
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A ladder including a sound system comprising a at least one pair of generally parallel legs, a plurality of steps extending between said pair of legs, and a sound system mounted between said pair of legs near the top thereof, the sound system including a media player, and at least one speaker operably connected thereto.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/334,383, filed Nov. 29, 2001, which is hereby incorporated by reference herein in its entirety, including but not limited to those portions that specifically appear hereinafter, the incorporation by reference being made with the following exception: In the event that any portion of the above-referenced provisional application is inconsistent with this application, this application supercedes said above-referenced provisional application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] 1. The Field of the Invention
[0004] The present invention relates generally to post mounting devices, and more particularly, but not necessarily entirely, to an internal compression mount system for hollow posts.
[0005] 2. Description of Related Art
[0006] Traditionally wooden posts were mounted to a deck by notching the bottom of the post to receive a joist of the deck. The use of plastic and other composite materials for the production of fence products led to the use of hollow fence posts made from the composite materials. However, the hollow configuration of composite fence posts makes them difficult to mount on a flat surface such as a deck or concrete.
[0007] A number of hollow fence post mounting systems have been developed. However, the prior art mounting systems are characterized by systems where only the base of the system is attached to the surface. These systems are ineffective because outward forces applied near the top of the fence cause undue stress on the surface and the base of the post mount. These stresses can loosen the attachment means of the post mount systems or damage the base of the mounting system.
[0008] For example, U.S. Pat. No. 5,444,951 (granted Aug. 29, 1995 to Scott et al.) discloses a bracket to be attached to a solid surface. The bracket allows a vinyl fence post to be fitted over it and locked in place to provide a rigid post without pouring concrete in the post. The bracket is secured to the solid surface with bolts. An expansion mechanism is provided at the top of the bracket including a tensioning bolt, which when tensioned, forces the expansion mechanism to expand and grip the fence post to hold the post on the bracket. However, since the bracket is attached to the solid surface using bolts at the bottom of the bracket, the top portion of the bracket is not under compression and can therefore move more easily.
[0009] Other attempts have been made to address the drawbacks in the prior art. For example, U.S. Pat. No. 6,141,928 (granted Nov. 7, 2000 to Platt) discloses a post mount for affixing a post having a cavity to a floor. The post mount is bolted to the floor using bolts and compression pins. A bolt extends though the center of the post mount, passes through the floor and is secured to the floor with a nut. The post mount is then inserted into the cavity of the post to affix the post to the floor. However, the post mount is designed with a pair of fins at each corner that contact the post in a manner that concentrates loads along the fins.
[0010] The prior art is thus characterized by several disadvantages that are addressed by the present invention. The present invention minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.
[0011] The features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the invention without undue experimentation. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:
[0013] [0013]FIG. 1 is a side view of a compression mount for hollow posts attached to a base surface in accordance with the principles of the present invention;
[0014] [0014]FIG. 2 is a top view of a compression mount and a hollow post in accordance with the principles of the present invention;
[0015] [0015]FIG. 3 is a side, break-away cross-sectional view of an alternative embodiment of the compression mount of FIG. 1;
[0016] [0016]FIG. 4 is a perspective view of a compression mount for hollow posts of FIG. 1;
[0017] [0017]FIG. 5 is a top perspective view of one embodiment of a bottom plate and shim;
[0018] [0018]FIG. 6 is a bottom perspective view of the bottom plate of FIG. 5;
[0019] [0019]FIG. 7 is a bottom view of an alternative embodiment bottom plate; and
[0020] [0020]FIG. 8 is a perspective view of an alternative embodiment shim.
DETAILED DESCRIPTION OF THE INVENTION
[0021] For the purposes of promoting an understanding of the principles in accordance with the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed.
[0022] It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
[0023] In describing and claiming the present invention, the following terminology will be used in accordance with the definitions set out below.
[0024] As used herein, “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.
[0025] As used herein, “consisting of” and grammatical equivalents thereof exclude any element, step, or ingredient not specified in the claim.
[0026] As used herein, “consisting essentially of” and grammatical equivalents thereof limit the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic or characteristics of the claimed invention.
[0027] Referring now to FIG. 1, a side view is shown of a post mounting system, indicated generally at 10 in accordance with the principles of the present invention. The post mounting system 10 may include a compression mount 12 having a substantially “I” shaped cross section as shown most clearly in FIG. 2. The compression mount 12 may be configured to support loads placed upon it through a hollow post 32 . It will be appreciated that the dimensions of the compression mount 12 may vary within the scope of the present invention. However, the compression mount 12 may be configured to fit snugly within the hollow post 32 and to maximize its load bearing capabilities. The compression mount 12 may have planar sidewalls 13 that provide a surface area to contact the post 32 . This allows for forces to be evenly distributed over the compression mount 12 and prevents the loads from being focused on a particular area of the post 32 or the compression mount 12 . The sidewalls 13 may be separated by a brace portion 15 . The brace portion 15 may extend in a direction substantially perpendicular to the sidewalls 13 and may define a cavity 17 for receiving shafts 18 .
[0028] The compression mount 12 may be rigidly attached to a bottom plate 20 . The bottom plate 20 may be attached to the compression mount 12 by any manner know to those skilled in the art such as welding or by forming the bottom plate 20 integrally with the compression mount 12 . The bottom plate 20 may include openings 21 for receiving leveling bolts (not shown) to enable the compression mount 12 to be properly leveled on the base 14 . Other leveling devices such as shims (not shown) may be used to level the bottom plate 20 with respect to the base 14 . The base 14 may be a floor or deck for example, or any other structure to which a post 32 is to be securely attached.
[0029] The post mounting system 10 may also includes a top plate 16 for attaching to a top of the compression mount 12 . The top plate 16 may include openings for receiving shafts 18 on opposing sides of the compression mount 12 . Shafts 18 may be dimensioned to extend the entire length of the compression mount 12 , and may be threaded to receive nuts 24 thereon. The number and position of the shafts 18 may be configured to provide beneficial strength characteristics for the compression mount 12 . However, it will be appreciated by those skilled in the art that the shafts 18 may be provided in different quantities and locations within the scope of the present invention.
[0030] The post mounting system 10 may also include a mounting plate 22 configured to be mounted beneath the compression mount 12 . The mounting plate 22 may include openings to receive the shafts 18 and may provide support for the nuts 24 to prevent the nuts 24 from becoming embedded in the base 14 .
[0031] [0031]FIG. 4 shows a perspective view of a post mounting system 10 in an assembled condition with a gap where the base 14 may be positioned. In use, holes may be drilled into the base 14 to accommodate the shafts 18 . The shafts 18 may be inserted through the top plate 16 , through the entire length of the compression mount 12 , through the bottom plate 20 , through the base 14 and the mounting plate 22 . Nuts 24 may be secured on the end of the shafts 18 and tightened such that the shafts 18 may be drawn into the nuts 24 and the compression mount 12 may be placed in compression and secured to the base 14 . Nuts 24 may be of the locking variety to prevent the shafts 18 from becoming loosened. The post mounting system 10 may be leveled by adjusting bolts inserted through the openings 21 in the bottom plate 20 or by inserting shims between the base 14 and the bottom plate. A hollow post 32 may be slid over the compression mount 12 to position and hold the post 32 in place. Additional fasteners such as brackets or screws (not shown) may be used to secure the post 32 to the compression mount 12 .
[0032] Reference will now to made to FIG. 3 to describe a second embodiment of the present invention. As previously discussed, the embodiments of the invention illustrated herein are merely exemplary of the possible embodiments of the invention, including that illustrated in FIG. 3.
[0033] It will be appreciated that the second embodiment of the invention illustrated in FIG. 3 contains many of the same structures represented in FIGS. 1, 2, and 4 and only the new or different structures will be explained to most succinctly explain the additional advantages which come with the embodiments of the invention illustrated in FIG. 3. The second embodiment of the invention shows how the post mounting system 10 may be used on a hard surface 30 such as concrete. In this embodiment, the shafts 18 may be threaded into a wedge 26 or other securing means such as epoxy 28 , rather than the nuts 24 . The securing means may be secured to the hard surface 30 in any manner known to those skilled in the art, such as by fasteners, adhesives, friction or expansion members for example. The tightening of the shaft 18 into the securing means in the concrete 30 provides a compression of the post mounting system 10 similar to that shown in FIG. 1.
[0034] Referring now to FIG. 5, a top perspective view of an embodiment of a bottom plate 20 a is shown. The bottom plate 20 a may include a groove 40 formed in the upper surface 42 . The groove 40 may be configured for receiving the compression mount 12 . Accordingly, the groove 40 may have a similar shape as the compression mount 12 as viewed from the top (see FIG. 2). It will be appreciated that the groove 40 may be configured to hold the compression mount 12 in place with respect to the bottom plate 20 a to prevent lateral movement of the compression mount 12 with respect to the bottom plate 20 a.
[0035] The bottom plate 20 a may also include a plurality of shaft openings 44 for receiving the shafts 18 , and adjustment bolt openings 21 a for receiving adjustment bolts (not shown) to level the bottom plate 20 a. Shims 50 may also be used to level the bottom plate 20 a. It will be appreciated that the shims 50 may be used in combination with the adjustment bolts, or the shims 50 may be used without the adjustment bolts, within the scope of the present invention. The shims 50 may be configured as a wedge for inserting in shim slots 52 to adjust the position of the bottom plate 20 a with respect to the base 14 so that the hollow post 32 may be installed in the desired orientation. It will be appreciated that a single shim 50 or a plurality of shims 50 may be used within the scope of the present invention to adjust the bottom plate 20 a to the desired orientation.
[0036] The bottom plate 20 a may also include a drain hole 54 passing through the bottom plate 20 a. The drain hole 54 may allow moisture to be drained so that water does not accumulate on top of the bottom plate 20 a within the hollow post 32 . This allows the mounting system 10 to function without problems such as undue warping or deterioration that may be caused by water accumulation. Moreover, the bottom plate 20 a may also include seepage channels 56 to transport the water from the drain hole 54 to an exterior of the bottom plate 20 a.
[0037] Referring now to FIG. 7, a top view of a further alternative embodiment bottom plate 20 b is shown. As previously discussed, the embodiments of the invention illustrated herein are merely exemplary of the possible embodiments of the invention, including that illustrated in FIG. 7. The bottom plate 20 b may have corner shim slots 58 encompassing adjustment bolt openings 21 b. The position of the corner shim slots 58 at the corners of the bottom plate 20 b may facilitate leveling of the bottom plate 20 b. A slotted shim 60 , as best shown in FIG. 8, may be inserted into the corner shim slots 58 to level the bottom plate 20 b. The slotted shim 60 may have a shim slot 62 for providing a space for the adjusting bolts to be passed. Accordingly, the slotted shim 60 may be used at the corners of the bottom plate 20 b without interference with the adjusting bolts, and fewer slotted shims 60 may be required to level the bottom plate 20 b as compared to other embodiments.
[0038] The embodiment of the bottom plate 20 b shown in FIG. 7 may also include polygonal openings 64 for receiving polygonal heads of adjustment bolts. However, it will be appreciated that the bottom plate 20 b may have openings of various different configurations to be compatible with any variety of adjustment bolts known in the art.
[0039] It will be appreciated that the structure and apparatus disclosed herein is merely one example of a means for securing the shaft to the base, and it should be appreciated that any structure, apparatus or system for securing the shaft to the base which performs functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a means for securing the shaft to the base, including those structures, apparatus or systems for securing the shaft to the base which are presently known, or which may become available in the future. Anything which functions the same as, or equivalently to, a means for securing the shaft to the base falls within the scope of this element.
[0040] In accordance with the features and combinations described above, a method of attaching a post to a base includes the steps of:
[0041] (a) drilling a plurality of holes in the base;
[0042] (b) passing a plurality of shafts through a compression mount member and through the plurality of holes in the base;
[0043] (c) tightening a securing member on the shafts to secure the compression mount member to the base and place the compression mount member in compression; and
[0044] (d) sliding a post over the compression mount member.
[0045] In view of the foregoing, it will be appreciated that the present invention provides a post mount device which slidably receives a hollow post. The present invention also provides a post mount device in which the top and bottom of the device are mounted to the mounting surface, such that even the top of the post mount device is under compressive forces. The present invention also provides a post mount device which is self leveling for attachment to a flat surface and which allows for even distribution of loads to the post.
[0046] It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements. Thus, while the present invention has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.
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An internal compression mount for attaching hollow posts to a base surface. A substantially “I” shaped post mount is fixedly attached to a bottom plate. The bottom plate and post mount may be leveled on the base surface with shims and leveling bolts. Threaded shafts may be inserted through a top plate, through the post mount, through the bottom plate, the base surface and through a mounting plate. The threaded shafts receive nuts, which are tightened to produce a compressive force on the post mount between the top plate and the mounting plate below the base surface. The compressive force between the base of the post mount and the mounting plate grasps the base surface in a vice like manner and securely affixes the post mount to the base surface. A hollow post can then slide in place over the post mount.
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RELATED APPLICATIONS
[0001] This application claims priority U.S. Provisional Application Ser. No. 62/012,916 filed Jun. 16, 2014 entitled Door Stop Device and Method, which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Devices that use magnets to hold a door open or to prevent a door from opening too wide are well documented in the art. Typical devices can be divided into 2 categories. The first category is devices that have a unit that attaches to a door and a unit that attaches to the wall. These devices prevent the door from slamming against the wall and they use magnetic force to prevent the door from closing. However, they require tools and screws to install; they require a wall for one component; they rely on a direct pull force to disengage the magnets, which can be difficult to disengage, and they only hold the door open to its widest position against a wall. The second category is devices that have a unit that attaches to a door and a unit that attaches to the floor. They prevent the door from slamming against the wall and they use magnetic force to prevent the door from closing. However, they require tools and screws to install; they are large and obtrusive, and present a tripping hazard; they rely on a direct pull force to disengage the magnets, which can be difficult to disengage; and they cannot adjust to differing heights between the bottom of the door and the floor.
SUMMARY OF THE INVENTION
[0003] Various embodiments of the invention include an adjustable-height magnet attached to the door and a second, low profile magnet attached to the floor. The adjustable-height door magnet and the floor magnet are aligned in such a way that when the door-mounted, adjustable-height magnet passes over the floor-mounted magnet, the opposing polarities of the magnets form an attraction causing the door-mounted magnet to slide down and connect to the floor-mounted magnet, holding the door firmly in place anywhere along the door's arc, preventing the door from closing, opening too wide or to hold the door open a specific amount to let in air or pets.
[0004] Various embodiments of the invention also provide an easy mechanism to close the door by simply pulling or pushing the door, which separates the door and floor magnets using a lateral pull force, which requires a lower amount of pull force than a direct pull force between magnets.
[0005] In various embodiments, when the door magnet and the floor magnet are separated, the door magnet retracts using a spring mechanism within the case of the door magnet to lift the adjustable arm, so the door can swing freely and shut easily.
[0006] According to specific embodiments, the door unit consists of an adjustable arm that lowers the door magnet when positioned over the floor magnet. The sliding arm is held in the up position using a spring and both the sliding arm and the spring are in a case attached to the door. The door magnet is attached to the sliding arm through a hinge mechanism and the magnet is held perpendicular to the floor by a small magnet on the case, which attracts the door magenta when the sliding arm is in the up position. In various embodiments of the invention, the case is held to the door by an adhesive material such as double-sided tape or double-sided foam. When the floor magnet is encountered, the door magnet swivels on the hinge and rotates 90 degrees so the magnet is parallel to the floor and the floor magnet, which increases the magnetic attraction between the door magnet and the floor magnet. As the magnetic force draws the door magnet and the floor magnet closer together, the spring in the arm compresses so the arm and attached door magnet move to the down position, allowing the door magnet and the floor magnet to move closer together, forming a tighter bond and holding the door in place.
[0007] In various embodiments of the invention, the door magnet is attached directly to the adjustable arm so no hinge is needed. When the magnet on the floor is encountered, the spring compresses and the arm slides straight down so the door magnet and the floor magnet can connect.
[0008] In various embodiments, the case that contains the arm and spring are imbedded in the door so the unit is not visible from the front, side or back of the door. Only when the imbedded door magnet passes over the floor magnet does the arm descend from the bottom of the door and connects to the floor magnet.
[0009] In various embodiments of the invention, the floor magnet is attached to the floor using an adhesive material such as double-sided tape or double-sided foam and the door magnet is attached to the door using an adhesive material such as double-sided tape or double-sided foam.
[0010] In various embodiments of the invention, the floor magnet has a cover that matches the color and/or texture of the floor so the unit containing the floor magnet can be indistinguishable from the floor.
[0011] In various embodiments of the invention, the floor magnet can be imbedded in the floor so the magnet does not protrude from the floor.
[0012] In various embodiments of the invention, one of the magnets, either the door magnet or the floor magnet, is replaced by a ferrous metal or magnetic-like material, which will attract the magnet attached to the door or floor.
[0013] In various embodiments of the invention, the spring that moves the sliding arm to the up and down position is replaced by opposing magnets with either the same polarity or opposite polarity to push or pull the sliding arm up or down.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Having thus described the various embodiments of the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, wherein:
[0015] FIG. 1 illustrates a door magnet, floor magnet, and floor magnet cover according to various embodiments of the invention.
[0016] FIG. 2 illustrates the interior of the door magnet with the cover removed according to various embodiments of the invention.
[0017] FIGS. 3A-3F illustrates the motion of the door magnet from the side view and front view as it passes over the floor magnet according to various embodiments of the invention.
[0018] FIG. 4 illustrates the door magnet imbedded inside the door and the floor magnet imbedded in the floor according to various embodiments of the invention.
[0019] FIG. 5 illustrates a door magnet according to various embodiments of the invention.
DESCRIPTION OF EMBODIMENTS
[0020] Various embodiments of the invention are described more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the embodiments of the invention are shown in the figures. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather these embodiments are provided so that this disclosure will satisfy applicable legal requirements.
[0021] FIG. 1 illustrates one embodiment of the invention. The case 2 of the door magnet unit is attached to the bottom of the free-swinging back or front of the door 1 with adhesive. Within the case 2 is the adjustable arm 7 that is held in the up position by a compression spring. The door magnet 4 is in a protective case 5 that attaches to the adjustable arm 7 with a hinge 6 . The hinge 6 allows the door magnet protective case 5 and the door magnet 4 to swing down when the door passes over the floor magnet 9 . A small magnet 3 attached to the case 2 holds the door magnet 4 and the protective case 5 in the up position through a magnetic connection between magnets so the door can move freely when not over the floor magnet 9 . Independent of the door unit is the floor magnet 9 in a floor magnet protective case 8 .
[0022] After the floor magnet protective case 8 containing the floor magnet 9 are attached to the floor with adhesive material, the floor magnet cover 10 , in a color that most closely matches the floor, is placed over the floor magnet protective case 8 and floor magnet 9 , so the floor unit is unobtrusive. The floor magnet protective case 8 may also have walls that slope downwards, away from the magnet.
[0023] When the door magnet 4 passes over the floor magnet 9 with an opposing polarity, the opposing charges of the magnets form a magnetic attraction, swinging the door magnet protective case 5 on the hinge 6 so the door magnet protective case 5 containing the door magnet 4 swings 90 degrees and becomes parallel to the floor magnet 9 . With the larger, oppositely polarized surface areas of the door magnet 4 and the floor magnet 9 facing each other, the magnets are drawn together.
[0024] The spring holding the arm 7 in the up position compresses, and the arm 7 is allowed to descend so the door magnet 4 and the floor magnet 9 can be drawn closely together, holding the door 1 in place. The more closely door magnet 4 and floor magnet 9 are together, the greater the pull force of the magnets holding the door in place in accordance with Coulomb's inverse square law. To close the door 1 thereby eliminating the strong magnetic connection between magnets 4 and 9 , the door is simply closed in the normal manner by pulling or pushing on the door or door handle. This separates magnets 4 and 9 , allowing the compression spring to expand, thereby pulling arm 7 to the up position. As arm 7 snaps up on the spring, it swings protective case 5 up on hinge 6 . This allows the opposing attraction of small magnet 3 to attract door magnet 4 and hold the protective case 5 and door magnet 4 in the up position, allowing the door to swing freely.
[0025] FIG. 2 illustrates one embodiment of the spring mechanism unit of the invention. The figures show the front view (left) and side view (right) with the case 2 cover removed. The spring 11 holds the adjustable arm 7 in the up position when there is no oppositely polarized floor magnet 9 below the door unit. The bottom of the spring 11 rests on a raised area 12 attached to the case 2 , which allows the spring to compress and decompress as the adjustable arm 7 moves up and down. When the door unit is positioned over the floor magnet 9 , the opposing polarities of the door magnet 4 and the floor magnet 9 cause the protective case 5 to swing on hinge 6 , increasing the surface area of the opposing magnets 4 and 9 , which increases the pull force, drawing the magnets together. As the magnets 4 and 9 are drawn together, the adjustable arm 7 is pulled down, compressing the spring 11 against the raised area 12 . When the door is moved away from floor magnet 9 , spring 11 is allowed to expand away from raised area 12 , pushing the adjustable arm 7 to the up position, allowing the door to swing freely.
[0026] FIGS. 3A-3F illustrates one embodiment of the range of motion of the invention. These figures show three positions of the invention from the side view on the left and front view on the right. FIGS. 3A and 3B show the up position of the adjustable arm 7 when there is no floor magnet 9 on the floor below door magnet 4 . FIGS. 3C and 3D show the initial action of protective case 5 and door magnet 4 as it pivots on hinge 6 when it is attracted to floor magnet 9 as the door passes over floor magnet 9 . FIGS. 3E and 3F show adjustable arm 7 as it moves to the down position, compressing the spring in case 2 . This allows the door magnet and floor magnet to reach their highest level of attraction, thereby holding door 1 in place.
[0027] When door 1 is moved forward or aft away from floor magnet 9 , the spring in case 1 snaps the protective case 5 and door magnet 4 up 90 degrees, thereby allowing the small magnet 3 to attract door magnet 4 , holding the protective case 5 in the up position. The decompression of the spring in case 2 holds the adjustable arm 7 in the up position and the small magnet 3 holds the protective case 5 and door magnet 4 in the up position, allowing the door to swing freely.
[0028] FIG. 4 illustrates another embodiment of the invention. In this embodiment, the door magnet unit is embedded in the door 1 and the floor magnet 9 is embedded in the floor 14 . In the left figure, when the door 1 is not positioned over the floor magnet 9 , the door unit is not visible from the front, side or back of the door. This unit is placed in the door by drilling a hole in the bottom of the door 1 and then drilling a larger diameter hole at the entry point of the first hole. The case 13 and internal components are then inserted in the holes and held in place by screws. The adjustable arm 7 is held up in case 13 by the spring 11 , which rests on the raised area 12 , which is attached to the case 13 . The door magnet 4 is attached to the adjustable arm 7 . The right figure shows the action when the door passes over the floor magnet 9 imbedded in the floor 14 . The door magnet 4 is attracted to the oppositely polarized floor magnet 9 , pulling the adjustable arm 7 towards the floor 14 and compressing the spring 11 . When the door 1 is moved away from the floor magnet 9 , the spring 11 decompresses, moving the adjustable arm 7 to the up position.
[0029] FIG. 5 illustrates another embodiment of the invention. In this embodiment, the door magnet 4 is attached to the door 1 and the floor magnet 9 is attached to the floor 14 . The polarity of door magnet 4 facing down is opposite of the polarity of floor magnet 9 facing up. If the bottom of the door 1 is close enough to the floor 14 , when door magnet 4 is aligned with floor magnet 9 , the attraction between the magnets is enough to hold the door in place.
[0030] Although this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be effected within the spirit and scope of the invention as described in the appended claims.
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A door stop device is described, having a first magnet connected to a door and a second magnet connected to a floor. The first magnet can be mounted on a movable arm so as to allow the first magnet to move upwards and downwards. The arm can be bias in an upward position via a spring or a third magnet so as to be maintained in an upward position when the first and second magnets are not aligned, but moves downward when the first and second magnets are aligned.
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This application claims priority from U.S. Ser. No. 11/073,389, filed Mar. 7, 2005, which claims priority from U.S. Ser. No. 10/860,682, filed Jun. 3, 2004, which claims priority from U.S. Ser. No. 10/171,798, filed Jun. 14, 2002, which claims priority to provisional patent application Ser. No. 60/371,756.
BACKGROUND OF THE INVENTION
The invention relates to a process and machinery (Preheaters and Recycling Machine) for accurately heating, milling/profiling, handling and placement to grade of 100% Hot In-place Recycled (HIR) asphalt mixed with various types of rejuvenating fluids, liquid polymers and aggregates, with or without the addition of new, virgin asphalt (produced by a standard asphalt plant). The asphalt pavement is heated and softened by two or more Preheaters, physically scarified by one or more sets of carbide cutters (rakes), profiled and collected by mills, measured and mixed with rejuvenating fluid, polymer liquid (if required) and washed aggregate (if required) in a pug mill. The type, and amount of additives required to 100% HIR asphalt pavement is specified by pre-engineering using core samples taken from the asphalt pavement at regular intervals.
The 100% HIR of asphalt pavement is achieved by the addition of rejuvenator fluid, liquid polymers (if required) and washed aggregate (if required). Rejuvenator fluid must be accurately metered, as too much rejuvenator fluid will cause the recycled asphalt to bleed (rejuvenator fluid rising to the surface) softening the compacted surface. Too little fluid will not restore flexibility back into the recycled asphalt.
Liquid polymers such as Latex are added to increase the performance of the 100% recycled asphalt (Superpave specifications) by increasing flexibility while reducing rutting and cracking over a wider operating temperature range.
Adding aggregate (typically washed sand) during the 100% HIR process will modify the asphalt's physical properties and the air void ratio (percentage of air entrenched in the asphalt and generally specified at between 3-5%).
Adding rejuvenating fluid alone to the recycled asphalt will generally reduce the air-void ratio while adding washed sand tends to increase the air-void ratio. Adding aggregates that contain dust (unwashed) will generally reduce the air void ratio. Pre-engineering determines the correct specification and application rates for rejuvenating fluid, polymer liquid and aggregate. The Recycling Machine is designed with modular pin-on attachments for increased flexibility.
SUMMARY OF THE INVENTION
The present invention has a wide range of processing capabilities. For example, it can be used in, among others, the following applications:
1. 100% HIR: The old asphalt pavement is heated by a plurality of Preheaters to soften the asphalt for processing by the Recycling Machine. The final Preheater may be fitted with carbide cutters, asphalt collection blades (rake assembly) and an aggregate distribution system. The old asphalt is physically scarified by carbide cutters (rakes), profiled and collected by mills, measured and mixed with rejuvenating fluid, polymer liquid (if required) and washed aggregate (if required) in a pug mill. In one embodiment of the present invention, as described below, the asphalt from the heated surface does not need to be lifted. The type and amount of additives required to 100% HIR asphalt pavement is specified by pre-engineering using core samples taken from the asphalt pavement at regular intervals.
The 100% HIR of asphalt pavement is achieved by the addition of rejuvenator fluid, liquid polymers (if required) and washed aggregate (if required). Liquid polymers such as Latex are added to increase the performance of the 100% recycled asphalt (Superpave specifications) by increasing flexibility while reducing rutting and cracking over a wider operating temperature range. Adding aggregate (typically washed sand) during the 100% HIR process will modify the asphalt's physical properties and the air void ratio (percentage of air entrenched in the asphalt and is generally specified at between 3-5%). The 100% recycled asphalt is placed to grade as a single course (layer) by a standard paving screed (attached to the Recycling Machine). The Recycling Machine can be equipped with an optional front asphalt hopper/variable speed chain slat conveyor, truck pusher bar, variable speed central belt conveyor and electronic belt scale and conveyor hopper/diverter valve. A surge bin/vertical elevator, auger/divider/strike off blade, and screed assembly are also provided. The Recycling Machine's mills, pug mill, auger/divider/strike off blade and screed assembly, process and place the 100%, recycled asphalt. When equipped with the optional equipment, the Recycling Machine's on-board computer meters the new asphalt, which may be stored in a hopper, into the surge bin/vertical elevator, auger/divider/strike off blade and screed assembly for startup. The optional equipment also allows the Recycling Machine to perform the 100% HIR Remix method.
2. 100% HIR (Remix): In this application, the old asphalt pavement is heated by three or more Preheaters to soften the asphalt for processing by the Recycling Machine. The final Preheater may be fitted with carbide cutters, asphalt collection blades (rake assembly) and an aggregate distribution system. The Recycling Machine can be equipped with a front asphalt hopper/variable speed chain slat conveyor, truck pusher bar, variable speed central belt conveyor and electronic belt scale, conveyor hopper/diverter valve, surge bin/vertical elevator, auger/divider/strike off blade, and screed assembly. New asphalt is delivered from the hot mix plant by highway dump trucks and discharged into the Recycling Machine's hopper. The Recycling Machine's on-board computer meters the new asphalt (stored in the hopper) proportionally (approximately 10% to 15% by weight of the asphalt being 100% recycled) on to the central belt conveyor. A hopper/diverter valve diverts the new asphalt into the surge bin's vertical elevator. The vertical elevator is positioned in the 100% processed asphalt's windrow to continuously pickup asphalt. The processed asphalt and the metered, new asphalt are blended at the vertical elevator and delivered to the surge bin. The new asphalt may also be diverted directly on to the 100% recycled asphalt (windrow) exiting the pug mill. 3. 100% HIR (Integral Overlay): In this application, the old asphalt pavement is heated by a plurality of Preheaters to soften the asphalt for processing by the Recycling Machine. The final Preheater may be fitted with carbide cutters, asphalt collection blades (rake assembly) and an aggregate distribution system. The Recycling Machine is equipped with a front asphalt hopper/variable speed chain slat conveyor, truck pusher bar, variable speed central conveyor, shuttle conveyor, primary asphalt distribution auger/divider/strike off blade, secondary asphalt distribution auger and primary/secondary screed assemblies. New asphalt is delivered from the hot mix plant by highway dump trucks and discharged into the Recycling Machine's front hopper. The Recycling Machine's mills, pug mill, primary auger/divider/strike off blade and screed assembly, process and place the 100% recycled asphalt. The Recycling Machine's on-board computer meters the new asphalt (stored in a hopper) via the central conveyor and shuttle conveyor to the secondary asphalt auger and screed assembly and if required, to the primary auger/divider/strike off blade and primary screed assembly. The new asphalt is placed by the secondary screed assembly on top of the 100% recycled asphalt (being laid to grade by the primary screed assembly) resulting in a hot, thermal bonding between the two layers. The 100% recycled and new asphalt is not mixed together, as in the Remix method. Both the primary and the secondary screed assemblies feature a novel grade control system used to place the asphalt to grade while also controlling the depth differential (generally 0.5 to 1 inch) of the asphalt laid between the two screed assemblies.
A standard, asphalt-paving machine used in the industry is designed to lay hot, plant mix asphalt delivered from the asphalt plant by dump trucks. The paving machines are either rubber tire or track driven machines. Neither type has any hydraulic suspension to raise and lower the paving machine's mainframe. The asphalt is generally dumped into the front hopper of the paving machine where it is conveyed rewards by two, independently controlled, slat conveyors. The conveyed asphalt drops into two, independently driven, variable speed, hydraulically driven augers. The left auger receives asphalt from the left conveyor and the right auger from the right conveyor. The augers convey asphalt out from the center of the paving machine to the ends of the screed's extensions. Electronic level sensors are attached to the ends of the left and right side extension screeds to control the speed of the independently driven augers and conveyors. If the level of asphalt drops in one or both of the extension screeds, the auger(s) and conveyor(s) will increase in speed, delivering more asphalt. The level of asphalt (head of material) should be maintained across the complete width of the screed assembly. Generally the asphalt will be to the height of the auger's drive shafts (half full) with the augers slowly turning (without stopping) while conveying asphalt to the screed's extensions. Behind the two augers is the screed assembly, which is responsible for spreading (laying) the hot asphalt to a specific depth and grade. The screed assembly consists of the main screed and a left and right extension screed. The main screed is fixed in width while the extension screeds can be hydraulically extended or retracted as the paving machine is operating, thereby altering the paving width. The screed is attached to the paving machine's mainframe by screed tow arms that reach forward to behind the front hopper. The screed tow arms are attached to the paving machine's mainframe by the left and right side tow points. The tow points can be pinned into position for manual control. A skilled operator uses crank handles at either side of the screed to adjust the screed's angle of attack. The screed allows more asphalt to flow under its plate (screed rises) when its angle of attack is increased (front of the screed plate is higher than the rear) and visa versa. For automated control of the screed, the left and right crank handles are locked into position. Hydraulically raising or lowering the screed arm's tow points controls the screed's angle of attack. Raising a tow point will increase the angle of attack and visa versa. The automatic grade control sensors that control the tow points are mounted to the rigid tow arms and sense the asphalt's grade using averaging beams, joint matcher, string lines or a non-contact, sonic sensor beams. The averaging beams and the joint matcher make physical contact with the asphalt's surface and are towed by the paving machine, generally one on either side. The string line is a long string or wire that is erected using surveying equipment. The paving machine uses the string line as a fixed, reference grade. The mounting position of the sensors can be adjusted (distance from the tow point) to control the response of the system. Generally the screed's reaction to grade deviations needs to be slow to produce a smooth riding, asphalt surface. The sensors should be mounted closer to the tow point to achieve a slow, smooth reaction. Mounting the sensor closer to the screed's pivot point (away from the tow point) speeds up the reaction time and is better suited to joint matching applications. For surfaces where the right hand averaging beam cannot practically be used due to obstructions, poorly graded shoulders, curbs, etc., an electronic slope sensor, attached to the main screed can be substituted in place of the right averaging beam and sensor. The slope sensor allows the percentage of grade to be electronically adjusted while the paving machine is processing. For accurate grade and slope control Topcon's Paver System Four or Five together with their Smoothtrack® 4 Sonic Tracker II™ averaging beams are highly recommend. Attached to each of the screed's tow arms is an aluminum beam fitted with four (non-contacting) sonic sensors that electronically average the surface's grade. Topcon's electronic. Slope Sensor is mounted to the screed assembly. The Sonic Trackers and the Slope Sensor work together to determine the screed's position relative to the desired grade and generate correction signals that are used by the Recycling Machine's on-board computer to hydraulically control the screed arm's tow points.
To produce a quality, asphalt surface that meets all engineering specifications requires considerable operator skill, knowledge and equipment capable of properly performing the work. Consistency is one of the keys when producing a quality; asphalt surface and the following major points should be followed when laying new asphalt with a paving machine or 100% recycled asphalt with a recycling machine with attached screed(s):
a. Processing should be continuous with no stops. Stopping the screed assembly allows it to settle into the hot asphalt, causing depressions. Stopping for too long a period causes the asphalt in front of the screed assembly to cool, resulting in the screed assembly rising when forward travel is resumed. b. The processing speed should remain as consistent as possible. An increase in speed will cause the screed assembly to rise while a decrease will cause the screed assembly to sink. c. The temperature of the asphalt in front of the screed assembly (head) should remain consistent. If the temperature drops the screed assembly will rise and visa versa. d. The asphalt in front of the screed assembly should remain at a consistent level, across the complete width of the main screed and the screed's extensions. An increase in asphalt level will cause to screed assembly to rise while a decrease will cause it to sink.
The cold planer (milling machine or grinder) is generally a heavy, high-powered machine fitted with a large diameter, cutting drum. Attached to the cutting drum are replaceable carbide teeth and holders. The cold planer is designed to mill to grade, asphalt and concrete surfaces. The carbide cutters are generally sprayed with water, which is used for cooling and dust control. The milling drum discharges the milled product on to a high capacity, rubber conveyor belt that delivers the material to a fleet of waiting dump trucks to be hauled away. The cutting drum's depth of cut (width is fixed) is manually or automatically controlled. Automatic grade control is generally accomplished by using the same sensors as the paving machine; however, long averaging beams are not generally used. More common, is the fixed string line, single sonic sensor on each side or Topcon's Smoothtrack® 4 Sonic Tracker II™ averaging beam on each side. The automatic grade control sensors on the cold planer automatically control the cutting drum's depth by raising or lowering the machine's mainframe to which the drum is attached. Three or four hydraulically activated legs (struts) are fitted with hydraulically driven tracks are used to propel the machine. The struts also turn to provide steering and raise and lower to provide the necessary grade control. The automatic grade control sensors that control the struts are mounted to the mainframe (generally close to the centerline of the cutting drum) and sense the asphalt's grade using left and right side sonic sensors. For surfaces where the right hand sensor cannot practically be used due to obstructions, poorly graded shoulders, curbs, etc., an electronic or hydraulic slope sensor, attached to the mainframe can be substituted in place of the right sensor. The slope sensor allows the grade (percentage) to be electronically adjusted while the planing machine is milling material.
Prior 100% HIR recycling machines have systems designed to process and lay 100% recycled asphalt to grade using a standard, asphalt-paving screed. Recycling machines fitted with an attached screed have had major problems with the varying amount of processed, recycled asphalt, which collects in front of the screed assembly, especially when milling to grade (averaging the high and low areas). Milling to grade causes the volume of recycled asphalt to vary as high and low areas of pavement are milled. High sections increase the amount of asphalt being processed, while low sections require supplemental asphalt, to make up any deficiency. The only way, until now, that the amount of asphalt in front of the screed assembly could be controlled was by manually increasing the angle of attack (raising) of the screed assembly to release excess asphalt, or reduce the angle of attack (lowering) to collect asphalt. Manual, operator adjustment of the screed assembly generally results in bumps and an inconsistent grade of the finished asphalt surface (mat). Others have tried to resolve the problem by removing the screed assembly from the recycling machine. The recycling machine (less screed) either conveys the heated, recycled asphalt into a standard paving machine positioned under the rear of the recycling machine, or leaves a windrow of hot asphalt on the milled asphalt's surface, which is picked up by a windrow conveyor attached to the paving machine. The front hopper of the paving machine stores any excess asphalt when not required by the screed assembly.
The following problems arise when the screed assembly is removed from the recycling machine:
a. Increased costs: A paving machine and windrow conveyor must be purchased and operated in addition to the recycling machine. Shipping both units requires a trailer as the units are not self transportable.
b. Reduced asphalt temperature: The temperature of the recycled asphalt contained in the windrow drops the further the windrow conveyor and paving machine are positioned from the recycling machine. Heat is also lost at the windrow conveyor and paving machine as the hot asphalt is handled. Low asphalt temperatures cause the screed assembly to tare the mat (open surface). This also causes a problem with final mat compaction during rolling. Asphalt meeting Superpave specifications generally requires higher temperatures to be maintained behind the screed assembly with the steel drum roller operating as close to the screed assembly as practicably possible.
c. Increased segregation: Hot asphalt should always be moved as a mass to prevent segregation. The windrow conveyor and paving machine increase the handling operations of the hot asphalt, causing the larger aggregate to separate (segregate) and tumble to the sides, causing marks in the finished mat. Asphalt meeting Superpave specifications generally uses a larger size aggregate than conventional asphalt. Segregation will become a greater problem with the larger aggregates.
d. Increased pollution and increased equipment train length: The windrow conveyor opens up the hot, asphalt windrow as the asphalt is conveyed upwards into the paving machine's front hopper. Excessive smoke (natural byproduct of hot asphalt) is produced (if the asphalt is at the correct temperature) causing a problem to the paving machine's operators. Asphalt meeting Superpave specifications will cause even greater problems with smoke due to the higher temperatures.
e. Safety: Safety is an issue when processing with an open windrow. It is quite common for automobiles to try and cross the heated windrow, only to become stuck in 200 to 300+ Deg F. asphalt. Animals have seriously burnt their feet, as have humans with open footwear! Recycling machines with an attached screed assembly do not suffer from the above problems, as there is no open windrow.
The following problems have, until now, prevented current 100% HIR systems and machines from producing quality, recycled asphalt that meets pre-engineered specifications:
1. Inconsistent heating of the asphalt pavement to the proper depth required for 100% HIR.
2. Inconsistent smoothness when milling with 100% HIR machines.
3. Inconsistent smoothness and surface defects, caused by asphalt handling problems when using an attached screed assembly using 100% HIR machines.
4. Inconsistent ratio of new asphalt to 100% recycled asphalt when using the Remix method.
5. Inability to process asphalt around utility structures and obstructions.
6. Inaccurate and inconsistent application of liquid additives.
7. Inaccurate and inconsistent application of additional aggregate.
8. Improper mixing of rejuvenator fluid, washed aggregate and reworked asphalt.
9. Inability to remove moisture from the reworked asphalt.
5. Inconsistent depth differential between the 100% recycled asphalt and the new asphalt when using the Integral Overlay method.
The present invention solves the above-mentioned problems.
1. Inconsistent Heating of the Asphalt Pavement to the Proper Depth Required for 100% HIR
A critical step in the 100% HIR of asphalt pavement is getting the heat down into the asphalt to a depth (2″ or more) that will produce an average temperature that is hot enough to properly process the asphalt, without damaging the asphalt. Experience has shown that different mixes of asphalt absorb heat at different rates. For instance, asphalt with the addition of steel mill slag absorbs heat at a much different rate than asphalt with the addition of asbestos or rubber. The amount of moisture contained in the asphalt also plays an important part in the way that heat is absorbed with high percentages reducing the heating efficiency. When asphalt is not heated to sufficient depth, the following problems will occur:
The milling equipment will fracture the aggregate (stone) in the asphalt, degrading the asphalt's physical structure. Insufficient moisture will not be driven out of the asphalt, in the form of steam, preventing the proper coverage and bonding of liquid additives to the asphalt's aggregate. The effective mixing of additives (aggregate and rejuvenator fluid) will be reduced due to the asphalt not flowing correctly in the mills and pug mill. The screed assembly will tear the finished mat due to low asphalt temperatures.
If the asphalt is over heated (generally the top surface) and the heat does not penetrate to the required depth, the following problems will occur:
The surface of the asphalt will be chard (burnt), causing degradation of the asphalt's asphalt cement (AC) content and high levels of pollution, caused by fire and smoke. The added rejuvenator fluid and polymer liquids will be degraded when they make contact with the overheated asphalt as the light fluid fractions will flash off (evaporate).
If the asphalt is inconsistently heated, to a sufficient depth, all of the above problems will occur, plus the screed assembly will sink and climb with the change in the asphalt's temperature. Cold asphalt will make the screed climb (raise) while overheated asphalt will cause the screed to sink. Both conditions will cause grade and surface smoothness problems.
It can be seen that the temperature of the asphalt is critical to the 100% HIR process.
The present invention is able to maintain a consistent temperature through the use of, among other things, a temperature sensor in the pug mill which is designed to measure the final temperature of the asphalt leaving the pug mill (windrow). In addition, the pug mill's discharge (100% recycled asphalt) is formed into a lightly compacted windrow by a parallelogram ski that measures the volume and temperature of the asphalt. An on-board computer monitors the windrow's temperature and makes small adjustments to the forward processing speed, set by the operator. A decrease in the asphalt's temperature will cause a slight decrease in forward processing speed, allowing the Recycling Machine's (and the Preheaters) heater boxes greater time to heat the asphalt to the required depth. An increase in the asphalt's temperature will cause a slight increase in forward processing speed, allowing the Recycling Machine's heater box less time to heat the asphalt surface. The final temperature (pug mill discharge) of the 100% recycled asphalt will be fairly consistent, as the on-board computers attached to the three or more Preheaters and the Recycling Machine automatically monitor and control the complete heating process.
For manual operation, (each Preheater under its own on-board computer control) the Preheaters are equipped with electronic ground speed and asphalt, surface temperature monitoring and control. Each Preheater is set to track a preset (asphalt surface) heat range. The Preheaters and the Recycling Machine, monitor the temperature before, during and after the heater boxes. The Preheater's front and rear heat sensors measure the asphalt surface's heat differential, across the heater box and control the amount of heat by turning on and off the individual, electronically controlled burners. A heat sensors in each burner monitor and control each individual burner, while flame detectors shut down burners when flame (caused by crack filler or painted lines) is detected.
The Preheaters and the Recycling Machine may also be linked by wireless control (Ethernet). Satellite communication may also be used to replace the wireless control system. Each machine may also be fitted with a satellite Global Positioning System (GPS). The Recycling Machine and Preheater's on-board GPS computers will allow all of the machines to self steer and maintain the correct spacing (in relation to the Recycling Machine) for proper heat transfer to the asphalt. Data for the on-board GPS computers will be determined by a pickup truck, fitted with a mechanical, center lane guide and GPS sensor(s) positioned at the center of the truck. Two sensors will be used to provide greater accuracy. The pickup truck will be driven down the road (mechanical center lane guide positioned over center of road) prior to processing, with the GPS sensors readings being recorded into a portable computer fitted with a removable disk or a memory card (Zip or flash). The data will be downloaded into all of the machine's on-board computers. The truck can also be equipped with a metal detection boom with left and right side, hydraulically operated extension booms. A series of metal detectors are attached to the booms and detect iron utility structures in the asphalt's surface. The extension booms are hydraulically moved in and out to follow the width of the asphalt surface to be recycled. Electronic position sensors (LVDT) measure the position of the boom's extensions. The GPS computer records and stores the location of all iron structures. The Recycling Machine and the Preheaters will also be fitted with GPS sensors. The sensors may be fitted to the front and the rear of Recycling Machine and the Preheaters. The on-board computers compare the machine's actual position, to the stored position, recorded by the pickup truck's sensors. The on-board, computers monitor the Preheater's spacing and monitors and controls the steering (front and rear) when the automatic steering mode is selected. All GPS equipped machines are programmed to steer accurately down the center of the lane, not the center of the road. The Recycling Machine's processing width can be varied, while in operation, therefore the operators can process varying lane widths on both sides of machine. For safety reasons the machine operators can override the GPS control system at any time.
For large areas or straight-line work, a laser beam can be used to automatically guide (self-steer) the pickup truck in a straight line. Once the data has been stored to disk or memory and downloaded in to each machine's on-board computer, each pass is programmed at a selected width from the last pass. It is also possible to use the on-board GPS system fitted to each machine to program the coordinates directly, rather than using the data obtained by the pickup truck GPS system.
The GPS's metal detection readings are used by the final Preheater (unit ahead of the Recycling Machine) and the Recycling Machine's GPS and on-board computers to automatically raise and lower the rake/blades assemblies, extension mills, main mill and the pug mill, preventing damage to the sub-assemblies and iron utility structures.
All machines fitted with the GPS system will also be equipped with sonic sensors mounted at the front of the machines. An operator warning horn will sound if an obstruction, such as an automobile is detected. The machine is programmed to stop when a minimum distance is reached.
The wireless data transmission will allow all of the machines to communicate with each other, providing accurate and efficient heating.
The system can be designed to operate under the following parameters:
All Preheaters and the Recycling Machine will be under their own control until processing speed and control has been established and stabilized. The Recycling Machine (master) will control the spacing of the Preheaters (slaves) using wireless, GPS or satellite control. The lead Preheater will produce as much heat as possible without damaging the asphalt's surface. All other Preheaters following the lead Preheater will regulate their heat output based upon the temperature of the asphalt's surface ahead and behind (heat differential) their heating elements (boxes). Each Preheater is designed to produce as much heat as possible without damaging the asphalt's surface. The final Preheater is equipped with a rake scarification/blade collection system and aggregate distribution bin, controlled by the Preheater's on-board computer. The aggregate bin must be occasionally filled with aggregate by a wheel loader. Space must be provided not only for the wheel loader, but also for the dump trucks discharging asphalt into the front hopper of the Recycling Machine. This necessitates the final Preheater being controlled by the operator (taken out of automatic control). All of the Preheaters ahead of the final Preheater will automatically move ahead once the final Preheater has reached a preset distance from the Preheater ahead (positions monitored by the on-board GPS systems). As the Preheaters move ahead their heating output will automatically increase (if possible) due to the increase in the heat differential across their heating elements (boxes). Once the aggregate bin has been filled or the dump truck has been released, the final Preheater is returned to automatic control. All of the Preheaters will slow down, allowing the Recycling Machine to catch up. The heating output of the Preheaters is automatically reduced during the catch up period due to the decrease in the heat differential across their heating elements (boxes), thereby preventing overheating of the asphalt. The Recycling Machines heating system is designed to fine-tune the asphalt's final temperature before the asphalt is processed by the rake scarification and milling systems. The heating system is programmed to operate at 50% or less of its heating capacity (50% or less of the electronically controlled burners on the main heater box turned on). When the final Preheater is fitted with a rake scarification/blade collection system and aggregate bin the Recycling Machine's heating system must produce enough heat to remove any remaining moisture in the aggregate without degrading the asphalt. The scarifying process breaks the asphalt's surface, limiting the amount of heat that can be applied. The average temperature of the heating system can be set and controlled by the on-board computer. Individual, electronic burners will maintain this average by regulating their heat output. Infrared sensors monitor the asphalt's temperature, ahead of the heating system. The mill's grade control shoes (located behind the heating system) are fitted with heat thermocouples that monitor the temperature of the asphalt's surface, ahead of the rakes and mill assemblies. This temperature information, together with the pug mill's discharge (windrow) temperature and the operator's input for the base processing speed, controls the actual processing speed of the Recycling Machine. For instance, the operator has set the base processing speed to 20 feet per minute, based upon information displayed upon his monitor (screen). The on-board computer is programmed to monitor key operating parameters such as Preheater/Recycling Machine's asphalt processing temperature differentials and the Recycling Machine's engine percentage load factor and will display a recommended base processing speed. The temperature of the asphalt in the windrow has been programmed at a set point of 320° F. The thermocouples on the grade shoes are reading 550° F. and the heating system is operating at 50% of its output. As the windrow temperature increases to 325° F. and the mill's grade shoes average temperature increases to 560° F. the Recycling Machine's actual processing speed increases automatically. The Recycling Machine's on-board computer will also send information by wireless or GPS to all of the Preheater's on-board computers to speed up their forward travel speed. When the Preheaters are at 100% of their heating capacity and the temperature differential across their heating systems begins to increase to a preset, set point, it signals that the train is getting to the point of going too fast for the asphalt to properly absorb heat. The Recycling Machine's on-board computer monitors all of the Preheater's temperature differentials (via wireless or satellite link) and will start to slow down its processing speed and the Preheaters, allowing more time for the asphalt to absorb the heat. The infrared temperature sensors in front of the Recycling Machine's heater box can instantly turn the heating system up to 100% capacity if the asphalt's temperature reaches a preset minimum set point. This can occur when the final Preheater's aggregate distribution system deposits a higher percentage of aggregate when its grade profiling system traverses a high section in the asphalt's surface. The increased volume of aggregate (generally washed, damp sand is used to modify the asphalt's air void ratio) will reduce the asphalt's surface temperature and the extra heat will be required to drive out the excess moisture and bring the aggregate up to the proper temperature. The temperature drop could also be the result of the Preheater's rake scarification/blade collection system (set to scarify at 2 inches or more) releasing large quantities of moisture (steam) out of the heated asphalt. The Recycling Machine's heating system is designed to operate at 100% of its heating output (all of the electronically controlled burners turned on), once the processing speed reaches a pre-set limit (around 22 feet per minute). 100% heating capacity is also used if the asphalt's temperature at the rear of the final Preheater heating system suddenly drops to a minimum temperature, set point when operating at below 22 feet per minute. If the temperature behind the final Preheater does not return to its normal operating temperature range within 10 feet, the Recycling Machine's on-board computer (using data obtained from the final Preheater by wireless or satellite transmission) will slow the Recycling Machine and Preheaters down using the GPS. This electronic monitoring, transmission and control loop is continuously repeated, providing maximum heating efficiency and processing speed.
2. Inconsistent Smoothness when Milling with 100% HIR Machines:
The accuracy of the milled surface (grade) and the accurate placement of asphalt on to the milled surface determine the smoothness of the compacted, asphalt mat. If either one is incorrect the riding quality (smoothness) will be reduced. The present invention is fitted with two types of on-board, computer controlled, automatic grade control systems that monitor pavement grade to automatically control all of the milling and screed assembly operations:
a. Full, mainframe grade control: For asphalt surfaces requiring the accurate milling and placement of asphalt (highway and airport runways) a novel grade and slope control system has been developed. When using full, mainframe grade control, the mills and screed arm tow points are mechanically, electronically or hydraulically locked to the grade of the Recycling Machine's mainframe. The system can utilize Topcon's Paver System Four or Five together with their Smoothtrack® 4 Sonic Tracker II™ (non-contact) averaging beam(s) or mechanical averaging beam(s) on one or both sides of the Recycling Machine's rear end. All of the mechanical averaging beams are attached and towed by the Recycling Machine's mainframe while Topcon's Smoothtrack® 4 Sonic Tracker II™ averaging beam(s) are fixed to the mainframe as they do not have to be towed. All of the beams longitudinal track the asphalt's surface. The longer the beam the greater the averaging effect.
Topcon's Smoothtrack® 4 Sonic Tracker II™ averaging beams are preferred as they do not make contact with the asphalt's surface, thereby eliminating marking (scuffing) of the previously finished mat and can also be used on the curb side (right) of the Recycling Machine. They also provide increased accuracy and easier setup/operation. The mechanical averaging beams use electrical or hydraulic sensors (attached to the Recycling Machine's rigid main frame) to sense the grade (position) of the beam. Wands or arms attached to the sensors make physical contact with the beams or travelling string line (string line attached to the beam). Whichever sensor system is used, the Recycling Machine's grade (mainframe) is controlled as explained in the following example. The Recycling Machine's rear, left side axle and mainframe begin to sink (lower) in grade, compared to the left side averaging beam's grade (the Recycling Machines right side grade remains on grade). The grade control system will signal for hydraulic oil to be sent to the left, rear axle's, hydraulic leveling cylinder (attached between the mainframe and the rear axle assembly). The left hydraulic cylinder extends and tilts the mainframe, keeping the mainframe on grade. The electronic or hydraulic sensor automatically stops the hydraulic oil supply to the left hydraulic cylinder as the mainframe is raised back to match the averaging beam's grade. The grade of the frame has to change to produce input into the sensors; however, this change in grade is small and has little or no effect on the final grade of the asphalt's surface. The right hydraulic leveling cylinder is under the control of the right averaging beam and sensor. For surfaces where the right hand, mechanical averaging beam cannot practically be used due to obstructions, poorly graded shoulders, curbs, etc., the electronic slope sensor (located at the rear end of the Recycling Machine's mainframe) can be substituted in place of the right averaging beam and sensor. The slope sensor allows the percentage of grade to be electronically adjusted while the Recycling Machine is processing. Topcon's Smoothtrack® 4 Sonic Tracker II™ averaging beams together with Topcon's frame mounted electronic slope sensor allow averaging on both sides or cross slope to be specified. To allow the above grade and slope control system to operate the Recycling Machine is designed with a hydraulic, three-point suspension system that lifts and lowers both ends of the Recycling Machine's main frame as well as tilting it. Two hydraulic cylinders per axle assembly are attached between the mainframe and front and rear axle assemblies. The two front cylinders (front axle assembly) are hydraulically connected in parallel, while the rear axle's hydraulic cylinders are individually controlled, thus forming a three-point suspension system. The front and rear axle assemblies are fitted with hydraulic wheel motors and rubber tires, inflated with dry nitrogen to high pressures to prevent the tire's side walls from deflecting which would have a negative effect on grade control. Both axle assemblies can steer 40 degrees in both directions, providing accurate steering. The rear tires contact the heated asphalt's surface, milled by the main and extension mills (located ahead of the rear axle). The front axle assembly follows the original, heated asphalt's surface and is free to oscillate when working on uneven surfaces. Grade changes will cause the front axle assembly and to some degree the front of the mainframe to rise and fall, however, this has little effect on the rear end of the mainframe due to the frame's long length. As noted above, input from the left and/or right side averaging beams or the left side averaging beam and electronic slope sensor are used to control the operation of the two individual hydraulic cylinders attached between the rear of the mainframe and the rear axle assembly. The Recycling Machine's main frame is said to be “locked to grade” by the sensors. The extension mills and the main mill are raised and lowered in relation to the mainframe by four, individual (left and right) hydraulically operated sliding struts, controlled by four automatic grade control sensors. When utilizing full, main frame, grade sensing, the mills automatic grade control sensors sense the mainframe's position. Fine adjustments can be made to the depth of cut by adjusting each, individual sensor. This is desirable when setting the cutting depth between the extension mills and the main mill. The screed arm's tow points can be locked mechanically (pinned) to the mainframe.
The screed is attached to the screed tow points (left and right side of the recycling machine) by pivoting, rigid arms. The tow points can be pinned into position for manual control by a skilled operator who uses crank handles at either side of the screed assembly to adjust the screed's angle of attack. The screed assembly allows more asphalt to flow under its plates (screed assembly rises) when its angle of attack is increased (front of the screed's plates higher than the rear) and visa versa. For automated control of the screed assembly, the left and right crank handles are locked into position. Hydraulically raising or lowering the tow points controls the screed assembly angle of attack. Raising a tow point will increase the angle of attack and visa versa. The automatic grade control sensors that control the tow points are mounted to the rigid screed arms and sense the asphalt's grade using Topcon's Smoothtrack® 4 Sonic Tracker II™ averaging beams, mechanical averaging beam(s), joint matcher or string lines. The mounting position of the sensors can be adjusted (distance from the tow point) to control the response of the system. When the mechanical averaging beams (towed) are used the screed arm's sensors, sense of the same averaging beams used by the Recycling Machine's mainframe grade control sensors. The right hand, screed tow point can be controlled by using a second electronic slope control, attached to the screed. Generally the mainframe and the screed assembly would both be operating with individual, electronic slope controllers. A major advantage of using the automatic grade controls to control the screed assembly tow points (even though the mainframe is locked to grade already) is due to the influence of varying, asphalt levels (in front of the screed assembly), travel speed, asphalt density and heat. Example: If the Recycling Machine is (fitted with mechanical averaging beams on both sides) slowed for traffic, the screed assembly will tend to sink (less asphalt flow under the screed plates) whereas the mainframe will remain at grade as the rear axle's wheels are tracking a solid, milled asphalt surface. The automatic grade sensors mounted on the screed's tow arms will sink with the screed assembly, however, the mechanical averaging beam's grade remains consistent. As the sensors sink they signal and control the hydraulic oil flow into the tow point's cylinders, raising the tow points, which increases the screed assemblies angle of attack, resulting in a consistent grade. Other recycling machines have manual adjustments on the mills for depth control or have automatic grade controls fitted to the mills with very short skis or pans. The problem with both systems is in following the original, uneven surface grade causes the mills to profile to the original grade, rather than averaging the grade as in the case of the long averaging beams. For example: A utility trench, stretching transversely across the complete width of the asphalt pavement has settled (depression) by 2 inches. The short grade skis or pans attached to the mills will follow in and out of the depression causing the mills to cut to the same profile. This depression will show up in the finished mat as a depression, after final rolling. The long averaging skies, by comparison, would hardly notice the same depression. Finally, if the milled grade is continuously varying (up and down) then the recycling machine's and/or the paving machine's wheels or tracks are following the undulating grade, causing their automatic grade controls to work harder while controlling the screed assembly grade. It is interesting to note that the grade of the asphalt being laid by any screed assembly, if the automatic grade controls are set properly, will remain very consistent, even with an undulating, milled base surface. However, during final compaction of the asphalt by the rollers, the finished mat will follow, to a degree, the profile of the undulating, milled base surface, thereby producing a mat with poor smoothness characteristics.
a. Left and right side averaging skies for the extension mills and the main mill: For secondary roads, city streets and asphalt surfaces where full, mainframe grade averaging is not practicable using long, mechanical averaging beams, the recycling machine is equipped with left and right side skis, or optional, averaging skis. The skis are located ahead of the extension and main mills. The two averaging ski assemblies contact the heated, unprocessed asphalt (original grade) and are manually adjustable in width, allowing setup for various processing widths. The extension mills (left and right side) are hydraulically adjustable in width and crown while the main mill, located behind the extension mills is of fixed width. The left ski automatically controls the grade (depth of cut) of the left extension mill and the left side of the main mill. The right ski controls the grade of the right extension mill and right side of the main mill. The left and right ski assemblies are connected by a jointed, cross beam to which various attachments, used to contact the heated asphalt surface, can be added. In its simplest form, two sliding shoes (the shoes contact the heated surface) are mounted to the cross beam and follow the profile of the asphalt's surface, generally in the wheel ruts created by traffic, as this is generally the smoothest part of the surface on badly rutted asphalt. In its most complex form two sets of shoes (one on either side of the Recycling Machine) are attached to the cross beam by pivoting beams, allowing the transverse surface across the asphalt to be averaged. Left and right extension beams are attached (when space permits) to the jointed, cross beam, allowing the shoes to reference the surface to the left and right of the Recycling Machine. The left side shoe(s) can be replaced by wheels attached to averaging beams, running in line (longitudinally) with the Recycling Machine and on the asphalt surface processed on the previous pass. The wheels are used to prevent marking of the previously finished mat. This allows the mills to profile to the grade of the previously finished surface. Shoes can also be used if wheels are not required. The mill's grade control system can transversely or longitudinally average the asphalt surface, providing far greater accuracy than simple, shorts shoe sensors, mounted directly on to the extension and/or main mill. The left and right side of the grade control cross beam are attached by two pivoting links to the left and right side, sensor control stations that house the hydraulic (electronic are optional) grade control sensors. The left, sensor control station controls the left extension mill and left side of the main mill, while the right, sensor control station controls the right side of the mills. Both the extension mills and main mill are raised and lowered by four (two for the extension mills, two for the main mill) hydraulically operated, sliding struts attached to the machine's main frame. The sliding struts on the extension mills attached between the Recycling Machine's main frame and the extension mill's mainframe. The left and right side extension mills are attached to the extension mill's main frame by hydraulic cylinders, allowing the extension mills to pivot (crown), independently to the extension mill mainframe. The sliding struts for the main mill attach directly to the main mill's main frame. Attached to each sliding strut is a manually adjustable height screw, which the grade control sensors touch (sense). Each grade control sensor (attached to the sensor control station) monitors the position of the height screws. The following example will explain the operation of grade correction for the right hand side. The Recycling Machine is entering an intersection with a raised section of asphalt pavement. The right hand averaging shoes (in contact with the heated asphalt surface) begins to rise, causing the sensor control station to rise. The two right hand, grade control sensors (attached to the sensor control station), move away from the sliding strut adjuster screws and supplies hydraulic oil to the hydraulic cylinders attached between the mainframe and the sliding struts. The sliding struts are automatically raised, moving the adjuster screws up to match the position of the sensor control station, cutting of the supply of hydraulic oil. The sliding struts/adjuster screws will always follow the position of the sensor control stations. Manual adjustment is provided to allow for fine adjustments to each individual strut to fine tune the milling height between the extensions and the main mill. Manually crowning of the left and right extension mill by the operator is possible without effecting the position of the sliding struts. This is desirable when working in city streets with poor grade, intersections, driveways and irregular curbs and/gutters. With this grade control system with both mills sensing the sensor control stations, any sliding strut can be manually raised or lowered, without effecting the other sensors. The left and right sensor control stations are mounted to the Recycling Machine's mainframe by a parallelogram linkage, which raises and lowers the grade control sensors in absolute alignment with the sliding struts. The sensor control stations are also attached to the mainframe by a hydraulic lift/damper cylinder. The function of the hydraulic lift/damper cylinder is to carry a percentage of the sensor control station, beam and averaging shoe's weight, preventing the shoes from sinking into the hot asphalt. The hydraulic lift/damper cylinder is also responsible for dampening the mechanical action of the grade system by restricting oil flow. The sensor control stations also incorporate flat springs for connection between the jointed, cross beam. The spring deflects if a sudden movement occurs as in the case of the shoes riding up and over a raised utility structure. The spring(s), working together with the hydraulic lift/damper cylinder prevent the sudden movement of the sensor control station(s), which in turn prevents the mills from suddenly raising, leaving a high section in the milled surface. The same applies if the shoes suddenly drop into a transverse depression, the spring deflects and the cylinder dampens. It is important to note that the rear wheels of the Recycling Machine follow the grade set by the main mill assembly.
3. Inconsistent Smoothness and Surface Defects, Caused by Asphalt Handling Problems when Using an Attached Screed Using 100% HIR Machines
As mentioned before (when discussing paving machines), producing a quality, asphalt surface that meets all engineering specifications requires considerable skill, knowledge and the proper equipment. Consistency is one of the keys, with the following innovations providing the consistency when 100% recycling with the Enviro-Pave Recycling Machine:
a. Processing should be continuous with no stops. Stopping the screed assembly allows it to settle into the asphalt, causing a depression. Weight transfer from the screed assembly to the Recycling Machine's mainframe has been tried and found to work, however when forward travel was resumed the screed assembly would still tend to sink. Two hydraulic cylinders (attached between the mainframe and screed assembly) are used to raise and lower the screed assembly. When processing, the two hydraulic cylinders are floating (oil can freely flow in and out of both ends of the cylinders). When forward travel must be stopped the cylinder's hydraulic float is cut off and oil is directed into one end of the cylinders (screed raise) at a pressure high enough to transfer weight from the screed assembly to the mainframe. Transferring weight prevents the heavy screed assembly from sinking into the mat. A time delay, controlled by the on-board computer has now been added, allowing the screed time to stabilize with asphalt flow as forward travel is resumed. This delay will be equal to one or more lengths of the screed's main plate. b. The processing speed should remain as consistent as possible. An increase in speed will cause the screed to rise while a decrease will cause the screed to sink. An optical encoder, mounted to one of the rear axle assembly drive motors will provides the equivalent of cruise control by monitoring the drive wheel's RPM. The on-board computer will control the flow of hydraulic oil in the drive system to maintain a consistent speed. Varying loads on the Recycling Machine will have no effect on the processing speed. c. The temperature of the asphalt in front of the screed (head) should remain consistent as noted in detail above. d. The asphalt in front of the screed assembly should remain at a consistent level across the complete width of the screed and screed extensions. An increase in asphalt level will cause to screed to rise while a decrease will cause it to sink. Generally, recycling machines fitted with an attached screed assembly have had problems when the screed assembly carried too much asphalt. This resulted in the screed assembly becoming uncontrollable. It was also common for the screed operator to load the screed assembly with an excessive amount of asphalt as it gave a reserve of asphalt for when the screed's extensions suddenly became low in asphalt due to poor asphalt flow from the auger assembly. Carrying too much asphalt with the screed assembly also allowed the asphalt to stop moving at the screed's extensions, resulting in the asphalt losing temperature and sticking to the screed's face. The cold asphalt caused quality problems in the finished mat, if and when it passed under the screed's extensions.
The following innovations are designed to control the head (amount) and distribution of asphalt across the main screed and screed extensions while reducing material segregation:
A heated (automated heat control and propane burner) and insulated, asphalt surge bin and vertical elevator, located inside the rear end of the Recycling Machine's mainframe, automatically stores and releases hot asphalt to maintain a constant volume (head) of material in front of the screed assembly. The surge bin and vertical elevator are connected to the Recycling Machine's main frame by two hydraulic cylinders. The surge bin discharges the stored, hot asphalt through two (left and right side), bottom discharging, rotary valves located above and in front of the auger/divider/strike off blade assembly, which is located in front of the screed assembly. The left rotary valve supplies the left auger while the right rotary valve supplies the right auger. An integral, vertical elevator picks up the excess, 100% recycled asphalt (not required by the screed assembly) from the windrow exiting the Recycling Machine's pug mill (mixing chamber) and elevates it up the front face of the elevator into the surge bin, for storage. The Recycling Machine's on-board computer automatically starts and stops the vertical elevator by measuring the pressure in the two hydraulic cylinders and the height of material exiting the pug mill by monitoring the pug mill's volume sensing ski. The hydraulic pressure is proportional to the weight of the asphalt in the bin. The surge bin's holding capacity is sufficient for continuous operation without having to add new asphalt and once full, provides enough stored asphalt for the start-up of the process before the Recycling Machine's windrow is established. Attached to the front side of the vertical elevator is a small hopper/diverter valve that can receive new asphalt from the optional front asphalt hopper/drag conveyor and the central conveyor. The hydraulically operated diverter valve allows new asphalt to be elevated by the vertical elevator into the surge bin for storage, or be discharged on to the windrow as additional material. Projects requiring additional asphalt include, shoulder widening, modification to existing grade or surfaces with a shortage of existing asphalt. Diverting new asphalt to the surge bin allows the bin to be filled at the beginning of the daily shift. Once the bin is initially filled recycled asphalt can be collected from the windrow for the remaining shift. This not only provides new asphalt, but also provides control over the startup procedure. The Recycling Machine's screed assembly is positioned over the asphalt's surface at the start of the new joint (the end of the previous joint). The screed assembly is set on to two starter spacers and the screed's cranks are nulled (neutralized) and set. The front asphalt hopper is filled with hot mix asphalt, delivered by truck from the asphalt plant. The variable speed drag chain conveyor (part of the front hopper) delivers the asphalt to the variable speed, central conveyor. The central conveyor (runs through the center of the machine) moves the asphalt to the hopper/diverter valve, attached to the surge bin's, vertical elevator. Asphalt is diverted to the vertical elevator and the surge bin is automatically filled to the correct level by monitoring the hydraulic pressure in the two surge bin support cylinders. The augers and surge bin's rotary valves are turned on to automatic, on-board computer control. The left and right augers will increase to maximum speed, as no asphalt is available to operate the two augers, electronic level sensors, located at the end of the screed's extensions. The surge bin's bottom discharging, rotary valves (left and right side) are automatically opened by sensing the speed of the individual augers, allowing asphalt to flow to the ends of the screed's extensions and the auger's electronic, level sensors. Once the screed's extensions are full of asphalt, the augers automatically slow down and stop, while the surge bin's rotary valves are automatically closed. As asphalt was flowing out of the surge bin's rotary valves the on-board computer was automatically replenishing the surge bin to a full state. Once full the on-board computer automatically stops the elevator by measuring the surge bin's hydraulic cylinders pressure. The hopper/diverter valve is fitted with an electronic sensor that controls the speed of the central conveyor. When the hopper is full the conveyor is stopped. Once the supply of asphalt to the screed assembly has been meet the Recycling Machine's processing equipment is put into operation and the machine moves forward, preventing the screed from settling. Asphalt is now diverted from the vertical elevator to the asphalt's surface to form a windrow of new material. As the diverter valve opens the electronic sensor detects the drop in the level of asphalt in the hopper/diverter valve and restarts the central conveyor and the front hopper's drag chain. The central conveyor (in this case a belt conveyor) is fitted with an electronic belt scale, used to measure the weight of asphalt being conveyed. The on-board computer is programmed to supply the correct amount of asphalt to form a windrow by monitoring the individual speed of the auger. Gradually, as the pug mill's discharge rate increase (greater volume of asphalt being processed), the on-board computer proportionally reduces the flow of new asphalt by monitoring the individual auger's speed, measuring the volume of material exiting the pug mill's, variable ski (asphalt volume measurement and the amount of weight on the conveyor belt's scale. When 100% HIR recycling is being conducted and new asphalt is not required after the initial startup period, the front hopper, belt conveyor and the hopper/diverter valve can be emptied by discharging and blending the asphalt automatically into the asphalt surge bin. The vertical elevator picks up the 100% recycled asphalt from the windrow while the new asphalt (delivered from the front asphalt hopper) is blended in the vertical elevator, preventing variations in the finished mat's surface texture. Generally the surge bin/vertical elevator are only required for 100% HIR once the process has been established. For asphalt surfaces requiring major grade corrections the front asphalt hopper and central conveyor can be used to automatically supplement and blend new asphalt into the process. In this case the on-board computer monitors the individual auger's speeds, measures the volume of 100% recycled asphalt exiting the pug mill's variable ski, the amount of weight on the conveyor belt's scale and the amount of asphalt stored in the asphalt surge bin/vertical elevator. The on-board computer will maintain the asphalt surge bin's level by scalping asphalt from the windrow, when processing volume is high and supplying new asphalt as processing volume decreases. An electronic temperature sensor monitors the new asphalt's temperature on the central belt conveyor and automatically discharges the conveyor (into the asphalt surge bin/vertical elevator) when the temperature drops to a minimum value. This situation is possible when new asphalt is not required over longer periods of time (the asphalt's grade has improved. The front asphalt hopper's discharge remains shut off as the conveyor discharges. The on-board computer always leaves sufficient space in the asphalt surge bin for the volume of asphalt carried by the conveyor. Temperature sensors also measure the temperature of the asphalt stored in the front asphalt hopper assembly. The asphalt tends to drop at a slower rate as the front hopper has an insulated bottom and sides. Also the asphalt retains heat better when stored in bulk. The Recycling Machine operator is visually warned when the temperature drops to a level requiring action. If new asphalt is not available to supplement the existing asphalt in the front hopper the on-board computer will automatically discharge the hopper by slowly restarting the hopper's discharge and the central belt conveyor, thereby delivering new asphalt to the rear hopper/diverter valve. The asphalt will be diverted to the heated windrow exiting the pug mill. The strike off blade, which is part of the auger/divider assembly, is designed to carry the excess amount of asphalt without effecting the operation of the screed assembly. The screed auger/divide/strike off blade assembly, located in front of the screed assembly is responsible for conveying the heated asphalt windrow to all areas of the main screed and the screed extensions. The screed extensions (left and right side) are hydraulically extendable and are used to vary the paving width. The screed auger/divider/strike off blade assembly has two, independently controlled augers (left and right side) designed to split the hot, asphalt windrow and distribute asphalt to either end of the main screed and screed extensions. Individual auger speed is automatically controlled by industry standard, proportional, electronic level controls (paddles), located at either end of the screed's extensions. As the asphalt level (head) drops at one or either end of the screed's extensions the paddles signal the on-board computer to increase the auger(s) speed to convey more asphalt. As the asphalt is conveyed from the centrally located windrow the head of asphalt in front of the main/extension screed rises, raising the paddle(s) thereby slowing the auger(s). Generally both augers will be running at a continuous, slow speed, supplying a consistent flow of asphalt across the screed assembly. The screed auger/divider/strike off blade assembly can be hydraulically raised or lowered to adjust for varying depths of asphalt being process by the Recycling Machine. The operation of the screed auger assembly, described above, can be found on any paving machine and works well when laying thick lays of asphalt. It has not proved to be as successful when used with 100% HIR Recycling Machines laying 50 mm or less of recycled asphalt, particularly when working on slopes. Generally there has always been a problem splitting the asphalt windrow with just the screed auger assembly, especially when working on slopes. The high side of the screed extension (crown of the pavement) would generally be starved of asphalt. To overcome the problem the screed auger/divider/strike off blade assembly is fitted with a centrally mounted, hydraulically controlled, mechanical divider, designed to physically split the windrow and feed it into the left or the right auger (the auger requiring the greater amount of asphalt). The angle of the divider is controlled by the on-board computer and uses the left or right auger's speed as a reference. As the auger(s) speed increases beyond a preset speed (level of asphalt dropping in front main screed and/or either screed extension) the on-board computer turns the hydraulic divider, diverting a greater percentage of the asphalt windrow into the auger requiring asphalt (the auger with the greatest speed). The position of the divider is electronically monitored, allowing the divider to turn proportionally to the individual auger's speed. If both augers are rotating at the same speed the divider remains in the straight-ahead position. If the on-board computer determines that any auger's speed is still increasing (divided windrow is not providing enough asphalt to the speeding auger) the rotary discharge valve of the asphalt surge bin, located above the speeding auger is automatically opened, providing additional, heated asphalt. The additional asphalt continues to flow from the asphalt surge bin until the auger slows to a predetermined speed, where upon the rotary discharge valve is automatically closed. If the on-board computer determines that the speed of both augers are too high (lack of asphalt in the windrow and at the screed assembly) both of the asphalt surge bin's rotary valves are opened, thereby providing additional heated asphalt to both augers. The operation and control of the screed auger/divider/strike off blade assembly and the asphalt surge bin are designed to handle the heated asphalt in a slow and gentle manner so as to reduce segregation, heat loss and emissions. The asphalt surge bin automatically refills from the windrow when the volume of asphalt exceeds the volume required by the screed assembly, typically when milling through a high area of asphalt pavement. Attached to the front of the auger/divider is the manually adjustable strike off blades (left and right side). The blades functions as tunnels for the augers allowing asphalt to be conveyed more efficiently, without causing segregation. The strike of blades also limits the amount of asphalt that can physically reach the left and right side augers flights and also the screed assemblies front face. The two, strike off blades are adjustable in height and taper with the height of blades becoming greater towards the end of the augers, allowing more asphalt to flow under the blades towards the end of the augers. If a sudden surge of asphalt (highly unlikely due to the electronic control, larger asphalt surge bin and high capacity, vertical elevator) does occur when milling through a high section of asphalt, the auger/divider/strike off blade will carry the extra head of asphalt.
4. Inconsistent Ratio of New Asphalt to 100% Recycled Asphalt when Using the Remix Method.
The general procedure used by other HIR recycling machines to introduce a percentage of new asphalt into the recycled asphalt (Remix) is to monitor the forward speed of the recycling machine. This procedure is not that desirable due to the fact that the volume of asphalt being recycled at any given time is constantly changing due to uneven surface grade and varying processing width, on variable width machines. The other problem is where the new asphalt is delivered for mixing with the recycled asphalt. which often results in the asphalt being dropped in front of the recycling machine's heating system. The problem with this approach is that the new asphalt is subjected to unnecessary heat, which rapidly deteriorates the new asphalt.
The following innovations allow the present invention to provide a true ratio between the 100% recycled and new asphalt without degrading the new asphalt.
The present invention is equipped with a front asphalt hopper/variable speed chain slat conveyor, truck pusher bar, variable speed central belt conveyor and electronic belt scale, conveyor hopper/diverter valve, surge bin/vertical elevator, auger/divider/strike off blade and screed assembly. The Remix process starts by using the same method as the 100% HIR process. The Recycling Machine's screed assembly is positioned over the asphalt's surface at the start of the new joint (the end of the previous joint). The screed assembly is set on to two starter spacers and the screed's cranks are nulled (neutralized) and set. The front asphalt hopper is filled with hot mix asphalt, delivered by truck from the asphalt plant. The variable speed drag chain conveyor (part of the front hopper) delivers the asphalt to the variable speed, central conveyor. The central conveyor (runs through the center of the machine) moves the asphalt to the hopper/diverter valve, attached to the surge bin's, vertical elevator. Asphalt is diverted to the vertical elevator and the surge bin is automatically filled to the correct level by monitoring the hydraulic pressure in the two surge bin support cylinders. The augers and surge bin's rotary valves are turned on to automatic, on-board computer control. The left and right augers will increase to maximum speed, as no asphalt is available to operate the two augers, electronic level sensors, located at the end of the screed's extensions. The surge bin's bottom discharging, rotary valves (left and right side) are automatically opened by sensing the speed of the individual augers, allowing asphalt to flow to the ends of the screed's extensions and the auger's electronic, level sensors. Once the screed's extensions are full of asphalt, the augers automatically slow down and stop, while the surge bin's rotary valves are automatically closed. As asphalt was flowing out of the surge bin's rotary valves the on-board computer was automatically replenishing the surge bin to a full state. Once full the on-board computer automatically stops the elevator by measuring the surge bin's hydraulic cylinders pressure. The hopper/diverter valve is fitted with an electronic sensor that controls the speed of the central conveyor. When the hopper is full the conveyor is stopped. Once the supply of asphalt to the screed assembly has been meet the Recycling Machine's processing equipment is put into operation and the machine moves forward, preventing the screed from settling. Asphalt is now diverted from the vertical elevator to the asphalt's surface to form a windrow of new material. As the diverter valve opens the electronic sensor detects the drop in the level of asphalt in the hopper/diverter valve and restarts the central conveyor and the front hopper's drag chain. The central conveyor (in this case a belt conveyor) is fitted with an electronic belt scale, used to measure the weight of asphalt being conveyed. The on-board computer is programmed to supply the correct amount of asphalt to form a windrow by monitoring the individual speed of the auger. Gradually, as the pug mill's discharge rate increases (greater volume of asphalt being processed), the on-board computer proportionally reduces the flow of new asphalt by monitoring the individual auger's speed, measuring the volume of material exiting the pug mill's variable ski (asphalt volume measurement and the amount of weight on the conveyor belt's scale).
Once the windrow has been established by monitoring the flow of asphalt through the pug mill, the on-board computer automatically switches to its Remix program. The surge bin/vertical elevator is used to scalp off a percentage of 100%, recycled asphalt in the windrow. An adjustable (proportional) electronic sensor is used to set and control the scalping depth of the vertical elevator, allowing the elevator to follow the varying windrow's height. The belt conveyor and the front hopper's drag chain start supplying new asphalt to the hopper/diverter valve, allowing the two asphalt flows to blend together in the vertical elevator's slats. The central belt conveyor is fitted with an electronic belt scale, used to measure the weight of asphalt being conveyed. The on-board computer is programmed to calculate and control the correct amount of new asphalt being blended into the 100% recycled asphalt (10% to 15%). This is accomplished by measuring the volume of material exiting the pug mill's variable ski (material volume measurement and the amount of weight on the conveyor's belt scale. The variable speed, drag chain in the front hopper and the variable speed central, belt conveyor supplies the correct amount of new asphalt. The belt conveyor is designed to operate at a higher speed than the hopper drag chain, preventing spillage at the drag chain's discharge point on to the belt conveyor. The two conveyors are fitted with optical encoders to monitor the speed of both units, allowing the on-board computer to monitor and control the speed ratio between the two conveyors. As the amount of new asphalt increases or decreases, based upon the volume of asphalt being recycled the vertical elevators speed is proportional changed to pick up more or less recycled asphalt. This is possible as the inlet to the vertical elevator is always flooded (built up) with asphalt. The blend of recycled and new asphalt is delivered to the heated and insulated surge bin. The on-board computer, monitoring the weight of the bin will always try and maintain the bin at 50% of its capacity. This is achieved by automatically controlling the discharge flow from the surge bin's two, rotary valves, by monitoring the individual screed auger's speed (auger/divider/strike off blade assembly). The auger with the highest speed will receive proportional, more asphalt. By blending the new asphalt with a proportion of the 100% recycled asphalt (picked up from the windrow) in the surge bin/vertical elevator provides a little more mixing than would otherwise be possible if the hopper/diverter valve dumped asphalt directly on to the windrow. If the extra blending (mixing) is found not to be required then the asphalt can be diverted and dropped on to the 100% recycled asphalt's windrow. It should be noted that the augers do mix the asphalt as it is moved across the front face of the screed assembly. One might ask why not introduce the new asphalt onto the mills or the pug mill. Pre-engineering, using core samples, taken at regular intervals, determine how much rejuvenator fluid and/or polymer liquid must be added by the Recycling Machine and how much washed aggregate the final Preheater must add. Adding new asphalt would complicate the testing procedure.
5. Inability to Process Asphalt Around Utility Structures and Obstructions.
Utility structures and other obstructions have until now presented one of the greatest challenges to the HIR of asphalt, especially in city work. An example would be a utility structure located in the center of the lane being processed. To prevent damage to the Recycling Machine's carbide milling teeth (main and extension mills) and to the iron utility structure(s) located in the asphalt's surface, the mill(s) are lifted, leaving an unprocessed section of asphalt across the width of the lane. When dealing with utility structures and obstructions the following methods are typically used:
a. Ignore the problem. Raise the scarification and/or mill systems and let the screed assembly place recycled asphalt on top of the old asphalt. The result is a width of asphalt up to 1 m (3 ft.) or more in length (in the direction of travel) that has not been recycled (rejuvenated) to pre-engineered specifications. The section will not be compacted to the same degree as the recycled asphalt by the rolling equipment, thus leaving a bump in the mat (asphalt surface) of old asphalt b. Raise the scarification and/or mill systems and use hand tools (rakes and shovels) to loosen the old asphalt. This is almost impossible without stopping the recycling machine and is dangerous to workers, as they must reach into the processing area of the machine. Recycling machines that have scarification systems that float over and around obstructions have been somewhat successful ARS as the asphalt is loose enough to hand move (where possible) without stopping the Recycling Machine. The asphalt remaining on the heated surface mixes with the recycled asphalt, collected and stored in front of the screed assembly. The asphalt picked up by hand shovel is generally, thrown back into the mills for processing. c. Before 100% HIR of the asphalt surface the area around the obstruction(s) is cold milled with a small milling machine. The milled asphalt is collected and removed and the surface is swept if processing is to be conducted at a later date. This works well, except that a reduction in the volume of material available for recycling occurs, resulting in new asphalt having to be added or a change in profile/grade at the time of recycling. Filling the cold milled sections with new virgin asphalt and compacting before recycling works well, but presents compaction problems (bump in surface) and in some cases, changes to the finished mat's surface texture. The major objection to this approach is the added cost, traffic delays and possible driving hazard due to the open, milled sections, if not paved immediately. d. Recycling machines that produce a windrow of asphalt (screed assembly removed) for pickup by a windrow conveyor, attached to a standard paving machine have a greater opportunity to work around utility structures and obstructions. To date hand-tools, powered machines and even a hydraulic arm fitted with a blade, mounted to the windrow conveyor, scrape and collect the unprocessed asphalt. The hydraulic arm requires the windrow conveyor/paving machine to stop, marking the finished mat (the screed sinks into the asphalt surface due to it's own weight, vibration from the windrow conveyor and the operation of the hydraulic arm). Other problems exist when using a separate windrow conveyor and paving machine, i.e. increased costs, reduced asphalt temperature, increased segregation, increased pollution and increased equipment train length. In addition, the proper mixing of the old asphalt (asphalt scraped from the heated surface) does not take place as the old asphalt is generally placed on to the open windrow, throwing off the quality of the recycled asphalt contained within the windrow. Safety is another issue when processing with an open windrow. It is quit common for automobiles to try and cross the heated windrow only to become stuck in 250 to 300+ Deg F. asphalt. Animals have seriously burnt their feet, as have humans with open footwear! Recycling machines with an attached screed do not suffer from the above problems, as there is no open windrow.
The present invention scarifies and cleans around utility structures and obstructions without stopping the ARSHIR Recycling Machine, allowing the scarified asphalt to be collected and properly mixed with additives:
The rake scarification/blade collection system fitted to the final Preheater (Preheater ahead of the Recycling Machine) and the Recycling Machine are identical. The blades are attached to the four, main rake, pivoting bodies, located behind the spring loaded, carbide cutters attached to the same bodies. When approaching a utility structure or obstruction (Preheater followed by the Recycling Machine) the Preheater's operator tilts the required, individual rake bodies, leaving the carbide cutters in the heated asphalt while at the same time lowering the trailing blades. Hydraulic force pushes the blades into the scarified surface 50 mm (2″) or more, scraping and collecting the heated asphalt. Once past the utility structure/obstruction, the blades are raised at a controlled rate (rate is adjustable and once set is automatic), releasing the collected asphalt in a 50 to 75 mm (2 to 3″) layer. Raising the blades does not effect the operation of the carbide cutters. Hand tools or a small two-wheel drive machine with adjustable blade, similar to a walk behind rotovator (without the rotor) are used (if required) for the final cleanup with the asphalt being spread on to the heated, scarified surface ahead or behind the area being scraped and cleaned. Plenty of space and time exists for this process as the Recycling Machine is generally trailing the Preheater by up to 9 to 12 m (30 to 40 ft.). The Recycling Machine's rake blades are available if further cleaning is required when approaching the same utility structure/obstruction using the same procedure as used by the Preheater. Raising the main mill on the Recycling Machine for utility structures/obstructions will automatically stop the flow of rejuvenator fluid to the main mill and the pug mill, preventing the fluid from reaching the milled, base surface, thereby eliminating eventual bleeding of the finished, compacted surface. When the main mill is manually raised for utility structures/obstructions, the on-board computer calculates and stores in it's memory the amount of rejuvenator fluid that would have been sprayed into the asphalt being recycled, if the main mill had not been raised. When the main mill is lowered (taken off manual control) into the heated surface (controlled again by the automatic grade/slope controls) it collects and feeds the asphalt into the pug mill for final mixing. Lowering of the main mill allows the rejuvenator fluid flow to commence. The stored (memory) amount of rejuvenator fluid, together with the required processing amount of fluid (determined by the pug mill) results in increased fluid flow required for the increased volume of asphalt at that particular section (rake scarified asphalt covered with a layer of asphalt collected by the rake blades). The ratio of rejuvenator fluid to asphalt being recycled remains consistent.
Blades are not required on the extension rakes as the extension mills are fully adjustable (raise/lower, in/out and tilt up/down) and can be used to cut and clean around most utility structures/obstructions in their path. The extension mills are fitted with a cutter blade at each outer end, providing cleaning to the edge of utility structures/obstructions and curbs and gutters. Final cleaning on each side of the Recycling Machine is easily accomplished with hand tools, even while moving. The above, innovations allows any processing work required around utility structures and obstructions to be accomplished before the Recycling Machine recycles the old asphalt, rather than after recycling and result in the following advantages: The old asphalt that has been moved from around utility structures, obstructions and sections across the asphalt's surface (where the mills can not be used) remains on the surface for 100% processing by the Recycling Machine. The complete width of the asphalt can be checked and worked upon. This is not the case after the Recycling Machine has processed the asphalt as the wide (approximately 36″) windrow covers the center section of the width.
6. Inaccurate and Inconsistent Application of Liquid Additives.
While other 100% HIR equipment have systems designed to monitor and control the application of rejuvenator fluid into the reworked (recycled) asphalt, none appears to have the ability to monitor and control the application of liquid polymers together with rejuvenating fluid. Generally, recycling machines control the rejuvenator's application rate by monitoring the machines processing speed (distance traveled). Distance traveled, by itself, produces inaccurate and inconsistent results as the volume of asphalt being processed changes constantly as density, depth of cut, pavement profile and width of cut (machines with variable width heating, scarification and milling systems) all vary.
The problem is solved by a liquid distribution system using two or more positive displacement, diaphragm pumps. The pumps accurately meter light (unheated) and heavy (heated) rejuvenator fluids and liquid polymers. Ground speed sensing (distance traveled) and application rate (manually input into the on-board computer using pre-engineered data) together with asphalt volume sensing and temperature correction factors, provide accurate and consistent results, which are verifiable through laboratory testing.
7. Inaccurate and Inconsistent Application of the Aggregate.
The present invention and methods often uses a plurality of Preheaters. Often three or more Preheaters are used, operating ahead of the AR Recycling Machine to soften the asphalt surface to a depth of 50 mm (2″) or more. The final Preheater is fitted with a rake/blade scarification/collection system and aggregate distribution system.
In prior processes, the machine's processing speed (distance traveled) is generally used to control the aggregate's distribution rate. Distance traveled, by itself, provides inaccurate and inconsistent application rates as the volume of aggregate being spread must be constantly changed as the volume of asphalt pavement being recycled constantly changes due to variations in processing depth (profile) and width. The problem is solved by the present invention through the spreading washed aggregate (sand, small stone, steel mill slag etc.) directly on to the heated asphalt surface by an aggregate distribution bin (controlled and monitored by the on-board computer) attached to the final Preheater. Ground speed sensing and application rate (manual input into the on-board computer using pre-engineered data), together with proprietary width measurement (width of asphalt being processed) and asphalt surface profile sensing, provide accurate and consistent results, which are verifiable, through laboratory testing.
8. Improper Mixing of Rejuvenator Fluid, Washed Aggregate and Reworked (Recycled) Asphalt:
The amount of time available for mixing has until now, been inadequate to produce a homogeneous mix. To date the mixing of rejuvenator fluid and aggregates into the reworked asphalt is generally accomplished by one of the following methods: a. The heated, milled asphalt is removed from the surface and conveyed to a pug mill on-board the recycling machine where mixing (rejuvenator fluid and aggregate) takes place as a continuous or batch process. The pug mill discharges the asphalt into the front hopper of a standard paving machine (attached to the recycling machine) or in front of the recycling machine's screed assembly for final placement and compaction. Aggregate segregation, loss of heat and emissions are all increased. b. The recycling machine mills and collects the heated asphalt and aggregate (if added) while leaving it on the heated surface. The collected, milled asphalt/aggregate passes into an in-line pug mill or mixing auger. The pug mill or mixing auger discharge is generally unrestricted, resulting in reduced retention (less mixing) of the recycled asphalt and additives and increased segregation caused by the larger aggregate (stone) rolling down the windrow's sides. c. Scarification systems (no mills, pug mill or other mixing devices) use cutters to penetrate into the heated asphalt's surface while aggregate and rejuvenator fluids are spread directly on to the heated asphalt. The only mixing that takes place is by the action of the cutters and to some degree, the action of the screed's distribution auger. Limited and inconsistent mixing result, as the scarified asphalt and additives are not collected and mixing by any mechanical apparatus.
The crown and curb (left and right) side, recycled asphalt, are not completely mixed together to form a homogeneous mix (only applies to processes where the asphalt is not removed from the surface). Dirty, curbside recycled asphalt will show up in the finished mat (asphalt behind the screed assembly) on the curbside section as discolored asphalt (dull, as the dirt/dust absorbs more of the asphalt's liquid). Sweeping the asphalt surface reduces the buildup of dirt and dust, but cannot remove it completely from the cracked or porous asphalt. The fine aggregates contained in and added to the recycled asphalt remain behind the mill(s), mixing auger or pug mill (if fitted) as a fine layer on the milled surface. To obtain a homogenous mix, all of the reworked asphalt and additives require collection for mechanical mixing.
The following innovations found in the present invention increase the mixing and/or mixing time in the ARSHIR Recycling Machine:
a. Three or more Preheaters, operating ahead of the HIR Recycling Machine softening the asphalt surface to a depth of 50 mm (2″) or more. The final Preheater is fitted with a rake/blade scarification/collection system and aggregate distribution system. The rake/blade system is the first of the processing equipment to break the heated asphalt's surface, releasing moisture (steam) and loosening the heated asphalt. The rake's carbide cutters form grooves 50 to 75 mm (2-3″) or more into which the washed aggregate (sand, small stone, steel mill slag etc.) falls. Spreading the damp aggregate on to a heated surface in a thin, ribbed layer not only allows any moisture to evaporate quickly, it also promotes greater mixing by the Recycling Machine's rakes, mills and pug mill. The deposited aggregate starts to absorb liquid asphalt from the heated asphalt (asphalt to be recycled) before being processed by the heating, milling and mixing stages. b. The Recycling Machine's heating system (heater box) features flexible, stainless steel mesh skirts around the parameter of the heater box to retain heat. The skirts are also designed to touch (drag) the heated asphalt's surface. The front skirt spreads the aggregate (applied by the final Preheater) into a thin layer. The Recycling Machine's heater box gently applies additional heat to the spread aggregate and asphalt surface, thereby removing any remaining, trapped moisture. Excess moisture in any part of the mixing process will prevent the proper coating and adhesion of existing asphalt binders, additional rejuvenator fluid and polymer liquid to the aggregates contained in or mixed into the recycled asphalt. The rake/blade system attached to the Recycling Machine further mixes the added aggregate and heated asphalt before the milling/mixing stages. c. The Recycling Machine's extension mill and main mill rotors (rotating carbide cutters) all feature shallow flighting designed to reduce the rotors material conveying efficiency. Attached to backside of the flighting are replaceable carbide cutting teeth and holders. The shallow flighting, together with the carbide cutters (rotating in a down-cut direction), causes the heated/milled asphalt to build up in front of the rotors rather than immediately being conveyed away. Rejuvenator fluid added at the main mill's rotor and aggregates distributed on to the heated asphalt surface, ahead of the 100% HIR Recycling Machine (by final Preheater) are continuously mixed by the main mill's carbide teeth. The main mill's material discharge is offset to one end of the rotor. The rotor provides premixing of the old (recycled) asphalt, rejuvenating fluid and aggregate before discharging into the offset front rotor of the pug mill. d. The offset front rotor of the pug mill (receives material from the main mill's offset discharge) is equipped with carbide-faced paddles (two per arm) arranged in a spaced, spiral pattern. The spaced, spiral pattern reduces material conveying efficiency, increases dwell time and the mixing action of the recycled asphalt and additives. The spiral section of the pug mill's offset front rotor feeds the recycled asphalt and additives into the pug mill's mixing chamber. The offset front rotor is also equipped with carbide faced, paddles (two and four per arm), arranged in an alternating left and right hand pattern (located in the mixing chamber). The spiral section and the alternating paddle section of the offset front rotor receive rejuvenator fluid and if required, polymer additive. The recycling Machine's on-board computer automatically controls (stages) the application of rejuvenator fluid and liquid polymer. The main mill is the first to receive rejuvenator fluid followed by the pug mill's front rotor (spiral section) and finally the alternating paddle section of the pug mill's front rotor. Liquid polymer is only sprayed into the pug mill when rejuvenator fluid flow is established in the main mill and/or the pug mill. Staging the rejuvenator fluid's application to the processed asphalt's flow through the mills and pug mill provides increased mixing time, greater coverage and less chance of the fluid additives coming into contact with the milled, base surface. The pug mill's offset front rotor completely mixes the left and right (crown and curb) side asphalt while the pug mill's rear rotor completes the final mixing and discharge of the asphalt into a formed windrow. The pug mill's rear rotor (discharge rotor) diameter is greater than the front rotor and is equipped with carbide-faced paddles (two and four per arm) arranged in an alternating left/right hand pattern. The front and rear rotors do not intermesh, allowing the rotor speeds to be set individually for varying, asphalt specifications. Both design features increase the throughput of recycled asphalt and promote increased mixing/tumbling and moisture (steam) release. e. An adjustable trip blade is located between the pug mill's front and rear rotor assemblies. The trip blade is the full width of the mixing chamber. The trip blade scrapes the milled, base surface, lifting any asphalt and additives missed by the front rotor assemblies paddles (the rotor paddles do not make contact with the milled base). As paddle tip wear increases the amount of asphalt missed would increase, reducing the mixing efficiency of the pug mill. Rejuvenator fluid (polymer additives were not tried) could not be sprayed into the prototype pug mill as the fluid would come into direct contact with the milled base surface in the mixing chamber and would not be collected and mixed by the rotor assemblies paddles. Bleeding of the finished mat (the width of the pug mill mixing chamber) resulted when using rejuvenator fluid. The trip blade improves mixing and allows rejuvenator fluid and polymer liquid to be sprayed directly into the pug mill's front rotor assembly. Competitive recycling machines fitted with a mixing auger or standard pug mill do not scrape the base surface in the mixing chamber or in the case of a mixing auger, the discharge section. The result is incomplete mixing, especially as rotating components wear. An external, single screw adjuster sets the trip blade's height. A hydraulic cylinder connects the trip blade to the screw adjuster. The hydraulic cylinder allows the trip blade to rotate if contact with a utility structure occurs, preventing damage to the trip blade and utility structure. The trip blade resets automatically. f. The asphalt being discharged out of the pug mill is restricted through a variable (mechanical) opening (parallelogram ski) located behind the pug mill's rear rotor assembly. The ski is hydraulically adjustable for pre-load (vertical pressure exerted on to the asphalt windrow) and provides light compaction to the windrow and resistance to asphalt flow through the pug mill. The ski also measures the volume of asphalt exiting the pug mill and generates a proportional electronic signal used in calculating the required amount of rejuvenator fluid and polymer liquid to be added to the reworked (recycled) asphalt. Other recycling machines do not restrict the asphalt's flow to improve mixing or compact the windrow to reduce segregation. g. Discharge from the pug mill's rear rotor is to the centerline of the Recycling Machine. Testing has shown that central discharging mills (not offset), even when used with an efficient in line pug mill or mixing auger (mixing on the milled surface) will not achieve complete crown and curbside mixing of the asphalt/additives into a homogeneous mix. The offset main mill's rotor assembly together with the pug mill's offset front rotor and rear rotor assemblies, completely mix the crown and curbside asphalt into a homogeneous mix. h. Spring loaded (floating) blades located behind the extension mills, main mill and pug mill collect the fine aggregates and fluid additives by scraping the milled surface. The blades (replaceable) are adjustable in height to compensate for blade wear and carbide rotor teeth (replaceable) wear. The springs keep the blades forced down on to the milled surface and also provide protection against damage to iron utility structures by allowing the blades to ride up and over the utility structure. Scraping the milled, asphalt surface collects the finer aggregates and liquid additives, thereby producing a consistent and homogeneous asphalt mix. Other recycling machines generally use fixed blades or no blades, resulting in a remaining layer of fine aggregates and liquid additives on the milled surface. Liquid additives remaining in direct contact with the milled surface produce bleeding of the finished mat (streaks).
9. Inability to Remove Moisture from Reworked Asphalt:
Moisture removal in prior systems is limited due to inadequate heat penetration, insufficient mechanical mixing and the lack of moisture extraction systems. The positive removal of moisture (steam) at the mills and pug mill or mixing auger is generally, not used.
Moisture removal in ARS the present invention may be done in four stages: a. Three or more Preheaters, operating ahead of the ARSRecycling Machine softening the asphalt surface to a depth of 50 mm (2″) or more. The final Preheater is fitted with a rake/blade scarification/collection system. The rake/blade system is the first of the processing equipment to break the heated, asphalt surface, releasing moisture (steam) and loosening the asphalt without damaging the asphalt's larger aggregate. The rake's carbide cutters are hydraulically adjustable for down force (pressure compensated), are spring-loaded and mounted on pivoting frames, allowing the cutters to follow varying pavement profiles and scarify around iron utility structures. Penetration into the heated asphalt is generally deeper than the Recycling Machine's main and extension mill profiling depth. The Preheater's rake/blade carbide cutters loosen the asphalt, allowing the trapped moisture (steam) to release before further scarification, milling and mixing by the Recycling Machine's rakes, mills and pug mill. b. The ARSRecycling Machine's electronically controlled and monitored heating system produces convection and infrared heating and is used to drive off any remaining moisture in the added aggregate (damp, washed sand, deposited on to the heated asphalt by the final Preheater's aggregate distribution system). The Recycling Machine's rakes/blades are identical in design and operation to the Preheater's rakes/blades and produce further mixing of the aggregate into the heated asphalt. The rakes also cut deeper into the loosened asphalt, releasing more moisture in the form of steam. c. Automatic grade/slope sensors control the depth of cut of the extension and the main mills. The mills mill and tumble the loosened, heated asphalt, mixing additives and releasing steam. A venturi (using the heater box blower air supply to create a negative air pressure) draws steam through the main mill's enclosed support frame, venting it to the top of the Recycling Machine. d. The offset pug mill is fitted with a moisture extraction system. A venturi (as above) creates a negative air pressure in the pug mill's mixing chamber. The pug mill's front and rear rotors tumble and mix the restricted asphalt enclosed in the mixing chamber. The air extraction system reduces the moisture level in the reworked (recycled) asphalt by drawing off and venting the released steam to the top of the Recycling Machine.
10. Inconsistent Depth Differential between the 100% Recycled Asphalt and the New Asphalt when Using the Integral Overlay Method.
Integral Overlay recycling machines have been around for many years. They are popular with contractors as the new asphalt can be used to hide the poorly recycled asphalt below and still produce a very good looking, new surface that generally stands up well over time. It is possible to hide all sorts of imperfections, as it is difficult to sometimes see the recycled surface as the secondary screed assembly is laying new material directly on to it. However, in prior systems and processes, three major problems are generally encountered:
a. The quality of heat produced by the preheaters and the recycling machine are incapable of producing a deep penetrating heat, without setting the asphalt's surface on fire. b. The recycled asphalt could not be processed using pre-engineering specifications as the machine was manually operated with no on-board computers to monitor and control the recycling process. c. The depth differential between the recycled asphalt and the new asphalt was inconsistent.
The following innovations of the present invention allow the Recycling Machine with Integral Overlay to 100% recycle existing asphalt while laying a high quality, new asphalt surface to grade, while meeting the smoothness tests.
The Recycling machine is equipped with the same, two grade control systems, as described earlier on. The front asphalt hopper and central belt conveyor are the same as for 100% HIR method, except that a short, shuttle conveyor is used to supply new asphalt to the rear, secondary auger and screed assemblies. The level of asphalt in the secondary auger and screed assembly controls the asphalt's flow from the front hopper and central belt conveyor assemblies. A proportional, electronic sensor (located in the feed chute used to supply asphalt to the secondary auger) signals the on-board computer to speed up the front asphalt hopper's and central belt conveyor's discharge rate. The position of the shuttle conveyor can be manually, or, automatically controlled by the on-board computer allowing new asphalt (delivered by the central conveyor) to spill into the primary auger/divider/strike off blade assembly when insufficient recycled asphalt is available to maintain the correct head of asphalt in front of the primary screed assembly. The design of the shuttle conveyor allows new asphalt to be delivered to both the primary and secondary auger and screed assemblies at the same time. The primary auger/divider/strike off blade is identical in operation and control, as described earlier on. The primary and secondary screeds are attached to the Recycling Machine's mainframe by screed arms attached to a left and right side adjustable tow points in the same manner as described earlier. The only difference being the length of the screed arms used on the primary and secondary screeds.
The major difference is in the control of the primary and secondary screed's grade and slope control system. Both the primary and secondary screed arms are attached to the same tow point (one on either side of the machine) which can either be pinned into position, or controlled by the automatic grade control system, as described earlier. Topcon's Smoothtrack® 4 Sonic Tracker II™ averaging beams and electronic slope sensor are again used, as described earlier, however the averaging beams and electronic slope control are only attached to the secondary screed's (rear screed) screed arms. The secondary screed assembly is allowed to float and features the same weight transfer system, as described earlier. The primary screed assembly requires no grade, or slope controls and is also allowed to float, but not to the same degree as the secondary screed assembly. The primary screed assembly senses the position of the secondary screed assembly through two, proportional, electronic or hydraulic sensors. The sensors are attached to the left and right side of the secondary screed's tow arms and sense the position of the left and right side of the primary screed's tow arms. The height of the sensor plates can be adjusted to set the height differential between the primary and the secondary screed assemblies, which is generally ½″ to 1½″. The two screed sensors send information to the on-board computer, which in turn, operates two hydraulic, 4 way proportional, directional control valves. The secondary screed assembly is the master while the primary is the slave and tries to match every move made by the secondary screed assembly (master). To accomplish this the primary screed assembly is attached to the Recycling Machine's mainframe by two identical, hydraulic cylinders, used to attach the secondary screed to the mainframe. The four hydraulic cylinder's prime function is to raise and lower both screed assemblies. The secondary screed assembly cylinders are allowed to float (move up and down freely) as all of the cylinder's hydraulic ports are connected to tank (return) when laying asphalt. The primary screed assembly cylinders are also allowed to float; however the hydraulic cylinder's ports are connected to tank through flow control valves. The system works in the following manner: At the start of the recycling operation the Recycling Machine is backed up to the previously finished joint that has been preheated. The secondary screed assembly is lowered on to starting blocks and the screed cranks are nulled out (neutralized) and set. The primary screed assembly is lowered on to the asphalt's surface and the screed cranks are nulled out and then given one turn up, to slightly raise the front of the screed's plates. This setting will allow the screed assembly to automatically rise when asphalt builds up in front of the screed. The machine operator places the Recycling Machine into automatic mode, allowing the on-board computer to monitor and control all of the automatically programmed operations. Asphalt is delivered from the front asphalt hopper, by the central conveyor to the shuttle conveyor. The shuttle conveyor supplies asphalt to the secondary screed augers. The augers feed the asphalt out to the ends of the secondary screed's extensions until the electronic asphalt sensors, attached to the screed extension's end plates stop the augers (the asphalt is at the correct level). Once the secondary auger and screed assemblies have been fully supplied with new asphalt the on-board computer moves the shuttle conveyor allowing new asphalt to spill into the primary auger/divider/strike off blade assembly. New asphalt will be delivered until the electronic asphalt sensors, attached to the primary screed extension's end plates stop the augers (the asphalt is at the correct level). At this position the secondary screed assembly is at a higher position than the primary screed assembly. The secondary screed's tow arm sensors are signaling the on-board computer to power the two proportional, directional control valves that send hydraulic oil to the primary screed's two hydraulic cylinders. The primary screed assembly is trying to be raised by hydraulic pressure, however this is not possible, as the hydraulic pressure is set at a low pressure, preventing the screed assembly from being raised. The operator then puts the processing equipment (scarification rakes, mills, pug mill, rejuvenator and heating system) into operation and moves the Recycling Machine briskly away, preventing the secondary screed from settling into the new asphalt while the primary screed assembly rises due to the asphalt in front of the screed assembly and also the limited hydraulic pressure trying to lift the screed. The front asphalt hopper will automatically provide new asphalt, on demand, to the primary and secondary screed assemblies. As the Recycling Machine starts to 100% recycle and rejuvenate the heated asphalt, as discussed previously, the primary auger/divider/strike-off plate begins to split and convey the windrow of 100% recycled asphalt, out to the primary screed's extensions. As the primary screed was rising, hydraulic oil was being forced out of the partially restricted cylinders through the cylinder's head end ports and flow control valves. The oil being supplied from the proportional valves (variable flow controlled by the sensor's outputs) to the rod end of the cylinders is also flowing through the rod end, flow control valves. The greater the flow of hydraulic oil from the proportional valves, the greater the differential in pressure across the flow control, valves. The screed sensors will eventually turn off the proportional valves when the primary screed assembly reaches the set point (differential height). The control of the system is to slowly change the forces working on the primary screed assembly, keeping it at the set, height differential. The sensors only respond when the primary screed tries to move away from the set differential. An example would be when the head of asphalt in front of the primary screed increases as the Recycling Machine mills through a high section. The primary auger/divider/strike off blade would hold back and control most of the mass, however there will be more asphalt reaching the screed (due to the pressure of the buildup), which will causes the screed to rise. When the reverse happens (lack of material), the screed will sink. As noted before the hydraulic pressure is too low to keep the screed raised and at the correct level. This is not a problem, as the secondary screed will continue to set the correct grade by laying a greater amount of new asphalt. This condition will rarely occur as the on-board computer monitors the primary auger/divider/strike off blade's individual auger's speeds and allows the shuttle conveyor to spill extra, new asphalt into the augers, maintaining the head of asphalt in front of the primary screed assembly. When using the Integral Overlay process, the primary screed assembly should be prevented from exceeding the height of the secondary screed. If this were allowed to happen, the 100% recycled asphalt would replace the new asphalt. To prevent the primary screed assembly from getting into this position the hydraulic pressure used for down force on the primary screed's hydraulic cylinders is set to a higher pressure than the pressure used to raise the screed assembly. This is possible as the Recycling Machine is heavy and will not by lifted by the pressure in the primary screed's hydraulic cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, objects and advantages of the present invention will become apparent from the following description and drawings wherein like reference numerals represent like elements in several views, and in which:
FIG. 1 a side view of the 100% HIR Recycling Machine and Preheater in the working mode
FIG. 2 a side view of the 100% HIR Recycling Machine showing major sub-assemblies
FIG. 3 a side view of the Preheater showing major sub-assemblies
FIG. 4 a plan and end view of the Recycling Machine's heater box and suspension
FIG. 5 a end view showing the Recycling Machine's heater box extension air supply pivot
FIG. 6 a front cross-section and plan view of the Recycling Machine's electronic burner
FIG. 7 a plan view of Recycling Machine's main heater box and extension burner layout
FIG. 8 a side view of the Recycling Machine's offset boom and cab
FIG. 9 a plan view of the Recycling Machine's offset boom and cab
FIG. 10 an end view of the Recycling Machine's rear axle assembly
FIG. 11 a plan view of the Recycling Machine's front and rear axle assembly
FIG. 12 an end view of the Recycling Machine's front axle assembly in a tilted position
FIG. 13 a side view of the Recycling Machine's grade control system for the main and extension mills
FIG. 14 a plan view of the Recycling Machine's grade control system for the main and extension mills showing the transversal, jointed cross beam
FIG. 15 a side view of the Recycling Machine's, mill grade control system
FIG. 16 an exploded side view of the Recycling Machine's, mill grade control system
FIG. 17 an end view of the Recycling Machine's, mill grade control standard two ski assembly
FIG. 18 an end view of the Recycling Machine's, mill grade control transverse averaging ski assembly
FIG. 19 a side view of the Recycling Machine's, mill grade control longitudinal averaging ski assembly
FIG. 20 a side view of the Recycling Machine's, mill grade control longitudinal averaging ski assembly with non-contact, sonic sensors
FIG. 21 an end view of the Recycling Machine's, mill grade control system with a single ski assembly and cross slope sensor
FIG. 22 a side view of the Recycling Machine's asphalt surge bin and vertical elevator
FIG. 23 an end view of the Recycling Machine's asphalt surge bin and vertical elevator
FIG. 24 a side view of the Recycling Machine's, hopper/diverter valve
FIG. 25 a side view of the Recycling Machine's, hopper/diverter valve shown in three modes of operation
FIG. 26 a side view of the Recycling Machine's auger/divider/strike-off blade assembly
FIG. 27 a plan view of the Recycling Machine's auger/divider/strike off blade assembly
FIG. 28 an end view of the Recycling Machine's auger/divider/strike off blade assembly
FIG. 29 a plan view of the Recycling Machine's auger/divider/strike off blade assembly showing the divider in two positions
FIG. 30 a side view of the Recycling Machine fitted with a front asphalt hopper, central belt conveyor and asphalt surge bin/vertical elevator
FIG. 31 a simplified side view of the Recycling Machine fitted with a front asphalt hopper, central belt conveyor and asphalt surge bin/vertical elevator
FIG. 32 a side view of the Recycling Machine and front asphalt hopper assembly and central belt conveyor in the raised position
FIG. 33 a side view of the Recycling Machine and front asphalt hopper assembly and central belt conveyor in the lowered position
FIG. 34 a side view of the Recycling Machine's front asphalt hopper assemblies clip-on attachment frame and safety locks
FIG. 35 a side view of the Recycling Machine's central belt conveyor assembly
FIG. 36 a side view of the Recycling Machine's automatic belt tension assembly
FIG. 37 a side, plan and end view of the Recycling Machine's rake scarification/blade collection assembly
FIG. 38 a side view of the Recycling Machine's rake scarification/blade collection assembly with a main rake/blade in the lowered position
FIG. 39 a side view of the Recycling Machine's rake scarification/blade collection assembly with a main rake/blade in the lowered position with the blade collecting asphalt
FIG. 40 a plan view of the Recycling Machine's rake scarification/blade collection assembly with a main rake/blade showing a utility structure
FIG. 41 a plan view of the Recycling Machine's extension mills, main mill and pug mill showing the flow of asphalt when processing
FIG. 42 an end view of the Recycling Machine's extension mills with one extension mill crowned
FIG. 43 an end view of the Recycling Machine's extension mill with spring loaded blade in the full down position
FIG. 44 an end view of the Recycling Machine's extension mill with spring loaded blade in the full up position
FIG. 45 an end view of the Recycling Machine's main mill
FIG. 46 a plan view of the Recycling Machine's main mill showing asphalt discharge
FIG. 47 an end view of the Recycling Machine's main mill with spring loaded blade in the normal working position and also the rejuvenator spray bar
FIG. 48 a schematic of the Recycling Machine's rejuvenator and supplemental liquid distribution system
FIG. 49 a plan view of the Recycling Machine's extension mills, main mill and pug mill showing the rejuvenator/liquid polymer spray bars
FIG. 50 a side view of the Recycling Machine's pug mill assembly
FIG. 51 an end view of the Recycling Machine's pug mill assembly
FIG. 52 a plan view of the Recycling Machine's pug mill showing the front and rear rotor assemblies
FIG. 53 a plan view of the Recycling Machine's pug mill showing the inlet and outlet of asphalt
FIG. 54 a side view of the Recycling Machine's pug mill with ski assembly at rest
FIG. 55 a side view of the Recycling Machine's pug mill with ski assembly in the raised position
FIG. 56 a end view of the Recycling Machine's pug mill with ski assembly at rest showing the electronic, rotary sensor
FIG. 57 a side view of the Recycling Machine's pug mill with trip blade
FIG. 58 a side view of the Recycling Machine's pug mill with trip blade in the tripped position
FIG. 59 a side view of the Recycling Machine's pug mill showing an exploded view of the trip blade
FIG. 60 a side view of the Recycling Machine's front asphalt hopper fitted with a metal detection boom assembly
FIG. 61 a plan view of the Recycling Machine's rake/blade and metal detection boom assembly
FIG. 62 an end view of the Preheater's aggregate distribution bin and width measuring system
FIG. 63 a side view of the Preheater's aggregate distribution bin
FIG. 64 a side view of the Preheater's aggregate distribution bin showing a spring loaded blade in the normal position
FIG. 65 a side view of the Preheater's aggregate distribution bin showing a spring loaded blade in the open position
FIG. 66 a side view of the Preheater's aggregate distribution bin and asphalt surface profile measuring system
FIG. 67 a side view of the Recycling Machine showing the major sub-assemblies used with the 100% HIR with Integral Overlay method
FIG. 68 a side view of the Recycling Machine's rear end showing the major sub-assemblies used with the 100% HIR with Integral Overlay method
FIG. 69 a side view of the Recycling Machine's rear end showing the primary and secondary screed assemblies and tow arms
FIG. 70 a cross section view of the Recycling Machine's secondary screed arm hydraulic cylinder
FIG. 71 a side view of the Recycling Machine in the highway transportation mode
FIG. 72 a side view of the Recycling Machine's clip-on, front transportation stinger assembly retracted
FIG. 73 a side view of the Recycling Machine's clip-on, front transportation stinger assembly extended
FIG. 74 a side view of the Recycling Machine's clip-on, front transportation stinger assembly exploded
FIG. 75 a side view of the Recycling Machine's clip-on, front transportation stinger showing the clip-on frame and safety latches
FIG. 76 a side view of the Recycling Machine's clip-on, rear transportation frame assembly
FIG. 77 a side view of the Recycling Machine's clip-on, rear transportation frame assembly in a forward position
FIG. 78 a side view of the Recycling Machine's clip-on, rear transportation frame assembly showing the safety latches
FIG. 79 a side view of the Recycling Machine with a clip-on, rear transportation frame and front asphalt hopper assembly in the highway transportation mode
FIG. 80 a side view of the Preheater with a clip-on, rear transportation frame and front stinger assembly in the highway transportation mode
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Set forth below is a description of what are currently believed to be the preferred embodiments or best examples of the invention claimed. Future and present alternatives and modifications to the preferred embodiments are contemplated. Any alternates or modifications in which insubstantial changes in function, in purpose, in structure or in result are intended to be covered by the claims of this patent.
FIG. 13 shows the ENVIRO-PAVE 100% Recycling Machine 1 configured for 100% HIR and a Preheater (only one shown), both shown in the working mode. A plurality of Preheaters may be used within three or more Preheaters typically being located ahead of the Recycling Machine. The Preheaters are responsible for delivering deep, penetrating heat into the asphalt. Preheaters not fitted with a clip-on aggregate bin 21 and the rake/blade scarification/collection system 11 can be fitted with an optional thermal insulation blanket, around the edges (not shown) which is used to reflect heat into the heated asphalt surface and shield the asphalt from the cooling effects of wind. The final Preheater (shown ahead of the Recycling Machine) is fitted with an on-board computer-controlled, aggregate distribution bin and rake/blade scarification/collection system. Aggregate, such as washed sand is added in controlled proportions (determined by prior testing of the asphalt) and adjusts the air-void ratio and the structural properties of the recycled asphalt. It is also possible to add combinations of aggregates by premixing or by fitting more than one Preheater with aggregate distribution bins. The Recycling Machine and Preheaters are fitted with main heater boxes 4 . Attached to the main heater boxes are the left and right side hydraulically operated, extension boxes, which provide on the go, variable heating width adjustment. The fuel is clean burning propane and is mixed with pressurized air in individual, electronically monitored and controlled burner assemblies. The air pressure, burner operation, heat shutdown and emergency heat shutdown is monitored and controlled by the on-board computer for safety and efficiency. The burners produce infrared heat (stainless steel cones and underside stainless steel mesh glow red) and forced hot air to heat the asphalt. The burner flame is of the high swirl type (flat flame) and does not contact the asphalt's surface. The spacing of the machines allows the heat to soak (penetrate) into the asphalt. Close spacing provides high surface heat, but less depth of heat. Spacing the machines further apart, can in some conditions, increase the depth of heat into the asphalt, however, in windy, cold or damp conditions, reduced depth of heat can result. Insulation blankets are available (mounted behind the Preheaters) to reduce the heat loss to the atmosphere and increase the heat penetration into the asphalt. Electronic monitoring and control of the heater boxes on the Preheaters and Recycling Machine provides automatic heat control.
2 ENVIRO-PAVE 100% Hot In-place Recycling Machine and Preheater 2 is shown in FIGS. 1 and 3 fitted with the clip-on aggregate bin 21 and rake/blade scarification/collection system 11 , 12 and 13 . The mainframes 3 , on both machines are fabricated out of carbon rectangular steel tubing with the main tubes forming air plenums. Pressurized air, supplied by a hydraulically driven, variable speed centrifugal blower (monitored by an electronic pressure sensor) maintains the mainframe's 3 tubes (plenum) at a constant pressure. The on-board computer controls a hydraulic, variable displacement, piston pump (driven by the diesel engine) using information provided by the air plenum's electronic pressure sensor. The pump provides oil flow to the air blower's hydraulic drive motor. Air pressure remains constant as ambient temperature, air density, altitude or air demand (volume) change. Changes in air demand occur as the extension boxes are raised and lowered. Raising the extension boxes automatically cuts off the air supply, reducing the required blower volume. The Preheater's main heater box 4 attaches to the main frame 3 by eight equally spaced pivoting links 5 . The pivoting links allow the heater box to thermally expand while also allowing the mainframe 3 to structurally support the heater box 4 . The air supply to main heater box 4 from mainframe 3 is by four equally spaced, flexible hoses (not shown). As shown in FIG. 2 , the Recycling Machine's main heater box 4 attaches to the mainframe 3 by four hydraulic cylinders and a suspension system 6 , allowing the heater box to raise/lower, tilt and side shift. Propane tanks 7 , on both of the machines are industry standard, mobile units fitted with fluid withdrawal from the tank bottom and vapor withdrawal from the top. Heated vaporizer(s) vaporize the liquid propane while a single stage regulator reduces the gas pressure for the burner's supply. Regulated vapor pressure (top of the propane tank) supplies the burners at a slightly higher pressure than set by the single stage regulator, thereby providing propane vapor discharge priority and reducing excessive tank pressure in high ambient temperatures. The Recycling Machine and Preheater both feature four wheel drive supplied by hydraulic, radial piston motors, driving wheels 8 while providing infinite speed in both directions. The drive wheels 8 steer 40 degrees to the left and right (front and rear) on both of the machines. Hydraulic booms 9 fitted to both machines allow the operators to move around the rear end of the machines for better viewing. The Preheater's boom allows a wheel loader to dump aggregate into the aggregate bin 21 with the boom swung completely to curb side for traffic safety. Cab 10 , attached to boom 9 are fitted on both machines and house the operator controls station (electronic) and machine monitoring readouts.
FIG. 2 illustrates the Recycling Machine's 1 sub-assemblies (described later, in detail) which comprise extension rakes 11 , main rakes 12 , rake blades 13 , extension mills 14 , main mill 15 , offset pug mill 16 , surge bin/vertical elevator 17 , auger/divider/strike-off blade 18 and screed/tow arms 19 . Stinger 20 hydraulically extends and retracts from the main frame 3 , reducing the Recycling Machine's length, while in the working mode. The Recycling Machine can also be fitted with an optional clip-on, front asphalt hopper with a 5 th wheel pin attachment. Either attachment allows towing by a highway truck tractor, without the removal of the front end, attachment. The Preheater's stinger 20 also allows towing by a highway truck tractor. The rear end of the Recycling Machine 1 and Preheater 2 mainframes 3 feature attachment tubes 22 allowing clip-on transportation frames (described in detail later) to be attached for highway transportation. The Recycling Machine and Preheater's sub-assemblies and/or clip-on attachments can be removed or left in-place for transportation. Attachments left in-place for transportations are also fitted with attachment tubes 22 as shown in FIG. 3 on the Preheater's aggregate bin 21 .
In summary, both machines feature a commonality of parts and systems, allowing for interchangeability of components for transportation, service and manufacturing.
FIG. 3 The Recycling Machine's and the Preheater's heater boxes are basically the same in construction and operation, however, the Recycling Machine's heater box will be described in detail due to additional features, such as hydraulic raise/lower, tilt and side shift a 45 . The Recycling Machine's heater box consists of the main box 30 and the left and right extension boxes 31 (only the R.H. one is shown on the plan view). The extension boxes are used to increase the heating width of the Recycling Machine as it is processing asphalt. FIG. 34 at the bottom shows the plan and front view with the left extension in the raised (transport) position and the right extension in the lowered, heating position. The two extension boxes 31 are supported and pivot on frames (two) 32 . Frames 32 also supply air to the individually controlled, electronic burners 35 , located on both the main and the extension boxes while gas supply tubes 33 supply propane to the burners. The middle support frame 34 spans the three gas tubes 33 and provides support for the main box's top deck.
FIG. 3 a FIG. 5 shows the extension box's frame/air tube 36 in both the raised and lowered (heating) position. The stationary pivot 37 is attached (bolted) to the main box's frame 32 . Frame/air tube 36 and has two rectangular air passages (“A” and “B”) located in the rotating pivot. Passage “A” (rotating pivot) is connected to the burner's air supply tubes while passage “B” (rotating pivot) slides past passage “C” in the stationary pivot 37 . When the extension box 31 is in the raised position passage “C” is blocked. In the lowered (heating) position passages “B” and “C” are aligned, allowing air to flow into the extension frame's air supply tubes 36 through passage “A”. The stationary pivots 37 allow the extension boxes 31 to be raised and lowered by hydraulic cylinders 38 that are attached between the middle support frame 34 and the extension frame 36 and also provide automatic air control to the extensions, reducing air consumption, by shutting off the air supply when the burners are not required. Electronic sensors detect the extension box's 31 position. The on-board computer automatically cuts off the gas supplies when the boxes are raised 10 degrees from heating position. As noted above, the main heater and extension boxes are constructed from rectangular steel tubing. The tubing is used to distribute propane and air to the individual burners. Passing propane and air through the tubes reduces weight, plumbing complexity and increases the surface area on propane delivery system, allowing the propane to completely vaporize, particularly in cold weather. Preheaters have their heater boxes mounted through equally spaced links 5 attached to the mainframe. The mainframe provides the structural rigidity to the heater box. The heater box and mainframe are raised, lowered and tilted using the Preheater's front and rear axle's, hydraulic cylinders. The Recycling Machine's main heater box 30 and extension heater boxes 31 , are raised, lowered and tilted by four (two per side) individual, hydraulic cylinders 39 that are mounted to the support frame 40 and the sliding suspension tube 41 . The two left and the two right cylinders are hydraulically plumbed in parallel, allowing each side to be raised individually (tilt) or together. Cylinders 39 are in compression (rod being forced into the cylinder) when carrying the weight of the heater box and together with hydraulic counterbalance valves prevents the box from drifting down (anti-drift) which allows the height of the box to be set and maintained at any position. The sliding suspension tubes 41 are raised and lowered by hydraulic cylinders 39 and slide through the support frame 40 . The suspension tubes 41 are attached to frames (two) 42 through universal joints, allowing movement for tilt and misalignment. Two hydraulic cylinders 43 are attach between frame 32 and frames 42 . The hydraulically cylinders are connected in parallel and are equalized in hydraulic flow, allowing the frames 32 (attached to main heater box) to slide through frames 42 , side shifting the heater box for operation around tight bends or for offset heating. The frames 42 receive air from the Recycling Machine's mainframe 3 through four flexible hoses (not shown). The hoses function as a flexible joints and also weak links (fuses), protecting against the unlikely event of combustion blow back. The on-board computer, providing for safety and efficiency, controls the air/fuel mixture, as well as the ignition and shut down. The electronically monitored and controlled burners 35 receive their air supply from frames 42 and their gas supply from tubes 33 . The on-board computer automatically controls the air pressure. The electronically controlled burners 35 produce infrared heat, (stainless steel cones glow red) and hot forced air to heat the asphalt. The stainless steel mesh 44 (heated by burners 35 ), also produces infrared heat, while flexible stainless steel wire mesh skirts 45 , surround the perimeter of the heater boxes, containing the heated air. Ceramic fiber insulation 46 surrounds the burner cones and is packed between the mesh 44 and the heater boxes top deck. The burner's flame features a flat, high swirl pattern, with no flame contact with heated surface. The burners are non-adjustable (only for initial setup) and are set up to provide a blue flame for reduced emissions and greater fuel economy.
FIG. 6 shows the individually controlled, electronic burner FIG. 3 , 35 and the stainless steel cone 47 . The burners 35 are attached to the heater box's top decks by studs and lock nuts, which are part of cone 47 . Heat resistant gaskets insulate the cones and burners from the deck, reducing the amount of heat transfer to deck's surface. Combustion air enters the burner through inlet 48 (“A”) and flows around air plenum housing 49 , and venturi tube 50 . Plenum “B” causes the air supply to continuously spin, due to the offset (tangential) inlet 48 (“A”). The spinning air is forced past vanes 51 in venturi tube 50 , and “C” the 'sTsection of reduced area “C” creates a venturi, which increases the air's velocity and causes a pressures drop, at the propane's 360 degree, supply orifice “G”. Propane enters the burner at “D”, through collar 52 and passes down between the gas tube 53 and the retainer tube 54 and exits through holes “E”, filing the surge chamber in inner tube 55 . The venturi plate 56 and the inner tube 55 are spaced apart by stainless steel wires 57 , forming a 360-degree orifice “G”. The reduced area “C” increases the air's velocity and together with the spinning air and 360 degree propane supply, produce an efficient, clean flame that clings to the burner cone's 47 , inside wall. The propane is completely burnt within the top 4 inches of the cone 47 , causing the cone to glow and producing infrared heat. The heat of combustion provides additional heat and drives away any moisture from under heater boxes through the heater box's flexible side skirts. Thermocouples (not shown) positioned at various locations throughout the heater box's underside, monitor the heater box's heat output Electronic flame detectors (not shown) monitor the asphalt's surface for local flame propagation. Each burner senses the surrounding heat at thermocouples 58 that is centrally located in the retainer tube 54 and attached to the burner cone 47 . The on-board computer receives information from each burner's thermocouples and controls the operation of the electrical gas valve 59 and the air control solenoid 60 . Solenoid 60 is attached to link 61 and together, rotates butterfly valve 62 , which in turn opens, or closes the air supply. Opening valve 59 allows propane (regulated at constant pressure) to flow through the tube 63 to trimmer valve 64 . Trimmer valve 64 is used for the initial setup of gas flow (air/fuel mixture). The burner's internal parts can be disassembled and cleaned by undoing the retainer nut 65 .rical 59
FIG. 3 c FIG. 7 The electronically controlled burners 35 feature left and right rotating air flows and are mounted to the heater boxes in a specific pattern, giving excellent heat coverage and heated air flow patterns. The main heater box is a two stage heating system. Under low heating requirements, (determined by the on-board computer) the main burners “A” and extension burners “C” (if extension (s) are energized) are operational. Gas supply to the “B” burners is shut-off by electrical gas valves FIG. 3 b 59 , however, the air supply remains on, providing cooling for the “B” burners. The on-board computer turns on the “B” burners when extra heat is required (as described in detail before). The on-board computer monitors each of the individual burner's thermocouples 58 and local flame detectors (not shown) and turns off the individual burner's gas supply when excessive, localized heat or flame is detected, such as crack filler or a paint lines flaring up. The solenoid 60 , link 61 and butterfly valve 62 shut off the air supply for re-ignition when the burner has automatically shut down. The electronic ignition system (not shown) fires the spark plug 63 , while the gas valve 59 turns on. The reduction of air (valve 62 closed) and the excess of propane gas produce a rich mixture at the orifice's 360 degree, discharge area “G”, FIG. 3 b , allowing the spark plug 63 to ignite the propane rich mixture. Once the heater boxes have reached their operating temperature (burner cone 47 glowing) ignition will take place without the use of the spark plug, however, the plug still fires as an added margin of safety
FIG. 4 89 shows the (Reference FIG. 2 ) Recycling Machine's mainframe 3 and operators cab 19 and offset boom assembly 9 . This designs allows not only the transportation frame to be attached easier, but also affords better access for the wheel loader when filling the aggregate bin. Pivot frame 70 is attached to the mainframe's top tube 22 on the left or the right hand side. Raising and lowering of the boom and cab assemblies is achieved by rotating pivot frame 70 around the mainframe's top cross tube 22 by hydraulic cylinder 71 . The boom height is restricted, preventing contact with power lines. Hydraulic counterbalance valves are fitted to the hydraulic cylinder 71 to prevent hydraulic drift. The boom's outer frame 72 is attached to the pivot frame 70 by pin 73 . The boom's outer frame 72 houses the inner, sliding tube 74 . The cab 19 is attached to the inner tube 74 by pivoting link 75 . The hydraulic cylinder 76 swings the boom and cab, allowing the operator to work from both sides of machine, while remaining out of way of screed operator and other ground personal. The hydraulic cylinder 77 slides the inner, sliding tube 74 through the outer frame 72 , extending the boom and cab. The Preheaters are fitted with a similar boom and cab assembly, the only difference being, a longer inner, sliding tube 74 . The boom's outer frame 72 is constructed to form a lower, enclosed channel 78 for the passage and protecting of the electrical and hydraulic hoses.
FIGS. 50 , 1 and 12 shows the Recycling Machine's front and rear axle assemblies and drive wheels 8 , FIG. 2 . The axle assemblies are lighter, have wider passages 80 (area “A”) and feature revised tilt geometry and hydraulic cylinder locations, compared to the prototype assemblies. The changes were made to allow the passing of a central belt conveyor through both axles and a clip-on, hydraulic stinger/5 th wheel pin 20 (hooks up to a highway, truck tractor unit for self-transportation) to pass through the front axle FIG. 12 . The central belt conveyor and the clip-on, stinger/5 th wheel pin are new innovations. The belt conveyor can be changed to any conveying system and will depend upon future innovations and processes. Both axles are raised and lowered by hydraulic cylinders 81 . The cylinders are attached to the front and rear axle's support frames 82 , both of which are attached to the Recycling Machine's mainframe 3 , FIG. 2 . The front axle's hydraulic cylinders are hydraulically connected in parallel, allowing the front axle's frame 83 to slide up and down the support frame 82 . The pivoting slider 84 (shown in tilted position) is attached to the support frame 82 by pin 85 and locates (prevents side to side movement while allowing the axle to tilt) the axle's frame 83 in support frame 82 . The slider also prevents the axle's frame 83 from bending in at its top section due to the natural bending moment when carrying the weight of the Recycling Machine. Hydraulic cylinders 81 are angled to help counter the bending forces on the axle's support frame 83 . Oil transfer between the hydraulic cylinders allows the front axle to tilt (follow ground surface) on the pivoting slider 84 without adversely effecting, the main frame's height. An electronic position sensor maintains the front axle's height position, relative to the position of pivoting slider 84 . This is used when lowering the front end of the Recycling Machine's mainframe (lower limit) and also prevents oil leakage in the hydraulic cylinders from causing the front end to settle over time. The electronic position sensor detects any relative change in height and signals the on-board computer to supply more or less hydraulic oil to the front cylinders, thereby raising or lowering the mainframe and cutting off the sensors signal. The rear axle assembly FIG. 10 slides up and down the pivoting slider 84 by the same manner as the front axle assembly. Oscillation of the pivoting slider 84 is around pin 85 allowing the mainframe 3 to be tilted in relation to the rear axle assembly. The rear axle's hydraulic cylinders 81 are operated individually by (hydraulic or electronic) automatic height controllers (two) or by the operator to control the mainframe's height and tilt (slope). Equal flow to both cylinders causes the rear axle's frame 83 to slide past the pivoting slider 84 causing the Recycling Machine's mainframe to raise or lower, but not tilt. Greater flow to one or the other cylinder causes the pivoting slider 84 to pivot around pin 85 , tilting the mainframe assembly. In normal operation it is the front axle assembly that automatically tilts (floats) due to the varying grade of the asphalt's surface, while the Recycling Machine's main frame stays level, due to the control of the rear axle's cylinders. Both of the pivoting sliders 84 have been lowered considerable in their support frames 82 to reduce the side-to-side movement of the front and rear axle frames 83 . This was required to provide side clearance for the central belt conveyor. The automatic slope control systems as described in detail above can be used to control the Recycling Machine's mainframe cross slope. Individual control of rear axle's hydraulic cylinders, together with the front axle's hydraulic cylinders connected hydraulically, in parallel, form a three-point suspension, allowing the mainframe to ride over undulating surfaces, thereby reducing stress in the mainframe. Machine operation is stable as the rear wheels are operating on a milled to grade surface, controlled by automatic grade controls. As mentioned earlier, the front axle's frame FIG. 12 , 83 is designed to allow a centrally located asphalt conveyor and transportation stinger (5 th wheel pin, not shown) to pass through its center section 80 (area “A”) allowing the axle to raise, lower and tilt the mainframe. The rear axle's frame FIG. 10 , 83 is configured to create a space which allows the pug mill's discharge (asphalt windrow) to pass under the frame (area “B”) and asphalt conveyor to pass over the top (area “A”). Future front clip-on units will be able to receive products consisting of granular, liquid or a mixture of both. Products will be metered and controlled by the on-board computer. Products will be conveyed to the rear of Recycling Machine for complete mixing by the main mill and/or the pug mill. The conveying of materials will be by chain conveyor, belt conveyor, auger, liquid, (wet line) or air conveyance. All conveying systems are designed to pass through the front axle and if required, the rear axle.
Both axles are fitted with steering hubs 86 , tag link 87 , and steering cylinders 88 . The steering hubs 86 pivot 40 degrees in both directions, around axle kingpins 89 , bushing 90 and thrust bearing 91 . The tag link 87 and steering cylinders 88 are mounted in a low position on the front axle, allowing the conveyor to pass. The rear axle has a high mounted tag link 87 and steering cylinders 88 , allowing the pug mill's windrow to pass under the axle's frame and the conveyor to pass through the top, center section. The four drive wheels 8 , are driven by low speed, high torque, radial piston, hydraulic motors 89 fitted with fail safe, spring applied, hydraulic pressure released, disc brakes. Speed and direction are infinitely variable. The combination of four-wheel drive, front and rear, 40 degrees wheel articulation (steering), in both directions, allow the Recycling Machine to work safely in hilly conditions and tight city work. One of the rear hydraulic motors 89 is fitted with an electronic ground speed encoder 92 , used by the on-board computer to calculate rejuvenator requirements and machine processing speed.
FIG. 61321 shows the side view of the Recycling Machine's main and extension mill's grade control system (the non-averaging system is shown. The two skis 100 assembly 101 contact the heated, unprocessed asphalt (original grade) slightly ahead of the midway point of the Recycling Machine's long wheelbase, mainframe assembly 3 . The extension 14 and the main mills 15 are located slightly behind the midway point of the machine's wheelbase. The rear wheels are riding on the milled grade, while the front wheels are following the original grade. Even if the front end of the Recycling Machine's mainframe 3 is moving up and down on an uneven grade, there is little error introduced into the milled grade, due to the location of the grade ski assemblies 100 and 101 .
FIG. 6 a shows the main and the extension mill's grade control system. It is manually adjustable, allowing setup for various surface conditions and processing widths. The extension mills (left and right side) are hydraulically adjustable in width and crown, while the main mill, located behind the extension mills is fixed in width. The left ski assembly 100 automatically controls the grade (depth of cut) of the left extension mill and the left side of the main mill. The right ski assembly 101 automatically controls the grade of the right extension mill and the right side of the main mill. The left and right ski assemblies are connected by a jointed, cross beam 102 to which various attachments (used to contact the heated asphalt surface) can be attached. The rotating/sliding joint 103 is located at the mid-point of the crossbeam 102 , allowing the beam to rotate and expand in length as the left and right ski assemblies move up and down. In its simplest form FIG. 6 a , two sliding shoes 104 contact the heated asphalt. As shown in FIG. 16 , shoes 104 attaches to pivot arms 105 allowing the shoes to pivot and follow the heated asphalt's surface. Pivot arms 105 attaches to flat springs 106 , which in turn attaches to the adjustable clamping brackets 107 . The flat springs 106 are used to prevent damage to the ski assemblies, if contact with a raised utility structure should occur. The springs are designed to bend and then spring back to their original position on hitting an obstruction. The clamping bracket 107 can be clamped on to the crossbeam 102 at any location. Generally the further out they are placed, the greater the accuracy (stability). The exception to the wide spacing is when following wheel ruts in the asphalt's surface (created by traffic). Pins 108 attach the crossbeam 102 to the left and the right side tow arms 109 that are attached by pins 110 to the mainframe of the Recycling Machine 3 . The tow arms pivot on pins 110 , allowing the ski assemblies to follow the asphalt's surface. Movement (raising and lowering) of the left and right side ski assemblies is transferred into the pivoting link 111 , which is attached between the tow arms 109 and flat spring clamp 112 .
The flat spring 113 is clamped to the grade control station's frame 114 . The grade control station's frame 114 is attached to the Recycling Machines mainframe 3 by pivoting links 115 and hydraulic cylinder 116 . The pivoting links 115 form a parallelogram linkage allowing the grade control station's frames 114 to remain absolutely parallel to the mainframe when being raised or lowered by the grade ski assemblies. Attached to the grade control station's frames are the hydraulic (or optional electronic) sensors 117 and wands 118 that make contact with the adjustable height control screws 119 . Brackets 128 attach the height control screws 119 to the extension mill sliders 120 and main mill sliders 121 . Four individually controlled, hydraulic cylinders 122 attached between the Recycling Machine's mainframe 3 and the mill sliders 120 and 121 are used to hydraulically raise and lower the left and right side of the extension and main mills. The left, sensor control station operates the left extension mill and left side of the main mill, while the right, sensor control station operates the right side of the mills. Each grade control sensor 117 (attached to the sensor control station) and wand 118 monitors the position of the height screws 119 allowing the height of each sliding strut to be adjusted individually to the position of the grade control station's frame 114 .
FIG. 6 b 16 shows a close up, side view of the mill's grade control system. As the ski assemblies 100 and 101 are pulled along by the Recycling Machine's mainframe they follow the grade of the asphalt's heated surface, which raises or lowers the pivoting link 111 , spring clamp 112 , flat spring 113 and grade control station's frame 114 . The function of the hydraulic lift/damper cylinder 116 is to carry a percentage of the grade control station's frame, crossbeam and averaging ski assembly's weight, preventing the shoes 104 from sinking into the hot asphalt. The amount of weight transferred by the cylinder 116 can be adjusted by varying the hydraulic pressure on the head end of the cylinder. The weight transfer pressure can be electronically switched in and out by the on-board computer. Increasing the hydraulic pressure will reduce the weight carried by the ski shoes 104 . The grade control station's frame movement must be dampened to prevent the mills from following major imperfection in the asphalt's surface. The hydraulic lift/damper cylinder 116 dampens the mechanical action of the grade system by restricting the cylinder's hydraulic, oil flow (similar to and automotive shock absorber). Adjustable hydraulic flow control valves are electronically switched in and out by the on-board computer when dampening is required. Dampening and weight transfer are both possible, at the same time. The hydraulic cylinder is also used to raise the complete grade system by increasing the hydraulic pressure on the head end of the cylinder. The flat spring 113 is designed to deflect if the ski assembly is suddenly pushed up by an obstruction or suddenly sinks due to a pothole or any other type of depression. The rate of the flat spring is adjustably by changing the outer pivot point of the spring by moving two pins 123 (located above and below the spring). a plurality of adjustment points 124 - 126 is 113 The spring is attached to the grade control station's frame 114 at point 127 . Moving the two pins 123 away from point 127 will increase the spring rate. In the dampening mode the hydraulic lift/dampening cylinder restricts the movement of the grade control station causing the flat spring 113 to deflect. The hydraulic and mechanical adjustments provide a wide range of control for all operating conditions and ski attachments. The grade sensors 117 (hydraulic type shown) are attached the grade control stations. The wands 118 are attached to the grade sensor's rotating shaft and rest on the adjustable height screws 119 , which are attached by brackets 128 to the sliders 120 of the extension and 121 of the main mills. Any change in the position of the grade control stations will raise both sensors 117 causing the wands 18 to pivot (move away from their neutral position) on the adjustable height adjuster screws 119 and rotate the sensor shafts. The sensors send hydraulic oil to the individual hydraulic cylinders 122 , raising or lowering the extension and main mill assemblies. As the mills are raised or lowered the height adjuster screws 119 return the wands back to their neutral position, cutting off the hydraulic oil flow to the hydraulic cylinders. The mill grade control system also corrects for grade changes caused by the Recycling Machine's front axle assembly following the uneven grade of old asphalt surfaces. Changes to the mainframe's front height, in relation to the ski assemblies, will cause the mainframe to pivot around the rear axle's wheel centerline. The ski assemblies 100 and 101 , which are following the asphalt's surface, position the grade control station's frames 114 . The height adjuster screws 119 are following the mainframe's position (hydraulic cylinders 122 have not moved at this point) causing the wand's position to change, which in turn will hydraulically (cylinders 122 receive hydraulic oil from the hydraulic sensors 117 ) raise or lower the sliders, mills and height adjuster screws, again neutralizing the system. The height adjustment screws 119 allow manual adjustment to each individual mill slider to fine-tune the milling height between the extension mills and the main mill. The extension mills 14 (left and right side) feature manually, hydraulic crowning of the milling rotors. The machine operator can adjust the crown without effecting the position of the slidingsliders, which. For processing requiring greater milling accuracy the standard two ski assemblies shown in 17 can be replaced by the transversal averaging ski assemblies 18 . Both assemblies are shown with one ski assembly riding over a 1.75″ bump. The standard ski would transmit an upward movement of 1.56″ into the tow arms 109 while would the of movement 111 the transversal averaging ski would reduce the upward movement to 0.82″ riding over the same bumping 111 . The wider the “A” dimensions the greater the averaging effect. 111 The sub beams 129 are attached to the jointed, crossbeam 102 by pivoting bracket 130 . When the width of processing allows, the length of the crossbeam 102 can be increased with plug-in extensions allowing the averaging skis to be moved further out from the Recycling Machine's longitudinal centerline, again improving the averaging effect.
FIG. 6 d shows the 19 longitudinal averaging ski assembly set up with the ski assemblies at a wide distance (“A”). This is only possible when the ski assemblies can be widened out to a width than the Recycling Machine's heater box, rake extensions and extension mills, such as multi-lane highways and airport runways. Adjustable brackets 131 attach the ski assemblies to longitudinal beam 132 that pivot around bracket 133 . The beam 132 can be increased in length by attaching plug-in extensions. It is also possible to attached longitudinal sub-pivoting beams together with four ski assemblies similar to the transversal setup but operating in the longitudinal axis. The ski assemblies can be replaced with wheel assemblies when operating on surfaces that could be marked by the ski assembly shoes 104 .
FIG. 6 e 20 shows the mechanical longitudinal averaging ski assemblies set up are with Topcon's Smoothtrack® 4 Sonic Tracker II™ non-contact, averaging beams (one on either side of the Recycling Machine). The longitudinal beam 132 is attached to the standard, jointed crossbeam 102 by fixed bracket 134 , which prevents beam 132 from pivoting. The non-contact sonic sensors 135 are attached to beam 132 . The hydraulic operation of the lift/damper cylinder 116 is controlled by Topcon's electronic control system. The hydraulic damper and pressure transfer system are not used in this application, as the hydraulic cylinder must operate in the standard, double acting mode. The mill's depth of cut is electronically set using the Topcon keypad. The electronic, sonic grade control system controls the oil flow to hydraulic cylinder 116 , which positively raises or lowers the grade control station's frames 114 , beam 132 and sensors 135 . The mills follow the position of the grade control station's frames.
FIG. 6 f 1 shows the standard, left-hand transverse ski assembly 100 (looking from the front of the Recycling Machine) attached to the jointed crossbeam 102 . Attached to the right side of the jointed crossbeam 102 is the electronic slope sensor 136 . Both the left-hand ski assembly 100 and the slope control 36 sensor are mounted as far away from the Recycling Machine's centerline as possible, increasing the slope sensor's accuracy. The left lift/damper cylinders 116 is set to operate on damper and weight transfer control, while the right cylinder is set for double acting operation (dampening and weight transfer turned off). In operation, the left-hand ski follows the asphalt's surface, which in turn raises or lowers the left side of the crossbeam 102 . The left-hand tow arm 109 transfers this motion into the left grade control station as discussed previously. The slope control sensor 136 (set to one-degree slope, in the drawing) electronically monitors the angle of the crossbeam 102 . The slope sensor will pick up any change in angle and the electronic control system will control the oil flow into the right-hand cylinder 116 , returning the right-hand grade control station and crossbeam 102 back to the one-degree setting. The main and extension mill grade control system can also be set up to operate the two rear axle cylinders 81 , providing the reference for full, main frame grade control (as discussed earlier). In this case fully extending the hydraulic cylinders 116 raises the left and right grade control station's frames 114 , thereby hydraulically locking the mills to the mainframe's grade. Adjusting the height adjustments screws 119 can individually control adjustments to the mills depth of cut.
FIGS. 7 22 and 23 shows the heated, insulated and covered asphalt surge bin/vertical elevator 17 12 , FIG. 2 . The vertical elevator 140 , consists of frame 141 , lower idler shaft 142 , inner chain guide 143 , middle chain guide 144 , outer chain guide 145 , drive shaft 146 , slated chain 147 , motor coupling 148 , and hydraulic drive motor 149 . Hydraulic cylinders 150 raise and lower the surge bin/elevator 17 into the 100% recycled asphalt's windrow 151152 . The on-board computer monitors a pressure transducer, used to record the head end hydraulic pressure (load carrying pressure) in the hydraulic cylinders 150 . At a set pressure increase (bin full of asphalt) the hydraulic drive motor 149 is stopped, stopping the pickup of recycled asphalt from windrow 151 . As asphalt is released out of the bin the cylinder's hydraulic pressure decreases. The hydraulic motor 149 is re-started when a preset minimum pressure is reached, again allowing asphalt to be picked up from the windrow. The vertical elevator 140 can also run in manual mode, controlled by the ground operator. Asphalt is lifted, vertically up the front face of the conveyor frame 152 , by slated chain 147 , operating between two vertical wear plates 144 and 145 . The wear plates are the full width of the slated chain, preventing the asphalt from falling back and segregating. The surge bin 17 is constructed with insulation attached to the outer walls and provides heat retention for stored asphalt. Propane (vapor from top of the propane tank) is supplied to the burner 155 , which is mounted in a horizontal, double walled tube 156 , spanning the complete width of the bin's sides 157 . The double wall tube prevents direct flame contact with the outer tube (in contact with asphalt), preventing the asphalt from being overheated. Two vertical tubes 158 are used to exhaust the horizontal burner tube to the top of the bin, for safety. The tubes are angled using bends and are attached to vertical baffle plates 159 Controlled heat, transmitted over a large effective area by 156 , 157 , 158 and 159 , increase the heat transfer to the stored asphalt and reduce oxidation. Burner control is automatic and is controlled by an adjustable bin thermostat 160 . The surge bin's rotary discharge valves (left and right side) 161 are mounted in four replaceable bearings 162 and are opened/closed by two independently controlled, hydraulic cylinders 163 attached to arms 164 . The arms 164 are used to turn the rotary discharge valves 161 allowing the stored (heated) asphalt to fall into the left and right auger screws (located in front of the screed assembly). Attached to the front of the vertical elevator is the hopper/diverter valve assembly 165 . The hopper receives new asphalt from the front asphalt hopper (an option attached to the front of the Recycling Machine) via the optional central belt conveyor (both described in detail later). Rotary valve 166 is attached by arm 167 to the hydraulic cylinder 168 . In the position shown, the valve would be directing the asphalt delivered by the central belt conveyor into the vertical elevator for delivery into the bin for storage.
FIG. 24 shows a close up side view of the hopper/diverter valve with the rotary valve 166 in the closed position.
FIG. 25 shows the hopper/diverter valve in the three operating modes traveling in the direction shown by arrow 152 . FIG. “A” 25 shows the belt conveyor discharging new asphalt into the hopper. In this mode the rotary valve 166 is closed and the vertical elevator 141 is running. New asphalt is carried up the front of the vertical elevator and fills the surge bin. This operation is used when the surge bin must be initially filled (no windrow has been established). FIG. “B” 25 shows the belt conveyor discharging new asphalt into the hopperR. In this mode the rotary valve is closed and the vertical elevator is running and also picking up 100% recycled asphalt from the windrow 151 left by the pug mill. New asphalt is being blended with the recycled asphalt in the vertical elevator and is being carried up the vertical elevator, filling the surge bin. FIG. “C” 25 shows the belt conveyor discharging new asphalt into the hopper. In this mode the rotary valve is open and the vertical elevator is not running. The amount of 100%, recycled asphalt contained in the windrow 151 , left by the pug mill, is not sufficient to maintain a constant head of asphalt in front of the screed assembly. New asphalt passes through the rotary valve (bypassing the vertical elevator) directly on to the windrow or the milled asphalt's surface. The on-board computer determines when the Recycling Machine's front hopper and belt conveyor supplies new asphalt by monitoring the volume of asphalt flowing through the pug mill's volume sensing ski. Both the “B” and “C” modes can be used when the “Remix Method” (new asphalt is proportionally mixed with 100% recycled asphalt) is required. The “B” and “C” also allow the Recycling Machine to process asphalt surfaces requiring more asphalt than is available, such as increasing the structural strength of the original asphalt, grade changes and shoulder widening.
FIG. 8 2629 shows the asphalt auger/divider/strike-off blade assembly 18 , FIG. 2 . The auger/divider/strike-off blade assembly 18 distributes material evenly to left and right side of the screed assembly 19 , FIG. 2 . The screed assembly 19 is an industry standard unit with all major adjustments being electric/electronic over hydraulic. The screed is may be equipped with left and right side extensions (variable width. The auger/divider/strike-off blade assembly 18 consists of a left 171 and right 172 auger (looking from the front of the machine) rotated by individual sprocket/chain drives 173 and hydraulic motors 174 . The auger's speed is infinitely variable in both directions, allowing asphalt contained in the windrow 151 to be moved in all directions across the front face of the screed assembly. The windrow divider 175 splits the asphalt windrow 151 and assists the left and right augers 171 and 172 in the distribution of the asphalt windrow 151 , especially on cross slopes and conditions requiring high volumes of continuous material to either side of screed assembly. Two hydraulic cylinders 173 are attached between the Recycling Machine's mainframe 3 , FIG. 2 , and the augers mainframe 183 , allowing the auger/divider/strike-off blade assembly 18 to be raised and lowered for varying depths of asphalt laid by the screed assembly. The windrow divider 175 is positioned (turned) by the hydraulic cylinder 176 and arm 177 and is controlled manually or, automatically by the on-board computer. Two electronic sensors (not shown) are located at the end of the screed's extensions and determine the level of the asphalt in front of the screed and screed extensions. As the level of asphalt in front of the screed assembly drops, the electronic sensor(s) automatically speed up the appropriate auger 171 or 172 , delivering more asphalt across the front face of the screed 178 . The angle of the divider 175 is controlled proportional to the speed of each individual auger. An electronic feedback LVDT 179 compares the divider's rotational position to each individual auger's speed. The divider is fitted with replaceable and adjustable blades 180 allowing the height of the divider to be set in relation to the auger's height. For major height adjustments, adding or removing spacers to the rotational shaft 181 moves the divider up and down.
FIG. 8 a 29 shows the asphalt auger/divider/strike-off blade assembly with the divider 175 in the straight-ahead position “A”. Both augers are being controlled to the same speed (20-RPM) by the electronic sensors mounted on the screed's extensions. The windrow 151 is being split equally to both augers and the asphalt head in front of the screed assembly is even. “B” shows the position of the divider at its maximum rotational angle (in one direction, deflecting a greater proportion of asphalt into the faster auger). The right-hand auger's speed has increased as a result of the right-hand side of the screed and screed extension running low on asphalt. The right-hand sensor has speed up the right-hand auger 172 20 to 40 RPM in an effort to maintain sufficient supply of asphalt laying the greatest volume of asphalt. The on-board computer has proportionally increased the rotational angle of the divider to match the increased speed of the right-hand auger. The divider angle can be programmed to degrees/per auger RPM, allowing the gain (sensitivity) of the system to be varied for varying applications and asphalt types. In actual operation the auger's speed and the divider's angle will change very little. The only time the divider will reach its maximum angle is when the windrow and the surge bin 15 , FIG. 2 can no longer provide sufficient asphalt. By that point the surge bin rotary valves 6 would have fully opened allowing all of the stored asphalt to be dumped into the augers. The manually adjustable strike-off blades 182 attached to the auger's mainframe 183 and are used to control the flow of asphalt to the left and right augers, preventing excessive asphalt build-up in the augers and in front of the screed assembly, which would cause the screed to rise, due to the increased pressure. The strike off-blades (left and right side) are slotted, allowing for adjustment in height and taper. The height of blade becomes greater towards the end of the augers, allowing more asphalt to flow under the blades towards the end of the augers.
FIG. 30 shows a detailed side view t Recycling Machine 1 with the attached by the clip-on, front asphalt hopper/5 th wheel pin assembly 190 and the central conveyor assembly 191 , which runs down the center of the machine to feed new asphalt to the hopper/diverter valve assembly 165 . As explained previously, the hopper and central conveyor are used to provide new asphalt when using the “Remix Method” or when extra asphalt is required, such as for shoulder widening.
FIG. 9 b 31 shows a simplified view of the Recycling Machine 1 with the major sub-assemblies removed for clarity. Shown are the mainframe 3 , clip-on, front asphalt hopper/5 th wheel-pin assembly 190 , central high temperature belt conveyor assembly 191 , hopper/diverter valve 165 and asphalt surge bin/vertical elevator 17 .
FIG. 9 b 32 shows the clip-on, front asphalt hopper/5 th wheel pin assembly 190 in its raised and 33 the clip-on, front asphalt hopper/5 th wheel pin assembly 190 in its lowered position. The clip-on frame 192 is attached to the Recycling Machine's mainframe 3 top and bottom tubes 193 . 34 shows the frame 192 with its safety locks 194 in the open and closed position. The two safety locks 194 (one on either side of the frame 192 ) are mechanically pinned into position by safety pins 195 . Pivot pins 196 allow the safety locks to be opened when the safety pins are removed. The safety locks can only by opened when the clip-on, front asphalt hopper/5 th wheel pin assembly 190 is in the lowered position as the top section of the frame assembly 197 is tapered at point 198 and only allows clearance in this position. This design feature provides a fail-safe attachment mechanism for transportation (raised position) as the frame assembly 197 physically prevents the safety lock from opening, even if the safety pins were not installed. The hydraulic cylinders 199 are attached between frame 192 and frame 197 . Extending the hydraulic cylinders 199 raises the front asphalt hopper/5 th wheel pin assembly 190 . An electronic pressure transducer is used to measure the pressure in the hydraulic cylinders 199 . The on-board computer to monitors the amount of asphalt in the front hopper using the pressure in the cylinders as a reference. The pressure is checked at the beginning of the work day by the on-board computer to determine a base line for the assembly weight of the front asphalt hopper/5 th wheel pin assembly, as it will change with accumulated asphalt deposits. The on-board computer gives the operator a graphical display of the weight of asphalt in the front hopper. The on-board computer may also informs the dump truck drivers when to discharge more asphalt into the front hopper by operating a red and green light, located on the front of the Recycling Machine. Both lights are visible in the truck's side mirror. When the green light is on, the hopper has sufficient asphalt, while a red light informs the operator to dump more asphalt until the green light comes on. Future systems using live bottom (moving floor) trailers will feature electronic wireless control of the hydraulically driven, variable speed, live bottom floor, which is generally a belt or slat conveyor. The Recycling Machine will automatically control the discharge rate of asphalt into the front hopper. The front asphalt hopper/5 th wheel pin assembly can be raised and lowered while asphalt is being discharged on to the belt conveyor assembly 191 , however the height is limited by electronically monitoring the position of frame assembly 197 . Two arms 200 (one on either side of the frame assembly) are attached to frame assembly 197 and contact the belt conveyor assembly 191 , allowing the front section of the belt conveyor to follow the movement (raise and lower) of the front asphalt hopper/5 th wheel pin assembly. The central belt conveyor assembly 191 is attached to the Recycling Machine's mainframe 3 at point 201 , allowing the front section of the belt conveyor to pivot. Any change in the belt's tension during this movement is automatically taken up by the hydraulic belt tension system. New asphalt is dumped into the front hopper 202 by dump truck and is conveyed by drag chain 203 to the belt conveyor assembly 191 . A fixed strike-off blade (not shown) controls the height of the asphalt being picked up by the drag chain. The hydraulic motor(s) 204 provide an infinite speed, drive for the drag chain 203 that is controlled by the on-board computer. The asphalt's discharge rate is controlled by electronically monitoring (electrical encoder attached to the rear drive shaft of the conveyor assembly 191 and the front idler shaft 205 of the drag chain 203 ) the conveyor's belt's speed. The ratio in drag chain speed to conveyor speed is programmed into the on-board computer and determines the depth of material deposited on to the conveyor belt. The amount of asphalt to be delivered by the conveyor belt is determined by the on-board computer (as described in detail in FIGS. 7 a,b and c ).
FIG. 359c shows the central belt conveyor assembly 191 passing through the Recycling Machine's front and rear axles 83 as shown in FIG. 5 , (area A). 33 The central belt conveyor delivers new asphalt to the hopper/diverter valve 165 FIG. 7 a or to the optional secondary auger/screed assemblies (not shown) and the primary auger/divider/strike off blade and screed assembles used in 100% HIR with Integral Overlay. For the Remix method, the hydraulic drive motor's 207 speed is adjusted proportionally to pug mill material discharge rate as noted in FIGS. 7 b and c . The ratio of new material that can be added to the 100% recycled asphalt exiting the pug mill is set between 0 to 50%, with 10 to 15% being the norm.
For the Integral Overlay method, the speed of the drive motor 207 is matched to the asphalt requirements of secondary auger/screed assemblies and also the primary auger/divider/strike off blade and screed assembles. A shuttle conveyor 23 is used to deliver asphalt from the central conveyor assembly 191 to either the secondary auger/screed assemblies or to the primary auger/divider/strike-off blade assemblies (as discussed in detail later). A proportional, electronic level sensor, mounted in the feed chute to the secondary auger assembly, electronically monitors the asphalt's level. As the material level drops, (more asphalt required by the secondary screed assembly) the drive motor's speed increases (proportional control). As the asphalt's level increases in the feed chute (less asphalt required by the secondary screed assembly) the drive motor's speed is decreased and will eventually stop.
The conveyor belt 208 is manufactured from a high temperature material and is carried by troughing idlers 209 and return idlers 210 . The idlers (except the front pivoting section that passes through the front axle) are mounted directly to the Recycling Machine's mainframe for most of the span to reduce weight. Troughing idler 211 is a single point belt scale and is used to measure the weight of asphalt on the belt. By measuring the volume of asphalt exiting the pug mill's discharge (volume sensing ski) and knowing the design weight of the asphalt being 100% recycled, the on-board computer can calculated the correct speed of the conveyor belt, based upon the weight of asphalt passing the scale. The belt scale is used when the Remix method is required. For greater accuracy the conveyor assembly is designed for the addition of a second belt scale troughing idler. When new asphalt is being supplied to the rear end of the Recycling Machine (100% HIR method) when there is occasionally a deficit of 100% recycled asphalt, the asphalt in the conveying system tends to loss heat at a greater rate than the asphalt stored in bulk in the front hopper. An infrared sensor 212 monitors the temperature of the asphalt on the belt. The on-board computer will automatically, slowly discharge the belt when the temperature drops to a minimum level. The front asphalt hopper's drag chain will remain shut down, keeping the asphalt in the front asphalt hopper in bulk form, which helps retain the asphalt's temperature. When using the Remix or Integral Overlay method heat loss is minimal as asphalt is being continuously supplied. The front asphalt hopper is also equipped with temperature sensors and will automatically discharge, as discussed previously. The belt conveyor is the preferred conveyor of asphalt, rather than a steel drag conveyor, as the rubber belt better retains the asphalt's temperature, requires less drive torque, reduces segregation, produces less noise, wears less and is lighter in construction. The belt is driven at the rear end of the Recycling Machine by reduction gearbox 206 by hydraulic motor 207 and a crowned and lagged pulley 213 .
FIG. 9 d 36 shows the automatic, hydraulic belt tension assembly. The drive pulley 213 and drive shaft 214 is supported by two adjustable bearings 215 , mounted to the pivoting bracket 216 . The hydraulic motor 207 is attached to the reduction gearbox 206 , which is supported by the drive shaft 214 (the driveshaft goes through the reduction gearbox). The torque link 217 attaches the reduction gearbox to the pivoting bracket 216 . The pivoting bracket is attached to the Recycling Machine's mainframe 3 by pivot bearings 218 (one on either side of the mainframe). The hydraulic cylinders 219 (one on either side of the main frame) are attached between the main frame 3 and pivoting bracket 216 . The hydraulic pressure in the head end of the two cylinders is fully adjustable, allowing the belt to be continuously tensioned while the belt is in operation. The hydraulic cylinders extend and turn the pivoting bracket 216 on the pivot bearings 218 , thereby pulling on the belt. The on-board computer only tensions the belt to full tension when the belt is going to be used. When the belt is not in use, the belt is relaxed to a low state of tension, thereby reducing the stress on the belt. The hydraulic control system allows the automatic belt tension assembly to float, under pressure, allowing the front of the conveyor to pivot (raise and lower) while retaining the correct belt tension.
As discussed earlier, utility structures and other obstructions found in asphalt pavement have, until now, presented one of the greatest challenges to the HIR of asphalt, especially in city work.
FIG. 37 shows the rake/blade scarification/collection system 11 , 12 and 13 fitted to the Recycling Machine, and the Preheater located ahead of the Recycling Machine, FIG. 2 , consisting of a mainframe 220 , mounted to the Recycling Machine and Preheater's mainframe 3 , FIG. 2 . The mainframe 220 receives a continuous flow of air from the Recycling Machine and Preheater's mainframe 3 , FIG. 2 and providing cooling for the hydraulic cylinders 221 and 222 . The e The extension rakes 11 , FIG. 2 extend hydraulically, allowing the processing width to be changed (operator control) while the machine is working. Hydraulic tilt cylinders 223 and parallel links 224 are attached to the mainframe 220 and the vertical legs 225 . The pivoting frames 226 are attached to the vertical legs 225 by pivot pins 227 allowing the four main rake/blade pivoting frames 226 to pivot and follow the asphalt's surface and also ride up and over iron utility structures. Hydraulic cylinders 228 are attached to the mainframe 220 and the bottom parallel links 224 allowings the vertical legs 225 , pivoting frames 226 , flat springs 229 , carbide cutter assemblies 230 and blade assemblies 231 to be raised and lowered. The flat springs and carbide teeth assemblies are attached to the front face of the pivoting frames 226 . The hydraulic pressure in cylinders 228 are adjustable, thereby increasing or decreasing the penetration force of the carbide teeth into the heated, softened asphalt. The carbide teeth are set back 15 degrees from vertical when at rest. Working forces bend the springs further back, increasing the set back angle, thereby reducing aggregate fracture and allowing the teeth to ride up and over undulating surface and/or iron utility structures. The on-board computer automatically raises all of the rakes when reverse drive direction is selected, preventing damage to the flat spring 229 . The hydraulic circuit for cylinders 228 allows oil to be forced out of the cylinder (float up) by the upward force developed by the carbide cutter assemblies. Hydraulic oil re-enters the cylinder, under controlled (adjustable) pressure, forcing the carbide cutter assemblies back into the heated asphalt. Other recycling machines that are only fitted with milling units (no scarification teeth) are limited to how close to obstructions they can mill. The milling units must be lifted to prevent damage to the milling unit's carbide teeth and iron utility structures. Scarified asphalt should be removed (scraped away) from any part of the asphalt surface that cannot be milled and collected by the main mill to facilitate proper mixing and the later placement of 100% recycled asphalt. Attached to the rear face of the four pivoting frames 226 are flat springs 229 fitted with a blades 231 . Blades 231 are mechanically adjustable in height, allowing adjustment for blade and carbide cutter wear.
FIG. 38 shows the operation of the rakea blade 231 in a raised and lowered position and FIG. 39 a 231 In the “blade raised” position (normal scarification) the tilt cylinder 223 remains collapsed (not hydraulically extended). Cylinder 223 , together with parallel link 224 form a parallelogram linkage, keeping the carbide cutters 230 at the correct angle of attack as they raise and lower (float) due to changes in the asphalt pavement's profile. FIG. 39 When the blades 231 are required to scrap and collect the scarified asphalt (main mill raised by the operator to clear obstruction), tilt cylinder 223 extends causing the vertical leg 225 to pivot around the rear pivot pin 232 attached to parallel link 224 and cylinder 228 . The carbide cutters 230 continue to scarify the heated asphalt as the blade pivots into position. 231231 as shown in FIG. 40. 233 in the heated asphalt's surface section Section 231 B's blade would remain raised to clear the utility structure 233 while sections 231 A, 231 C and 231 D's blades would be lowered to collect asphalt. 23126 Cylinder 223 bottoms out (fully extends) holding the blades in the lowered position. Cylinder 228 still provides hydraulic down pressure (force) on the carbide cutters 230 and blades 231 . When encountering an obstruction while scraping, cylinder 228 together with carbide cutter springs and blade springs 229 allow the complete assembly to hydraulically float up and over the obstruction, as before. In the event of blade 231 being overloaded by excessive asphalt or an obstruction, cylinder 223 will collapse, allowing the blade 231 to automatically raise. The hydraulic pressure setting (relief valve) of the head end oil supply to the hydraulic cylinder 223 adjusts the amount of load required to collapse the cylinder. The operation of the blades can be fully controlled by the on-board computer when the optional metal detection assemblies are fitted, as described in detail later on.
Cylinders 221 , FIG. 37 attached to the mainframe 220 and the extension frames 234 allow the extension rakes 11 , FIG. 2 , to hydraulically extend and retract, varying the scarification width on the fly. The extension frames (left and right side) 234 slide in and out of the mainframe 220 . The extension's pivoting frame 235 is fitted with the same flat springs 229 and carbide cutter assemblies 230 as the main rake assemblies. Pivoting frame 235 is raised/lowered by pivot arm 236 and hydraulic cylinder 222 . The cylinder's hydraulic pressure is variable (same as cylinder 228 , explained above), increasing or decreasing the penetration force of the carbide cutter assemblies 230 into the heated, softened asphalt. Extending or retracting the extension rakes automatically raises the pivot arm 236 , preventing the carbide cutter assemblies 230 from jamming sideways into the heated asphalt. The extension rakes are not fitted with blade assemblies as clean up around obstructions can be performed by the extension mills (sliding in and out) and/or hand shoveling. Shoveling is possible on either side of the Recycling Machine with material returned to the extension or main mill for processing.
FIG. 41 shows the flow of heated asphalt through the extension mills 14 , offset discharging main mill 15 , and offset pug mill 16 . The carbide cutting teeth are not shown on the extension and main mill for clarity. The extension and main mills are directly behind the Recycling Machine's rake scarification and blade collection system and are responsible for profiling and collecting the heated and loosened asphalt surface. As mentioned previously the mills also release further moisture in the form of steam. The main mill and the pug mill are also responsible for the mixing of liquid additives into the recycled asphalt. The pug mill provides the final mixing of all products into a homogeneous, 100% recycled asphalt windrow 151 .
FIG. 42 shows the extension mills 14 (looking from the rear of the Recycling Machine). They are, FIG. 2 , attached to the Recycling Machine's mainframe 3 , FIG. 2 by R.H. sliders 240 , L.H. slider 241 and wobble link 242 . Sliders 240 and 241 slide through adjustable wear plates (not shown) attached to the Recycling Machine's mainframe 3 , FIG. 2 , preventing wear to the mainframe. The cross frame 243 is raised, lowered and tilted by two hydraulic cylinders 245 , mounted inside the sliders 240 and 241 . The wobble link 242 prevents the sliders from binding when the cross frame 243 is fully tilted. Pins 246 are the pivots for the cross frame 243 and the left and right crown frames 247 . The hydraulic cylinders 248 are attached to the cross frame 243 and the crown frames 247 allowing positive and negative, left and right crowning (tilt) of the crown frames 247 , independently of the cross frame 68243 . The extension frames 248 are slide in and out (varying the extension mill width of cut) on the crown frames 247 by hydraulic cylinders 249 attached between the crown frames and the extension frames. Independent raise/lower (tilt), crown and extension provide complete control over the extension millsControl can be manual or by automatic grade/slope control. w, Changes to grade and/or slope, working around iron utility structures in the asphalt surface, processing driveways, intersections, varying pavement width and damaged curbs FIGS. 43 and 44 show side views of the extension mills. The two, extension mill rThe rotors 2(two) 50 feature shallow flighting 251 , tooth holder 252 and replaceable carbide teeth 253 and rotate in a down-cut direction (teeth impinge down on to the heated surface). The rotors 250 are driven by a direct drive, hydraulic motor 254 , through coupling 255 . End plates 256 incorporate the rotor support/thrust bearing 257 used to support the non-driven end of the rotors. The rotors 250 are quickly removed for servicing by removing the end plates 256 , allowing the rotor's couplings 255 to slide off the splined shafts of hydraulic motors 254 . The rotors float free on the hydraulic motor's splined drive shafts, while bearings 257 absorb all end-thrust. Asphalt flow is towards the drive end of the rotors (center of machine) with the asphalt being discharged through openings in the blade bodies 258 into the main mill's rotor. The rotors mill the heated and loosened asphalt in a down-cut direction to reduce the conveying efficiency, thereby causing the asphalt to build up in front of the rotors. The build up of asphalt increases the mixing/steam release time and provides a degree of surge capacity when milling through high areas, allowing the feed of milled asphalt into the main mill's rotor to remain fairly consistent. The down-cut feature of the rotors also prevents damage to the mill rotor's carbide teeth and iron utility structures located in the asphalt. The on-board, computer-control of the hydraulic system (initiated by the ground operator) reduces the hydraulic cylinder's 245 down pressure (force), rotor speed and cutting torque, allowing the rotors to float and freewheel over obstructions. An on-board computer may control this operation AAttached to the blade bodies 258 are adjustable blades 259 . The flat springs 260 , force 258 and 259 on to the milled surface, scraping and collecting the fine asphalt, for processing. Competitive equipment generally leave a layer or patches of fine asphalt and/or rejuvenator fluid behind the mills (rotary scarifiers), resulting in varying quality of the reworked (recycled) asphalt and eventual bleeding of the finished, compacted surface (mat).
FIG. 4 a shows an extension mill rotor 50 in greater detail. Two labyrinth seals 58 , machined from carbon steel, form deep channels in which the rotor tube 59 rotates. Asphalt builds up in the channels and provides sealing from further asphalt ingression into the bearing and motor area. A grease tube 60 runs from the left end of the rotor shaft (supported by bearing 57 ) to the coupling 55 , providing grease to the coupling and the hydraulic motor's 54 splined shaft. The left and right-hand shallow flighting 51 moves asphalt away from the two labyrinth seals 58 . The left and right hand flighting join at the center of the asphalt's discharge area shown in FIG. 4 a , forcing asphalt into the main mill's rotor.
FIG. 43 shows a blade body 258 in the relaxed position. FIG. 44 shows the blade body in the maximum up position having pivoting around pin 261 and bending the flat spring 260 . The adjustable blade 259 is set below grade (grade is established by the mill rotor's carbide teeth 253 when milling) to pre-load the flat spring 260 thereby keeping a constant force on the blade 259 and forcing it into contact with the milled surface. The flat spring 260 is anchored (bolted) to the extension frame 248 by attachment plate 262 . The flat spring's fulcrum point is the underside of the blade bodies pivot boss, pivoting around pin 261 .
FIGS. 45 , 46 and 47 show the main mill assembly 15 , FIG. 2 , attached to the Recycling Machine's mainframe 3 by the R.H. sliders 270 , L.H. slider 271 and wobble link 272 . The sliders 270 and 271 slide through adjustable wear plates (not shown) attached to the mainframe 3 , FIG. 2 , preventing wear to the mainframe. The rotor assembly 273 is driven and supported at either end by two direct-drive, hydraulic motors 274 . The motors are attach to removable end plates 275 , allowing the rotor to be quickly removed for servicing by removing one of the end plates. The rotor assembly 273 is spring loaded 276 (in one direction) and floats on the hydraulic motor's 274 splined drive shafts. The hydraulic motors provide main support and one takes the thrust generated by the rotor assembly 273 . The couplings 277 allow for rotor misalignment, deflection and thermal expansion. Asphalt flow is towards one end of the rotor with asphalt discharge through the blade body 278 into the offset pug mill's front rotor. The shallow rotor flighting 279 , together with closely spaced carbide teeth 280 and holders 281 milling in a down-cut direction, reduce asphalt conveying efficiency, thereby causing the heated asphalt to build up in front of the rotor. The build up of milled asphalt increases mixing/steam release time and provides a degree of surge capacity when milling through high areas, allowing the flow of milled asphalt into the pug mill's front rotor to remain fairly consistent. The down-cut feature of the rotor also prevents damage to the mill rotor's carbide teeth and iron utility structures located in the asphalt. The blade bodies 278 are forced down by flat springs 260 . The blades 281 pivot around pin 282 and operates in the same manner as shown in FIGS. 43 and 44 . A venturi (not shown) in the air extraction system creates a negative air pressure at vent tubes 283 and in the boxed in mainframe 284 . The mainframe 284 has cut outs 285 located directly above the rotor assembly 273 allowing rejuvenator fluid to be sprayed directly on to the spinning rotor assembly by spray bar 286 . Rejuvenator fluid is thereby, prevented from direct contact with the milled surface while the spinning rotor assembly spreads the fluid, providing maximum coverage to the milled asphalt. Steam released from the hot, tumbling asphalt also rises through cutouts 285 , mainframe 284 and vent tubes 283 . The air extraction system draws off and vents the released steam to the top of the Recycling Machine. tubes 283 on the extension mills.
The mainframe 284 is raised, lowered and tilted by hydraulic cylinders 287 mounted inside the sliders 270 and 271 . Control of the hydraulic cylinders is manual or by automatic grade controls as discussed before.
FIG. 5 a shows the left-hand end of the spring loaded (in one direction), fully floating rotor assembly 65 , hydraulic drive motor 66 , splined, internal tooth coupling (teeth not shown) 68 and steel ring 76 . The coupling 68 receives grease through plug 77 . The opposite end of the rotor assembly is identical in design, except that spring 78 is not used. Compression of the spring 78 takes place during assembly of the rotor assembly 65 into the main mill's main frame 73 FIG. 5 . The spring 78 forces the hardened steel spacer 79 against the hydraulic motor's splined drive shaft 80 . The other end of the spring applies force against the end of the coupling's mounting flange 81 , forcing the rotor assembly 65 to the right-hand drive motor (non spring loaded end). Main thrust is absorbed by the right-hand motor's bearings (tapered roller) as rotor assembly 65 moves asphalt predominately to the left end for discharge into the pug mill's offset front rotor. The spacer 79 and spring 78 prevents the rotor couplings 68 from wearing (moving in and out on the hydraulic motor's, splined drive shaft) by pre-loading the rotor in one direction. The spring 78 also allows for rotor assembly deflection, thermal expansion and assembly tolerances. Direct drive of the rotor assembly 65 (other manufactures generally use chain drive) reduces maintenance, wear, noise and power requirements. A parallel hydraulic oil supply to the hydraulic motors 66 provides equal torque to both ends of the rotor assembly 65 . The steel outer ring 76 , hydraulic motor's 66 outer housing and rotor assembly's 65 inner tubing surface form a deep labyrinth seal, preventing hot asphalt and steam from reaching the motor's seal and coupling 68 .
FIG. 48 shows the hydraulic schematic for the Recycling Machine's fluid application system. Competitive machines use positive displacement pumps (gear, vane and roller) fitted with variable speed drive systems to pump and meter only rejuvenator fluid. The application rate of the rejuvenator fluid is generally controlled by operator input (distribution rate, liters/sq. m.) and by monitoring the Recycling Machine's processing speed (distance traveled). Distance traveled, by itself, provides inaccurate and inconsistent results as the volume of asphalt being processed changes constantly as density, depth of cut, pavement profile and width of cut vary. The rejuvenator pump/motor RPM (monitored by electronic pickup) and/or an electronic flow meter measure and control (microprocessor) the rejuvenator fluid application rate. Both systems (either measuring RPM or flow) can produce inaccurate results and are limited to a narrow viscosity range. Both systems also suffer from contamination, as most rejuvenator fluids are unfiltered or not filtered to the level required by positive displacement hydraulic pumps and flow meters containing moving parts. Placing full flow filters into the system reduces contamination, however, constant monitoring of the filter's condition is required, as are frequent filter changes. The more accurate of the two systems is the variable speed, positive displacement pump with an in-line flow meter to monitor/control system flow (microprocessor). Flow meters are available without moving parts, however, they are very expensive and their maximum temperature range is limited at present. Systems using only a variable speed, positive displacement pump with electronic monitoring and control are inaccurate. The pump flow rate changes as internal wear increases, rejuvenator fluid temperature changes (viscosity change) and pressure differential across the pump (delta P) caused by filter restriction increases. Both systems are limited to the lighter types of rejuvenator fluids that do not require heating.
FIG. 48 shows the ARS 100% HIR fluid application system used to accurately meter light (unheated), heavy (heated) rejuvenator fluids and polymer liquids. An on-board computer controls and monitors all of the functions of the application system. FIG. 49 shows the liquid spray bar 286 mounted above the front rotor assembly 273 on the main mill and liquid spray bars 289 and 290 mounted above the front rotor assembly 291 of the pug mill 16 . Spraying fluid directly on to the rotating rotor assemblies distributes the fluid over a greater area and reduces the possibility of the fluid coming into direct contact with the milled, base surface. Air is also used to aerate the liquids (described in detail later) exiting the spray bars, providing even greater coverage. The rejuvenator fluid is stored in a heated, insulated and pressurized tank (0.1-0.5 psi) 292 on-board the Recycling Machine. An automated, propane fired burner 293 heats the tank (only required for viscous fluids). The tank is also fitted with heat exchanger tubes 294 (mounted in the tank bottom). When the rejuvenator fluid temperature (monitored by the on-board computer) is below a preset temperature the returning high temperature hydraulic oil from the Extension mills, main mill and pug mill motors, case drain (internal leakage), is diverted through the heat exchanger tubes 294 , thereby heating the rejuvenator fluid. The on-board computer prevents reverse heat transfer (rejuvenator fluid heating the hydraulic oil when the propane heater is used) by diverting hydraulic oil flow around the in-tank heat exchanger 294 . FIG. 50 The on-board computer processes information received from the pug mill's variable area discharge, windrow forming ski 343 (asphalt volume measurement), rejuvenator tank temperature (correction factor), operator input (distribution rate, liters/ton) and the Recycling Machine's distance traveled (m/min.). An air operated, positive displacement, diaphragm pump 295 (electronically pulsed by the on-board computer) pumps and meters the fluid stored in the rejuvenator tank 292 delivering it to a hydraulically operated two-way valve 296 . Valve 296 allows fluid to be directed either to the main mill/pug mill spray bars or returned to the tank through two-way valve 297 . Viscous rejuvenator fluids require constant heating to prevent fluid setup. The diaphragm pump 295 runs (pulsed) continuously, returning the rejuvenator fluid back to the tank (when not required by the process), keeping the diaphragm pump, lines, pipes and valves hot. The on-board computer calculates and stores (in memory) the quantity of fluid used when the rejuvenator fluid exits the main mill/pug mill spray bars. N.C. shut off valve 298 (on-board computer controlled) opens when sufficient milled asphalt is flowing through the pug mill's front rotor. Adjustable flow control valve 299 alters the ratio of rejuvenator fluid delivered to the main mill and pug mill spray bars 289 and 290 when shut off valve 298 is open. At startup (no asphalt flowing through the pug mill) shut off valve 298 is closed allowing all of the rejuvenator fluid (low flow) to flow from the main mill's spray bar 286 . As the volume of asphalt flowing through the pug mill increases, the on-board computer opens shut off valve 298 . The sprayed rejuvenator fluid (staged) follows the flow of asphalt through the main mill 15 and the pug mill 16 , allowing accurate and complete mixing of the rejuvenator fluid, added aggregate additives and milled asphalt. The spray bars 286 , 289 and 290 FIG. 49 are small-bore, varying diameter steel tubes with drilled orifices of varying sizes and spacing. As the rejuvenator fluid flow rate increases (greater volume of milled asphalt), pressure in the spray bars increases, forcing the fluid further along the bars. The main mill's spray bar is supplied fluid at one end (above the offset, asphalt discharge to the inlet of the pug mill's front offset rotor) and is equipped with spray orifices of decreasing size and increased spacing as the fluid travels along the spray bar. As the fluid flow increases, pressure in the spray bar increases, forcing the fluid further along the spray bar towards the center of the main mill. This feature makes sure that fluid is sprayed into the greatest concentration (volume) of milled asphalt, preventing fluid contact with the milled surface. FIG. 49 Located between the pug mill's spray bars 289 and 290 is an adjustable flow control valve 300 used to balance the liquid's rate of flow between the front rotor's spiral paddle section (asphalt inlet to pug mill from main mill's offset discharge)) and the alternating paddle section located in the pug mill's mixing chamber. Generally, the flow control valve 300 only comes into play when the rejuvenator flow rates are in the higher range or when polymer additives are being added, as described later. Spray bar tube size and hydraulic supply hoses are small in diameter to reduce the volume of liquid to a minimum, thereby reducing the chance of spray bar drip.
Viscous rejuvenator fluids require purging from the diaphragm pump, lines, pipes and valves after use (end of shift) to prevent setup. The use of compressed air, followed by diesel fuel to dilute and clean, prevents fluid setup. While purging, fluid flow to the spray bars is shut off by the two-way valve 296 . Rejuvenator fluid is diverted too the two-way valve 297 and then back to the storage tank 292 . The on-board computer controls the complete purging and cleaning cycle. The fluid supply to the positive displacement pump 295 is shut-off by the N.C. shut off valve 301 (pump stopped). Metered compressed air flows through the N.C. shut-off valve 302 into the inlet line of the diaphragm pump, lines, pipes and two-way valves 296 and 297 , forcing the fluid back to the rejuvenator storage tank 292 . The top of the tank is fitted with a low-pressure relief valve (0.1-0.5 psi) 303 , which allows the compressed air to escape. Adjustable, air flow control valve 304 limits the maximum amount of air flow and the one way check valve 305 prevents rejuvenator fluid from entering the air supply system. After air purging, the fluid return line to the tank (through the two-way valve 297 ) is closed, preventing rejuvenator fluid from flowing back (reverse flow) through the system. The two-way valve 297 now connects, through a hose to a removable fluid catch container 307 . Metered diesel fuel flows through the N.C. shut-off valve 306 into the diaphragm pump's, inlet line. Diesel (along with the air already purging the system) flows into the diaphragm pump, lines, pipes and two-way valves 296 and 297 , diluting any remaining rejuvenator fluid and flushing it into the catch container 307 for disposal. Adjustable diesel flow control valve 308 limits the maximum amount of diesel flow and the one way check valve 309 prevents rejuvenator fluid from entering the diesel supply system. During flushing and cleaning the diaphragm pump is intermittently cycled during the diesel injection stage to help clean the two diaphragms and ball check valves. After flushing, valves 297 , 302 and 306 are automatically closed. For safety and servicing the rejuvenator tank outlet and return connections are fitted with manually operated ball type shut off valves 310 . Tank air pressure automatically bleeds down when the Recycling Machine is not in use.
The positive displacement, diaphragm pump 295 delivers rejuvenator fluid accurately, as each stroke delivers an absolute volume. Air pressure (0.1-0.5 psi) in the storage tank 292 applies a pressure to the inlet of the diaphragm pump, reducing the possibility of cavitation. The pump can accurately pump fluid with particle sizes up to ⅛″ in diameter, however, an in-tank wire mesh strainer 311 limits particle size to less than 50 mesh. As mentioned earlier, spraying the rejuvenator fluid directly on to the main mill's rotor and pug mill's front rotor provides maximum coverage and mixing with the heated, milled asphalt. Also, by reducing direct fluid contact with the milled base surface, bleeding of the finished asphalt surface is eliminated. The rejuvenator fluid also lubricates the main mill's milling teeth and holders, preventing the teeth from sticking (not turning) in their holders, thereby reducing uneven wear. Positive shut down of the rejuvenator fluid flow (at the spray bars) by the two-way valve 296 almost eliminates fluid dripping by preventing the rejuvenator system components from leaking down. The N.C. shut-off valve 312 supplies air to the main mill spray bar 186 to be mixed (depending on the type of fluid) with the rejuvenator fluid (at the outlet of two-way valve 296 ), causing it to aerate. Aerating some rejuvenator fluids provides better coverage (reduced droplet size) of the liquid to the milled asphalt. The air continues to flow (if previously being mixed with the rejuvenator fluid) after the two-way valve 296 is closed (fluid flow shut off) thereby blowing (purging) the remaining fluid out of the spray bars. The N.C. shut-off valve 313 supplies air to the pug mill spray bar 289 and 290 to be mixed (depending on the type of fluid) with the polymer liquid, causing it to aerate. The N.C. shut-off valve 312 and 313 remain on after the liquid supply is stopped, providing additional air as the Recycling Machine slows to a stop. This allows the complete purging of the spray bars of fluid by the time the Recycling Machine has stopped. The air supply is automatically shut-off after an adjustable time delay. The N.C. shut off valves 312 and 313 also supplies air blasts while the purging and cleaning cycle is underway. Adjustable air flow control valves 314 limits the maximum amount of air flow (fluid aeration) and the one way check valves 315 prevents rejuvenator fluid and polymer liquid from entering the air supply system. The on-board computer monitors the volume of asphalt being processed through the pug mill and together with the programmable rejuvenator flow rate (determined by pre-engineering of the asphalt to be recycled), produce consistent and accurate metering of the rejuvenator fluid. Proper mixing and application of rejuvenator fluid is critical to the process. Excess fluid will prevent the recycled asphalt from setting up when compacted by the rolling equipment. Too little fluid will not rejuvenate the recycled asphalt to pre-engineered specifications.
Polymer liquid (used in Superpave applications) is applied to the recycled asphalt by the addition (optional) of the supplemental liquid application system. Polymer liquid is stored in a non-heated, pressurized tank 316 mounted to the front, clip-on frame or the mainframe 3 of the Recycling Machine. An air operated, positive displacement, diaphragm pump 317 (electronically pulsed by the on-board computer) pumps and meters the fluid stored in the supplemental tank 316 delivering it to a hydraulically operated two-way valve 319 . N.C shut-off valve 320 shuts off the supply flow to pump 317 automatically during system shut down and air flushing. The positive displacement, diaphragm pump 317 delivers liquid accurately, as each stroke delivers an absolute volume. Air pressure (0.1-0.5 psi) is applied to the storage tank 316 to reduce the possibility of cavitation of the diaphragm pump 317 . The pump can accurately pump fluid with particle sizes up to ⅛″ in diameter, however, an in-tank wire mesh strainer 321 limits particle size to less than 50 mesh. Hydraulically operated two-way valve 319 allows liquid to be directed either to the pug mill's spray bars 289 and 290 or returned to the tank 316 . Check valve 322 prevents rejuvenator fluid and purge air from reverse flow. In normal operation the pug mill's spray bars 289 and 290 receive rejuvenator fluid from the pump 295 and polymer liquid from pump 317 with or without aeration (using compressed air). The two-way valve 323 allows air purging of pump 317 , valve 319 , check-valve 322 and the pug mill's spray bars 289 and 290 . Purging air is supplied through N.C. shut-off air valve 302 , flow control valve 304 , one way check valve 305 and hydraulically operated two-way valve 323 . Hydraulically operated two-way valve 319 is cycled while air purging, allowing air to first force liquid back to the tank 316 and secondly purge the pug mill's spray bars 289 and 290 . The top of the storage tank 316 is fitted with a low-pressure relief valve (0.1-0.5 psi) 303 , which allows the compressed air to escape A one way check valve 324 prevents purging air and polymer liquids from reaching the main mill's spray bar 186 . The one way check valve 324 also prevents polymer liquid from reaching the main mill's spray bar 186 when only polymer liquid is being sprayed in the pug mill. The tank discharge and return lines are fitted with shut-off valves 310 for system servicing and positive shut off. The supplemental application system is controlled and monitored by the on-board computer and is programmed to perform. Menus provide operator input for the varying rejuvenator fluids and polymer liquids being applied, application rates and flushing cycles. Electronic readouts (screen) provide information on application rates, accumulated totals, tons of recycled asphalt processed, distance traveled, asphalt temperature, tank temperature and system status. FIGS. 50 , 51 , 52 and 53 shows the offset pug mill 16 . FIG. 2 used for the final mixing, moisture removal (steam) and volume measurement of the milled (recycled) asphalt. The main housing 330 , is attached to the Recycling Machine's mainframe 3 , FIG. 2 draft tube by plates 331 and 332 . The bottom links (two) 333 , features plain replaceable steel bushings and threaded joints, allowing the links to twist and turn. The bottom links 333 prevent pug mill side movement, but allow for raising/lowering and tilting. The top links (two) 334 , feature spherical bearing at both ends, allowing movement in all directions, and are adjustable in length, allowing the pug mill to be set flat to the milled, asphalt surface. The hydraulic cylinders (two) 335 , attached to plates 332 and main housing 330 , raise and lower the pug mill. The cylinders 335 provide adjustable (hydraulic) down pressure allowing the pug mill to float but preventing it from riding up when full of asphalt. Three skids 336 attach to the main housing 330 and are responsible for maintaining the front rotor assembly 292 and the rear rotor assembly 337 paddle's 338 distance to the milled surface. Skid wear is low as the hydraulic down pressure is balanced against the lifting action of pug mill, while mixing. Attached to the offset front rotor assembly 292 and the rear rotor assembly 337 are paddle assemblies 338 fitted with replaceable carbide wear pads. The paddle layout of the offset, front rotor assembly 292 has two distinct areas. Area FIG. 52 “A” consists of paddles (2 paddles per arm), forming a double spiral with spaces, resulting in an inefficient conveying and mixing auger. Area “B” consists of left and right facing paddles (two and four paddles per arm) used for mixing and tumbling the asphalt and additives. The rear rotor assembly 337 faces area “B” of the offset front rotor assembly 292 . The rear rotor assembly diameter is larger than the front rotor assembly and provides improved mixing and greater material throughput than previous, equally sized rotors. Hydraulic motors 339 (attached to housing 330 ) and drive couplings 340 directly rotate rotor assemblies 292 and 337 in a down-ward direction, thereby reducing damage to the paddles and iron utility structures (compared to up-ward rotating rotors) located in the asphalt pavement to be recycled. The rotor assemblies end thrust and end support is by bearings 341 , attached to the end plates 342 . The end plates 342 allow for the quick and easy removal of the rotors assemblies for servicing. Rotor speed is variable and independent of the Recycling Machine's ground speed, or optionally, tied to ground speed. The non-intermeshing rotors do not require timing, as in the case of intermeshing rotors used in conventional pug mills, allowing rotational speeds to be set individually, promoting better mixing and greater moisture removal (steam).
The windrow forming ski 343 , located between the windrow forming plates 344 , causes resistance to asphalt flow through the pug mill's discharge, allowing the pug mill chamber to become loaded with asphalt. The rotors assemblies 292 and 337 tumble the asphalt and additives from the alternating left and right hand paddles, providing complete mixing and steam release. Resistance to asphalt flow through the pug mill also causes resistance to flow through the main mill, thereby increasing contact time between the asphalt, additives and mechanical mixing elements (mill carbide teeth and pug mill paddles). Close operating distances between the extension mills, main mill and the pug mill reduce the asphalt's heat loss and result in lower emissions. The main housing 330 incorporates a plenum chamber 345 and a steam pipe 346 . The production of negative air pressure at the pipe 346 is by a venturi (not shown), using the heater box blower, air supply. The tumbling and restricted asphalt enclosed in the pug mill's mixing chamber maintains the asphalt's temperature and together with the negative pressure, air extraction system, reduces the level of moisture in the asphalt. Blade 347 operates in the identical manner to main mill and extension mill's blade assemblies, its function being, to scrape the previously milled surface (main mill) and collect the fine asphalt for complete mixing.
Located between the two rotor assemblies 292 and 337 and scraping the complete width of the milled surface covered by the pug mill mixing chamber is the trip blade 348 . The trip blade scrapes the milled surface, picking up the asphalt missed by the pug mill's front rotor paddles. Rejuvenator fluid and polymer liquid inlets 349 and 350 are located directly above the front rotor assembly (spray bars are not shown).
FIGS. 54 , 55 and 56 show the windrow forming ski 343 , bottom link 360 , top link 361 , link pins 362 , top pivot pin 363 , electronic sensor 364 , counterbalance hydraulic cylinder 365 and door 366 . The links 360 and 361 form a parallelogram linkage, keeping the windrow-forming ski 343 parallel to the milled asphalt's grade. The on-board computer adjusts the hydraulic pressure in the cylinder 365 electronically by measuring the pressure required to hydraulically drive the pug mill's rear rotor assembly 337 . It is also possible to electronically measure the front rotor assemblies 292 drive pressure to adjust the hydraulic pressure in cylinder 365 . Hydraulic drive pressure increases as the volume of asphalt in the pug mill's mixing chamber increases. Hydraulic pressure in cylinder 365 increases proportionally to the rear rotor's drive pressure and tries to pivot the top link 361 around the top pivot pin 363 , reducing the effective down force of the windrow-forming ski 343 . The pressure in the hydraulic cylinder never reaches a high enough value to physically lift the windrow-forming ski. Less down force on the windrow-forming ski reduces the resistance to the recycled asphalt's flow under the windrow-forming ski, allowing a greater volume of recycled asphalt to by forced out of the mixing chamber by the rear rotor assembly 337 . A reduction of hydraulic drive pressure reduces rotor assembly the hydraulic pressure in cylinder 365 , increasing the resistance to flow of recycled asphalt under the windrow-forming ski. The windrow-forming ski maintains a balance between the volume of recycled asphalt in the mixing chamber and the hydraulic pressure driving the rear rotor assembly. The rear rotor's hydraulic drive pressure remains fairly consistent once the mixing chamber has initially filled. The windrow-forming ski forms a slightly compacted, asphalt windrow with a flat top section, resulting in the accurate volume measurement of the recycled asphalt, reduced emissions, maintained heat and reduced segregation by preventing the larger aggregate (stone) from rolling down the windrow's sides.'sswindrow-forming ndwindrow-forming The varying asphalt volume passing under windrow-forming ski 343 raises and lowers the windrow-forming ski, rotating the top pivot pin 363 , attached to the top link 361 . Electronic sensor 364 measures the rotation of the top pivot pin 363 , producing an electronic signal used by the on-board computer for processing the amount of rejuvenator fluid and/or polymer liquid to be added to the old asphalt and added aggregate. The electronic signal is proportional to the height of the windrow-forming ski 343 . The pug mill's discharge width is constant and together with the varying windrow-forming ski's height, calculates the volume of asphalt being processed. Door 366 is pushed back by the asphalt flow against the windrow-forming ski 343 , preventing the asphalt from flowing up and past the windrow-forming ski.
FIGS. 57 , 58 and 59 show the pug mill's trip blade assembly 348 in its working and tripped position and also in an exploded view. The trip assembly 348 rotor assembly 292 the assembly 337 370 heated, blade assembly 348 and polymer liquid's 338 292 The trip blade body 371 is attached to arm 372 . Hydraulic cylinder 373 is attached between arm 372 and adjuster link 374 . Adjuster link 374 is attached to adjuster screw 375 by threaded pivot 376 and stationary bracket 377 . Adjuster screw 375 is located by stationary bracket 377 attacked to main housing 330 . The trip blade body 371 is adjusted for height by turning adjuster screw 375 while raising or lowering adjuster link 374 and hydraulic cylinder 373 . Hydraulic cylinder 373 is continuously pressurized (head end only) with hydraulic oil, thereby forcing the cylinder rod out to its maximum travel (bottomed out). Adjuster screw 375 can be adjusted while the pug mill is in operation, allowing fine adjustment of the blade's height. Normally the blade is set to just contact the milled surface. The trip blade is fitted with a replaceable, bolt on, carbide-faced blade 377 . When the screw adjustment is at its limit the blade 377 can be lowered (blade has slots for the clamping bolts) allowing the adjuster screw 375 to be returned to the beginning of its adjustment. In the tripped position ( FIG. 58 ), the trip blade assembly 348 has rotated sufficiently allowing the blade to ride up and over the utility structure 378 . The trip blade assembly 348 is mounted and rotates in steel bushings 379 located in the left and center, wear shoes 380 . Hitting a utility structure rotates the trip blade assembly and arm 372 , forcing the hydraulic cylinder's rod into the cylinder 373 . The cylinder's head end hydraulic oil is displaced, allowing the trip blade to rotate, changing the blade's angle-of-attack into a ramp, causing the blade to ride up and over the utility structure. Hydraulic oil re-enters the head end of the hydraulic cylinder, automatically returning the trip blade to its working position (after the utility structure is cleared). Hydraulic pressure in the head end of the hydraulic cylinder is adjustable and is used to change the amount of force required to rotate the trip blade. In normal operation, the ground operator is responsible for manually raising and lowering the working sub assemblies, thereby preventing damage to utility structures. The Recycling Machine's rakes, mills and pug mill are all designed to withstand the abuse of hitting a utility structure. The pug mill's front rotor assembly 292 rotates in a down wards direction and is the first part to contact the utility structure. If the ground operator does not raise the pug mill, the front rotor will force the pug mill up with little or no damage to the front rotor's carbide paddles. Manually raising the pug mill cuts off the pug mill's rejuvenator fluid flow (main mill continues to receive rejuvenator fluid) and the windrow-forming ski's electrical sensor 364 signal, used by the on-board computer in calculating the volume of asphalt flowing through the pug mill. The on-board computer locks to the ski's sensor signal value (before manually raising the pug mill) whenever the pug mill is raised. Polymer liquid application to the pug mill is generally not stopped if the pug mill is raised for a brief period, however if the period exceeds a preset number of seconds, flow will be stopped. Lowering the pug mill restores the pug mill's rejuvenator flow and the ski's electrical sensor signal. An electrical limit switch (not shown) monitors the trip blade's position. Tripping the blade (contacting a utility structure) automatically allows the pug mill to raise by reducing the head end, hydraulic pressure (controlled by the on-board computer) in cylinders 335 , FIG. 7 . Force generated by the pug mill's front and rear rotor assemblies allows the pug mill to be forced up (away from the milled surface), thereby reducing the force of the trip blade assembly upon the utility structure.
It can be seen that iron utility structures located in the asphalt's surface are cause for concern, especially when working in city applications. Normally the Preheater operator will mark the asphalt's surface with a paint marker (spray can) indicating to the Recycling Machine operators where the structures are located. This works well, however some structures have been found to be below the asphalt's surface. To overcome the problem of dealing with iron utility structures the GPS's metal detection readings (described earlier) are used by the final Preheater (unit ahead of the Recycling Machine) and the Recycling Machine's GPS and on-board computers to automatically raise and lower the rake/blades, extension mills, main mill and the pug mill, preventing damage to the sub-assemblies and iron utility structures. For machines not equipped with the optional GPS system a metal detection boom is fitted to the front end of the Recycling Machine's mainframe 3 , or attached to the front asphalt hopper assembly 190 , (when fitted). The metal detection boom assembly is also fitted to the front end of final Preheater mainframe 3 (Preheater ahead of the Recycling Machine) when the rake/blade scarification system 11 , 12 and 13 is fitted. The metal detection boom is hydraulically adjustable in width to allow for varying processing widths.
FIG. 60 shows the main metal detection boom assembly 400 and the extension metal detection boom assemblies 401 , which are hydraulically extended from hopper frame 190 . The booms are located at the front end of the machines where heat and moisture are at the lowest levels. FIG. 61 shows a plan view of the boom assemblies 400 and 401 fitted with a series of metal detector heads 402 . The distance between the booms to the machines sub-assemblies is mechanically fixed. In the example shown the rake/blade assemblies 11 and 12 are at a set distance to the boom assemblies as are the main mill, extension mills and the pug mill. The main boom 400 is about to detect an iron utility structure 233 located in the heated asphalt's surface. Sensors 402 , A, B, and C detect the structure and the electronic input is stored into the on-board computer's memory. The position (location on the mainframe 3 ) of the rakes/blades, extension mills, main mill and pug mill is known. The position of the sensors on the main boom 400 and extension booms 401 is fixed and known. The position of the extension booms is electronically monitored as they are hydraulically moved in and out to adjust for the varying processing width. The on-board computer calculates the distance traveled (by monitoring the Recycling Machine's drive wheel rotary encoder) and the width location of the iron structure(s) by monitoring the individual sensors 402 and the two extension boom's location and sequentially raises and lowers the appropriate rakes/blades, extension mills, main mill and pug mill, preventing damage to the structure and sub-assemblies. The same system is used for Preheater's fitted the rake/blade assemblies 11 , 12 and 13 , FIG. 8 shows the asphalt's flow through (reference FIG. 2 ) the extension mills 9 , main mill 10 , and offset pug mill 11 . “A” shows the asphalt's flow through a conventional in-line main mill and in-line pug mill. “B” shows the asphalt's flow through the main mill with an offset discharge and offset pug mill, showing the left and right side asphalt joining at the pug mill's offset front rotor. Joining of the left and right side asphalt provides a homogeneous mixing of the heated asphalt and additives. The curbside asphalt degrades at a higher rate than asphalt located at the centerline due to water run off, curb cracking and dirt buildup. however the booms are mounted directly to the front of the Preheater's mainframe 3 .
FIGS. 62 , 63 , 64 and 65 show the Preheater's pin-on aggregate bin 21 used to spread aggregate on to the heated asphalt's surface, ahead of the Recycling Machine. The aggregate bin (hopper) 410 typically receives aggregate from a wheel loader. The rotor assembly 411 is mounted and driven (direct drive) at both ends by two, high torque, hydraulic motors 412 . The rotor assembly discharges aggregate as it rotates and it's speed is infinitely variable. The rotor assembly is fitted with equally spaced flutes 413 (bars) running the complete length of the rotor. The adjustable, rotating strike-off blades 414 controls the aggregate's depth on the flutes 413 as the rotor assembly turns. The adjustable, rotating strike-off blades can be adjusted to suit aggregates ranging from washed sand to Superpave sized stone. The flutes 413 provide a positive grip on the aggregate and prevent unwanted aggregate flow around the rotor assembly. The only problem encountered with the prototypes rigidly mounted, fixed blade/rotating rotor was jamming caused by large foreign objects (obstructions), generally large stones picked up by the wheel loader's bucket when loading from a stockpile. To clear an obstruction generally meant climbing into the bin hand digging with shovels, resulting in the stopping of the recycling process. Large obstructions are now automatically discharged as the rotor turns. The rotating, strike-off blades (3 units) are mounted across the full width of bin inline with the rotor assembly and are attached to the bin by hinges 415 . Flat springs 416 force the blades into the working (normal) position. An obstruction caught between the rotor's flutes 413 causes the blade to rotate around hinge 415 , allowing the obstruction to pass without damaging (rotor or blade) or stalling the rotor. Recycling continues uninterrupted. Aggregate is dropped on to the heated asphalt's surface in lines (caused by the flutes) allowing the operator and inspector to visually monitor the quantity and distribution pattern. The Recycling Machine's heater box skirts (front and rear) drag the heated aggregate and smooth (flatten) out the lines as the aggregate passes under the heater box 4 , providing complete aggregate drying and surface coverage. The rotor assembly 411 and flutes 413 are manufactured using stainless steel, thus preventing rusting and sticking when using small, damp aggregate. The discharge rate is computer monitored and controlled by measuring the Preheater's groundspeed, width of pass and asphalt surface profile (depth change). The rotor's discharge rate is measured and calibrated (lbs./cu. ft./1 RPM of the rotor assembly) by placing measuring pans on the asphalt's surface to catch the aggregate. The Preheater is used to heat and dry out the aggregate prior to electronic weighing. The dry weight is calculated and entered into the on-board computer as a reference. The operator selects the application rate (lbs./cu. ft.) as determined by prior laboratory testing of the asphalt and the depth of processing to be performed by the Recycling machine (inches). The rotor assemblies width is fixed, therefore the application rate can not be determined only by the distance traveled but must use distance traveled, processing width and asphalt profile (depth change) in the calculation. The wider the Recycling Machine's processing width or the greater the asphalt's processing depth, the faster the rotor assembly 411 must rotate to maintain the correct application rate and visa versa. High sections (greater volume of asphalt to be processed) will require more aggregate, while low sections will require less.ies 11 and 12 with, For width measurement with Preheater that are not fitted with the rake scarification and blade collection system the operator uses two hydraulically operated weighted markers 417 attached to ABS (plastic) pipes 418 , sliders 419 and hydraulic cylinders 420 . The replaceable ABS pipes 418 prevent damage to the sliders 419 if contact with solid objects, such as trees, poles etc., occur. As processing width varies the Preheater operator simply moves the weighted markers 417 in and out by supplying hydraulic oil to either hydraulic cylinder 420 attached to the sliders 419 . The right marker normally would hang above the edge of curb (gutter) and left marker, the center of the road. Individually monitored (electronically) sliders 419 provide processing width information to the on-board computer. The electronic sensor 421 , measures the actual rotor assembly speed in relation to the stored (calculated) reference speed (closed loop), insuring that the rotor assemblies speed remains correct, even under varying load conditions. This measuring system insures accurate width measurement, without the operator ever having to get off the Preheater and physically measure (with a tape measure) and manually enter the width into the on-board computer. other For Preheaters fitted with the optional rake scarification and blade collection system the width measuring system's weighted markers, pipes, sliders and hydraulic cylinders are not required. Instead, the position of the extension rakes 11 is electronically monitored. The extension rakes are hydraulically extended or retracted by the operator as the width of processing (scarification) varies. If the rake scarification system is not required the operator uses the rake extensions as markers (rake teeth not lowered).
FIG. 66 shows the surface profile measuring system attached to the aggregate distribution bin 21 . Two averaging beams 430 (one on either side at the rear of the Preheater) are fitted with three sonic (beam) sensors targeting the heated (scarified or non-scarified) asphalt surface. Each beam has two base height sensors 431 , (one at the front and rear of the beam) and one grade height sensor 432 located in the center of the beam. The grade height sensor 432 is located under the centerline of the aggregate bin's discharge rotor assembly 411 . The on-board computer processes and stores the individual height readings of the front and rear base height sensors 431 (the actual height is not important) in relation to distance traveled (electronic pickup on Preheater drive wheel). The grade height sensor's 432 height is compared to the base height of the front sensor 431 . The rear sensor 431 provides a correction factor to the system, i.e. if the operator lifted the front of the Preheater to its upper limit while processing. Beams 430 would be tilted back resulting in the rear sensor height being less than the front sensors and also the grade height sensor 432 . The front base height sensor 431 provides cleaner target distance information than the rear sensor, due to the fact that the rear sensor is also measuring the lines of deposited aggregate. The programming code recognizes the varying height of the lines of aggregate and the base surface and provides in a consistent (filtered) reference. The difference between the base height and grade height is referred to as reference height. The two reference heights (left and right averaging beams) are then averaged and used by the on-board computer to correct for grade changes such as bumps and depressions. The accuracy of the system does not change when the operator raises or lowers the Preheater while working. The profile measuring system improves the accuracy of the aggregate distribution system when working with poor surface grades. For greater accuracy the number of averaging beams can be increased across the width of the asphalt being processed. The profile measuring system duplicates the grade profile to be milled by the Recycling Machine when operating on automatic grade and slope controls. For instance, a depression 3 feet wide by 2 inches deep across the width of the asphalt being processed would cause the volume of aggregate applied at the depression to be reduce as the amount of material to be milled to grade when reaching the depression will also be reduced. Without the profile measuring systems correction factor the distribution rate for aggregate would be based purely on the processing width and operator input for depth and would have resulted in excessive aggregate at the depressed area. A bump would have the reverse effect by providing too little aggregate for the amount of asphalt being milled to grade.other Other systems and equipment spread aggregate (as noted before) by only measuring the distance traveled and therefore are not accurate. Systems that do not add aggregate are not capable of 100% Hot In-place Recycling of asphalt pavement while meeting pre-engineered specifications. The Remix method (mixing a percentage of new asphalt with the old asphalt) has become popular as the accurate control of rejuvenator fluid, addition of aggregate and the complete mixing of additives and asphalt are not required to the same degree as with 100% HIR.
FIG. 1067 shows the 100% Hot In-place Recycling Machine with for 100% HIR with Integral Overlay. The sub-component numbers from 1 to 16 are the same as described in FIG. 2 the. The Recycling Machine's sub-assemblies (described later, in detail) required for the Integral Overlay method comprise of the primary auger/divider/strike-off blade 23 , primary screed/tow arms 24 , secondary auger/strike-off blade 25 and secondary screed and tow arms 26 . The clip-on front asphalt hopper 190 and the central central belt conveyor 191 and shuttle conveyor 29 are required to bring new asphalt to the secondary auger/strike-off blade 25 and secondary screed assembly 26 . The Recycling Machine's mainframe 3 is designed to incorporate the additional sub-assemblies, without having to be modified.
FIG. 10 a 68 and 69 show a close up view of the rear end of the Recycling Machine set up for the Integral Overlay method. The primary auger/divider/strike-off blade 23 incorporates the shuttle conveyor 29 that directs new asphalt from the central central belt conveyor 191 to the secondary auger 25 and screed assembly 26 or to the primary auger/divider/strike off blade 23 and screed assembly 24 . The position of the shuttle conveyor can be manually, or, automatically controlled (hydraulically moved towards the back end of the machine) by the on-board computer allowing new asphalt (delivered by the central conveyor) to spill off the front end of the shuttle conveyor into the primary auger/divider/strike off blade assembly when insufficient recycled asphalt is available to maintain the correct head of asphalt in front of the primary screed assembly. The design of the shuttle conveyor allows new asphalt to be delivered to both the primary and secondary auger and screed assemblies at the same time as the on-board computer monitors the asphalt requirements for both the primary and secondary operations and will increase the central conveyors delivery rate to match the increase demand. New asphalt can spill off the front of the shuttle conveyor while it is also conveying asphalt to the secondary operations.
Four hydraulic cylinders 450 and 451 attach the primary and the secondary screed to the Recycling Machine's mainframe 3 . The primary auger/divider/strike-off blade 23 is identical in construction and operation as described in FIG. 8 and FIG. 8 b . The secondary auger/strike-off blade assembly is identical in construction, except that the divider is not attached. Electronic asphalt level sensors are fitted to the secondary auger/strike-off blade assembly 23 and move the new asphalt away from the chute 452 . As mentioned before, an electronic, proportional sensor monitors the level of asphalt in the chute 452 and the on-board computer controls the flow of new asphalt from the front asphalt hopper assembly 190 , central conveyor assembly 191 and the shuttle conveyor 29 into the chute 452 . The shuttle conveyor 29 is driven by hydraulic motor 453 and is electronically matched in speed to the central conveyor's speed. The primary and secondary screeds are attached to the primary and secondary tow arms 454 and 455 . Both of the tow arms are attached to the same pickup point 456 , which is part of the fulcrum arm 457 . Attached between the fulcrum arm 457 and the secondary screed tow arm 454 is the hydraulic cylinder 458 (one on both sides of the machine). The primary screed tow arm 455 does not require a hydraulic cylinder. The hydraulic cylinder is modified with a third port, allowing the rod's piston to float against a small flow (0.5 to 1 GPM) of high-pressure oil entering at a specific point in the cylinder barrel. The Recycling Machine pulls along the screed assemblies that are attached to the machine's mainframe 3 by housing 459 , horizontal fulcrum 460 , fulcrum-arm 457 and the screed's tow arms 454 and 455 . The horizontal fulcrum 460 can be pinned to the housing 459 if automatic grade controls are not required. The hydraulic cylinder 462 is attached between the horizontal fulcrum 460 and the housing 459 and receives hydraulic oil from the automatic grade control system (described in detail before). The horizontal fulcrum 460 is raised and lowered (by pivoting around point 461 ) by hydraulic cylinder 462 , which in turn raises and lowers the horizontal fulcrum's pivot point 456 . The screed tow arms are attached to pivot 456 . The automatic grade control of the screed assembly was discussed in detail previously and works in exactly the same manner when two screeds are being controlled.
FIG. 10 a 70 shows a cross section of hydraulic cylinder 458 . Hydraulic oil enters the cylinder barrel at port “A” at a controlled flow rate of 0.5 to 1 GPM. The maximum pressure is limited to 3000 psi. The oil flow entering port “A” is allowed to exit port “B”. Port “C” is connected to tank (low pressure). As the rod 463 is pushed into the cylinder the attached piston 464 begins to block off the oil passage at port “B”. The force pushing on rod 194 determines the hydraulic pressure at port “A”, which changes with the load on the screeds. Hydraulic pressure balances the load (pull). Two electronic pressure transducers monitor the pressures in each the two hydraulic cylinders (one on the left and right side, secondary tow arms). This pressure is graphically shown on the machine and the screed operator's terminal as a bar graph and is used in balancing the load on the screeds. This can be accomplished by the offset of the Recycling Machine and the screed's extension position. For example, if the left extension is extended to two feet and the right extension is not extended the pull on the left side of the screeds will be greater. This causes the machine to be pulled to the side with the greatest load, resulting in constant steering corrections at the rear steering axle. The solution is to move the machine over to the left and extend the right extension and retract the left extension. The On-board computer also uses the transducer information to make small adjustments to the tow arm position by raising or lowering the tow arm pivot point 456 by controlling the operation of the hydraulic cylinder 462 . An electronic sensor measures the position of the horizontal fulcrum 460 . This feature is generally only used when the Recycling Machine is operating with the one screed assembly and with no automatic grade controls (city streets). With the single screed configuration the on-board computer makes small changes to the position of the tow arm pivot point to compensate for the varying load on the screed assembly. If the pressure increases in one or both of the cylinders 458 the horizontal fulcrum 460 will lower the tow arm pivot point. The ratio of pressure increase in the hydraulic cylinder 458 and the amount of movement of the horizontal fulcrum 460 are programmed into the on-board computer, and can be simply changed. The other function of hydraulic cylinder 458 is to prevent unwanted feedback into the screed assemblies. This can happen when a truck driver backs the dump truck to fast into the front asphalt hopper causing the Recycling Machine to be pushed back. When this happens the cylinder's rod 463 and piston 464 , are pulled out of the cylinders until the pistons hit the end of the cylinders. This gives plenty of travel and prevents the screed(s) from being pushed backwards. A make-up valve, located in the hydraulic manifold takes care of oil cavitation at port “A”. As soon as the Recycling Machine moves forward again the rod and piston is forced back into the “B” port position.
FIG. 11 69 shows the primary 24 and secondary 26 screed assemblies. The secondary screed 26 is allowed to float and features the same weight transfer system, as described earlier. The primary screed 24 requires no grade or slope controls and is also allowed to float, but not to the same degree as the secondary screed. The primary screed 24 senses the position of the secondary screed 26 through two proportional, hydraulic or electronic sensors 465 (electronic sensor are shown). The sensors are attached to the left and right side of the secondary screed tow arms 454 and sense the position of the left and right side of the primary screed tow arms 455 . The height of the sensor plates 466 can be adjusted by adjuster screw 467 to set the height differential between the primary and the secondary screed assemblies, which is generally ½″ to 1½″. The two screed sensors send information to the on-board computer, which in turn operates two hydraulic, 4-way, proportional, directional control valves. The secondary screed is the master while the primary is the slave and tries to match every move made by the secondary screed (master). To accomplish this the primary screed is attached to the Recycling Machine's mainframe 3 by two hydraulic cylinders 450 and the secondary screed by cylinders 451 . The four hydraulic cylinders prime function is to raise and lower both of the screeds. The secondary screed cylinders are allowed to float (move up and down freely) as all of the cylinder's hydraulic ports are connected to tank (return hydraulic oil) when laying asphalt. The primary screed's cylinders are also allowed to float; however the hydraulic cylinder's ports are connected to tank through flow control valves. The sensors that are attached to the left and right side of the secondary screed's tow arms 454 , sense the position of the left and right side, sensor plates 466 , that are attached to the primary screed's tow arms. The varying height differential is used by the on-board computer to controls the proportional valves (variable flow depending on the sensor output) which send a varying flow of hydraulic oil to the rod or head end of the hydraulic cylinders 450 . Oil is also flowing through the flow control valves. The greater the flow of hydraulic oil, the greater the pressure differentials across the flow control valves. The pressure varying pressure differential influences the position of the primary screed assembly. The screed sensors will eventually turn off the proportional valves when the primary screed reaches the set point (differential height). The crank handles 467 on the primary screed can be adjusted to manually set the depth of asphalt being laid in relation to the secondary screed 26 if the system is being run in the manual mode. The crank handles must also be initially, manually adjusted in the automatic mode to make sure that the screed plates are operating at the correct angle, otherwise excessive screed plate wear will occur. To assist in the correct adjustment of the crank handles 467 , LED's (light emitting diodes) located on the control panels (on either side of the machine); monitor the operation of the two proportional valves. When the cranks are set properly and the primary screed is laying the correct differential of asphalt, no LED's will be on. The primary screed is setting its own height (grade). An example; the LED indicating that hydraulic oil is being supplied to the rod end, of the left side cylinder is on (the screed is low on that side), indicating to the operator that the crank handle for that side of the screed must be turned to raise the screed. The flow control valves allow the primary screed's cylinders to float in the same manner as the secondary screed's cylinders. The flow of oil through the flow control valves is approximately 1 to 2 GPM. This low rate is sufficient to allow the screed to float and find its own level, while at the same time, allowing the oil flow from the proportional valves to build up pressure in the appropriate cylinder.
One of the major problems associated with this type of recycling equipment has been the transportation to and from sites and the removal of equipment from major highways at the end of the day. Both the Recycling Machine and Preheaters are designed to be self-transportable (do not require a trailer) using a highway tractor to tow the machines.
IG. 71 s RMP (Recycling Machine shown with all sub-assemblies removed for clarity, except the screed assembly 473 ) s 204703 a 471472 the 473 , as shown in the lower view 72 , 73 74 and 75 assembly 20 and “D”a 474 , the mainframe's 3 bottom or attachment points 475474 , 476477474478 g 475479474375 in the in the s 480476474476479476 The h 477 3476476480481
76 , 77 and 78 s 719149293 aced 4949592495767796 s 3 3 FIG. 2 , 22979895 399784959897492495
79 Recycling Machine 3 (all major sub-assemblies removed for clarity) fitted with the, front asphalt hopper/5 th wheel pin 190 and the central conveyor 191 , both described in detail before. When 190 and 191 are attached to the Recycling Machine the clip-on stinger assembly 20 is not required as the clip-on, front asphalt hopper is fitted with a 5 th wheel pin attachment allowing the tractor 470 to reverses and lock into the 5 th wheel pin 500 for transportation when said hopper is in a raised position. For normal paving operations, the bin will be in a lowered position as shown in the drawings. A rear clip-on transportation frame 471 transports the rear end of the Recycling MachineP, when the clip-on aggregate bin 21 is not attached. Generally only one Preheater is fitted with the aggregate bin 21 . For transportation, the bin may be removed and the 71 attached, or a fixed frame, clip-on transportation frame 501 (as shown in FIG. 80 ) may be attached to the aggregate bin, cross tubes FIG. 3 , 22 . The aggregate bin remains attached to the Preheater's mainframe tubes 22 . The Recycling Machine and Preheaters hydraulic system is used to retract all of the attached sub-assemblies (including the front and rear axle assemblies 8 ) once the transportation frames and tractors have been attached, providing the necessary ground clearance for highway transportation.
Changes may be made to various components and the interconnecting thereof as described in the disclosure or the preferred embodiment, without departing from the spirit and scope of the present invention.
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A process and device for the recycling of asphalt including at least one preheater unit. The preheater having a heater, scarifying rakes, and a bin to dispense aggregate. Also include is a recycling machine having a heater, scarifying rakes, a plurality of extension mills, a main mill, as well as a pug mill having first and second downwardly rotating rotors, the pug mill mixes asphalt and liquid additives together to form a homogenous mix; and at least one screed for laying the homogeneously mixed asphalt to grade.
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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 windows and specifically to a brake shoe and pivot assembly for a window counterbalance.
2. Description of the Related Art
Double hung windows are provided with counterbalances for maintaining a sash in an elevated position. Springs or weights connected to the sash to act as the counterbalance. Many window sashes are adapted for tilting inwardly for cleaning. The sash tilts on a pivot assembly at the bottom of the sash. Spring operated tilt latches at the top of the sash retain the sash in the vertical position and are released for pivoting of the sash.
The pivot assembly commonly is associated with a brake that firmly maintains the sash in place when the sash is tilted. Examples of such pivots and brakes are shown in U.S. Pat. Nos. 4,610,108 to Marshik, 5,069,001 to Makarowski, 5,139,291 to Schultz, 5,237,775 to Hardy and 5,243,783 to Schmidt et al, all incorporated herein by reference. The pivot assembly is typically fastened to the sash with screws or otherwise, as shown in U.S. Pat. Nos. 5,251,401 and 5,371,971 to Prete.
SUMMARY OF THE INVENTION
The present invention provides a pivot assembly for a window assembly having a window sash with a notch defining a pair of opposed tracks and having a brake assembly slidably disposed in a frame of the window assembly. The pivot assembly includes a rigid body and a pivot bar projecting from the body. The pivot bar has an end adapted for being received in the brake assembly. A flange extends from the body and has walls spaced from walls of the body so as to define a pair of opposed channels. The assembly is slidable into the window sash and the channels are adapted for receiving the opposed tracks of the window sash therein.
The flange and body define a generally I-shaped cross section. The flange walls are flexible for accommodating deformations and thickness variations of edges of the track received in the channels. The walls of the body are sloped for accommodating deformations and thickness variations of edges of the track received in the channels. The body is generally parallelepipedic and includes a longitudinal bore receiving the pivot bar therein, wherein the bore is stepped so as to define a lip and a stop, the pivot bar is provided with a detent engaging the lip, and an end of the pivot bar engages against the stop to limit longitudinal movement of the pivot bar and retain the pivot bar in the body.
A detent projects from the body and is adapted for engaging a wall of the window sash for retaining the pivot assembly therein. The body is generally parallelepipedic and further comprises a longitudinal bore receiving the pivot bar therein. The bore is stepped so as to define a lip and the pivot bar is provided with a detent engaging the lip to limit longitudinal movement of the pivot bar and retain the pivot bar in the body. The bore is stepped so as to define a stop and an end of the pivot bar engages against the stop to limit longitudinal movement of the pivot bar and retain the pivot bar in the body. A flange projects from the pivot bar and is adapted for engaging in the brake assembly. The flange is spaced from an end of the pivot bar to define a nose.
The invention also provides a pivot and brake assembly for a window assembly. The invention includes a brake assembly having a housing slidably disposed in a frame of the window assembly; a brake movable to engage the frame so as to resist movement of the housing in the frame; a cam disposed in the housing and rotatable for moving the brake.
The pivot and brake assembly also includes a pivot assembly having a rigid body; a pivot bar projecting from the body and having an end received in the cam so that pivoting of the pivot bar rotates the cam; and a flange extending from the body and having walls spaced from walls of the body for defining a pair of opposed channels, the assembly being slidable into a notched window sash of the window assembly and the channels being adapted for receiving opposed tracks of the window sash therein.
The cam includes a central passage in which the pivot bar is received, the bore having a lip therein, and the pivot bar includes a flange projecting from the pivot bar and engaging the lip to limit longitudinal movement of the pivot bar and retain the pivot bar in the cam. The flange is spaced from an end of the pivot bar to define a nose and the cam is provided with a back wall for engaging the nose to limit longitudinal movement of the pivot bar and retain the pivot bar in the cam. The pivot bar is eccentric and the cam includes an eccentric passage in which the pivot bar is received, the bar and passage mating so as to limit rotation of the bar relative to the cam.
The invention also provides a window assembly including a frame having two spaced, opposing, generally parallel slide channels. A sash has two spaced, generally parallel stiles and spaced, generally parallel header and footer rails assembled to form a generally rectangular shape. Each of said stiles is adapted for sliding along a corresponding one of the slide channels, and said footer rail has a hollow construction and a notch at each end thereof, each notch defining a pair of opposed, generally parallel tracks. A pair of brake assemblies as described above are slidably disposed in the respective slide channels. The brake is movable to engage the slide channel so as to resist movement of the housing in the slide channel. A pair of pivot assemblies as described above are slidable into the notch of the sash and the channels receiving opposed tracks of the respective window sash notch therein. A counterbalance is disposed in each of the slide channels and attached to the corresponding brake assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a double hung window assembly;
FIG. 2 shows an exploded perspective view of a lower corner of a sash and a pivot assembly;
FIG. 3 shows an end view of the pivot assembly;
FIG. 4 shows a side view of the pivot assembly;
FIG. 5 shows a sectional side view of the pivot assembly taken from line 5--5 of FIG. 3;
FIG. 6 shows a side view of a pivot bar;
FIG. 7 shows an end view of the pivot bar;
FIG. 8 shows a top view of the pivot bar;
FIG. 9 shows an exploded perspective view of a brake assembly;
FIG. 10 shows a sectional view of a cam taken from line 10--10 of FIG. 9;
FIG. 11 shows an elevational view of brake assembly installed in a window frame;
FIG. 12 shows the elevational view of FIG. 11 in a locked position; and
FIG. 13 shows a top sectional view of the window frame taken from line 13--13 of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a double hung window assembly 10 includes an upper sash 11 and a lower sash 12 that are slidable in a window frame 14. The lower sash 12, for example, includes vertically disposed stiles 16 and horizontally disposed rails 18 including an upper header rail and a lower footer rail. The window frame includes vertical jambs 20 defining opposed vertical slide channels 22 or tracks. Brake assemblies 24 are slidable in respective slide channels 22. Lower corners of the sash 12 are provided with pivot assemblies 26 that are associated with respective brake assemblies 24 to define pivot and brake assemblies. The brake assemblies 24 are supported by respective counterbalances, such as balance springs 28 disposed in the slide channels 22. Tilt latches 30 are disposed in upper corners of the sash 12 for releasably retaining the upper end of the sash in the slide channels 22.
Referring to FIGS. 2 through 5, the pivot assembly 26 includes a housing 32 and a pivot bar 34 located therein. The housing 32 includes a body 36 having a longitudinal bore 38. The bore 38 shown is generally rectangular, but other shapes are suitable as is apparent from the following description of the pivot bar 34. The bore 38 is stepped, that is, different parts of the bore have different cross-sectional dimensions and shapes. One end of the bore defines a mouth 40 slightly wider than the pivot bar 34 to facilitate installation and allow slight flexing thereof. A main part 42 of the bore is sized to snugly retain the pivot bar 34 therein. Another end of the bore is circular in cross section and defines a stop 44 against which the pivot bar 34 abuts. Adjacent the stop, a bottom wall is recessed to define a lip 46.
The bottom of the housing 32 is provided with a flange 48 or pair of flanges spaced above the body 36 and defining a pair of walls 50. The flange 48 and body 36 define a generally I-shaped cross section. The bottom of the body 36 has sloped walls 52. The walls 50, 52 define channels 54 that are wider toward the center of the body. A retaining detent 56 projects from the top of the body near one end.
Referring to FIGS. 2 and 5, the pivot bar 34 has a U-shaped cross section of formed metal. One end of the pivot bar is provided with laterally extending flanges 60. A detent 62 projects from a bottom wall of the pivot bar near another end. The pivot bar 34 is located within the bore 38 of the housing 32 so that the pivot bar detent 62 engages behind the lip 46 to prevent longitudinal movement of the pivot bar in one direction, as shown in FIG. 5. An end of the pivot bar 34 engages the stop 44 to prevent longitudinal movement of the pivot bar in another direction. The pivot bar projects from the housing 32 so that the flanges are spaced from the housing.
Other configurations of the pivot bar are also suitable. For example, referring to FIGS. 6-8, the pivot bar 34a can be cast as a bar having a rectangular cross section with rounded corners. The Flanges 60a extend from long edges of the bar and have ends 64 defining segments of a single circle. The flanges 60a can be set back from the end of the bar to define a longitudinally projecting nose 63. The detent 62a projects from one of the long edges near an end of the pivot bar 34a. The pivot bar 34a fits in the bore 38 similarly to the pivot bar 34 previously discussed. For other configurations of the pivot bar, the bore of the housing is correspondingly sized and shaped to accommodate the pivot bar.
Referring to FIG. 2, the lower end of the sash stile 16 is provided with a notch 66 or slot to allow passage of the pivot housing 32 therethrough. A second notch 67 or slot is cut in a lower wall of the lower rail 18 to define a pair of opposed tracks 68 or rails. The second notch 67 is as long as the housing 32. The pivot housing 32 is installed in the notch 66 so that the tracks 68 are received in the channels 54. The detent 56 (FIG. 4) engages behind an outer wall of the stile 16 immediately above the notch 66 to retain the housing 32 in place.
As a result of forming and welding the sash 12 and cutting the notches 66, 67, the tracks 68 have inconsistent thickness along their length and are deformed somewhat at their edges. The width of the channels 54 at their openings is such that the tracks snugly fit therein. The sloped walls 52 provide a larger space to accommodate the deformations and inconsistent thickness of the track edges. The channels 54 are deep enough that the walls 50 of the flange 48 are somewhat flexible for accommodating the deformations and inconsistent thickness of the track edges.
Referring to FIGS. 9-12, the brake assembly 24 includes a housing 70, a cam 72, and a movable or deformable brake 74, such as a shoe or spring. The cam 72 has a central passage 76 provided with a lip 78 (FIG. 10) and a lateral opening 80. The passage 76 has a height slightly greater than the thickness of the pivot bar 34a permitting insertion of the pivot bar therein, as shown in FIG. 10. The pivot bar 34, 34a and central passage 76 are eccentric so that they mate, thereby limiting rotation of the pivot bar relative to the cam. The lip 78 is spaced from an internal back wall 82 such that one of the flanges 60a is received behind the lip. The back wall 82 limits longitudinal travel of the pivot bar 34a in one direction by engaging the nose 63 and the lip 78 limits longitudinal travel of the pivot bar 34a in another direction by engaging the flange 60a. A flange 84 is provided on the cam 72 for retaining the cam in the housing 70.
Referring to FIGS. 11-13, the cam 72 and brake 74 are installed in the housing. The housing is slidably disposed in the slide channel 22. Rotation of the cam 72 with the pivot assembly causes outward movement or expansion of the brake 74, as shown in FIG. 12. The brake engages walls of the slide channel 22 to prevent movement of the brake assembly 24. Thus, when the window sash 12 is tilted as shown in FIG. 1, the pivot and brake assembly 24, 26 locks the sash in place. When the sash is in the vertical position, as shown for the upper sash 11, the brake is in the nonlocking retracted position of FIG. 11 and the sash is vertically slidable. Numerous variations of such brake assemblies are suitable, examples of which have been previously cited above.
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 brake is disposed in a window frame. The brake includes a cam that causes the brake to engage the frame to resist movement of the brake. The cam is operated by a pivot assembly mounted in a sash of the window. A body of the pivot assembly slides into a notch in the sash and is retained by a detent. The pivot assembly includes an eccentric pivot bar that is received in an eccentric passage of the cam. The pivot bar engages a stop in the body and has a detent that engages a lip in the body.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
This invention relates generally to borehole logging apparatus for performing nuclear radiation based measurements. More particularly, this invention relates to a new and improved apparatus for effecting formation density logging using gamma rays wherein the improved nuclear logging apparatus includes a sleeve designed to adapt the nuclear instrument for use in different sizes of boreholes.
BACKGROUND OF THE INVENTION
Oil well logging has been known for many years and provides an oil and gas well driller with information about the particular earth formation being drilled. In one type of oil well logging, after a well has been drilled, a probe, or sonde is lowered into the borehole to measure certain characteristics of the formations through which the well has passed. The probe hangs on the end of a cable which gives mechanical support to the sonde and which provides power to the sonde. The cable also conducts information up to the surface. Such "wireline" measurements are made after the drilling has taken place.
A wireline sonde usually contains a source which transmits energy into the formation as well as a suitable receiver for detecting energy returning from the formation. The energy can be nuclear, electrical, or acoustic. Wireline "gamma-gamma" probes, for measuring formation density, are well known devices incorporating a gamma ray source and a gamma ray detector. During operation of the probe, gamma rays emitted from the source enter the formation to be studied, and interact with the atomic electrons of the material of the formation by the photoelectric absorption, by Compton scattering, or by pair production. In photoelectric absorption and pair production phenomena, the particular gamma rays involved in the interaction are consumed in the process.
In the Compton scattering process, the involved gamma ray loses some of its energy and changes its original direction of travel, the amount of energy loss being related to the amount of change in direction. Some of the gamma rays emitted from the source into the formation are scattered by this process toward the detector. Many of these rays fail to reach the detector, since their direction is again changed by a second Compton scattering, or they are absorbed by the photoelectric absorption process or the pair production process. The scattered gamma rays that ultimately reach the detector and interact with it are counted by the electronic circuitry associated with the detector.
Wireline formation evaluation tools such as the aforementioned gamma ray density tools have many drawbacks and disadvantages, including loss of drilling time and the expense involved in pulling the drillstring so as to enable the wireline to be lowered into the borehole. In addition, a substantial mud cake can build up, and the formation can be invaded by drilling fluids during the time period that drilling is suspended. An improvement over these wireline techniques is the technique of measurement-while-drilling (MWD), which measures many of the characteristics of the formation during the drilling of the borehole. Measurement-while-drilling can totally eliminate the necessity for interrupting the drilling operation to remove the drillstring from the borehole. The present invention relates to a measurement-while-drilling apparatus. Specifically, this invention is most useful in such an instrument which measures the density of the formation wherein the source emits gamma rays.
In a typical MWD density tool, an instrument housing, such as a drill collar, is provided which incorporates a single gamma ray source and a pair of longitudinally displaced and mutually aligned detector assemblies. A nuclear source is mounted in a pocket in the drill collar wall and partially surrounded by gamma ray shielding. The two detector assemblies are mounted within a cavity or hatch formed in the drill collar wall and enclosed by a detector hatch cover under ambient pressure. The detector assemblies are spaced from the source and partially surrounded by gamma ray shielding to provide accurate response from the formation. The hatch cover contains radiation transparent windows in alignment with the detector assemblies.
The density instrument housing may include a central bore for internal flow of drilling fluid. The drill collar wall section adjacent to the source can be expanded radially so as to define a lobe which essentially occupies the annulus between the drill collar and the borehole wall. A radiation transparent window is provided in the lobe to allow gamma rays to reach the formation, and the surrounding lobe material reduces the propagation of gamma rays into the annulus. Reduction of the gamma ray flux down the annulus is desirable to reduce the number of gamma rays which reach the detector through the drilling fluid without passing through the formation.
Another means frequently used to reduce the gamma ray flux through the drilling fluid to the detectors is a threaded-on fluid displacement sleeve positioned on the drill collar and over the detector hatch cover. Examples of such a sleeve can be found in U.S. Pat. Nos. 5,091,644 and 5,134,285. In lieu of the lobe around the source port described above, the fluid displacement sleeve can extend over the source port as well as the detector ports. This sleeve displaces borehole fluids as mentioned above, reduces mudcaking which might have an adverse effect on the measurement, and maintains a relatively constant distance between the formation and the detector. The sleeve typically used has blades which are full gage diameter, matching the borehole diameter, or they can be slightly under gage, and adequate flow area for drilling fluids is provided between the blades. One blade is positioned between the detectors and the borehole wall to displace fluid from the annular space between the detectors and the formation. The other blades are positioning blades which position the instrument centrally within the borehole and which hold the fluid displacement blade against the formation. The blades are hard faced with wear resistant material. The threading and shoulders of the sleeves are configured so as to adequately secure the sleeve to the drill collar without rotation while drilling. The sleeve may be replaced at the drilling site when worn or damaged.
The problem with MWD instruments of this type is that a different instrument is required for each diameter of borehole. Detector to formation distance is critical, and drilling fluid must be displaced from the annular space between the detector and the borehole wall. Therefore, each borehole diameter requires the design and manufacture of an instrument, instrument housing, and fluid displacement sleeve specifically intended for use only in a borehole of the given diameter. Not only is design and manufacture of a full range of tools expensive, but each tool must be extensively modeled and mathematically calibrated for use in the given diameter of borehole, and acceptance testing must be performed on each different design. Even if a single instrument were used, with different diameters of fluid displacement sleeves, calibration and modeling effort would be necessary for each sleeve design. Further, the use of a different tool in each diameter of borehole requires a logging company to maintain a large inventory of tools, along with the associated difficulty in handling, storing, and testing such tools.
There is a continuing need, therefore, for an improved MWD density tool in which a single design instrument can be used in a variety of different sizes of boreholes without the need for recalibration, computer modeling, or repeated acceptance testing. Specifically, improvements are possible in achieving accurate and reliable measurements, with a single instrument, in different size boreholes, while minimizing the presence of drilling fluid between the tool's nuclear detectors and the formation.
SUMMARY OF THE INVENTION
The present invention comprises a fluid displacement sleeve designed to convert a single design of nuclear instrument for use in a variety of different diameter boreholes. The conversion from one size of borehole is accomplished by using a fluid displacement sleeve specifically designed for the desired size of borehole.
Given a nuclear instrument designed for use in a nominal size of borehole, the original fluid displacement sleeve will have blades of a given thickness, designed to center the instrument within the borehole. Typically, three blades are used, but other numbers of blades are possible. One of the blades will have the radiation transparent windows, and this blade will be the fluid displacement blade intended for placement between the detector and the borehole wall. The positioning blades on the sleeve for which the instrument is originally designed will have thicknesses matching the thickness of the fluid displacement blade, thereby centering the instrument within the borehole. Therefore, the original sleeve is a concentric fluid displacement sleeve.
When it is desired to use the instrument in a larger or smaller borehole, the original sleeve is removed from the drill collar and replaced with a sleeve of the present invention. If the new borehole diameter is larger than the nominal diameter for which the instrument is designed, the new sleeve will have a fluid displacement blade with the same thickness as the original blade, but the positioning blades will be thicker. This creates an eccentric sleeve which displaces the instrument housing centerline from the borehole centerline, keeping the fluid displacement blade in contact with the borehole wall. Significantly less computer modeling, acceptance testing, or recalibration is required, since the detector maintains the same distance from the borehole wall as in the original design.
On the other hand, if the new borehole diameter is smaller than the nominal diameter for which the instrument is designed, the new sleeve will still have a fluid displacement blade with the same thickness as the original blade, but the positioning blades will be thinner. This creates an eccentric sleeve which displaces the instrument housing centerline from the borehole centerline, allowing the instrument to fit in a smaller hole than the nominal diameter, and keeping the fluid displacement blade in contact with the borehole wall. Here again, no new computer modeling, acceptance testing, or recalibration is required, since the detector maintains the same distance from the borehole wall as in the original design.
The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best 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 perspective view of an MWD instrument, as known in the prior art, in use in a drillstring in a borehole;
FIG. 2 is a longitudinal section view of the MWD instrument shown in FIG. 1, showing the typical layout of the detectors and the fluid displacement blade;
FIG. 3 is a transverse section view of the MWD instrument shown in FIG. 1, showing the equal blade lengths found in the prior art concentric sleeve;
FIG. 4 is a transverse section view of the MWD instrument with an eccentric sleeve of the present invention, showing the increased thickness of the positioning blades, intended for use in a borehole with a larger than nominal diameter; and
FIG. 5 is a transverse section view of the MWD instrument with an eccentric sleeve of the present invention, showing the decreased thickness of the positioning blades, intended for use in a borehole with a smaller than nominal diameter.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, a diagram of the basic components for a gamma-ray density tool 10 as known in the prior art is shown. This tool comprises a drill collar 24 which contains a gamma-ray source 12 and two spaced gamma-ray detector assemblies 14 and 16. All three components are placed along a single axis that has been located parallel to the axis of the tool. As seen in FIG. 2, detectors 14, 16 can be mounted in cavity 28, along with associated circuitry (not shown), by known means. The detector 14 closest to the gamma-ray source will be referred to as the "short space detector" and the detector 16 farthest away is referred to as the "long space detector". Gamma-ray shielding is located between detector assemblies 14, 16 and source 12. Windows open up to the formation from both the detector assemblies and the source.
Drilling fluid, indicated by arrows, flows down through a bore in drillstring 18 and out through bit 20. A layer of drilling fluid returning to the surface is present between the formation and the detector assemblies and source. Drill cuttings produced by the operation of drill bit 20 are carried away by the drilling fluid rising up through the free annular space 22 between the drillstring and the wall of the borehole. An area of drill collar 24 overlying source 12 is raised to define a fluid displacing lobe 39. Lobe 39 displaces drilling mud between drill collar 24 and the borehole wall thereby improving the density measurement.
The tool 10 is placed into service by loading it with a sealed gamma source and lowering it into a formation. Gamma-rays are continuously emitted by the source and these propagate out into the formation. Two physical processes dominate the scattering and absorption of gamma rays at the energies used in density tools. They are Compton scattering and photoelectric absorption. The probability of Compton scattering is proportional to the electron density in the formation and is weakly dependent on the energy of the incident gamma ray. Since the electron density is, for most formations, approximately proportional to the bulk density, the amount of Compton scattering is proportional to the density of the formation.
Formation density is determined by measuring the return of gamma rays through the formation. Shielding within the tool minimizes the flux of gamma rays straight through the tool. This flux can be viewed as background noise for the formation signal. As seen in FIG. 2, the windows 36, 38, 50, 52 in the detector hatch cover 30 and fluid displacement blade 42 increase the number of gamma rays returning from the formation to the detectors. The thickness of the layer of mud between the tool and the formation is minimized by the use of fluid displacement sleeve 40.
Fluid displacement sleeve 40 displaces borehole fluids, reduces mud cake which might have an adverse effect on the measurement, and maintains a relatively constant formation to detector distance. Fluid displacement sleeve 40 is threadably attached over drill collar 24 at threads 25,27. Sleeve 40 surrounds the nuclear instrument and particularly the two windows 36 and 38 in hatch cover 30. An internal bore 26 carries drilling fluid down through instrument 10.
As seen in FIG. 3, the outer surface of sleeve 40 is provided with three blades 42, 44, and 46. Each blade 42, 44, and 46 may be formed by any number of known methods. Preferably, each blade is formed by machining out the area between the blades as shown in FIG. 3. In a manner similar to lobe 39, each blade of sleeve 40 is fully gaged to the radius 62 of the borehole, or nearly full gage, and provided with a hardened surface 48 on the outer edges thereof made from an appropriate material such as tungsten carbide. The valley areas between blades 42, 44, and 46 are optimized so as to give adequate flow area for drilling fluid flowing through the annulus between the borehole wall and the density tool. Openings 50, 52 through blade 42 and are spaced from each other so as to be positioned over windows 36 and 38. Each opening 50, 52 is filled with a low atomic number (low Z), low density, high wear filler material such as rubber or epoxy. Windows 36, 38 are formed of a radiation transparent, high strength, low Z material such as beryllium.
Thread 27 on the outer surface of drill collar 24 mates with thread 25 internally provided on sleeve 40 for effecting the attachment of sleeve 40 to drill collar 24. The internal radius of sleeve 40 is slightly larger than the outer radius 60 of drill collar 24. Angular alignment with the detector assemblies is achieved by selecting the proper spacer 54 that will yield an acceptable makeup torque when in position. Torquing can be done with tongs or with a free standing torque machine.
Fluid displacement sleeve 40 may be easily replaceable when worn or damaged, or when it is desired to convert the instrument 10 for use in a different size borehole. As seen in FIG. 4, when it is desired to use instrument 10 in a larger than nominal diameter borehole, sleeve 40 can be unthreaded from drill collar 24 and replaced with sleeve 40'. On sleeve 40', fluid displacement blade 42' has the same thickness as fluid displacement blade 42 on sleeve 40. However, positioning blades 44', 46' are thicker than positioning blades 44, 46 on sleeve 40. This increases the outer radius 62' of sleeve 40' to match the radius of the larger borehole.
Similarly, when it is desired to use instrument 10 in a smaller than nominal diameter borehole, sleeve 40 can be unthreaded from drill collar 24 and replaced with sleeve 40". On sleeve 40", fluid displacement blade 42" has the same thickness as fluid displacement blade 42 on sleeve 40. However, positioning blades 44", 46" are thinner than positioning blades 44, 46 on sleeve 40. This decreases the outer radius 62" of sleeve 40" to match the radius of the smaller borehole.
While the particular eccentric fluid displacement sleeve as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.
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An eccentric fluid displacement sleeve is disclosed for use with a measurement-while-drilling instrument, to convert the instrument for use in different size boreholes. The sleeve is made eccentric by either increasing or decreasing the thicknesses of positioning blades on the periphery of the sleeve, while maintaining the thickness of the fluid displacement blade aligned with the detectors.
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RELATED APPLICATION
This application claims the priority of provisional application No. 60/334,094, filed Nov. 29, 2001.
BACKGROUND
1. Field
The present disclosure relates to swimming pool covers, and, more particularly, to a method and apparatus for attaching webbing to the edges of pool covers.
2. Background
Swimming pools are commonly covered to prevent debris from entering the pool, to preserve chemical treatments in the water and to heat the pool in the case of a solar cover. Typically, a pool cover will extend over the entire surface of the pool during periods of non-use and then be retracted during periods of use. The cover may be extended and retracted by mechanical or automatic means. In either case, a track assembly is usually connected to or built into the walls for guiding the edges of the cover as it traverses the pool. The pool cover typically has some means connected along the edge of the cover interacting with the track assembly to facilitate movement of the pool cover.
The pool cover may be fabricated from a vinyl-coated mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating. The result is a strong, durable and waterproof material that is ideal for long-term, maintenance-free use. The webbing may be made out of canvas or sail cloth, so that it can endure the mechanical stresses and wear placed on it as the bead slides along the tracking assembly and as weight is placed on the cover.
The webbing may be connected to the pool cover by thread stitches running along the webbing. Although the stitches are made of strong and durable thread, they are vulnerable to wear and may eventually wear out before the cover or the webbing. This wear occurs as the result of several factors, including ultraviolet rays from sunlight, chemical corrosion from pool chemicals and the mechanical stresses described above. Accordingly, it is not unusual for periodic repairs to be required to the thread stitching in order to maintain the integrity of the connection between the webbing and the pool cover.
Accordingly, there is an important need for an improved connection between the pool cover and the webbing that forms the edge bead for the pool cover. An improved webbing material and method of attaching the material to the pool cover is needed to reduce maintenance on the pool cover and to increase safety and durability for the pool cover.
SUMMARY
The present disclosure provides an improved method for attaching border webbing to an edge of the pool cover to form a bead for guiding the webbing along an encapsulated track. The border webbing is heat sealed to the edge of the pool cover to form a durable attachment thereto. The webbing and the edge of the pool cover are made of heat sensitive material that become plastic and form a bond with the application of heat.
One application of the disclosure comprises a method for attaching an elongated webbing member to an edge of a pool cover, wherein the edge of the pool cover is positioned so that a portion of the pool cover edge is in contact with a portion of the webbing. The portion of the pool cover edge is then heat sealed to the portion of the webbing.
The method further comprises wrapping the webbing around an elongated filler member, so that at least one flap extends from the filler member, positioning the portion of the pool cover edge to overlap the flap, and applying heat to cause a heat seal between the portion of the pool cover edge and the flap. Preferably, the portion of the pool cover edge and/or the flap are composed of a heat sensitive material that will form the heat seal.
Another application comprises a pool cover having at least one pool cover edge, a webbing coupled to at least a portion of the pool cover edge by a heat seal between a portion of the webbing and a portion of the pool cover edge.
Additionally, the portion of the webbing and/or the portion of the pool cover edge may be made of a thermoactive material, such as vinyl, that becomes plastic with the application of heat, to form the heat seal. As used herein, the term “thermoactive material” means a material that is sufficiently sensitive to heat to become pliable or plastic in consistency, so as to provide a surface appropriate for heat welding. The webbing may be wrapped around a filler element to form a bead, so that the bead substantially maintains its shape under mechanical stress to guide the edge of the pool cover along a mechanical track.
Another implementation includes an apparatus for forming a webbing attached to the edge of a pool cover, comprising a positioning element for disposing a portion of the webbing in contact with a portion of the pool cover edge and a heating element for applying heat to form a heat seal between the webbing portion and the pool cover edge portion.
Additional optional features include a pressing element for consolidating the heat seal between the webbing portion and the pool edge cover portion. The positioning element may provide a flap extending from the webbing to overlap the portion of the pool cover edge and form the heat seal therewith. The apparatus may further comprise an element for wrapping the webbing around an elongated filler element, wherein the wrapping element forms the portion of the webbing to include at least one flap extending from the filler element. The portion of the pool cover edge may extend between first and second flaps of the webbing. The heating element may include a first nozzle to apply heat to the first flap and a second nozzle to apply heat to the second flap.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure will be better understood by reference to the following description of an example taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a plan view of a pool showing a pool cover guided by a tracking assembly in the pool walls;
FIG. 2 is a perspective view of a prior art structure showing a webbing and bead formed along the edge of the pool cover and carried in the tracking assembly;
FIG. 3 is a perspective view of a prior art structure including an edge of a pool cover sewn to a webbing and bead for attaching to the tracking assembly of FIG. 2 ;
FIG. 4 is a perspective view of another prior art structure including an edge of a pool cover sewn to webbing and bead for attaching to the tracking assembly of FIG. 2 ;
FIGS. 5A–C are schematic views showing the steps involved in fabricating a webbing structure;
FIG. 6A is a perspective view showing the webbing structure connected to an edge of the pool cover;
FIG. 6B is a side view of the webbing structure shown in FIG. 6A ;
FIGS. 7A and 7B are side views of another implementation showing a webbing structure connected to an edge of the pool cover;
FIG. 8 is another perspective view showing the webbing structure of FIG. 6A ;
FIG. 9 is a schematic view of an apparatus for forming the webbing structure;
FIGS. 10 and 11 are side views of the apparatus of FIG. 9 ;
FIG. 12 is a cross-section partial view of the side views of FIGS. 10 and 11 ;
FIG. 13 is a side view of the apparatus of FIG. 9 with part of the apparatus rotated;
FIG. 14 is a perspective view of the apparatus of FIG. 9 with part of the apparatus rotated; and
FIG. 15 is another perspective view of the apparatus of FIG. 9 with the apparatus in operation.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one example, in one form, and such exemplification is not to be construed as limiting the scope of the disclosure in any manner.
DETAILED DESCRIPTION
In FIG. 1 , a rectangular swimming pool 10 is shown having a pool deck 12 and coping 14 surrounding the pool. An automatic pool cover 16 extends from a pool cover mechanism 18 in a cover assembly box 20 disposed at one end of the pool. A leading edge bar 22 at the front edge of the pool cover 16 rides in a track assembly 24 along the interior walls of the pool. Deck 12 is generally horizontal and is preferably constructed from concrete. Coping 14 connects to deck 12 in a substantially coplanar fashion along the edge of deck 12 facing the interior of swimming pool 10 . Track assembly 24 may be of any suitable structure to retain the edge of the pool cover as it slides in the track.
FIG. 2 shows an encapsulation track assembly 30 having an elongated chamber 32 therein. The pool cover 16 is connected along its edge to an elongated bead 36 comprised of a wrapped rope or filler 35 that is captured in chamber 32 . The pool cover 16 extends out through a slot 38 in chamber 32 . Chamber 32 is sufficiently large to allow the bead 36 to slip therethrough as the cover 16 moves. Likewise, slot 38 is ample in width to allow the pool cover edge to move easily along the slot, but is small enough to restrain the bead 36 within chamber 32 .
In FIGS. 3 and 4 , prior art methods are shown, wherein bead 36 is formed by wrapping an elongated webbing member 40 around rope 36 and attaching it to pool cover 16 . The webbing member 40 is wrapped around the rope 36 and then sewn to the edge 31 of the pool cover 16 .
In FIG. 3 , a first fold portion 41 is formed along the edge 31 of the pool cover 16 and then sewn onto the webbing 40 , using a line of thread stitching 42 . A second fold portion 43 is formed over the top of portion 41 and a second line of thread stitching 44 is added to secure the second fold portion 43 to the webbing 40 . This approach requires two sewing passes but protects one of the threads from sunlight. In FIG. 4 , first and second fold portions 41 and 43 are formed first and then sewn with two stitch lines 45 and 46 providing a double stitching through both folds in one pass, but exposing both lines of stitching to the sunlight.
As previously mentioned, the pool cover 16 may be fabricated from a vinyl-coated mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating. The result is a strong, durable and waterproof material that is ideal for long-term, maintenance-free use. The webbing may be made out of canvas or sail cloth, so that it can endure the mechanical stresses and wear placed on it as the bead 36 slides along the encapsulation assembly 30 and as weight is placed on the cover 16 .
The thread stitches 45 and 46 or 42 and 44 are vulnerable to extensive wear. Although very strong and durable thread is used and multiple stitch lines are applied, the thread may eventually wear out before the cover or the webbing. This wear occurs as the result of several factors, including ultraviolet rays from sunlight, chemical corrosion from pool chemicals and the mechanical stresses described above. Accordingly, it is not unusual for periodic repairs to be required to the thread stitching in order to maintain the integrity of the connection between the webbing and the pool cover.
Looking now at FIGS. 5A–C , a preferred application of the method of the present disclosure is shown. As shown in FIG. 5A , in a first step, a pool cover 50 includes a pool cover edge 51 disposed adjacent to an elongated rope or filler member 52 . A webbing member 55 is disposed on the other side of the rope member 52 . Preferably the pool cover 50 is composed of a mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating. The webbing member 55 is composed of an extremely strong and durable fabric mesh having one side 53 coated by vinyl and the other side 56 not coated by vinyl.
As shown in FIG. 5B , in a second step, an appropriate mechanism (not shown) folds webbing member 55 over filler member 52 to form upper and lower flaps 57 and 58 extending above and below pool cover edge 51 . The surfaces 59 and 60 of flaps 57 and 58 , respectively, that are adjacent to pool cover edge 51 are part of the vinyl-coated surface 53 and extend over the vinyl-coated pool cover edge 51 .
FIG. 5C shows a third step, wherein upper and lower flaps 57 and 58 are formed around filler member 52 to form bead 62 . Flaps 57 and 58 are rolled flush with pool cover edge 51 . Heat and pressure are applied to form a heat weld or seal 55 comprised of bonded flaps 57 and 58 bonded on either side of pool cover edge 51 .
FIG. 6A shows a perspective view of the heat sealed webbing 55 and pool cover edge 51 according to the present disclosure. Bead 62 is formed by wrapping webbing 55 around the rope or filler element 52 . Flaps 57 and 58 are heat sealed to the pool cover edge 51 to form a strong, durable heat seal between the flaps 57 and 58 of the webbing 55 and the pool cover 50 .
FIG. 6B shows a side view of the structure shown in FIG. 6A . Preferably, the bead 62 formed by the elongated filler element 52 and the webbing 55 are impervious to wear along the track assembly 30 , shown in FIG. 2 , and the filler element 52 is composed of a material that substantially maintains its shape when mechanical stress and tension is applied. Thus, as shown in FIG. 2 , the bead 36 can slide in chamber 32 along the encapsulated track 30 without risk that the bead will deform and be pulled out of the slot 38 in chamber 32 by transverse forces acting on pool cover 16 .
FIG. 7A shows an alternative implementation of the present disclosure wherein a webbing is attached to only one side of a pool cover by heat sealing. A webbing member 55 a and a filler member 52 a are disposed adjacent to the edge 51 a of a pool cover 50 a . Webbing member 55 a has at least one side 53 a that has a surface of vinyl or other thermoactive material.
As shown in FIGS. 7A–B , webbing member 55 a is wrapped around filler member 52 a to form a bead 62 a . The top portion of webbing 55 a forms a flap 57 a lying in contact with the top surface of pool cover edge 51 a. The bottom portion 54 a of webbing 55 a is disposed in contact with the undersurface 53 a of webbing member 50 a . The adjoining surfaces of 54 a and 55 a may be connected together by heat sealing, stitching or other procedure sufficient to secure 54 a to the portion of flap 57 a as shown. The adjoining surfaces of flap 57 a and pool cover edge 51 a are connected together by heat sealing, using a procedure substantially the same as previously described with respect to FIGS. 5A–5C and 6 A– 6 B.
One advantage to the implementation disclosed in FIGS. 7A and 7B is that only a single heat seal need be formed between two adjoining surfaces. This approach will be effective if the single heat seal is strong enough to withstand the wear and stress applied to the pool cover and webbing.
FIG. 8 is another view showing pool cover 50 attached to the heat sealed webbing 55 with a beaded edging 62 . Flap 57 of webbing member 55 is securely heat sealed to pool cover 50 . Filler element 52 is preferably a ¼ inch woven rope, but could be made of a dacron vinyl thread or any other durable material that will hold its shape when subjected to mechanical stress and tension.
FIGS. 9–15 show one implementation of an apparatus 70 used to form the heat sealed web element 55 . As best seen in FIGS. 10–12 , flaps 57 and 58 are wrapped around filler element 52 and extended adjacent to the pool cover edge 51 . An upper heater element 76 forces hot air through nozzle 78 and out of nozzle spout 80 . Spout 80 rides between upper flap 57 and the upper surface of pool cover edge 51 to apply heat to both surfaces. Similarly, a lower heater element 82 forces hot air through a nozzle 84 and out of nozzle spout 86 between lower flap 58 and the under surface of pool cover edge 51 .
Looking particularly at FIG. 12 , the hot air partially melts the adjoining surfaces of the pool cover edge 51 and the inside surfaces 59 and 60 , respectively, (shown in FIG. 5B ) of upper flap 57 and lower flap 58 , respectively, so that these surfaces can form heat welded connections. As seen in FIGS. 10 and 11 , upper roller 72 and lower roller 74 press flaps 57 and 58 against pool cover edge 51 while said surfaces are heated to form secure heat seals between the surfaces, so that the web element 55 is firmly attached to the pool cover edge 51 .
The hot air generated by heater elements 76 and 82 may be heated to a temperature between approximately 1000–1300 degrees Fahrenheit. Fifty pounds or more of pressure may be applied by the rollers 72 and 74 to the heated flaps 57 and 58 . The result is an extremely strong heat weld or seam in the heat sealed web element 55 that will withstand forces that might be expected to be applied to the pool cover 50 . The heat seal is not susceptible to deterioration from the sunlight or from chemical erosion. Methods of constructing such an apparatus are well known to those of skill in the art.
Moreover, the heat sealed web structure 55 above and below the pool cover edge 51 , as described above, is formed in one pass of the materials through the apparatus. Heat is applied to the webbing flaps 57 and 58 at substantially the same time, and the rollers 72 and 82 confirm the heat seals to complete the sealing operation. This one pass procedure minimizes the amount of labor required to form the heat sealed webbing.
In operation, an operator may feed the webbing member 55 and the pool cover 50 to mate with each other, as further shown in FIGS. 10–12 and as described above. The apparatus may be manned by one person feeding the bead 52 , the webbing member 55 , and the pool cover edge 51 between rollers 72 and 74 . Accordingly, the entire structure may be quickly and efficiently formed along the edge of a pool cover 50 .
Referring now to FIGS. 13 and 14 , it can be seen that the nozzles 78 and 84 may be rotated away from the rollers 72 and 74 when the apparatus is not in use. This action makes it easier to set up the apparatus for operation and to clean the apparatus. When the apparatus is ready for operation, the nozzles 78 and 84 are rotated back into an aligned position, as best seen in FIG. 10 . Then nozzles 78 and 84 are slid forward toward the rollers 72 and 74 until they are in close proximity therewith, as best seen in FIG. 11 .
FIG. 15 is another perspective view showing the apparatus 70 in operation. Heater element 76 and nozzle 78 have been rotated into alignment with roller 72 . Nozzle 78 is twisted slightly so that nozzle spout 80 will slip beneath webbing flap 57 without nozzle 78 interfering. A first guide member 92 guides flap 57 toward the roller 72 . A second guide 94 directly in front of roller 72 maintains a slight separation between flap 57 and the edge 51 of pool cover 50 . This separation provides a space for nozzle spout 80 to inject hot air into the space to partially melt the vinyl undersurface of flap 57 and the top surface of pool cover edge 51 , as previously shown in FIGS. 10–12 .
An substantially identical operation occurs on the underside of apparatus 70 . Although not shown, heater element 82 and nozzle 84 , seen in FIGS. 10 , 11 and 13 , have also been rotated in alignment with roller 74 . Guides (not shown) similar to guides 92 and 94 direct the webbing 55 to roller 74 , maintaining a space for nozzle spout 86 to inject heated air to partially melt the appropriate surfaces just prior to roller 74 applying pressure to confirm the heat seal between the top surface 60 of flap 58 and the under surface of pool cover edge 51 .
It is understood that variations of the above preferred implementation might be employed within the scope of the disclosure. For example, in some cases the hot air coming from nozzle foot 80 and nozzle foot 86 may provide too much heat to the flaps 57 and 58 and the pool cover edge 51 . In such case the upper or lower mechanisms may be offset by a a sufficient distance (not shown) to allow cooling of the flaps 57 and 58 and pool cover edge 51 between applications of hot air from the nozzle feet 80 and 86 .
Thus, the upper mechanisms, including roller 72 , heater element 76 , nozzle 78 and nozzle foot 80 might be offset longitudinally along the service line of the pool cover edge 51 by some distance from the lower roller 76 , heater element 82 , nozzle 84 and nozzle foot 86 . In the interim space, cool air may be applied to the flaps 57 and 58 and the pool cover edge 51 to allow the bond between the lower flap 58 and the pool cover edge 51 to cool and bond. Conversely, the hot air could be applied first to the upper flap and pool cover edge 51 and then the lower flap 58 and pool cover edge 51 could be bonded further down the service line of the pool cover edge.
Although the above applications are representative of the present disclosure, other applications will be apparent to those skilled in the art from a consideration of this specification and the appended claims, or from a practice of the applications of the disclosure. It is intended that the specification and applications therein be considered as exemplary only, with the present disclosure being defined by the claims and their equivalents.
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A method is provided for attaching an elongated webbing member to an edge of a pool cover, comprising positioning the edge of the pool cover so that a portion of the pool cover edge is in contact with a portion of the webbing, and heat sealing the webbing portion to the pool cover edge portion. An assembly is provided for coupling a pool cover to a connector mechanism attached to a pool, comprising a pool cover comprising at least one pool cover edge, and a webbing coupled to at least a portion of the pool cover edge by a heat seal between a portion of the webbing and a portion of the pool cover edge. An apparatus is also provided for forming a webbing attached to the edge of a pool cover.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage under 35 U.S.C. 371 of International Application PCT/CA2011/001387, filed on Dec. 22, 2011 (currently pending). International Application PCT/CA2011/001387 cites the priority of U.S. Patent Application 61/460,195, filed Dec. 27, 2010.
FIELD OF THE INVENTION
The present invention relates to the drilling and stimulating of subterranean rock formations for the recovery of hydrocarbon and natural gas resources. In particular, the present invention relates to a method of fracture treating a wellbore while the drilling operation is underway.
BACKGROUND
Subterranean reservoir rock formations that contain hydrocarbons and gases are often, if not usually, horizontal in profile. It was therefore of immense economic value and a great benefit to society when modern drilling techniques were developed that could create horizontal wellbores from a vertical well over a distance to gain access to a larger portion of hydrocarbon and natural gas resources in a reservoir.
A problem to overcome, however, was that such horizontal reservoirs (for instance, shale formations), are generally quite tight and compressed in nature, meaning that they often don't contain natural fractures of sufficient porosity and permeability within the formation through which hydrocarbons and gas can readily flow into the well at economic rates. Engineers, however, were able to develop methodologies whereby rock formations can be “perfed” (perforated) and “fracked” (fractured) to create pathways in the rock formations through which hydrocarbons and gas can much more readily flow to the well.
While such fracking has led to a great increase in the amount of hydrocarbons and gas that can be readily recovered from a formation, engineers found that it was important to be able to isolate one fracture from another so that the same part of the well was not being repeatedly fractured. Repeated fracturing can cause rock chips and fine rock particles to enter cracks and pore space, thereby reducing the porosity and permeability of the fracked area into the well. The same is true for vertical or deviated wells.
In the known methodology, drilling, and perfing and fracking rock formations involves separate operations. In particular, the well is drilled first, and then the drilling rig is moved off location before a fracturing “spread” is moved on to the location to perf and frac the wellbore for the subsequent recovery of hydrocarbon or natural gas resources. The timing between the drilling of the well and the fracture treatment of the same well can vary from immediately thereafter to as much as 18 months depending on the availability of frac equipment which is in high demand. There are therefore several inefficiencies in the known methods of resource recovery.
It is useful to more fully discuss the conventional drilling and fracking methodology in order to assist in distinguishing the method of the present invention.
Conventional Drilling
A drill bit(s) is mounted on the end of a drill pipe, and a mixture of water and additives (“mud”) is pumped into the hole to cool the bit and flush the cuttings to the surface as the drill bit(s) grinds away at the rock. This mud generally cakes on the walls of the wellbore, which assists in keeping the well intact. The hole is generally drilled to just under the deepest fresh water reservoir near the surface, where the drill pipe is then first removed. Surface casing is then inserted into the drilled hole to a point below the water reservoir in order to isolate the fresh water zone. Cement is subsequently pumped down the casing, exits through an opening called a shoe at the bottom of the casing and wellbore, and is then forced up between the outside of the casing and the hole, effectively sealing off the wellbore from the fresh water. This cementing process prevents contamination of the freshwater aquifers. The drill pipe is then lowered back down the hole to drill through the plug and cement and continue the vertical section of the well. At a certain depth above the point where a horizontal well is desired (the “kick-off point” or “KOP”), the well will slowly begin to be drilled on a curve to the point where a horizontal section can be drilled. The KOP is often located approximately 220 meters above the planned horizontal leg. Up to this point, the process is the same as drilling a vertical well.
Once the KOP is reached, the pipe and bit are pulled out of the hole and a down hole drilling motor with measurement drilling instruments is lowered back into the hole to begin the angle building process. In general, it takes approximately 350 m of drilling to make the curve from the KOP to where the wellbore becomes horizontal (assuming an 8° angle building process, for instance). Then, drilling begins on the “lateral”, the well's horizontal section.
When the targeted horizontal drilling distance is reached on the lateral, the drill bit and pipe are removed from the wellbore. Production casing is then inserted into the full length of the wellbore. Cement is again pumped down the casing and out through the hole in the casing shoe, forcing the cement up between the outside of the casing and the wall of the hole, thus filling the “annulus”, or open space. At this point, the drilling rig is no longer needed so this equipment is moved off-site and a well head is installed. The fracturing or service crew then moves its equipment on-site to prepare the well for production and the recovery of hydrocarbon and gas resources.
Conventional Perfing and Fracking of the Wellbore
The first step in the known method is to perf the casing. In this respect, a perforating gun is lowered by wire line into the casing to the targeted section of the horizontal leg (i.e. in general, to the end of the lateral so that the process can work back along the horizontal leg from the “toe” to the “heel” of the wellbore). An electrical current is sent down the wire line to the perf gun, which sets off a charge that shoots small evenly-spaced holes through the casing and cement and out a short distance into the rock formation (often shale). This causes fractures in the rock formation, but is generally not sufficient in itself to create proper fairways through which hydrocarbons or gas can readily flow into the wellbore due to the tight or compressed nature of the rock formation (as previously stated, compressed reservoirs do not generally contain natural fractures and therefore hydrocarbons or gas cannot be produced economically without additional manipulation). As a result, a further step is needed to increase the porosity and permeability of the rock by providing more significant pathways through which the hydrocarbons or gas can flow more readily. To do this, the perf gun is removed from the hole, and the well then needs to be “fracked” to create proper fairways.
Fracking (or fracing) is the process of propagating the fracture in the rock layer caused by the perforation in the formation from the perf gun. In this respect, it is hydraulic fracturing that is usually undertaken, which is the process whereby a slurry of, for example, mainly water, and some sand and additives are pumped into the wellbore and down the casing under extremely high pressure to break the rock and propagate the fractures (sufficient enough to exceed the fracture gradient of the rock). In particular, as this mixture is forced out through the vertical perforations caused by the perf gun and into the surrounding rock, the pressure causes the rock to fracture. Such fracturing creates a fairway, often a tree-like dendritic fairway, that connects the reservoir to the well and allows the released hydrocarbons or gas to flow much more readily to the wellbore. Once the injection has stopped, often a solid proppant (e.g. silica sand, resin-coated sand, man-made ceramics) is added to the fluid and injected to keep the fractures open. The propped fractures are permeable enough to allow the flow of hydrocarbons or gas to the well.
In order for the next section of the horizontal leg to be perforated and fracked (i.e. multi-stage fracking from the “toe” all along to the “heel” of the horizontal leg), a temporary plug is placed at the nearest end of the first-stage frac to close off and isolate the already perforated and fracked section of the wellbore. The process of perfing, fracking, and plugging is then repeated numerous times until the entire horizontal distance of the wellbore is covered. Once such a process has been completed, the plugs are drilled out, allowing the hydrocarbons or gas to flow up the wellbore to a permanent wellhead for storage and distribution. Unfortunately, in this known method, a well operator is unable to determine whether any particular fracture treatment has been successful in increasing the porosity and permeability of the rock formation at a given location of the wellbore, whether the treatment is having a net positive or negative effect on overall flow of hydrocarbons or gas into the well, and whether a modification to the fracturing fluid/slurry, for example, would have produced better results.
Persons skilled in the art would be aware of other similar or related completion methodologies that have the same limitations. For instance, engineers may employ an open hole completion where no casing is cemented in place across the horizontal production leg. Pre-holed or slotted liners/casing may be employed across the production zone. Swellable/inflatable elastomer packers may be used, for instance, to provide zonal isolation and segregation, and zonal flow control of hydrocarbons or gas. Perfing may be accomplished by perforating tools or by a multiple sliding sleeve assembly, etc. Regardless, the methodologies operate in essentially the same manner—the operation proceeds from the “toe” of the well back to the “heel”, and the well operator is unable to determine whether any particular fracture treatment has been successful in increasing the porosity and permeability of the rock formation at any given location of the wellbore, whether the treatment is having a net positive or negative effect on overall flow of hydrocarbons or gas into the well, and whether a modification to the fracturing fluid/slurry, for example, would have produced better results.
A method that would allow for the creation of fracture treatments into a wellbore while the drilling operation is under way would overcome several problems and inefficiencies associated with the known hydrocarbon and gas recovery process in the oil and gas industries.
SUMMARY OF THE INVENTION
The method of the present invention involves placing fracture treatments into a wellbore while the drilling operation is still under way (drilling ahead). The fracture treatment is bounded in the open hole on one side by the current end of the hole and on the other side by a temporary pack off isolation fluid that has been introduced to the well by way of either pumping down the existing drill string or by pumping down a separate frac string. In particular, the drill string or frac string remains in the wellbore, and the annulus between same and the wellbore is packed off with the temporary isolation fluid/material. The objective is to place the frac in the reservoir and flow it back very quickly after placement, thus increasing the chances of flowing back harmful formation damaging materials and increasing the relative productivity of the newly placed fracture treatment (compared to conventionally placed fracs).
Drilling then continues (with hydrocarbon and gas resources being recoverable even at this early stage) and fractures can be placed as closely to one another as practical. This is only limited by the effectiveness of the isolation fluid/material given the pressure created at the fracture site (called fracture initiation pressure) in the context of the subterranean formation at issue—the better the isolation fluid/material works, the shorter the required distance between fracture intervals. In this manner, multi-stage fractures can be placed in a wellbore as the well is drilled ahead, each one contributing cumulatively as the wellbore length is increased.
The net effect of the method of the present invention is that the well operator is able to determine in real time if a fracture treatment has been successful, including whether the fracture treatment composition is sufficient/should be changed, and whether this is having a net positive or negative effect on overall flow of the hydrocarbons or gas into the well. Based on the composition of the inflow up the well, the operator may determine, for instance, that the frac treatment has been effective or may determine that a different fracturing fluid/slurry should be employed for subsequent frac treatments based on the rock formation encountered. This is to be distinguished from conventional fracking techniques where there is no real time feedback, no way to know whether a proper fracturing fluid/slurry was used at a particular stage/site, and no way for an operator to know what must be done to improve performance.
Finally, this “Frac Ahead” process allows the operator to place multiple fractures (much like the dendritic pattern observed in leaf patterns) in multi lateral wellbores, thereby increasing swept reservoir volume to a previously unattainable level.
According to one aspect of the present invention, there is provided a method of drilling and completing a wellbore in a subterranean formation for the recovery of hydrocarbon or natural gas resources comprising the steps of:
(i) drilling an intermediate wellbore in a subterranean formation by means of a drill string; (ii) inserting a frac string into the wellbore and pumping into the wellbore through an opening in the frac string an isolation fluid that is sufficient to withstand fracture initiation pressure; (iii) pumping into the wellbore through an opening in the frac string a frac fluid at a pressure sufficient to create fractures in the subterranean formation in the vicinity of the end of the frac string; (iv) removing the frac string from the wellbore; (v) inserting the drill string into the wellbore and through the isolation fluid to flow any residual frac fluid and the isolation fluid back out of the wellbore; and (vi) extending the wellbore by means of the drill string,
whereby hydrocarbon or natural gas resources may flow from the fractures into the wellbore for the recovery thereof while drilling proceeds, and whereby steps (ii) to (vi) may be repeated throughout the entire length of the wellbore to create multi-fractured zones in the wellbore that cumulatively add to the recovery of hydrocarbon or natural gas resources.
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 exemplary embodiments in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the attached figures, wherein:
FIG. 1 is a diagram showing the drilling of an intermediate hole;
FIG. 2 is a diagram showing an open wellbore before intermediate casing is inserted;
FIG. 3 is a diagram showing the insertion of intermediate casing into the wellbore;
FIG. 4 is a diagram showing the cementing of the intermediate casing in the wellbore;
FIG. 5 is a diagram showing the intermediate casing cemented in the wellbore;
FIG. 6 is a diagram showing the drilling out of the shoe in the intermediate casing;
FIG. 7 is a diagram showing the drilling of a first section beyond the intermediate casing;
FIG. 8 is a diagram showing the open first section of the wellbore;
FIG. 9 is a diagram showing the insertion of a frac string into the first section of the wellbore;
FIG. 10 is a diagram showing the pumping of isolation fluid from the frac string into the first section of the wellbore;
FIG. 11 is a diagram showing the pumping of frac fluid from the frac string into the first section of the wellbore;
FIG. 12 is a diagram showing fractures created in the subterranean formation from the frac treatment to the first section of the wellbore;
FIG. 13 is a diagram showing the removal of the frac string from the wellbore;
FIG. 14 is a diagram showing the insertion of the drill string through the isolation fluid in the first section of the wellbore;
FIG. 15 is a diagram showing the flow of hydrocarbons or gas from the fractures into the first section of the wellbore;
FIG. 16 is a diagram showing the drill string extending to the end of the first section of the wellbore;
FIG. 17 is a diagram showing the drilling ahead of a section of the wellbore;
FIG. 18 is a diagram showing the open second section of the wellbore before the frac string is inserted;
FIG. 19 is a diagram showing the insertion of a frac string into the second section of the wellbore;
FIG. 20 is a diagram showing the pumping of isolation fluid from the frac string into the second section of the wellbore;
FIG. 21 is a diagram showing the pumping of frac fluid from the frac string into the second section of the wellbore to create fractures in the subterranean formation;
FIG. 22 is a diagram showing the removal of the frac string from the wellbore;
FIG. 23 is a diagram showing the insertion of the drill string through the isolation fluid in the second section of the wellbore;
FIG. 24 is a diagram showing the drilling ahead of a third section of the wellbore;
FIG. 25 is a diagram showing the open third section of the wellbore before the frac string is inserted;
FIG. 26 is a diagram showing the insertion of a frac string into the third section of the wellbore;
FIG. 27 is a diagram showing the pumping of isolation fluid from the frac string into the third section of the wellbore;
FIG. 28 is a diagram showing the pumping of frac fluid from the frac string into the third section of the wellbore to create fractures in the subterranean formation;
FIG. 29 is a diagram showing the removal of the frac string from the wellbore;
FIG. 30 is a diagram showing the insertion of the drill string through the isolation fluid in the third section of the wellbore;
FIG. 31 is a diagram showing the drilling ahead of a fourth section of the wellbore while hydrocarbons or gas are flowing into the wellbore;
FIG. 32 is a diagram showing the flowing of hydrocarbons or gas from fractures in the first, second, and third sections into the wellbore;
FIG. 33 is a plan view of hypothetical fractures in a single leg horizontal wellbore;
FIG. 34 is a plan view of hypothetical fractures in a single leg horizontal wellbore with an overlay showing the swept reservoir area;
FIG. 35 is a plan view of a hypothetical dendritic wellbore configuration in a subterranean formation;
FIG. 36 is a plan view showing production/flow of hydrocarbons or gas from fractures into the dendritic wellbores;
FIG. 37 is a plan view of a hypothetical dual horizontal wellbore configuration;
FIG. 38 is a plan view of a hypothetical dual horizontal wellbore configuration with an overlay showing the swept reservoir area; and
FIG. 39 is a plan view showing production/flow of hydrocarbons or gas from fractures into the dual horizontal wellbore.
The same reference numerals are used in different figures to denote similar elements.
DETAILED DESCRIPTION
The method of the present invention is generally used in horizontal wells but can also be used on vertical or deviated wells.
In an exemplary embodiment, with reference to FIG. 1 , an intermediate wellbore 2 is drilled in a subterranean formation 4 using a conventional drill string 6 with a conventional drill bit 8 attached to the end thereof. The drill string 6 is then withdrawn from the intermediate wellbore 2 (see FIG. 2 ) and an intermediate casing 10 is run into the wellbore 2 (see FIG. 3 ). The space between the outside of casing 10 and the wellbore 2 is called the annulus 12 . With reference to FIG. 4 , suitable cement 14 is pumped into the casing 10 under high pressure where it exits the end of the casing 10 (known as the shoe 16 ) and fills in the annulus 12 . In this respect, casing 10 is generally cemented into place, such that the cement 14 generally fills the space both inside at least an end section (shoe joint) of casing 10 as well as the annulus 12 . FIG. 5 shows the casing 10 wherein the cement 14 is hardened in place such that the shoe 16 is closed off. A person skilled in the art to which the invention relates will understand, however, that the use of the casing 10 in the manner described above is optional as methods according to the present invention can also be applied to “mono-bore” wellbore configurations.
With reference to FIG. 6 , the drill string 6 is then run into the casing 10 and drills out the shoe 16 of the intermediate casing 10 . With reference to FIG. 7 , the drill string 6 then continues drilling a first section of the wellbore 2 (indicated generally at 18 ) extending from and beyond the intermediate wellbore 2 . The drill string 6 is then withdrawn (see FIG. 8 ) and a frac string 20 is run into the first section 18 (see FIG. 9 ).
With reference to FIG. 10 , an isolation fluid 22 is introduced into the first section 18 through openings in the frac string 20 to fill all or part of the first section 18 . The isolation fluid 22 is one which can withstand the pressure created at the fracture (called fracture initiation pressure) and that therefore does not allow significant movement of a fracturing fluid to another part of the well. The isolation fluid 22 can be a suitable gel, for example.
With reference to FIG. 11 , a fracturing fluid 24 is then pumped into the first section 18 through an opening 26 in the frac string 20 at a pressure sufficient to create fractures 28 (i.e. sufficient enough to exceed the fracture gradient of the rock) in the subterranean formation 4 in the vicinity of the end of the frac string 20 and the end of the first section 18 . The fracturing fluid 24 is often a slurry of, for example, mainly water, and some sand and additives, but can include any suitable fluid including but not limited to water, salt water, hydrocarbon, acid, methanol, carbon dioxide, nitrogen, foam, emulsions, etc. Such fracturing fluids are well known to persons skilled in the art. FIG. 12 shows a different perspective view of the fractures 28 (tree-like dendritic fairways) propogating throughout the formation 4 in the vicinity of the end of the frac string 20 .
With reference to FIG. 13 , the frac string 20 is then withdrawn and the drill string 6 is run to the end of the first section 18 through the isolation fluid 22 (see FIG. 14 ). The isolation fluid 22 is then “cleaned up” by rotating the bit 8 through and flowing it back out of the well through the annulus between the drill string 6 and the open hole and between the drill string and the intermediate casing 10 , along with drilled material being circulated to the surface (not shown) and production (hydrocarbons or gas 30 ) from the newly formed fractures 28 (see FIGS. 15 and 16 ). The drill string 6 is then moved ahead to the end of the first section 18 , and a second section (indicated generally at 32 ) is drilled to extend the wellbore 2 (see FIG. 17 ). In so doing, an operator can then perform multi-stage fracking while the wellbore is being drilled/extended by repeating the isolation and fracturing steps described above. It is important to note that at this time, hydrocarbons or gas 30 are flowing into the well, and are therefore recoverable at this stage, even while drilling proceeds. As a result, the well operator is able to determine in real time if the recent fracture treatment has been successful at this early stage, including determining the sufficiency of the fracture treatment composition, and whether the fracture treatment is having a net positive or negative effect on flow of the hydrocarbons or gas 30 . Based on the composition of the inflow up the well, an operator may determine, for instance, that a given frac treatment has been effective or may determine that a different fracturing fluid/slurry should be employed for subsequent frac treatments based on the rock formation encountered. This is to be distinguished from conventional fracking techniques where there is no real time feedback, no way to know whether the fracturing fluid/slurry used was effective, and no way for an operator to know what must be done to improve performance.
The repeated isolation and multi-stage fracturing steps are shown in FIGS. 18 to 32 . In particular, with reference to FIG. 18 , the drill string 6 is withdrawn from the wellbore (see FIG. 18 ) and a frac string 20 is run into the second section 32 (see FIG. 19 ). With reference to FIG. 20 , an isolation fluid 22 is introduced into the second section 32 through openings in the frac string 20 to fill all or part of the second section 32 . With reference to FIG. 21 , a fracturing fluid 24 is then pumped into the second section 32 through an opening in the frac string 20 at a pressure sufficient to create fractures 28 in the subterranean formation 4 in the vicinity of the end of the frac string 20 and near the end of the second section 32 . With reference to FIG. 22 , the frac string 20 is then withdrawn and, with reference to FIG. 23 , the drill string 6 is run to the end of the second section 32 through the isolation fluid 22 (not shown). The isolation fluid 22 is “cleaned up” by rotating the bit 8 through and flowing it back out of the well through the annulus between the drill string 6 and the open hole and between the drill string and the intermediate casing 10 , along with drilled material being circulated to the surface (not shown) and production (hydrocarbons or gas 30 ) from the newly formed fractures 28 . In particular, with reference to FIG. 24 (which shows the drilling/extension of a third section 34 of the wellbore 2 ), because hydrocarbons or gas 30 are now flowing into the well from fractures 28 from both the first section 18 and the second section 32 , as noted above, the well operator is able to determine in real time if the second fracture treatment has been successful at this early stage, including whether the fracture treatment composition should be changed, and whether such treatment is having a net positive or negative effect on overall flow of the hydrocarbons or gas 30 into the well. Based on the composition of the inflow up the well, the operator may determine, for instance, that the given frac treatment has been effective or may determine that a different fracturing fluid/slurry should be employed for subsequent frac treatments based on the rock formation encountered. Once again, this is to be distinguished from conventional fracking techniques where there is no real time feedback, no way to know whether a proper fracturing slurry was used at a particular stage/site, and no way for an operator to know what must be done to improve performance.
The repeated process then continues at FIG. 25 . The drill string 6 is withdrawn and a frac string 20 is run into the third section 34 (see FIG. 26 ). With reference to FIG. 27 , an isolation fluid 22 is introduced into the third section 34 through openings in the frac string 20 to fill all or part of the third section 34 . With reference to FIG. 28 , a fracturing fluid 24 is then pumped into the third section 34 through an opening in the frac string 20 at a pressure sufficient to create fractures 28 in the subterranean formation 4 in the vicinity of the end of the frac string 20 and near the end of the third section 34 . With reference to FIG. 29 , the frac string 20 is then withdrawn and, with reference to FIG. 30 , the drill string 6 is run to the end of the third section 34 through the isolation fluid 22 (not shown). The isolation fluid 22 is “cleaned up” by rotating the bit 8 through and flowing it back out of the well through the annulus between the drill string 6 and the open hole and between the drill string and the intermediate casing 10 , along with drilled material being circulated to the surface (not shown) and production (hydrocarbons or gas 30 ) from the newly formed fractures 28 . In particular, with reference to FIG. 31 (which shows the drilling/extension of a fourth section 36 of the wellbore 2 ), because hydrocarbons or gas 30 are now flowing into the well from fractures 28 from both the first section 18 , the second section 32 , and the third section 34 (see FIG. 32 ), the well operator can determine in real time if the third fracture treatment has been successful at this early stage, including whether the fracture treatment composition should be changed, and whether such change is having a net positive or negative effect on overall flow of hydrocarbons or gas 30 into the well. Based on the composition of the inflow up the well, the operator may determine, for instance, that the given frac treatment has been effective or may determine that a different fracturing fluid/slurry should be employed for subsequent frac treatments based on the rock formation encountered. Once again, this is to be distinguished from conventional fracking techniques where there is no real time feedback, no way to know whether a proper fracturing slurry was used at a particular stage/site, and no way for an operator to know what must be done to improve performance. A person skilled in the art would understand that such a process could continue further throughout the entire desired length of the wellbore.
In another exemplary embodiment (not shown), the process may proceed as shown in FIGS. 1 to 5 , however, at this stage a hybrid drill/frac string with a drill BHA on the end (not shown) is then run into the casing 10 , the shoe 16 is drilled out, and a first section 18 extending from and beyond the intermediate wellbore 2 is drilled (as in FIG. 7 ). The drill BHA part would then be disconnected from the hybrid drill/frac string and withdrawn back up to the surface through the string using a wireline or similar arrangement. An isolation fluid 22 is then introduced into the first section 18 through the hybrid drill/frac string to fill all or part of the first section 18 . The isolation fluid 22 is one which can, as stated previously, withstand the pressure created at the fracture (called fracture initiation pressure) and that therefore does not allow significant movement of a fracturing fluid to another part of the well. The isolation fluid 22 can be a suitable gel for example. A fracturing fluid 24 is then introduced through the hybrid drill/frac string into the first section 18 at a pressure sufficient to fracture the subterranean formation 4 in the vicinity of the end of the string, in a manner similar to that shown in FIG. 11 . The fracturing fluid can, once again, be a slurry of, for example, mainly water, and some sand and additives, but can include any suitable fluid including but not limited to water, salt water, hydrocarbon, acid, methanol, carbon dioxide, nitrogen, foam, emulsions, etc. The isolation fluid is cleaned up by flowing it back out of well through the hybrid drill/frac string annulus. The hybrid drill/frac string is then moved ahead and a second section beyond the first section is drilled to extend the wellbore. The isolation and fracturing steps described above can then be repeated.
FIG. 33 shows a plan view of a single leg horizontal wellbore 2 with fractures 28 propogated in a subterranean formation 4 in accordance with the methods of the present invention. FIG. 34 shows the plan view of FIG. 33 with a grid overlay showing that a horizontal wellbore 1000 m in length, with fractures extending 200 m both above and below the wellbore, will catch hydrocarbons or gas from a reservoir area of approximately 40,000 m 2 .
FIG. 35 shows that vertical or deviated wellbores 38 can be created from a horizontal wellbore 2 in accordance with the methods of the present invention in order to create a further dendritic fracture pattern in the subterranean formation. Such a wellbore and fracture pattern can be used to increase the production of hydrocarbons or gas 30 from a well site, as shown in FIG. 36 . In particular, by having, for instance, a dual wellbore configuration, as shown in FIG. 37 that is 1000 m in length, with each such wellbore having fractures that extend 200 m both above and below each wellbore, the reservoir drainage area increases significantly to approximately 80,000 m 2 (see FIG. 38 ). FIG. 39 shows how each fracture in a dual wellbore contributes to the overall production of the well.
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A method of drilling and stimulating subterranean formations is provided that allows a well operator to determine in real time if a fracture treatment has been successful, and whether the fracture treatment composition is sufficient for subsequent fracking. The method involves placing fracture treatments into a wellbore while the drilling operation is still under way. The fracture treatment is bounded in the open hole on one side by the current end of the hole and on the other side by a temporary pack off isolation fluid that has been introduced to the well by way of pumping down the existing drill string or by pumping down a separate frac string. The objective is to place the frac in the reservoir and flow it back very quickly after placement, thus increasing the chances of flowing back harmful formation damaging materials and increasing the relative productivity of the newly placed fracture treatment.
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PRIORITY DOCUMENTS
[0001] This application is a divisional of U.S. patent application Ser. No. 13/336,981, filed Dec. 23, 2011 and entitled “Controlled Pressure Pulser for Coiled Tubing Applications” which is a nonprovisional filing of U.S. provisional application No. 61/529,329 entitled “Full Flow Pulser for Measurement While Drilling (MWD) Device” and filed on Aug. 31, 2011. In addition the entire contents of both applications, along with U.S. Pat. No. 7,958,952 entitled “Pulse Rate of Penetration Enhancement Device and Method” and filed on Dec. 17, 2008, are hereby incorporated by reference.
FIELD OF DISCLOSURE
[0002] The current invention includes an apparatus and a method for controlling a pulse created within drilling fluid or drilling mud traveling along the internal portion of a coiled tubing (CT) housing by the use of a flow throttling device (FTD). The pulse is normally generated by selectively initiating flow driven bidirectional pulses due to proper geometric mechanical designs within a pulser. Coiled Tubing (CT) is defined as any continuously-milled tubular product manufactured in lengths that requires spooling onto a take-up reel, during the primary milling or manufacturing process. The tube is nominally straightened prior to being inserted into the wellbore and is recoiled for spooling back onto the reel. Tubing diameter normally ranges from 0.75 inches to 4 inches and single reel tubing lengths in excess of 30,000 ft. have been commercially manufactured. Common CT steels have yield strengths ranging from 55,000 PSI to 120,000 PSI and the limit is usually reached at no more than 5 inch diameters due to weight limitations. The coiled tubing unit is comprised of the complete set of equipment necessary to perform standard continuous-length tubing operations in the oil or gas exploration field. The unit consists of four basic elements:
1. Reel—for storage and transport of the CT 2. Injector Head—to provide the surface drive force to run and retrieve the CT 3. Control Cabin—from which the equipment operator monitors and controls the CT 4. Power Pack—to generate hydraulic and pneumatic power required to operate the CT unit.
[0007] Features of the combined pulsing and CT device include operating a full flow throttling device [FTD] that provides pulses providing more open area to the flow of the drilling fluid in a CT device that also allows for intelligent control above or below a positive displacement motor with downlink capabilities as well as providing and maintaining weight on bit with a feedback loop such that pressure differentials within the collar and associated annular of the FTD inside the bore pipe to provide information for reproducible properly guided pressure pulses with low noise signals. The pulse received “up hole” from the tool down hole includes a series of pressure variations that represent pressure signals which may be interpreted as inclination, azimuth, gamma ray counts per second, etc. by oilfield engineers and managers and utilized to further increase yield in oilfield operations.
BACKGROUND
[0008] This invention relates generally to the completion of wellbores. More particularly, this invention relates to new and improved methods and devices for completion, extension, fracing and increasing rate of penetration (ROP) in drilling of a branch wellbore extending laterally from a primary well which may be vertical, substantially vertical, inclined or horizontal. This invention finds particular utility in the completion of multilateral wells, that is, downhole well environments where a plurality of discrete, spaced lateral wells extend from a common vertical wellbore.
[0009] Horizontal well drilling and production have been increasingly important to the oil industry in recent years due to findings of new or untapped reservoirs that require special equipment for such production. While horizontal wells have been known for many years, only relatively recently have such wells been determined to be a cost effective alternative (or at least companion) to conventional vertical well drilling. Although drilling a horizontal well costs substantially more than its vertical counterpart, a horizontal well frequently improves production by a factor of five, ten, or even twenty of those that are naturally fractured reservoirs. Generally, projected productivity from a horizontal well must triple that of a vertical hole for horizontal drilling to be economical. This increased production minimizes the number of platforms, cutting investment and operational costs. Horizontal drilling makes reservoirs in urban areas, permafrost zones and deep offshore waters more accessible. Other applications for horizontal wells include periphery wells, thin reservoirs that would require too many vertical wells, and reservoirs with coning problems in which a horizontal well could be optimally distanced from the fluid contact.
[0010] Horizontal wells are typically classified into four categories depending on the turning radius:
1. An ultra-short turning radius is 1-2 feet; build angle is 45-60 degrees per foot. 2. A short turning radius is 20-100 feet; build angle is 2-5 degrees per foot. 3. A medium turning radius is 300-1,000 feet; build angle is 6-20 degrees per 100 feet. 4. A long turning radius is 1,000-3,000 feet; build angle is 2-6 degrees per 100 feet.
[0015] These additional lateral wells are sometimes referred to as drainholes and vertical wells containing more than one lateral well are referred to as multilateral wells. Multilateral wells are becoming increasingly important, both from the standpoint of new drilling operations and from the increasingly important standpoint of reworking existing wellbores including remedial and stimulation work.
[0016] As a result, the foregoing increased dependence on and importance of horizontal wells, horizontal well completion, and particularly multilateral well completion, important concerns provide a host of difficult problems to overcome. Lateral completion, particularly at the juncture between the vertical and lateral wellbore is extremely important in order to avoid collapse of the well in unconsolidated or weakly consolidated formations. Thus, open hole completions are limited to competent rock formations; and even then open hole completions are inadequate since there is no control or ability to re-access (or re-enter the lateral) or to isolate production zones within the well. Coupled with this need to complete lateral wells is the growing desire to maintain the size of the wellbore in the lateral well as close as possible to the size of the primary vertical wellbore for ease of drilling and completion.
[0017] Conventionally, horizontal wells have been completed using either slotted liner completion, external casing packers (ECP's) or cementing techniques. The primary purpose of inserting a slotted liner in a horizontal well is to guard against hole collapse. Additionally, a liner provides a convenient path to insert coiled tubing in a horizontal well. Three types of liners have been used namely (1) perforated liners, where holes are drilled in the liner, (2) slotted liners, where slots of various width and depth are milled along the line length, and (3) pre-packed liners.
[0018] Slotted liners provide limited sand control through selection of hole sizes and slot width sizes. However, these liners are susceptible to plugging. In unconsolidated formations, wire wrapped slotted liners have been used to control sand production. Gravel packing may also be used for sand control in a horizontal well. The main disadvantage of a slotted liner is that effective well stimulation can be difficult because of the open annular space between the liner and the well. Similarly, selective production (e.g., zone isolation) is difficult.
[0019] Another option is a liner with partial isolations. External casing packers (ECPs) have been installed outside the slotted liner to divide a long horizontal well bore into several small sections. This method provides limited zone isolation, which can be used for stimulation or production control along the well length. However, ECP's are also associated with certain drawbacks and deficiencies. For example, normal horizontal wells are not truly horizontal over their entire length; rather they have many bends and curves. In a hole with several bends it may be difficult to insert a liner with several external casing packers. Finally, it is possible to cement and perforate medium and long radius wells as shown, for example, in U.S. Pat. No. 4,436,165.
[0020] While sealing the juncture between a vertical and lateral well is of importance in both horizontal and multilateral wells, re-entry and zone isolation is of particular importance and pose particularly difficult problems in multilateral wells completions. Re-entering lateral wells is necessary to perform completion work, additional drilling and/or remedial and stimulation work. Isolating a lateral well from other lateral branches is necessary to prevent migration of fluids and to comply with completion practices and regulations regarding the separate production of different production zones. Zonal isolation may also be needed if the borehole drifts in and out of the target reservoir because of insufficient geological knowledge or poor directional control; and because of pressure differentials in vertically displaced strata as will be discussed below.
[0021] When horizontal boreholes are drilled in naturally fractured reservoirs, zonal isolation is seen as desirable. Initial pressure in naturally fractured formations may vary from one fracture to the next, as may the hydrocarbon gravity and likelihood of coning. Allowing different fractures to produce together, permits cross flow between fractures and a single fracture with early water breakthrough, which may jeopardize the entire well's production.
[0022] As mentioned above, initially horizontal wells were completed with uncemented slotted liner unless the formation was strong enough for an open hole completion. Both methods make it difficult to determine producing zones and, if problems develop, practically impossible to selectively treat the right zone. Today, zone isolation is achieved using either external casing packers on slotted or perforated liners or by conventional cementing and perforating.
[0023] The problem of lateral wellbore (and particularly multilateral wellbore) completion has been recognized for many years as reflected in the patent literature. For example, U.S. Pat. No. 4,807,704 discloses a system for completing multiple lateral wellbores using a dual packer and a deflective guide member. U.S. Pat No. 2,797,893 discloses a method for completing lateral wells using a flexible liner and deflecting tool. U.S. Pat. No. 2,397,070 similarly describes lateral wellbore completion using flexible casing together with a closure shield for closing off the lateral. In U.S. Pat. No. 2,858,107, a removable whipstock assembly provides a means for locating (e.g., re-entry) a lateral subsequent to completion thereof.
[0024] Notwithstanding the above-described attempts at obtaining cost effective and workable lateral well completions, there continues to be a need for new horizontal wells to increase, for example, unconventional shale plays—which are wells exhibiting low permeability and therefore requiring horizontal laterals increasing in length to maximize reservoir contact. With increased lateral length, the number of zones fractured increases proportionally.
[0025] Most of these wells are fractured using the “Plug and Perf” method which requires perforating the zone nearest the toe of the horizontal section, fracturing that zone and then placing a composite plug (pumped down an electrical line) followed by perforating the next set of cluster. The process is repeated numerous times until all the required zones are stimulated. Upon completing the fracturing operation, the plugs are removed with a positive displacement motor (PDM) and mill run on coiled tubing. As the lateral length increases, milling with coiled tubing becomes less efficient, leading to the use of jointed pipe for removing plugs.
[0026] Two related reasons cause this reduction in efficiency of the CT. First, as the depth increases, the effective maximum weight on bit (WOB) decreases. Second, at increased lateral depths, the coiled tubing is typically in a stable helical spiral in the wellbore. The operator sending the additional coiled tubing (and weight from the surface) will have to overcome greater static loads leading to a longer and inconsistent transmission of load to the bit. This phenomenon is referred to as “stick/slip” in field operations. The onset of these two effects is controlled by several factors including; CT shell thickness, wellbore deviation and build angle, completion size, CT/completion contact friction drag, fluid drag, debris, and bottomhole assembly (BHA) weight and size. CT outer diameter less than 4 inches tends to buckle due to easier helical spiraling, thus increasing the friction from the increased contact surface with the wall of the bore hole. CT outer diameter above 4 inches is impractical due to weight and friction limitations, wellbore deviation is normally not well controlled, friction drag is a function of CT shell thickness and diameter, leaving end loads as one of the variables most studied for manipulation to achieve better well completion.
SUMMARY
[0027] The need to effectively overcome these challenges for both lateral reach and improved plug milling has led to the development of the current CT/pulser tool. The tool allows for improved methods that provide better well completions, the ability to re-enter lateral wells (particularly in multilateral systems), achieving extended reach zone isolation between respective lateral wells in a multilateral well system, communicating uphole the downhole formation information, better rate and direction of penetration with proper WOB, as well as providing for controlled pulsing of the pulser in a proper directional manner.
[0028] Current pulser technology utilizes pulsers that are sensitive to different fluid pump down hole pressures, and flow rates, and require field adjustments to pulse properly so that meaningful signals from these pulses can be received and interpreted uphole using Coil Tubing (CT) technology. Newer technology incorporated with CT has included the use of water hammer devices producing a force when the drilling fluid is suddenly stopped or interrupted by the sudden closing of a valve. This force created by the sudden closing of the valve can be used to pull the coiled tubing deeper into the wellbore. The pull is created by increasing the axial stress in the coiled tubing and straightening the tubing due to momentary higher fluid pressure inside the tubing and thus reducing the frictional drag. This task—generating the force by opening and closing valves—can be accomplished in many ways—and is also the partial subject of the present disclosure.
[0029] The present disclosure and associated embodiments allows for providing a pulser system within coil tubing such that the pulser decreases sensitivity to fluid flow rate or overall fluid pressure within easily achievable limits, does not require field adjustment, and is capable of creating recognizable, repeatable, reproducible, clean [i.e. noise free] fluid pulse signals using minimum power due to a unique flow throttling device [FTD]. The pulser is a full flow throttling device without a centralized pilot port, thus reducing wear, clogging and capital investment of unnecessary equipment as well as increasing longevity and dependability in the down hole portion of the CT. This augmented CT still utilizes battery, magneto-electric and/or turbine generated energy to provide (MWD) measurement while drilling, as well as increased (ROP) rate of penetration capabilities within the CT using the FTD of the present disclosure.
[0030] Additional featured benefits of the present inventive device and associated methods include having a pulser tool above and/or below the PDM (positive displacement motor) allowing for intelligence gathering and transmitting of real time data by using the pulser above the motor and as an efficient drilling tool with data being stored in memory below the motor with controlled annular pressure, acceleration, as well as downhole WOB control. The WOB control is controlled by using a set point and threshold for the axial force provided by the shock wave generated using the FTD. Master control is provided uphole with a feedback loop from the surface of the well to the BHA above and/or below the PDM
[0031] The coiled tubing industry continues to be one of the fastest growing segments of the oilfield services sector, and for good reason. CT growth has been driven by attractive economics, continual advances in technology, and utilization of CT to perform an ever-growing list of field operations. The economic advantages of the present invention include; increased efficiency of milling times of the plugs by intelligent downhole assessments, extended reach of the CT to the end of the run, allowing for reduction of time on the well and more efficient well production (huge cost avoidances), reduced coil fatigue by eliminating or reducing CT cycling (insertion and removal of the CT from the well), high pressure pulses with little or no kinking and less friction as the pulses are fully controlled, and a lower overall power budget due to the use of the intelligent pulser.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is an overview of the full flow MWD.
[0033] FIG. 2 is a pulsar control flow diagram for coil tubing application
DETAILED DESCRIPTION
[0034] The present invention will now be described in greater detail and with reference to the accompanying drawings.
[0035] With reference to FIG. 1 , the pulser assembly [ 400 ] device illustrated produces pressure pulses in drilling fluid main flow [ 110 ] flowing through a tubular hang-off collar [ 120 . The flow cone [ 170 ] is secured to the inner diameter of the tubular hang-off collar [ 120 ] and includes a pilot flow upper annulus [ 160 ]. Major assemblies of the MWD are shown as provided including aligned within the bore hole of the hang-off collar [ 120 ] are the pilot flow screen assembly [ 135 ], the main valve actuator assembly [ 229 ], the pilot actuator assembly [ 335 ] (comprising a rear pilot shaft [ 336 ], front pilot shaft [ 337 ], pilot shield [ 270 ], and pilot [ 338 ]), and the helical pulser support [ 480 ].
[0036] In FIG. 1 , starting from top is the pilot flow screen assembly [ 135 ] which houses the pilot flow screen [ 130 ] which leads to the pilot flow upper annulus [ 160 ], the flow cone [ 170 ] and the main orifice [ 180 ].
[0037] In FIG. 1 , starting from an outside position and moving toward the center of the main valve actuator assembly [ 229 ] comprising a main valve [ 190 ], a main valve pressure chamber [ 200 ], a main valve support block [ 350 ], main valve seals [ 225 ] and pilot flow seals [ 245 ]. Internal to the main valve support block [ 350 ] is a main valve feed channel [ 220 ] and the pilot orifice [ 250 ].
[0038] The pilot actuator assembly [ 335 ] houses the pilot valve [ 260 ], pilot flow shield [ 270 ], bellows [ 280 ] and the anti-rotation block [ 290 ], rotary magnetic coupling [ 300 ], the bore pipe pressure sensor [ 420 ], the annular pressure sensor [ 470 ], as well as a helically cut cylinder [ 490 ] which rests on the helical pulser support [ 480 ] and tool face alignment key [ 295 ] that keeps the pulser assembly rotated in a fixed position in the tubular hang-off collar [ 120 ]. This figure also shows the passage of the drilling fluid main flow [ 110 ] past the pilot flow screen [ 130 ] through the main flow entrance [ 150 ], into the flow cone [ 170 ], through the main orifice [ 180 ] into and around the main valve [ 190 ], past the main valve pressure chamber [ 200 ], past the main valve seals [ 225 ] through the main valve support block [ 350 ], after which it combines with the pilot exit flow [ 320 ]] both of which flow through the pilot valve support block [ 330 ] to become the main exit flow [ 340 ].
[0039] The pilot flow [ 100 ] flows through the pilot flow screen [ 130 ] into the pilot flow screen chamber [ 140 ], through the pilot flow upper annular[ 160 ], through the pilot flow lower annulus [ 210 ] and into the pilot flow inlet channel [ 230 ], where it then flows up into the main valve feed channel [ 220 ] until it reaches the main valve pressure chamber [ 200 ] where it flows back down the main valve feed channel [ 220 ], through the pilot flow exit channel [ 360 ], through the pilot orifice [ 250 ], past the pilot valve [ 260 ] where the pilot exit flow [ 320 ] flows over the pilot flow shield [ 270 ] where it combines with the drilling fluid main flow [ 110 ] to become the main exit flow [ 340 ] as it exits the pilot valve support block [ 330 ] and flows past the bore pipe pressure sensor [ 420 ] and the annulus pressure sensor [ 470 ] imbedded in the pilot valve support block [ 330 ] on either side of the rotary magnetic coupling [ 300 ], past the drive shaft [ 305 ] and the drive motor [ 310 ]. The pilot flow lower annulus [ 210 ] extends beyond the pilot flow inlet channel [ 230 ] in the main valve support block [ 350 ], to the pilot valve support block [ 330 ] where it connects to the bore pipe pressure inlet [ 410 ] where the bore pipe pressure sensor [ 420 ] is located. Inside the pilot valve support block [ 330 ] also housed an annulus pressure sensor [ 470 ] which is connected through an annulus pressure inlet [ 450 ] to the collar annulus pressure port [ 460 ]. The lower part of the pilot valve support block [ 330 ] is a helically cut cylinder [ 490 ] that mates with and rests on the helical pulser support [ 480 ] which is mounted securely against rotation and axial motion in the tubular hang-off collar [ 120 ]. The helical pulser support [ 480 ] is designed such that as the helically cut cylinder [ 490 ] of the pilot valve support block [ 330 ] sits on it, the annulus pressure inlet [ 450 ] is aligned with the collar annulus pressure port [ 460 ]. The mating area of the pressure ports are sealed off by flow guide seals [ 240 ] to insure that the annulus pressure sensor [ 470 ] receives only the annulus pressure from the collar annulus pressure port [ 460 ]. The electrical wiring of the pressure sensors [ 420 , 470 ] are sealed off from the fluid of the main exit flow [ 340 ] by using sensor cavity plugs [ 430 ] and the wires are routed to the electrical connector [ 440 ].
[0040] The pilot actuator assembly [ 335 ] includes a magnetic pressure cup [ 370 ], and encompasses the rotary magnetic coupling [ 300 ]. The magnetic pressure cup [ 370 ] and the rotary magnetic coupling [ 300 ] may comprise several magnets, or one or more components of magnetic or ceramic material exhibiting several magnetic poles within a single component. The magnets are located and positioned in such a manner that the rotary movement or the magnetic pressure cup [ 370 ] linearly and axially moves the pilot valve [ 260 ]. The rotary magnetic coupling [ 300 ] is actuated by the drive motor [ 310 ] via the drive shaft [ 305 ].
[0041] The information flow on the Pulser Control Flow Diagram in FIG. 2 details the smart pulser operation sequence. The drilling fluid pump, known as the mud pump [ 500 ] is creating the flow with a certain base line pressure. That fluid pressure is contained in the entirety of the interior of the drill string [ 510 ], known as the bore pressure. The bore pipe pressure sensor [ 420 ] is sensing this pressure increase when the pumps turn on, and send that information to the Digital Signal Processor (DSP) [ 540 ] which interprets it. The DSP [ 540 ] also receives information from the annulus pressure sensor [ 470 ] which senses the drilling fluid (mud) pressure as it returns to the pump [ 500 ] in the annular (outside) of the drill pipe [ 520 ]. Based on the pre-programmed logic [ 530 ] in the software of the DSP [ 540 ], and on the input of the two pressure sensors [ 420 , 470 ] the DSP [ 540 ] determines the correct pulser operation settings and sends that information to the pulser motor controller [ 550 ]. The pulser motor controller [ 550 ] adjusts the stepper motor [ 310 ] current draw, response time, acceleration, duration, revolution, etc. to correspond to the pre-programmed pulser settings [ 530 ] from the DSP [ 540 ]. The stepper motor [ 310 ] driven by the pulser motor controller [ 550 ] operates the pilot actuator assembly [ 335 ] from FIG. 1 . The pilot actuator assembly [ 335 ], responding exactly to the pulser motor controller [ 550 ], opens and closes the main valve [ 190 ], from FIG. 1 , in the very sequence as dictated by the DSP [ 540 ]. The main valve [ 190 ] opening and closing creates pressure variations of the fluid pressure in the drill string [ 510 ] on top of the bore pressure which is created by the mud pump [ 500 ]. The main valve [ 190 ] opening and closing also creates pressure variations of the fluid pressure in the annulus of the drill string on top of the base line annulus pressure created in the annular of the drill pipe [ 520 ] because the fluid movement restricted by the main valve [ 190 ] affects the fluid pressure downstream of the pulser assembly [ 400 ] through the drill it jets into the annulus of the bore hole. Both the annulus pressure sensor [ 470 ] and the bore pipe pressure sensor [ 420 ] detecting the pressure variation due to the pulsing and the pump base line pressure sends that information to the DSP [ 540 ] which determines the necessary action to be taken to adjust the pulser operation based on the pre-programmed logic [ 530 ].
[0000] Operation—Operational Pilot Flow—all when the pilot is in the closed position;
[0042] In FIG. 1 the drive motor [ 310 ] rotates the rotary magnetic coupling [ 300 ] via a drive shaft [ 305 ] which transfers the rotary motion to linear motion of the pilot valve [ 260 ] by using an anti-rotation block [ 290 ]. The mechanism of the rotary magnetic coupling [ 300 ] is immersed in oil and is protected from the drilling fluid flow by a bellows [ 280 ] and a pilot flow shield [ 270 ]. When the drive motor [ 310 ] moves the pilot valve [ 260 ] forward [upward in FIG. 1 ] into the pilot orifice [ 250 ], the pilot fluid flow is blocked and backs up in the pilot flow exit channel [ 360 ], pilot flow inlet channel [ 230 ], the pilot flow lower annulus [ 210 ] and in the pilot flow upper annular[ 160 ] all the way back to the pilot flow screen [ 130 ] which is located in the lower velocity flow area due to the larger flow area of the main flow [ 110 ] and pilot flow [ 100 ] where the pilot flow fluid pressure is higher than the fluid flow through the restricted area of the main orifice [ 180 ]. The pilot fluid flow [ 100 ] in the pilot flow exit channel [ 360 ] also backs up through the main valve feed channel [ 220 ] and into the main valve pressure chamber [ 200 ]. The fluid pressure in the main valve pressure chamber [ 200 ] is equal to the drilling fluid main flow [ 110 ] pressure, and this pressure is higher relative to the pressure of the main fluid flow in the restricted area of the main orifice [ 180 ] in the front portion of the main valve [ 190 ]. This differential pressure between the pilot flow in the main valve pressure chamber [ 200 ] area and the main flow through the main orifice [ 180 ] causes the main valve [ 190 ] to act like a piston and to move toward closure [still upward in FIG. 1 to stop the flow of the main fluid flow [ 110 ] causing the main valve [ 190 ] to stop the drilling fluid main flow [ 110 ] through the main orifice [ 180 ]. As the drilling fluid main flow [ 110 ] stops at the main valve [ 190 ] its pressure increases. Since the pilot flow lower annulus [ 210 ] extends to the bore pipe pressure inlet [ 410 ] located in the pilot valve support block [ 330 ] the pressure change in the pilot fluid flow reaches the bore pipe pressure sensor [ 420 ] which transmits that information through the electrical connector [ 440 ] to the DSP [ 540 ] as shown in FIG. 2 . The DSP [ 540 ] together with pressure data from the annulus pressure sensor [ 470 ] adjusts the pilot valve operation based on pre-programmed logic [ 530 ] to achieve the desired pulse characteristics.
Opening Operation
[0043] When the drive motor [ 310 ] moves the pilot valve [ 260 ] away [downward in FIG. 1 ] from the pilot orifice [ 250 ] allowing the fluid to exit the pilot exit flow [ 320 ] and pass from the pilot flow exit channel [ 360 ] relieving the higher pressure in the main valve pressure chamber [ 200 ] which causes the fluid pressure to be reduced and the fluid flow to escape In. this instance, the drilling fluid main flow [ 110 ] having higher pressure than the main valve pressure chamber [ 200 ] is forced to flow through the main orifice [ 180 ] to push open [downward in FIG. 1 ] the main valve [ 190 ], thus allowing the drilling fluid main flow [ 110 ] to bypass the main valve [ 190 ] and to flow unencumbered through the remainder of the tool.
Pilot Valve in the Open Position
[0044] As the drilling fluid main flow [ 110 ] combined with the pilot flow [ 100 ] enter the main flow entrance [ 150 ] and flow through into the flow cone area [ 170 ], by geometry [decreased cross-sectional area], the velocity of the fluid flow increases. When the fluid reaches the main orifice [ 180 ] the fluid flow velocity is and the pressure of the fluid is decreased relative to the entrance flows [main flow entrance area vs. the orifice area] [ 180 ]. When the pilot valve [ 260 ] is in the opened position, the main valve [ 190 ] is also in the opened position and allows the fluid to pass through the main orifice [ 180 ] and around the main valve [ 190 ], through the openings in the main valve support block [ 350 ] through the pilot valve support block [ 330 ] and subsequently into the main exit flow [ 340 ].
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An apparatus, method, and system for generating pressure pulses in a drilling fluid flowing within coiled tubing assembly is described that includes; a flow throttling device longitudinally and axially positioned within the center of a main valve actuator assembly that allows main exit flow fluid to flow past a drive shaft and motor such that the pilot fluid and the main exit flow fluid causes one or more flow throttling devices to generate large, rapid controllable pulses. The pulses generated by the flow throttling device thereby allow transmission of well-developed signals easily distinguished from any noise resulting from other vibrations due to nearby equipment within the borehole or exterior to the borehole, or within the coiled tubing assembly wherein the signals also provide predetermined height, width and shape of the signals.
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PRIORITY AND CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 14/584,981, filed on Dec. 29, 2014, which is a continuation of U.S. patent application Ser. No. 13/854,795, filed on Apr. 1, 2013, now U.S. Pat. No. 8,959,863, which claims the benefit of U.S. Provisional Patent Application 61/650,179, filed on May 22, 2012, the disclosures of each incorporated herein by reference in their entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates in general to a method and apparatus for filling and fire-proofing holes in concrete floors, and more specifically, to a method for utilizing an apparatus or precast plug to repair and restore holes.
COPYRIGHT & TRADEMARK NOTICE
[0003] A portion of the disclosure of this patent application may contain material that is subject to copyright protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever.
[0004] Certain marks referenced herein may be common law or registered trademarks of third parties affiliated or unaffiliated with the applicant or the assignee. Use of these marks is by way of example and should not be construed as descriptive or to limit the scope of this invention to material associated only with such marks.
BACKGROUND OF THE INVENTION
[0005] Typically, a condition in a lease contract between a commercial building owner and a tenant is that at the end of the lease the tenant must return the leased premises in the same condition that it was in at the time the tenant took possession, save for normal wear and tear. During the course of a tenancy, a lessee will typically cause numerous holes to be drilled into the concrete floor and/or ceiling of his suite to accommodate the routing of electrical wires, plumbing pipes, voice cables, and other such items that run through the floors. In the great majority of mid and high rise office buildings, these floors are constructed of a lightweight aggregate poured on a metal underlayment or pan. This flooring assembly provides a fire break between floors. When the tenant vacates the premises, the drilled holes during the tenancy are left wide open as a result of the removal of the wiring, plumbing, etc. that had been previously installed. This is potentially a breach of the fire control properties of the flooring assembly. These holes are typically three to four inches in diameter, but can range up to twelve inches or larger. Until recently, most property owners did not recognize this as a problem, and as a result did not require the vacating tenant to repair and restore these holes. More recently, it has been recognized, however, as an issue that must be remedied before a new tenant can take possession of the property.
[0006] There are several products on the market that can be used to restore the fire break properties of the flooring assembly. Most utilize a mechanical closure of the hole by installing an expandable metal plug or cap, and require that they be installed through the bottom of the hole. This solution often requires that access to the underside of the floor be granted by another tenant or the owner. Such access may be disruptive, cause security and liability issues, necessitate that the repair work be performed after normal working hours, and cause possible damage to another tenant's property. The parts and labor associated with these products tend to be rather expensive as well.
[0007] Another problem with other products is that the final repair results in a protruding floor surface. This is a design flaw that complicates future use of the floor where the protrusion is located.
[0008] Yet another problem related to repairing holes after a lease has expired is shoddy repair work. To honor the lease, a tenant may merely stuff a rag or other such material in the hole and then fill it with a plaster, such as FIX-IT-ALL™. Such a repair is insufficient, as there is nothing to keep the rag and plaster from falling through the floor into the suite below. Moreover, such a repair may be prone to water leaks and likely does not conform to the fire code, and testing these properties would be overly burdensome, defeating the purpose of the repair in the first place.
[0009] Therefore, there are several problems with the current state of the art, which have not been adequately addressed. The problems persist because a need to provide a method and apparatus for filling & fire-proofing holes in concrete floors has not been adequately met. It is to these ends that the present invention has been developed.
BRIEF SUMMARY OF THE INVENTION
[0010] To minimize the limitations in the prior art, and to minimize other limitations that will be apparent upon reading and understanding the present specification, the present invention describes a method and apparatus (or precast plug) for sealing a hole in a floor comprising a concrete housing and at least one rod whereby the distal end of said at least one rod makes at least one protrusion from at least one edge of said concrete housing.
[0011] An apparatus, in accordance with an exemplary embodiment of the present invention, comprises: a concrete housing configured to substantially seal a hole in the floor of a building; a rod situated within the concrete housing, the rod including a first and second portions protruding from the concrete housing, wherein the first and second portions are configured to register with one or more grooves on the surface of the floor and adjacent to the hole; and a support component coupled to the rod, the support component embedded within the concrete housing.
[0012] A method, in accordance with an exemplary embodiment of the present invention, comprises: dry-fitting a precast plug into a hole of a floor assembly; drawing an outline of one or more rods that extend from the concrete housing of the precast plug; creating grooves adjacent to the hole, the grooves configured to receive portions of the rod external to the concrete housing; applying a sealant to the interior surface of the hole; applying sealant to the concrete housing of the precast plug; and inserting the precast plug into the hole in a manner so that: the external portions of the rod register with the grooves adjacent to the hole, and the external portions of the rod are substantially flush with the surface of the floor.
[0013] Another method, in accordance with an exemplary embodiment of the present invention, comprises: preparing a wet cement mixture; pouring said wet cement mixture into a form mold housing; installing into said form mold housing a first rod whereby the distal end of said first rod makes a first protrusion from a first edge of said form mold housing and the proximal end of said first rod makes a second protrusion from a second edge of said form mold housing; allowing said mixture to cure with said first rod in place, thereby creating said pre-cast plug; grinding a first and second groove into said floor to house said distal and proximal ends of said first rod; coating said precast plug's edges with said sealant; placing said precast plug into said hole such that the distal and proximal ends of said first rod rest in said first and second grooves; and allowing said sealant to cure.
[0014] It is an objective of the present invention to seal a hole in a floor such as to make it fire resistant, water resistant, and structurally sound.
[0015] It is another objective of the present invention to allow for ease of installation, making a repair job quick and efficient.
[0016] It is yet another objective of the present invention to repair a hole in a floor, such that the apparatus is flush with the floor's surface.
[0017] These and other advantages and features of the present invention are described herein with specificity so as to make the present invention understandable to one of ordinary skill in the art.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] Elements in the figures have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of these various elements and embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the apparatus and method.
[0019] FIG. 1 is a three dimensional exploded cross-section view depicting an apparatus, in accordance with an exemplary embodiment of the present invention, above a cutout section of a floor assembly with a hole, before it is place in said hole.
[0020] FIG. 2 is a three dimensional cross-section view of an apparatus that has been placed in a hole in a cutout section of a floor assembly.
[0021] FIG. 3 depicts a top view of an apparatus used to fill a hole, in accordance with an exemplary embodiment of the present invention, fully installed into a hole.
[0022] FIG. 4 depicts a cross-sectional side view of the apparatus as shown in FIG. 3 .
[0023] FIG. 5 depicts a top view of an apparatus used to fill a hole, in accordance with another exemplary embodiment of the present invention.
[0024] FIG. 6 depicts a cross-sectional side view of the apparatus as shown in FIG. 5 .
[0025] FIG. 7 depicts a top view of an apparatus used to fill a hole, in accordance with another exemplary embodiment of the present invention.
[0026] FIG. 8 depicts a cross-sectional side view of the apparatus as shown in FIG. 7 .
[0027] FIG. 9 depicts a top view of an apparatus used to fill a hole, in accordance with another exemplary embodiment of the present invention.
[0028] FIG. 10 depicts a cross-sectional side view of the apparatus as shown in FIG. 9 .
[0029] FIG. 11 is a three dimensional exploded cross-section view depicting an apparatus, in accordance with another exemplary embodiment of the present invention, above a cutout section of a floor assembly with a hole, before it is place in said hole.
[0030] FIG. 12 is a perspective view of the apparatus depicted in FIG. 11 , showing a rod situated within a housing, and a support component coupled to the rod.
[0031] FIG. 13 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 12 .
[0032] FIG. 14 is a perspective view of the apparatus depicted in FIG. 11 , which includes another embodiment of a supporting component coupled to the rod.
[0033] FIG. 15 is a side-view of the supporting component depicted in FIG. 14 .
[0034] FIG. 16 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 14 and FIG. 15 .
[0035] FIG. 17 is a top view of the apparatus depicted in FIG. 11 or FIG. 14 , used to fill a hole.
[0036] FIG. 18 is a perspective view of another exemplary embodiment, wherein an additional support rod is used.
[0037] FIG. 19 is a top view of the apparatus depicted in FIG. 18 , used to fill a hole.
[0038] FIG. 20 is a flow-chart describing one exemplary method for filling a hole in accordance with practice of the present invention.
[0039] FIG. 21 is a flow-chart describing one exemplary method for creating an apparatus in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part thereof, where depictions are made, by way of illustration, of specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the invention. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims.
[0041] FIG. 1 is a three dimensional exploded cross-section view depicting an apparatus, in accordance with an exemplary embodiment of the present invention, above a cutout section of a floor assembly with a hole, before it is place in said hole. More specifically, FIG. 1 depicts precast plug 101 before it is placed in hole 102 . This embodiment is a basic depiction of how precast plug 101 may function, namely to seal hole 102 . It also depicts the various components of precast plug 101 including rod 104 .
[0042] Precast plug 101 may be constructed off site, i.e., from where the hole it intends to repair is located. However, this is not to limit the scope of precast plug 101 . If a particular location required precast plug 101 to be made on site, such as a remote location and time was of the essence, this could be accomplished by making precast plug 101 at the site of hole 102 .
[0043] In either case, precast plug 101 may be constructed of the same material as floor 103 , which in the typical scenario will be a lightweight aggregate or other cement, which has fire and water resistant properties in addition to structural integrity, similar to floor 103 . For example, Rapid Set® Cement All™ may be used to construct precast plug 101 , but this is not to limit the scope of the apparatus and method. In another embodiment, precast plug 101 may be constructed of plastic, steel, or any other material suitable for filling a hole or cavity. Where a cement-like material is used to prepare precast plug 101 , it may be mixed with the requisite amount of water (and coloring if desired) to form a wet mixture. This mixture may then be poured into a form mold.
[0044] The shape and size of form mold, and therefore precast plug 101 , may vary depending upon the type of repair job—for example, this may depend on the thickness of the floor assembly needing repair. The embodiment depicted in FIG. 1 shows precast plug 101 as having a cylindrical shaped housing with a top planar surface, an outer wall, and a bottom planar surface that are integral to and unitarily form the concrete housing. The outer walls may have a slight inward taper from the top of precast plug 101 where logo 105 is located to the bottom of precast plug 101 . However, a straight cylindrical form mold may also be employed to create precast plug 101 with no taper. Other embodiments of precast plug 101 may be cast in square, rectangular, triangular, and other variable sized and shaped form molds to create variable sized and shaped precast plugs 101 . Precast plug's 101 diameter (or general width) is also variable depending upon the actual size of hole 102 to be repaired. A larger hole may necessitate a larger diameter form mold while a smaller hole may necessitate a smaller diameter form mold. Finally, the height of hole 102 is relevant to the size of the form mold to be used, which in the typical repair job may be three and one half inches. As mentioned above, this may vary depending upon the type of repair job—for example, this may depend on the thickness of the floor assembly needing repair. Typically, the thickness of the floor will vary with 3.5″ being the minimum thickness. Nevertheless, exemplary embodiments may be designed to provide a certain fire rating (e.g. a 2.0-hour fire rating) when installed according to directions, regardless of actual thickness of floor assembly. The embodiment shown in FIG. 1 depicts precast plug 101 to be of substantially the same height as the height of hole 102 , meaning from the top of floor 103 to the bottom of floor 103 , however the actual height of precast plug 101 may vary. In exemplary embodiments, the height of the concrete housing is the minimum height of the hole.
[0045] Before the cement mixture cures in the properly sized form mold, an appropriately sized rod 104 may be inserted into the wet cement housing of precast plug 101 . Rod 104 may be comprised of any number of materials, including steel, plastic, multiples of rods, etc., as will be further discussed below. As depicted in FIG. 1 , rod 104 may be constructed of steel and may also be bent or molded such that it forms a “C” like shape in the center of rod 104 . This allows for the “C” portion of rod 104 to be fully embedded within the form mold cement mixture, and the ends of rod 104 to extend from either side of what is soon to become precast plug 101 after curing. The ends, or “wings” of rod 104 , may give precast plug 101 support when resting in hole 102 and prevent precast plug 101 from falling through the floor.
[0046] Precast plug 101 may also be embossed as depicted in FIG. 1 with logo 105 before cement mixture cures. However, this is not to limit the scope of the invention. Logo 105 may also be a stamp, painting, etching, or any other mark to indicate who made precast plug 101 . In FIG. 1 , logo 105 consists of a capital “C” and a capital “P” indicating for example, a trademark. However, logo 105 may also consist of other combinations of letters, numbers, symbols, and/or pictures.
[0047] Precast plug 101 may also be stamped, as depicted in FIG. 1 , with size indicator 106 . Again, size indicator 106 may also be embossed, painted, etched, or generally engraved in such a way that it clearly communicates information about precast plug's 101 and/or hole's 102 dimensions. In FIG. 1 , it may be noted that size indicator 106 is represented by a “#30”. This may be a shorthand method of indicating that hole 102 is three inches for example. It could also be used to communicate that the width of precast plug 101 is three inches, if that would be a preferable method of measuring. However, other methods of communicating the size of precast plug 101 or the size of hole 102 may be employed such as a size indicator 106 depiction of “(3″)” or “3 In.”.
[0048] Logo 105 and size indicator 106 may also be used to communicate other desirable information, such as implied information. Implied information may be apprised from both logo 105 and size indicator 106 to indicate to appropriate authorities, such as a fire marshal, that the plug that is going to be installed or already has been installed into floor 103 is of such a quality and design that it meets appropriate fire codes and/or other safety regulations. Accordingly, information that may be stamped, embossed, or otherwise applied to the housing of precast plug 101 may include a batch control number, a date of manufacture, or any other pertinent information that may be useful to an installer, inspector, or user of the apparatus.
[0049] Further depicted in FIG. 1 are grooves 107 on either side of hole 102 . Grooves 107 may not be preexisting. If not, grooves 107 may be ground out, for example, with an angle grinder, chiseled with a chisel, or carved out using some other device, tool or mechanism to accommodate the portions of rod 104 that are situated external to the concrete housing—or “wings” of rod 104 . Once the appropriate number of grooves 107 are carved out (and in the proper places), precast plug 101 may be inserted into hole 102 such that each “wing” of rod 104 may rest snugly within its own groove 107 and the top of precast plug 101 may rest flush with floor 103 . This may be desirable for several reasons, including so that the finished repair does not protrude above the floor surface—this facilitates installation of finish floor surface material.
[0050] In another embodiment, rather than utilizing the technique of grooves 107 , holes may be drilled in either side of the wall of hole 102 , beneath the surface of floor 103 . Similar tools may be employed as may be used to carve out grooves 107 , including a right angle drill. Utilizing this technique, it would be possible not only to repair a hole in a floor below one's feet, but also a floor above one's head, i.e. a ceiling. In such a case, various embodiments of precast plug 101 may include logo 105 and size indicator 106 embossed or otherwise marked on the bottom side of precast plug 101 , or rather on both ends of precast plug 101 to make it visible to one viewing precast plug 101 from above or below. The “wings” of rod 104 may also extend from a more central portion of precast plug 101 rather than being substantially flush with the top of precast plug 101 . To accommodate the “wings” of rod 104 it may be necessary to drill deeper holes on either side of hole 102 . After drilling the holes, one “wing” of rod 104 may be fully inserted into said drilled hole such that the side of precast plug 101 and interior of hole 102 are flush and the other “wing” of rod 104 is fully within hole 102 and extended in the direction of the drilled hole that it is to occupy. The entirety of precast plug 101 may then be laterally moved in that direction such that it is centered in hole 102 and both “wings” of rod 104 come to rest in either drilled hole.
[0051] FIG. 2 is a three dimensional cross-section view of precast plug 101 , which has been placed in hole 102 of floor 103 . This embodiment is a basic depiction of how precast plug 101 functions, i.e. to seal hole 102 such that hole 102 is fire resistant, water resistant, and structurally sound. FIG. 2 also depicts how the top portion of precast plug 101 may not protrude from floor 103 , but is relatively flush with floor 103 . FIG. 2 further depicts how the bottom of precast plug 101 may be flush with the bottom side of floor 103 .
[0052] Before appropriately sized precast plug 101 is fitted into hole 102 , however, sealant 201 may be beaded around the exterior wall of precast plug 101 and the interior wall of hole 102 , after which precast plug 101 may be fitted into hole 102 . Once the wings of rod 104 are snugly within grooves 107 , sealant 201 may be inserted into any voids such that hole 102 is completely full and/or excess sealant 201 may be wiped away from the area of hole 102 . Sealant 201 may also be applied over the top of the wings of rod 104 to further secure rod 104 in place. After sealant 201 cures, what is left is a fire resistant, water resistant, and structurally sound repair job, which may be impliedly indicated by logo 105 as discussed above. As an example, 3M™ Fire Barrier Sealant IC 15WB+ or CP 25WB+ may be used as sealant 201 , however, this is not to limit the scope of the invention. Other products with similar properties may be employed in lieu of said brand. Typically, the sealant used should comply with fire stop properties in accordance with jurisdictional codes or well-known standards (for example as set forth in ASTM E 814-13a).
[0053] FIG. 3 depicts a top view of precast plug 101 fully installed into hole 102 in a cutout section of floor 103 . FIG. 3 also introduces another aspect of the present invention, namely, various dimensions of an apparatus in accordance with the present invention. Before installation of precast plug 101 , it may be necessary to measure the size of hole 102 that is to be repaired. For example, size indicator 106 depicts a “#30”, which may mean that before installation, it was measured that the size of hole 102 to be repaired was three inches. In such a case, whatever the width of hole 102 may be, D 2 represents this dimension. D 1 represents the width of precast plug 101 . Finally, both d's represent the portion of how far rod 104 extends into floor 103 . Depending upon the nature of the repair to be made, any and all of these dimensions may be lengthened or shortened to accommodate the repair. FIG. 3 also depicts sealant 201 surrounding precast plug 101 . Sealant 201 , however, may also be applied over the top rod 104 to give further stability.
[0054] FIG. 4 depicts a cross-sectional side view precast plug 101 fully installed into hole 102 in a cutout section of floor 103 . The location of the cross section is indicated in FIG. 3 by the 4 - 4 cross-section line. As can be seen in this embodiment, rod 104 has a “C” shaped bend allowing for rod 104 to penetrate into the center of precast plug 101 . This bend into the center of precast plug 101 allows for rod 104 to lend structural support to precast plug 101 . Also seen from this view, the wings of rod 104 extend into floor 103 on either side of precast plug 101 , where grooves 107 may have been chiseled or carved to allow for proper installation of precast plug 101 . This embodiment also depicts the slight inward taper of precast plug 101 at an unspecified degree. However, as mentioned above, this taper is not necessary, and in another embodiment, precast plug 101 may have an outward taper, which may make it easier to apply sealant 201 . Another dimension depicted in FIG. 4 is the height h of floor 103 . As mentioned above, precast plug 101 may be adapted to accommodate the varying heights of concrete floors in different buildings.
[0055] FIG. 4 also depicts sealant 201 as extending from the bottom edge of floor 103 to the top edge of floor 103 and fully encompassing the space between floor 103 and precast plug 101 . In another embodiment, less sealant 201 may be applied such that enough is applied to fulfill its purpose, which is to seal hole 102 .
[0056] FIG. 5 is a top view depicting an alternative embodiment of precast plug 101 comprising multiple (i.e. two in this embodiment) rods 104 housed within precast plug 101 rather than one as in previous figures. Multiple rods 104 may be suitable to lend further support for a larger precast plug 101 to repair a wider diameter hole 102 or a floor 103 of an increased height. In one embodiment (as shown), multiple rods 104 are substantially parallel to each other and configured to register with grooves (i.e. multiple grooves 107 ) adjacent to the hole. FIG. 5 depicts a different sized precast plug 101 as indicated by size indicator 106 . As discussed above, size indicator may refer to the size of precast plug 101 or the size of hole 102 . For example, the “#65” in FIG. 5 may indicate that hole 102 has a diameter of six point five inches.
[0057] FIG. 6 depicts a cross-sectional side view of the embodiment shown in FIG. 5 . The location of the cross-section is indicated in FIG. 5 by the 6 - 6 cross-section line. This embodiment generally depicts, however, how multiple rods 104 may be lengthened and positioned in order to accommodate a larger precast plug 101 that may be situated in a deeper hole 102 as may be the case with floor 103 of a greater height, such that multiple rods 104 may still penetrate the center of precast plug 104 and lend full support.
[0058] FIG. 7 is a top view of yet another embodiment of the present invention, which also utilizes multiple rods. However, as shown and as clarified further by the 8 - 8 cross section line in FIG. 8 , the two rods 104 act as their own wings so that a pair of rod wings in this embodiment are not part of a single rod. These separate rods 104 may be inserted into precast plug 101 in a similar fashion as described above, i.e., before the wet cement mixture fully cures within the form mold and such that the wings are substantially flush with the top of precast plug 101 . In another embodiment, rods 104 may be positioned such that the wings of said rod extend from a central or lower position on either side of precast plug 101 , rather than being flush with the top of precast plug 101 . Utilizing one of these embodiments, precast plug 101 may be inserted into a ceiling as described above.
[0059] FIG. 7 further depicts another potential embodiment as represented by size indicator 106 , which shows a “#45”. This may represent that either hole 102 or precast plug 101 has a width of four and one-half inches. However, the embodiments depicted in FIGS. 7 and 8 are not to be construed as limiting the scope of the present invention. For example, rods 104 in FIG. 7 need not be within substantially the same plane as one another, but may be cured into precast plug 101 in a staggered fashion such that they are rather substantially parallel to one another. In another embodiment, four separate rods 104 similar to those used in FIGS. 7 and 8 may be cured into a single precast plug 101 and arranged in a fashion such that there are two pairs of rods 104 (see FIG. 7 for an example of an arrangement of one pair of rods) with each pair on substantially the same plane when viewed from above and the first pair being substantially parallel with the second pair.
[0060] In yet another embodiment, four separate rods 104 similar to the rods 104 depicted in FIGS. 7 and 8 may be cured into precast plug 101 such that each wing when viewed from above would point in a different direction, such as twelve o'clock, six o'clock, three o'clock and nine o'clock substantially bisecting precast plug 101 both vertically and horizontally. With such an embodiment, the method of installation may be modified to account for the requisite number of grooves 107 to house such wings.
[0061] FIG. 9 depicts a top view of an apparatus used to fill a hole, in accordance with yet another exemplary embodiment of the present invention. Rather than a tubular shape as discussed above, rod 104 may take on a substantially rectangular shape. In this embodiment, rod 104 may be comprised of a plastic “T” bar with a break away joint at the “T” intersection, as can be seen in the 10 - 10 cross section line in FIG. 10 . The breakaway joint and base of the “T” of rod 104 may be a cylindrical arrow-like shape. Such an embodiment allows for this breakaway joint and base to grip the housing of precast plug 101 , providing additional support so that precast plug 101 does not fall through hole 102 . Rod 104 in plastic form, is not to limit the scope of the present apparatus and method. Other embodiments may include iron, wood, silicone, or other durable composite materials. Also, as mentioned above sealant 201 may be applied between precast plug 101 and floor 103 , and over the top of rod 104 in the embodiment depicted in FIG. 9 .
[0062] Size indicator 106 depicts a “#112”. As explained above, this may indicate that either hole 102 or precast plug 101 may be eleven point two inches wide for example. FIG. 10 also depicts precast plug 101 with no tapered edge, an alternative embodiment to the present invention. An even column of sealant 201 fills the space between floor 103 and precast plug 101 . In another embodiment, however, more or less sealant may be applied, e.g., if precast plug 101 were to taper outward or inward, or hole 102 were to taper inward or outward. In yet another embodiment sealant 201 may be applied such that it covers the bottom edge of precast plug 101 and/or the top edge of precast plug 101 , such as to give further protection to precast plug 101 and floor 103 .
[0063] Turning to the next figure, FIG. 11 depicts a three dimensional exploded cross-section view of another exemplary embodiment of precast plug 101 , before it is place in hole 102 . In this embodiment, precast plug 101 may be adapted for a much narrower construction. That is, there may be certain circumstances in which a narrower housing such as housing 101 a is preferred. Such embodiments may employ rod 150 rather than rod 104 as shown with reference to FIG. 1 . Rod 150 may have a smaller C shape bend, or dip, in a middle portion of the rod to accommodate the narrower construction of housing 101 a . That is, in instances where housing 101 a is so narrow that a support rod of appropriate diameter or width may not be easily implemented, precast plug 101 may implement rod 150 , which is configured to couple with an anchor or support component 151 .
[0064] Support component 151 may be a rod with a smaller diameter than rod 150 , and which is shaped in a manner so that support component 151 may couple with rod 150 —for example at the bend or dip of rod 150 . Furthermore, rod 151 may be shaped in a variety of forms in order to provide a keyway that will lock the support component into the concrete housing, thereby providing support for precast plug 101 .
[0065] FIG. 12 is a perspective view of the apparatus depicted in FIG. 11 , showing rod 150 and support component 151 situated within housing 101 a . In this embodiment, support component 151 is helical or having the shape or form of a helix or spiral so that a body of support component 151 may wound or twist uniformly and around in a cylindrical or conical manner. In exemplary embodiments, support component 151 comprises an elongated body such as a rod with a lesser diameter than rod 150 , and which is shaped in a manner so that it can be embedded securely within the concrete housing of a precast plug, such as concrete housing 101 a . Although the shown embodiment includes a shape that twists or is helical in shape, other shapes that allow support component 151 to be embedded securely within concrete housing 101 a may be implemented.
[0066] A top portion of support component 151 may be configured to wrap around or hook onto a portion of rod 150 that is within concrete housing 101 a of precast plug 101 . In exemplary embodiments, a top portion of support component 151 may be hooked or wrapped around, or otherwise coupled to a middle bent portion of rod 150 . Of course, other means of coupling the two components may be implemented, including gluing, soldering, or any other manner of securely coupling the support component to the rod. Further, support component 151 may be typically coupled in a manner so that it is substantially perpendicular to rod 150 . Of course, other variations may include configurations in which rod 150 and support component 151 are not substantially perpendicular but at other angles in relation to each other. Whatever the configuration, it may be desirable that support component 151 is embedded within an internal portion of the concrete housing of precast plug 101 the will provide the most support—to these ends, in exemplary embodiment, support component 151 may be embedded within a middle portion of the concrete housing.
[0067] FIG. 13 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 12 , which shows how support component locks into place within concrete housing 101 a of precast plug 101 . The location of the cross section is indicated in FIG. 17 by the 10 - 10 cross-section line. This embodiment of support component 151 is embedded within the concrete housing so that a cross-section of the concrete housing with the embedded support component includes a first plurality of vertically oriented cross-sections 153 of support component 151 running parallel to a second plurality of vertically oriented cross-sections 154 of support component 151 , situated below a cross-section of rod 150 . Further, a cross-section 155 of support component 151 is shown in FIG. 13 , corresponding to a top portion of support component 151 , which wraps around or hooks onto rod 150 at a middle bent portion of the rod.
[0068] FIG. 14 is a perspective view of the apparatus depicted in FIG. 11 , which includes another embodiment of a support component 151 coupled to rod 150 . In this embodiment, support component 151 may be a rod with a smaller diameter and shaped in a manner so that the support component 151 forms a plurality of curves situated and aligned along a single plane (i.e. flat) as depicted in FIG. 14 and FIG. 15 . A top portion of support component 151 may be configured to wrap around or hook onto rod 150 . FIG. 15 is a side-view of the support component depicted in FIG. 14 . Although this embodiment of support component 151 is shown as flat (wherein all curving elements of support component 151 are situated in a single plane), in other embodiments, each curving portion may be situated in alternating planes or different planes, without deviating from the scope of the present invention.
[0069] FIG. 16 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 14 and FIG. 15 . The location of the cross section is indicated in FIG. 17 by the 10 - 10 cross-section line. This embodiment of support component 151 is embedded within the concrete housing so that a cross-section of the concrete housing with the embedded support component includes a plurality of cross-sections 156 that form a single vertical line substantially directly below cross-section 157 of support component 151 , corresponding to a top portion of support component 151 .
[0070] FIG. 17 is a top view of the apparatus depicted in FIG. 11 or FIG. 14 , used to fill a hole. As may be appreciated, the embodiments discussed with reference to FIG. 11 - FIG. 16 differ internally due to support component 151 , and externally merely due to the size of housing 101 a.
[0071] FIG. 18 is a perspective view of another exemplary embodiment, wherein an additional support rod is used. This configuration may be desirable for additional support in situation in which, for example, an odd-shaped hole must be filled and fire-proofed. In this embodiment, a second rod 152 may be utilized, wherein the second rod is crossed over the first rod 150 in a manner so that it sits atop a portion of rod 150 (e.g. over the bend or dip on rod 150 ). In some embodiments, rods 150 and 152 may be positioned so that they each lay substantially horizontally or longitudinally along the top planar surface of the concrete housing of precast plug 101 , and are perpendicular to each other so that an angle β along lines A and B (parallel to rods 152 and 150 , respectively) forms a ninety-degree angle. In other embodiments, rods 150 and 152 may be positioned so that they cross at an angle β other than a ninety-degree angle. FIG. 19 is a top view of the apparatus depicted in FIG. 18 , used to fill a hole—this embodiment showing rods 152 and 150 perpendicular to each other.
[0072] Turning now to the last set of figures, FIG. 20 is a flow-chart describing one exemplary method for filling a hole in accordance with practice of the present invention, more specifically, the flow-chart depicts method 2000 for filling a hole using a precast plug for which installation may be achieved from above a floor assembly; method 2000 may comprise of several steps as follows:
[0073] In step 2001 , an apparatus in accordance with the present invention such as a precast plug may be dry fit into a hole of a floor assembly from above. For example, a precast plug comprising of a concrete housing and a rod partially situated within the concrete housing, may be simply placed inside the hole to make sure that the correct size housing is being utilized.
[0074] In step 2002 , outlines of the rods that extend beyond the concrete housing may be drawn so as to determine the location of the grooves to be carved adjacent to the hole. Once marked, the precast plug may be removed and set aside. In this step, an installer may desire to install temporary material within the hole in order to prevent grinding dust or debris from falling through the empty hole. Notably, step 2001 may not be necessary for several reasons—for example, a template or other guidelines for outlining where the grooves may be placed on the floor surface adjacent to the hole may be used so that a dry fit is unnecessary.
[0075] In step 2003 , a grinder or other tools may be used to grind or carve the grooves or slots for receiving the outer portions (or wings) of the rod (or rods) external to the concrete housing. In some embodiments, this step may include grinding slots in the floor that are approximately 5/16 of an inch deep and of sufficient length to allow the precast plug to rest slightly below the surface of the floor or in a manner so that installation of the precast plug results in a top surface of the apparatus being flush with the surface of the floor. Removal of the temporary material used to plug the hole may be required if this precaution was taken in step 2002 .
[0076] Moreover, this step may further include dry fitting the precast plug again to be sure the entire apparatus rests below surface of floor or is otherwise flush with the surface of the floor adjacent to the hole. Afterwards, the precast plug may be removed and the interior walls of the floor's hole may be wiped cleaned with a damp sponge, rag or paper towel to remove debris.
[0077] In step 2004 , sealant may be applied. In exemplary practice, a bead of sealant (of approximately on-half inch thickness) may be applied below the top of the hole. In some embodiments, a spreader may be used to spread the sealant around the entire internal circumference of the hole. Furthermore, a similar thickness of sealant may be applied to the circumference of the concrete housing of the precast plug, particularly to the bottom circumference of the concrete housing then spreading throughout the entire circumference or outer walls of the concrete housing.
[0078] In step 2005 , the precast plug may be inserted into the hole using a twisting motion into the concrete housing so that the protruding portions of the rod (or rods) rest in the previously carved out grooves or slots, allowing the entire precast plug to rest slightly below the surface of the floor. A spreader may be used in this step to level and remove any sealant that protrudes above the surface of the floor. In order to facilitate installation inspection, an installer may desire to keep the top surface of the precast plug clean (especially when the top portion may include a logo and other information relevant for inspection).
[0079] Now turning to the last figure, FIG. 21 is a flow-chart describing one exemplary method for creating an apparatus in accordance with the present invention, the flow-chart depicts method 2100 for creating or constructing a precast plug; method 2100 may comprise of several steps as follows:
[0080] In step 2001 , a wet cement mixture may be prepared. In step 2002 , the wet cement mixture may be poured into a form mold housing for creating the concrete housing of the precast plug.
[0081] In step 2003 , one or more rods may be installed into the form mold housing whereby a distal end of one of the one or more rods makes a first protrusion from a first edge of said form mold housing and the proximal end of the rod makes a second protrusion from a second edge of the form mold housing. This step may be repeated depending on whether a single or multiple rods will be implemented with the precast plug being created. In alternative embodiments, the one or more rods may be positioned on the form mold housing prior to pouring the wet cement mixture.
[0082] In step 2004 , the mixture may be allowed to cure with said the one or more rods in place, thereby creating said precast plug. This step may also include embossing the precast plug with a logo and or a size indicator, or stamping the precast plug with a logo and a size indicator, or otherwise including any pertinent inspection-relevant information onto the concrete housing as the cement mixture cures.
[0083] Naturally, the steps above should not be limiting, and these steps and additional steps may be performed in the same sequence or alternative sequence without deviating from the scope of the present invention. As may be appreciated by a person of ordinary skill in the art, one of the advantages of the present invention is that an apparatus to fill and fire-proof a hole in a concrete floor may be achieved with installation from above. Typically, in order to meet the requirements under well-known standards access from below a floor assembly is required. As described above, an apparatus in accordance with the present invention may be simply placed inside the hole, sealed using certain sealants, and adjusted so that it is flushed with the surface of the floor adjacent to the hole.
[0084] A method and apparatus for filling and fire-proofing holes in concrete floors has been described. The foregoing description of the various exemplary embodiments of the invention has been presented for the purposes of illustration and disclosure. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit of the invention.
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The present apparatus and method relates in general to sealing a hole in a floor with a precast plug. A precast plug is created by pouring a wet aggregate mix into a form mold and thereafter inserting a pre formed rod into the uncured mixture, positioning it such that the center of the rod rests in the center of the form mold and the ends of the rod extend outward near the top of the form mold. The mix is then cured. The precast plug may then be transported to the hole that it is destined to fix. Grooves may be carved on either side of the hole to accommodate the rod's ends. The interior of the hole and the exterior of the plug may then be covered with a sealant, after which the plug may be inserted into the hole. Once the sealant cures, the hole is fully repaired.
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TECHNICAL FIELD
[0001] The present invention relates to concrete dowel devices and, more particularly, to a plate and a sleeve concrete dowel device with break-away alignment tabs.
BACKGROUND
[0002] Concrete dowels are embedded into joints between adjacent slabs of concrete to prevent vertical displacement between the slabs to maintain a smooth pavement surface and increase the strength of the concrete in the region of the joint. While the dowels are provided to prevent excessive vertical displacement between the slabs, they are typically designed to allow a small amount of horizontal separation and lateral displacement between the slabs to relieve internal stress to accommodate drying shrinkage and thermal expansion and contraction of the slabs. This permits a normal amount of slab movement to prevent excessive cracking while still maintaining a smooth top surface of the pavement.
[0003] Traditionally, two foot lengths of rebar rods were used as the concrete dowels. But rod dowels tend to cause cracking in the concrete due to concentration of the stress on the relatively small surface area of the rods. Concrete dowels configured as larger bars and load plates were therefore developed to reduce cracking by increasing the surface area of the dowel. In comparison to rebar rods historically used as concrete dowels, larger dowel bars and plates provide a flat and significantly increased dowel surface area to improve the dowel's load transfer capability and reduce the tendency of cracking to form at the dowel location. U.S. Pat. No. 6,354,760 and U.S. patent application Ser. No. 11/109,781 describe examples and the benefits of this approach.
[0004] To assist in embedding the dowels within adjacent slabs of concrete while the concrete is being poured, dowel devices including dowel bars (or plates) and sleeves have been developed. U.S. Pat. No. 6,145,262 describes this approach. The sleeved dowel bar has the benefit of permitting the bar to slide within the sleeve to accommodate a small amount of horizontal separation between the slabs to relieve internal stress. To accommodate lateral displacement between the slabs the sleeve is a little bit wider than the bar, which allows the bar to move laterally within the sleeve after the concrete slabs have cured. But simply making the sleeve wider than the bar removes positive registration between the bar and sleeve making it difficult to determine when the bar has been properly centered within the sleeve. As a result, construction workers have to install the bars carefully to ensure the proper spacing on either side of the plate within the sleeve, which can be a lot to ask of construction workers in some setting. To solve this problem, the sleeve described in U.S. Pat. No. 6,145,262 contains fins along the side walls of the sleeve to help align the dowel bar within the sleeve.
[0005] However, providing dowel sleeves with elongated fins along the interior side walls is an expensive solution. Including the fins along the internal surfaces of the sleeve complicates the manufacturing process and can require multiple molds to create the sleeve. Although a structure containing the fins may be manufactured separately and inserted into to the sleeve after the sleeve has been molded, this significantly complicates the manufacturing process and increases the cost of the dowel. For example, manual assembly steps may be required to insert and secure the fins within the sleeve.
[0006] In addition, even when fins are included, it is still possible with prior sleeved dowel devices to install the bar on a slant deflecting the fins prior to pouring the concrete slabs, which can reduce or eliminate the effectiveness of the fins. A plate installed on an angle within the sleeve with the fins deflected before the concrete is poured reduces or eliminates the lateral play that the dowel was designed to allow. With this system, it can also be difficult for the construction workers in the field to see whether the fins have been deflected when the plate is inserted, leading to some portion of the plates being installed without proper alignment within the sleeves.
[0007] As a result, there is a persistent need for a lower cost and more reliable concrete dowel solution and, more particularly, a need for a concrete dowel device to ensure proper registration of the plates within the sleeves without requiring cumbersome manufacturing or assembly procedures.
SUMMARY OF THE INVENTION
[0008] The present invention meets the needs described above in a concrete dowel device including a sleeve and plate in which the sleeve includes break-away alignment tabs at the opening of the socket to ensure proper alignment of the plate within the sleeve during field installation. The tabs are positioned at the sleeve opening, rather than along the length of the socket, to avoid misalignment of the plate within the sleeve, simplify use and reduce the manufacturing costs of the product. The plate may have a tiered structure to enhance registration between the place and sleeve. Alternatively or additionally, the sleeve and plate may include additional alignment surfaces at the rear corners or along the rear side of the plate and sleeve. For example, slanted corners and/or a “V” shaped grove can be provided to assist in properly aligning the plate within the sleeve.
[0009] To facilitate manufacturing, the break-away alignment tabs may be formed as molded components of the sleeve, which are rotated and snapped into position after the sleeve has been molded. Alternatively, the break-away alignment tabs may be formed as part of an insert plate that is molded separately and attached to the flange of the sleeve after the sleeve has been molded. Both approaches allow the sleeve (without the insert plate) to be molded as a single part without the need to insert fins or another alignment structure along the side walls of the sleeve.
[0010] In view of the foregoing, it will be appreciated that the present invention provides an improved plate and a sleeve concrete dowel device with break-away alignment tabs. The specific structures and techniques for accomplishing the advantages described above will become apparent from the following detailed description of the embodiments and the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a top view of a plate and sleeve concrete dowel device with the plate positioned outside the sleeve.
[0012] FIG. 1B is a front view of the sleeve showing the break-away alignment tabs before insertion of the plate into the sleeve.
[0013] FIG. 2A is a top view of a plate and sleeve concrete dowel device with the plate inserted within the sleeve.
[0014] FIG. 2B is a front view of the sleeve showing the break-away alignment tabs with the plate inserted within the sleeve.
[0015] FIG. 3A is a plan view of the sleeve nailed to a concrete form before pouring of a first concrete slab over the sleeve.
[0016] FIG. 3B is a cross-section plan view of the sleeve nailed to a concrete form after the first concrete slab has been poured over the sleeve.
[0017] FIG. 3C is a cross-section plan view of the sleeve embedded within the first concrete slab after the first slab has set and the form has been removed.
[0018] FIG. 3D is a cross-section plan view of the sleeve embedded within the first concrete slab after the plate has been inserted into the sleeve.
[0019] FIG. 3E is a cross-section plan view of the dowel formed by the sleeve and plate embedded at the joint between the first and second concrete slabs.
[0020] FIG. 4A is a top view of a first alternative concrete dowel device with the plate located outside the sleeve.
[0021] FIG. 4B is a top view of the first alternative concrete dowel device with the plate inserted within the sleeve.
[0022] FIG. 4C is a top view illustrating a waste-free approach for stamping the plated for the first alternative concrete dowel device from sheet stock material.
[0023] FIG. 5 is a top view of a second alternative concrete dowel device with the plate located outside the sleeve.
[0024] FIG. 6 is a top view of a third alternative concrete dowel device with the plate located outside the sleeve.
[0025] FIG. 7 is a top view of a sleeve for the concrete dowel device with break-away alignment tabs formed as molded components rotated and snapped into position.
[0026] FIG. 8A is a top assembly view of an alternative sleeve design utilizing a plate insert for the break-away tabs.
[0027] FIG. 8B is a front assembly view of the alternative sleeve design utilizing the plate insert for the break-away tabs.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] The present invention may be embodied in a concrete dowel device, a method for constructing concrete structures using the concrete dowel devices, and concrete structures that include embedded concrete dowel devices. The innovative concrete dowel represents a significant improvement over the concrete dowel approaches shown in U.S. Pat. No. 6,354,760; U.S. Pat. No. 6,145,262; U.S. Pat. No. 4,733,515 and U.S. Pat. No. 8,454,265, which are incorporated by reference.
[0029] The concrete dowel device includes a sleeve and plate configured for use with a concrete form typically constructed with wooden boards. The dowels are embedded at the joints between adjacent concrete slabs to provide vertical support to keep the surface of the concrete level while allowing a small amount of horizontal and lateral movement to accommodate thermal expansion of the slabs while curing and during normal use, vibration, and other normal types of movement between adjacent concrete slabs. Providing for this type of relative movement between the slabs relieves stress to prevent or reduce cracking in the concrete during normal use while maintaining a smooth top surface of the pavement at the joints.
[0030] The concrete dowel accommodates a small amount of movement of the slabs away and towards each other transverse to the joint as well as lateral displacement between the slabs in the direction of the joint, while preventing substantial vertical movement to maintain a smooth, level surface at the joint between the concrete slabs. An improvement resides in the break-away tabs positioned at the opening of the sleeve to guide insertion of the plate into the sleeve during construction without inhibiting normal lateral movement between the slabs after they have cured. Additional guide structures, such as slanted corners ore a “V” groove in the sleeve and plate may provide additional guide structures to ensure proper registration of the plate within the sleeve.
[0031] The sleeve is designed to be nailed to a wooden form defining the edge of the first slab (one side of the joint between adjacent slabs) where a dowel is desired prior to pouring the first slab. The first slab is then poured with the sleeve held in place by the form, which embeds the sleeve within the first slab. Once the first slab has set sufficiently, the form is removed and the plate is inserted into the sleeve so that about half the plate extends into the sleeve and half extends into the area where the second concrete slab is to be poured. The second slab is then poured with the plate held in place by the sleeve. Once the second slab sets, the dowel formed by the sleeve and plate is embedded into the joint between the slabs, while the plate can slide a small amount within the sleeve to accommodate horizontal separation and lateral displacement between the slabs while maintaining the slabs in vertical alignment.
[0032] The present invention includes break-away alignment tabs positioned at opposing sides of the opening to the socket of the sleeve. The alignment tabs remain in place during slab construction to guide proper alignment of the plate with the sleeve. The tabs are configured to break away as forced by relative movement of the concrete slabs after the concrete has cured to allow a small amount of displacement between adjacent slabs. Various embodiments include additional alignment mechanism, such as angled corners and a “V” groove along the rear side of the sleeve, with corresponding guide surfaces in the plate, to facilitate proper registration between the sleeve and the plate.
[0033] Turning now to the figures, FIG. 1A is a top view of a plate 10 and sleeve 12 forming a concrete dowel device with the plate positioned outside the sleeve. The sleeve 12 includes a socket 13 configured to snugly receive the plate 10 and typically includes ridges, dimples or other internal surface features to ensure a snug interference fit between the plat and the socket. The sleeve 12 also includes a flange 14 at the opening of the socket 13 that includes two nail guides 16 a - b that typically support two pre-installed nails 18 a - b positioned ready for nailing into a wooden form.
[0034] FIG. 1B is a front view of the sleeve 12 showing the flange 14 defining a plate opening 20 flanked by two break-away alignment tabs 22 a - b before insertion of the plate into the sleeve. FIG. 2A is a top view of a plate and sleeve concrete dowel device with the plate 10 inserted within the sleeve 12 . FIG. 2B is a front view of the sleeve 12 showing the break-away alignment tabs 22 a - b with the plate inserted within the opening 20 of the sleeve, as guided by the alignment tabs to center the plate within the sleeve. The socket of the sleeve is a bit wider than the plate to accommodate some lateral movement of the plate within the sleeve after the concrete slabs have set, and the break-away alignment tabs are provided to facilitate proper centering of plate within the sleeve during construction of the concrete slabs. For example, the plate may be about eight inches wide and the socket in the range of about nine inches wide. The break-away alignment tabs are attached sufficient strongly to the flange to remain in place during construction, but are thinner than the rest of the sleeve, have thinner seams, are scored or interference fit in place to break away after the concrete has set to accommodate lateral movement between the concrete slabs joined by the dowel. The interference fit between the plate and the sleeve accommodates a bit of horizontal separation between the concrete slabs as wells as lateral displacement while maintaining smooth vertical alignment of the top surface of the slabs.
[0035] FIGS. 3A-E illustrate use of the dowel during construction of the concrete structure, such as a pavement. Many dowels are used in a typical pavement project and the figures depict a representative dowel. FIG. 3A is a plan view of the sleeve 12 nailed to a concrete form 30 before pouring of a first concrete slab over the sleeve. The nail 18 a is typically pre-installed allowing the construction worker to easily nail the sleeve to the form in the desired position with a few hammer strikes. As shown in FIG. 3B , once the dowel has been nailed in place on the form, the first slab 32 is poured, which embeds the sleeve 12 within the first slab 32 . Once the first slab has set, the form 30 is removed as shown in FIG. 3C . This exposes the socket opening of the sleeve at the edge of the first concrete slab. A construction worker then inserts the plate 10 into the sleeve 12 as shown in FIG. 3D . It is at this point when the alignment tabs assist the construction worker to properly align the plate 10 within the sleeve 12 to ensure that the dowel accommodates the desired amount of lateral movement. It will be appreciated that dowel will not function as designed if the plate is not aligned properly in the center of the sleeve and construction worker are prone to work hastily with variable levels of attention. The alignment tabs do a good job of squaring the plate within the sleeve when the plate is jammed into the sleeve, for example when a worker pushes or hits the plate with a board, hammer, hand or foot. The second slab 34 is then poured as shown in FIG. 3E leaving the dowel formed by the sleeve and plate embedded at the joint between the first and second slabs.
[0036] It will be appreciated that ensuring proper registration between the plate and sleeve is of primary importance when installing the dowels. Several alternatives may be utilized to further ensure proper registration and, once these techniques are understood, other variations will become apparent to those skilled in the art. FIGS. 4A-C show a first alternative designed to ensure proper registration, which includes a plate 40 that has a wider portion 42 designed to remain outside the sleeve and a narrower portion 44 designed to be fully inserted into the sleeve. When the plate is fully inserted into the sleeve, transition edges 46 a - b between the wider and narrower portions are designed to bottom out against the flange 14 providing a visual and physical indication of positive registration of the plate in the sleeve. Basically, this allows the construction worker to hand push, kick, or hit the plate with a board or hammer until the transition edges 46 a - b of the plate are flush against the flange 14 . A quick visual inspection will confirm that all of the plates are properly installed. As shown in FIG. 4C , the wider and narrower portions 42 , 44 can have the same depth so that the plates can be formed (typically stamped) from sheet stock without waste.
[0037] FIG. 5 illustrates a second alternative to ensure proper registration of the plate 50 within the sleeve 52 . This alternative includes beveled corners 54 a - b on the plate 50 configured to mate against beveled corners 56 a - b one the sleeve 52 . The beveled corners cause the plate 50 to square up as the plate 50 is forced into the sleeve 52 . FIG. 6 illustrates a variation on this theme, which utilizes mating “V” grooves 64 , 66 in the plate 60 and sleeve 62 , respectively, serving the same purpose. The various registration techniques may be employed individually or combined, as desired. For example, the “V” groove alternative shown in FIG. 6 also includes the two-tiered plate configuration shown in FIGS. 4A-C .
[0038] Ease and efficiency of manufacturing is another aspect of the present invention. The undercut nature of the alignment tabs over the side portions of the socket of the sleeve could prevent the sleeve from being molded as a single part due the undercut nature of the tabs preventing easy extraction of the sleeve from the mold. To alleviate this problem, the sleeve may be configured for injection molding as a single structure with the alignment tabs pointed away from the opening of the socket with a thin, flexible seam at the junction between the tab and sleeve body and small interference structures on the tabs or sleeve body. After molding, the tabs can then be rotated and snapped into position with an interference fit as shown in FIG. 7 . Small taps, grooves or ridges may be provided as interference structures to ensure a positive interference fit when the tabs are rotated and snapped into place.
[0039] Another alternative is shown in FIGS. 8A-B , in which the alignment tabs are formed as part of an insert plate 80 that is molded separately from the sleeve 12 . The insert plate 80 defines the plate opening 20 flanked by the break-away alignment tabs 22 a - b and fits within an inset area 82 in the flange 14 of the sleeve. The insert plate 80 can be secured within the inset area 82 using an interference fit, adhesive, heat seal or any other suitable attachment technique.
[0040] Although the terms “horizontal” and “vertical” have been used to describe use of the dowel in the context of a horizontal pavement, it will be appreciated that the dowel is well adapted for but not limited to the pavement application and can be used for any concrete joint of sufficient size regardless of its orientation. For example, the invention is equally applicable to joints in concrete walls, ceilings, abutments and other structures Those skilled in the art will appreciate that the foregoing describes preferred embodiments of the invention and that many adjustments and alterations will be apparent to those skilled in the art within the spirit and scope of the invention as defined by the appended claims.
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A concrete dowel device including a sleeve and plate in which the sleeve includes break-away alignment tabs at the opening of the sleeve to ensure proper alignment of the plate within the sleeve during field installation. The tabs are positioned at the sleeve opening, rather than along the length of the socket, to avoid misalignment of the plate in the sleeve, simplify use and reduce manufacturing costs of the product. The sleeve and plate may include additional alignment surfaces on the plate, at the rear corners, or along the rear side of the plate and sleeve. To facilitate manufacturing, the break-away alignment tabs may be formed as molded components rotated and snapped into position. Alternatively, the break-away alignment tabs may be formed as part of an insert plate manufactured apart from and attached to the flange of the sleeve.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority and benefit to U.S. Provisional Application No. 61/140,937 that was filed on Dec. 27, 2008, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
The present application generally relates to perforating activities, and more specifically to reduction of debris in a wellbore.
BACKGROUND
Productivity or injectivity of a well relates to the wellbore radius. The larger the wellbore radius, the better the productivity or infectivity. However, drilling a larger borehole could be prohibitive because of substantial increase of drilling and completion cost for a larger borehole. For a weak or unconsolidated formation, it would be beneficial to enlarge the wellbore by producing sand to some extent before fracture packing and other gravel packing operations. Perforating in such weak or unconsolidated sand formations often induces collapse of the perforation tunnels and even the near wellbore formation. Hence, the perforation naturally allows sand production from the formation for enhancement of the productivity or injectivity. However, conventional perforation in weak or unconsolidated sand also results in sand accumulation in the wellbore. The produced sand in the wellbore can clog the gun and complicate the completion operations. For example, sand control and other completion devices may not be able to be positioned at the right place before the sand in the wellbore is completely cleaned out. Therefore, although producing some sand from formation through perforations may increase the well productivity and infectivity, it is beneficial not to produce any sand into the wellbore after perforation.
Except for sand production from the perforation in weak or unconsolidated formation, debris in the perforation tunnels for consolidated formation is also detrimental for well productivity and injectivity. Dynamic underbalanced perforating techniques, disclosed in U.S. Pat. No. 6,554,081, U.S. Pat. No. 6,598,682, U.S. Pat. No. 7,121,340 and U.S. Pat. No. 7,182,138, can be very efficient to remove the crushed zone near the wall of the perforation tunnels and clean the debris in the perforation tunnels out of formation. However, for weak or unconsolidated sand formation, dynamic underbalance perforating can actually sometimes make the sanding worse. Without proper control, the produced sand could lead to the failure of the completion operations.
Hence, it is desirable to have a better perforating technique in weak or unconsolidated formation.
SUMMARY
The following summary highlights features of preferred embodiments and is in no way meant to unduly limit the scope of any present or future related claims.
According to various features and embodiments of the present application, a perforating method includes lowering the perforating system into a well to the targeted formation interval, orienting the gun and all charges at a pre-selected direction or within a confined angle around the azimuth of the wellbore, using mechanical means to allow the perforation gun sufficiently contacting/closing the casing in the targeted direction, and detonating the charges and establishing communication between the inner volume of the gun carrier and the formation, and allowing formation fluids, loosening sand and other debris to flow into the gun carrier without discharging into the annulus between the gun carrier and casing. In one embodiment, the perforating system includes sealing rings that restricts the flow communication between wellbore space and the inner gun carrier. In another embodiment, flow restrictors are installed on the perimeter of the gun carrier and surround the shaped charges. In another embodiment, the perforating system includes a sliding sleeve that closes the perforated holes in the gun carrier after some times of the charges being detonated.
An embodiment includes a perforating system having a perforating gun with a tubular gun housing defining an inner volume and extending in an axial direction. A shaped charge is held in a loading tube. The loading tube is located in the gun housing. The loading tube extends along the axial direction. The shaped charge faces in a firing direction substantially perpendicular to the axial direction. A portion of the gun housing adjacent to the shaped charge in the firing direction is a perforating portion for removal upon firing of the shaped charge. An eccentralizer member extends from the perforating gun in a second direction that is substantially opposite and parallel with the firing direction. A first retainer part extends from an outer surface of the gun housing adjacent to the perforating portion. A second retainer part extends from the outside of the gun housing adjacent to the perforating portion. The inner volume of the gun housing is insulated from pressure outside of the gun housing until firing of the shaped charge perforates the perforating area.
This and other features and embodiments are discussed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a brief description of the figures herein which illustrate various features of embodiments.
FIG. 1 is a schematic of features of a perforating system according to an embodiment.
FIG. 2 shows a top sectioned view of features of the system of FIG. 1 according to an embodiment.
FIG. 3 shows a top sectioned view of features of the system of FIG. 1 after firing according to an embodiment.
FIG. 4A shows a front view of features including a sealing ring according to an embodiment.
FIG. 4B shows a top section view of features including the sealing ring and a portion of a perforating system according to an embodiment.
FIG. 4C shows a sealing ring according to an embodiment.
FIG. 4D shows a top view of a sealing ring and portions of the perforating system according to an embodiment.
FIG. 5 shows a top cut away view of a perforating system with a sleeve according to an embodiment.
FIG. 6 shows a top cut away view of a perforating system with vertical flow restrictors.
FIG. 7 shows a front view of a perforating system with horizontal flow restrictors.
FIG. 8 shows a front view of a perforating system with vertical flow restrictors and horizontal flow restrictors.
The preceding brief description of figures is meant to help understand the features of embodiments discussed in the present application and is in no way meant to be used to limit any claims in this application or any subsequent related claims.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of features and embodiments of the present application. However, it will be understood by those skilled in the art that features and embodiments within the present application may be practiced without many of these details and that numerous variations or modifications from the described embodiments are possible. These details are not meant in any way to be used to unduly limit claims in this application or any future related claims.
As used here, the terms “above” and “below”; “up” and “down”; “tipper” and “lower”; “upwardly” and “downwardly”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or diagonal relationship as appropriate.
FIG. 1 shows an embodiment of a perforating gun system 10 . The perforating gun system 10 includes a wireline cable 11 connected to a cable head 13 . It should be noted that other conveyance devices can be used in place of wireline, e.g., coiled tubing, piping, slickline, etc. The gun system 10 also includes a casing collar locator (CCL) 15 and a gyroscope module 17 . Both such devices are available commercially, e.g. from Schlumberger (CCL tool and/or Wireline Oriented Perforating Tool). The CCL 15 measures the location of the perforating system 10 along a borehole while the gyroscope 17 provides the azimuthal measurement of the system 10 , e.g., with respect to the magnetic north. An upper eccentralizer 19 can include bowed springs and can be connected beneath the gyroscope 17 . A firing head 21 is located below the eccentralizer 19 . A gun carrier 44 is connected to the firing head 21 . The lower eccentralizer 27 is below the gun carrier 44 . The upper and lower eccentralizer 19 and 27 have the same setting direction. Charges 47 in the gun carrier 44 are preferably loaded in a 180° phasing angle opposite to the setting direction of the eccentralizers 19 and 27 , but given various circumstances, can be slightly deviated from a 180° phase. Device 26 is an empty volume adapted to hold produced sand and debris. The device 26 can be the bottom part of the gun carrier 44 if all charges are loaded at the upper portion of the gun carrier 44 . Alternatively, a properly sized chamber can be used for the chamber 26 . The chamber 26 is attached beneath the gun carrier 44 to hold the produced sand and debris and is internally communicated to the gun carrier 44 . Although this embodiment is valid for the device 26 being either the bottom portion of the gun carrier 44 or an individual chamber, a chamber 26 is assumed to hold the sand and debris in the following description.
A first step of a perforating method according to embodiments in the present application includes running the perforating system 10 into the wellbore. Based on the CCL measurements, the perforating system 10 is set at the formation interval to be perforated.
A second step is to orient the perforating system 10 at the pre-defined azimuthal direction based on the measurements from the gyroscope 17 . Once the pre-defined azimuthal direction is achieved, the eccentralizers 19 and 27 are set to push the charge shooting portion of the gun carrier 44 against the casing wall. The cross-section view of the perforating system 10 is shown in FIG. 2 . The perforating system 10 is positioned inside the casing 42 with the shooting side (perforating portion) of the gun carrier 44 adjacent to, and preferably, contacting the casing wall 42 after the bowed springs of the eccentralizers 19 and 27 are properly set in 180° phasing from the charge firing direction.
A third step is to control the pressure differentials among the major regions before the charge detonation. Referring to FIG. 2 , the entire working space can be distinguished into three major regions. The first region is the formation sand 40 , which is isolated from the wellbore space 43 , which is the second region, by the cement sheath 41 and the casing 42 . The formation sand region 40 contains formation fluid. The fluid pressure in the formation sand region 40 is denoted by P pore . The wellbore space 43 can contain completion fluid. The wellbore fluid pressure at the location of the gun carrier 44 is P well . The third region is the inner gun space 46 , which is isolated from the wellbore 43 by the gun carrier 44 . The inner gun space 46 is filled with air or other low pressure gases. Shaped charges 47 and loading tube 45 are inside the gun carrier 44 , so they are preferably completely isolated from the wellbore space 43 and formation sand region 40 before the cement sheath 41 , casing 42 and the gun carrier shell 44 are perforated by the shaped charges 47 . The loading tube 45 could be other designs other than a tube so long as the charges 47 are held properly. The loading tube 45 preferably is not completely pressure insulated so that the fluid pressure inside the gun carrier 44 and inside the loading tube 45 has the same pressure P gun before the perforation. The current embodiment adjusts P well and P gun to setup the suitable pressure differentials among the three regions. Through properly designing the gun carrier 44 , loading tubing 45 , charges 47 , e.g. number of charges per foot of perforation, the P gun is maintained below the P pore and P well , i.e., achieving dynamic underbalance after a short time after the charge detonation. These ideas are discussed in U.S. Pat. No. 6,554,081, U.S. Pat. No. 6,598,682, U.S. Pat. No. 7,121,340 and U.S. Pat. No. 7,182,138, which are incorporated herein by reference in their entirety. Although not absolutely necessary, it is preferable that P well be close to or somewhat less than P pore before the first perforating run. An appropriate P well value can be set by using a particular density and height of the completion fluid in the wellbore 43 . If the communication between the wellbore space 43 and the formation 40 is established after the first run and the formation 40 has a single hydrostatic pressure gradient system, the P well can be equal or very close to P pore in the subsequent runs.
A fourth step is to detonate the charges in the perforating system 10 . The perforated cement sheath 41 , casing 42 and gun carrier shell 44 establish communications between the formation fluid 40 and the inner gun volume 46 . P gun is substantially lower than P pore and P well after a very short period of time after the charge detonation (e.g., about several to tens of milliseconds). This results in the dynamic underbalance phenomenon which can lead to collapse of some perforation tunnels for weak or unconsolidated formation and the formation fluid 40 and wellbore fluid 43 filling in the inner gun volume 46 . Because the shooting portion of the gun carrier 44 is set against the casing wall 42 at the perforated holes 48 and 49 as shown in FIG. 3 , the communication between formation 40 and the inner gun volume 46 is maximized while the communication between the wellbore space 43 and the inner gun volume 46 is substantially restricted. This directs surge fluid flow from the formation 40 to the inner gun volume 46 . The directed surge flow enables the loose sand and debris in the perforation tunnel 49 to move into the inner gun volume 46 while reducing/minimizing sand and debris production in the wellbore space 43 .
After sufficient time, the produced sand and debris settle down to the sand and debris holder 26 . The eccentralizers 19 and 27 are unset and the perforating system 10 is retrieved from the wellbore. Enlarging wellbore radius behind casing by producing some formation sand without the sand accumulation in wellbore is achieved at the same time using the present embodiment.
The perforating system 10 can be reloaded and rerun numerous times as needed to perforate the well in the same or other azimuthal directions. In each of these runs, sand and debris accumulation in the wellbore will be reduced/minimized. Therefore, the goal of reduced, preferably no, debris perforating can be better realized while productivity of the well is enhanced by removing some sands near the perforating tunnels.
The eccentralizers 19 and 27 with bowed springs used in the perforating system 10 are only one example of various devices applicable in this application. Other devices may be installed in the perforating system 10 with similar functionality, e.g., springs, magnets, telescoping devices or arms. Also, more than one eccentralizer spaced radially can be used so long as they are evenly spaced from 180° of the firing direction of the shaped charge 47 , e.g. one on each side.
To further restrict the flow communication between the wellbore space 43 and the inner gun volume 46 , retainer parts can be applied to an outside surface of the gun carrier 44 in proximity to the perforating portion of the gun carrier 44 . For example, sealing rings 102 can be used on scallops 100 on the gun carrier 44 . FIG. 4B shows the sealing ring 102 and its application in reducing the fluid flow from the wellbore space 43 to the inner gun volume 46 . FIG. 4A shows the sealing ring 102 installed on a scallop 100 of the gun carrier 44 . FIG. 4B is the side view of the sealing ring 102 installed on a scallop 100 in the gun shell 44 . FIG. 4C shows the front view of the sealing ring 102 while FIG. 4D is its side view. The curvature of the sealing ring 102 used in the perforating system 10 is determined by the curvature of the casing inside diameter 42 for the job. The outer edge 105 of the sealing ring 102 has a curvature substantially close to that of the casing inside diameter 42 . This minimizes flow communication between the wellbore space 43 and the inner gun space 46 while maximizing the flow communication between the formation 40 and the inner gun volume 46 . Preferably, the sealing rings 102 are made with conventional elastomer in this application but other materials can also be used. For example, the sealing rings could be made from high temperature polymers. Also, the sealing rings 102 can be made from metal, e.g. steel. The sealing rings 102 can be installed on the gun carrier 44 through the spiral grooves on the sealing rings 102 and the scallops 100 . The sealing rings 102 can also be attached with adhesives, by fasteners, by clamps, or by welding. Alternatively, the sealing rings 102 can be an extension of the material making up the gun carrier 44 . Note that the inner diameter of the sealing rings 102 should be larger than that of the perforating portion of the gun carrier 44 , i.e., perforated holes on the gun carrier 44 , in that the sealing rings 100 would not be damaged by the perforators during perforation.
Another method to reduce the debris and sand production in the wellbore is to close the perforated holes on the gun carrier 44 after the gun volume 46 contains debris, e.g. is filled up. FIG. 5 shows a sliding sleeve 60 for this purpose. The sliding sleeve 60 has a pre-manufactured hole 62 coaxially aligned with the shaped charge. The diameter of the hole 62 is larger than that of the perforated hole on the gun carrier 44 so that the jet of a detonated charge 47 would not be spent in penetrating the sleeve 60 . Therefore, the penetration of the shaped charge 47 would not be reduced by the existence of the sleeve 60 . Note that the sleeve 60 can close either all perforated holes or a portion of the holes in gun carrier 44 . For closing a portion of the holes, it is preferable to close those at the lower part of the gun carrier 44 . Also note that the sleeve 60 can close the perforated holes through longitudinal movement along the axis of the gun carrier 44 . Alternatively, it can close them through rotating along the azimuth of the gun carrier 44 , or the combination of the longitudinal and azimuthal movements. Closing the perforated holes in the gun carrier 44 is particularly beneficial for perforating a horizontal or large deviated well. The holes on the gun carrier 44 can be closed either just after the charges are detonated or at the termination of the dynamic under-balance response or after the complete settlement of the produced sands inside the gun carrier 44 . The exact timing of perforated-hole closure by the sleeve 60 depends on operational considerations in each individual dynamic under-balance operation. The closure can be performed automatically by setting time delay after the detonation of the charges or controlled by operators on the surface.
In another embodiment, flow restrictors are used to reduce the flow communication between the inner gun volume 46 and the wellbore 43 . FIG. 6 shows an application of the flow restrictors 150 and 151 on the gun 23 . The flow restrictors 150 and 151 can be made by various materials with a variety of geometries. The flow restrictors 150 and 151 can be installed in any locations that straddle (preferably symmetrically) the zero phasing line 153 of the perforating. The two flow restrictors 150 and 151 should contact the casing 42 and allow a small gap 155 between the gun shell 44 and the inside diameter (ID) of casing 42 . This gap enables the flow communication between the formation 40 and the gun inner space 46 when the perforated tunnels on the casing and holes on gun carrier 44 do not line up if there is a gun movement after perforating. The devices 150 and 151 substantially reduce the fluid flow moving from outside of the two restrictors into the gap 155 within the two restrictors. This maximizes the fluid flow from the formation 40 to the inner gun space 46 so that the produced solid debris and sands are drawn into the inner gun volume 46 . Another benefit of using the flow restrictors 150 and 151 is that the perforating does not have to be zero phasing. A range of azimuthal angles of perforating phasing is possible depending on the position and height of the flow restrictors 150 and 151 installed on the gun carrier 44 .
FIG. 7 is the front view of the flow restrictors 150 and 151 that are assembled on the perimeter of the gun carrier 44 . The two clamps 160 and 161 are connected to the two ends of the gun 23 . A number of holes 170 and 171 with spiral grooves are distributed in the clamps 160 and 161 . The flow restrictor 150 is attached to the gun carrier 44 by the two screws 164 and 165 into the threaded holes 170 and 171 on the clamps 160 and 161 , respectively. The flow restrictor 151 is attached to the gun carrier 44 through the two screws 166 and 167 on the clamps 160 and 161 , respectively. In another embodiment, the holes 170 and 171 with the spiral grooves are manufactured near the end of the gun carrier 44 rather than on the clamps 160 and 161 . To secure the flow restrictors 150 and 151 on the gun carrier 44 , there may be one or more groups of the threaded holes 173 in the middle of the gun carrier 44 . The screws 174 and 175 further secure the flow restrictors 150 and 151 , respectively, on the gun carrier 44 . Other types of assembly are also possible to install the flow restrictors 150 and 151 on the gun carrier 44 . For example, the flow restrictors 150 and 151 can be welded on the gun carrier 44 .
In addition to the flow restrictors 150 and 151 that reduce the lateral fluid flow from the wellbore 43 into the gap 155 between the two restrictors, the vertical fluid flow from the wellbore 43 above and below the gun carrier 44 into the gap region 155 should also be confined. FIG. 8 shows the vertical flow restrictors 190 installed between the two horizontal flow restrictors 150 and 151 on the upper end of the gun carrier 44 . The outer curvature of the restrictor 190 has substantially similar to that of the casing ID 42 , while its inner curvature is substantially similar to that of the gun OD. Screws 191 can be used to connected the vertical flow restrictor 190 to the gun carrier 44 . The same installation of the vertical flow restrictor can be applied on the bottom end of the gun. The vertical flow restrictor 190 can also be installed at the bottom of the gun carrier 44 .
In another embodiment, multiple flow restrictors can be used to replace the single vertical flow restrictor 190 . As shown in FIG. 8 , the multiple vertical flow restrictors 195 are installed on the bottom end of the gun carrier 44 . Each piece of the multiple vertical flow restrictors 195 is connected to the gun carrier 44 through a screw 196 and the holes with spiral groove on the gun. The inner and outer curvatures of the multiple vertical flow restrictors 195 are substantially similar to those of the gun carrier 44 and the casing ID 42 , respectively. The multiple vertical flow restrictors 195 can also be installed on the top of the gun carrier 44 .
The vertical flow restrictors 190 and 195 may be installed without the horizontal flow restrictors 150 and 151 , and vice versa. There is also no restriction that the vertical flow restrictors are installed within the horizontal flow restrictors 150 and 151 . The vertical flow restrictor 190 or 195 can be installed on the entire periphery of the gun carrier 44 , or just a portion thereof.
In addition to the wireline, the perforating system 10 can also be conveyed to the targeted location in a well by other methods. For example, the perforating system 10 can be installed in drill pipes, tubing pipes, coiled tubing or other convey means to realize the same perforating results with low debris in the wellbore. All the embodiments herein are applicable regardless of the conveyance differences.
The preceding description is mean to illustrate various features described in the present application and is not meant to limit the present or future related claim scope in any way.
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A perforating system having a perforating gun with a tubular gun housing defining an inner volume and extending in an axial direction. A shaped charge is held in a loading tube. The loading tube is located in the gun housing. The loading tube extends along the axial direction. The shaped charge faces in a firing direction substantially perpendicular to the axial direction. A portion of the gun housing adjacent to the shaped charge in the firing direction is a perforating portion for removal upon firing of the shaped charge. An eccentralizer member extends from the perforating gun in a second direction that is substantially opposite and parallel with the firing direction. A first retainer part extends from an outer surface of the gun housing adjacent to the perforating portion. A second retainer part extends from the outside of the gun housing adjacent to the perforating portion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to provisional patent application 61/588,271 which was filed on Jan. 19, 2012, and is hereby expressly incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] There are numerous concrete products used in the construction industry in a variety of applications, such as foundations for supporting structures, as bridge and deck panels, and as beams for structures, just to name a few. Concrete is a material that is very strong in compression but relatively weak in tension. Masonry structures and the mortar holding them together have similar properties to concrete and also have a limited ability to carry tensile loads.
[0003] In order to compensate for this imbalance in the behavior of concrete and masonry structures, reinforcement bars, which are common steel bars, are typically used as a tensioning device to produce reinforced concrete and reinforced masonry structures. These reinforcement bars, commonly called “rebars”, are usually formed from carbon steel, and are given ridges for better mechanical anchoring into the concrete. While any material with sufficient tensile strength could conceivably be used to reinforce concrete, steel and concrete have similar coefficients of thermal expansion. Therefore, a concrete structural member reinforced with steel will experience minimal stress as a result of differential expansions of the two interconnected materials caused by temperature changes.
[0004] Traditional reinforced concrete is based on the use of rebars cast into a poured concrete structure. In addition, pre-stressed concrete is a method for further overcoming concrete's natural weakness in tension. It can be used to produce beams, floors or bridges with a longer span than is practical with ordinary reinforced concrete. Pre-stressing tendons, generally of high tensile steel cable, are used to provide a clamping load which produces a compressive stress that balances the tensile stress that the concrete compression member would otherwise experience due to a bending load.
[0005] One concrete product that utilizes the foregoing principles is a prefabricated concrete pile used to support foundations. These piles are driven into the ground using a device such as a pile driver. Concrete piles are available in a variety of cross-sectional shapes, including square, octagonal, and round cross-sections, and they are reinforced with rebar and are often pre-stressed. Foundations relying on concrete driven piles often have groups of piles connected by a pile cap (a large concrete block into which the heads of the piles are embedded) to distribute loads which are larger than one pile can bear. Pile caps and isolated piles are typically connected with the piles to tie the foundation elements together, so that lighter structural elements bear on the piles while heavier elements bear directly on the pile cap.
[0006] In the manufacture of reinforced and pre-stressed concrete structures, such as piles, a form of the desired shape is used with reinforcing spaced-apart steel bars positioned to create a frame. Then rebars or grout tubes are used to further strengthen the structure. When utilized, the rebars or grout tube must be centered and held in place as the concrete is poured to form the structure. Securing the rebars or grout tube within the steel bar frame is currently done by hand, using wires and cables to tie the rebars or grout tube to the frame. This is a time consuming and expensive process.
[0007] There is therefore a need for an improved way of securing a grout tube and rebars in place while the concrete is poured to form the concrete structure.
SUMMARY OF THE INVENTION
[0008] The invention is for preformed wire spacers that are shaped to grasp a grout tube and secure it to the steel frame within a concrete form. The spacer is formed from a continuous length of spring steel, wire that has a circular central portion of sufficient size to surround the grout tube. The free ends of the spacer extend outwardly from the central portion and are formed with hooks extending, with one free end having both a handle and a hook. Being a continuous length of spring steel, the central portion has a double wrap or overlapping portion which provides for the diameter of the central portion to be temporarily expanded in diameter by grasping the free ends and applying force to expand the central portion's size. This allows the spacer to be easily combined with the grout tube, since the spacers and tube can move relative to each other. Multiple spacers are used on a single tube and are spaced apart a distance to provide the proper support and positioning of the tube relevant to the frame and the finished concrete form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a front view of a first embodiment of the invention;
[0010] FIG. 2 is a side view of the first embodiment of the invention;
[0011] FIG. 3 is a perspective view of the invention;
[0012] FIG. 4 is a perspective view of a steel frame for a concrete beam which shows the spacers secured in place on the steel frame;
[0013] FIG. 5 is a perspective view showing a grout tube with spacers in place to illustrate the positioning of the spacers on the tubes; and
[0014] FIG. 6 is a perspective view of a finished concrete beam and shows the opening created by the grout tube.
DETAILED DESCRIPTION OF THE INVENTION
[0015] FIGS. 1 , 2 and 3 show the preferred embodiment of the invention. A spacer 20 comprises a central portion 22 and a pair of free ends 24 . The free ends 24 , 26 extend outwardly from the central portion 22 . Preferably the free ends 24 , 26 extend in opposite directions and are one-hundred eighty degrees apart. The spacer 20 is formed from a single continuous length of spring steel wire.
[0016] In the preferred embodiment, the central portion 22 transitions to the free ends 24 , 26 at an angle. Additionally, the angle designated as A in FIG. 1 is preferably between 60 and 90 degrees, with 75 degrees being shown in FIG. 1 . The angle A can have an effect on the force needed to expand the central portion 22 as further discussed below.
[0017] Free end 24 has a fastener 27 which is preferably a hook 28 formed at its outer end 29 while free end 26 has a fastener 31 again preferably a hook 32 , and a handle 34 at its outer end 35 . The hooks 28 , 32 engage a frame 40 of a future concrete structure as shown in FIG. 4 , Hooks 28 , 32 grasp rebars 44 that form the frame 40 for the concrete structure, or, can be hooked over cables 46 on opposite sides of the frame 40 . The preferred embodiment has the handle 34 on one free end only, in the figures, free end 26 .
[0018] Handle 34 provides a grip for installing the spacer 20 by first securing the hook 28 over a portion of the frame 40 or cable 46 after which handle 34 is grasped to secure the hook 32 over a portion of the frame 40 or the cable 46 on the opposite side of the frame 40 . Again, the angle of the handle 34 and the hook 32 can be varied, however, the angle designated as B shown in FIG. 1 is approximately 45 degrees. The angle B can allow a user easier access to the handle and allow the user to more easily apply force to the spacer 22 during installation.
[0019] The curved portions 50 of the spacer 20 are contiguous and form a secondary structure 52 in the central portion 22 . Preferably the curved portions 50 touch against each other within at least a portion of the central portion 22 , as shown in FIGS. 2 and 3 . The secondary structure 52 in the preferred embodiment is a loop 54 which is circular. This structure and the use of spring steel for the spacer 20 provide for quick and easy installation of the spacer 20 on the frame 40 .
[0020] Once spacers 20 are installed on the frame 40 , a grout tube 12 can easily be slid through the spacers which position the grout tube 12 in the approximate center of the form resulting in a finished product as shown in FIG. 6 . FIG. 5 shows a grout tube 12 with spacers 20 installed on it. In this instance, the grout tube 12 can be positioned inside the frame 40 and the spacers 20 hooked onto the frame 40 in the manner described above. In either case, it is evident that use of spacers 20 greatly reduces the time and effort to produce concrete products of this type and therefore significantly reduces the cost of the products a reinforced concrete beam or concrete pile 10 produced using a grout tube 12 . Referring to FIG. 6 , the grout tube 12 provides an opening through which rebars (not shown) can be inserted to anchor the pile or beam 10 in place in a structure where beams 10 or piles are used.
[0021] As is well known to those skilled in the art, a typical concrete pile or beam 10 is produced in a concrete form (not shown) of the desired length and cross-sectional shape. Referring to FIG. 4 , the pile or beam almost always is produced using rebars 14 to form the frame 40 and high tensile cables 46 which may be pre-stressed, as described above. FIG. 4 illustrates the skeleton metal frame in which a grout tube 12 can be placed.
[0022] Although it is contemplated that the spacer 20 will have a set diameter “d” for accommodating a specific sized grout tube, the size of the spacer 20 , particularly the diameter of the central portion 22 can be varied during the manufacturing process to accommodate a specific sized grout tube. Additionally, the preferred material used to make the spacer 20 is spring steel which allows the spacer to have some flexibility. The flexibility allows the spacer 20 to go from its static first position to a second position when force is applied on the free ends 24 , 26 toward the center portion 22 . This application of force expands the diameter of the center portion 22 . The greater the force applied the greater the expansion of the diameter of the center portion. Once the force is released, the spacer 20 returns to its normal first position. The ability to expand allows a particular spacer 20 to accommodate a variety of sizes of grout tubes.
[0023] The above description is for a preferred embodiment. There are numerous contemplated changes to the spacer which could vary from the preferred embodiment. Beginning with the free ends 24 , 26 , a variety of fasteners, other than hooks, with the ability to engage a portion of the frame 40 or cables 46 . Similarly, the shape of the center portion 22 could be varied without making the spacer 20 inoperable. Furthermore, another embodiment could utilize a center portion 22 which does not entirely wrap around the grout tube. Instead, the center portion 22 could be a semi circle which wraps around only a portion of the grout tube 12 . For instance, if the center portion wrapped the left side of the grout tube 12 , then the next flanking spacer 20 could wrap the right side of the grout tube 12 . Accordingly the grout tube 12 could be secured within the frame 40 without a complete circular center portion 22 .
[0024] Having thus described the invention in connection with certain embodiments, 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 invention.
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A spacer for securing a grout tube to a frame prior to the pouring of concrete to form a concrete structure. The spacer comprises a central portion and two free ends extending from the central portion. The central portion surrounds at least a portion of the grout tube and the free ends are fastened in some fashion to the frame. A plurality of spacers can be utilized for securing the grout tube in place. The central portion is preferably circular and the manipulation of the free ends can expand or contract the diameter of the central portion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of co-pending application U.S. Ser. No. 08/398,311, entitled "DIRECTIONAL BORING HEAD WITH BLADE ASSEMBLY," filed Feb. 27, 1995, now U.S. Pat. No. 5,779,740 which was a continuation-in-part of U.S. application Ser. No. 163,756, entitled DIRECTIONAL MULTI-BLADE BORING HEAD, filed Dec. 9, 1993, now U.S. Pat. No. 5,392,868 which was a continuation-in-part of application Ser. No. 67,298, entitled DIRECTIONAL MULTI-BLADE BORING HEAD, filed on May 25, 1993, now U.S. Pat. No. 5,341,887, which was a continuation-in-part of application Ser. No. 857,167, entitled METHOD OF AND APPARATUS FOR DRILLING A HORIZONTAL CONTROLLED BOREHOLE IN THE EARTH, filed Mar. 25, 1992, now U.S. Pat. No. 5,242,026, which was a continuation-in-part of application Ser. No. 780,055, entitled METHOD OF AND APPARATUS FOR DRILLING A HORIZONTAL CONTROLLED BOREHOLE IN THE EARTH, filed Oct. 21, 1991, now abandoned. The contents of each of these applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to methods of making underground bores and to methods of changing the direction of underground bores by oscillating the boring head. This invention also relates to boring heads adapted to bore holes and to change the direction of a borehole via oscillation of the boring head.
SUMMARY OF THE INVENTION
The present invention is directed to a method of making an underground bore using a boring machine capable of axially advancing and rotating a drill string about an axis of rotation underground. The drill string has a first end operatively connectable to the boring machine and a second end terminating in a boring head having a roller cone and a deflection structure. The method comprises the steps of rotating the boring head to bore a generally straight borehole and oscillating the boring head to deviate the direction of the borehole.
The present invention further is directed to a directional boring head for a boring machine, the boring machine capable of axially advancing and rotating a drill string about an axis of rotation underground, the drill string ending in a directional boring head. The directional boring head comprises a body having a longitudinal axis and a roller cone mountable on the body. The position of the roller cone is offset with respect to the axis of the body, so that when the boring head is thrust forward and rotated, the boring head bores a generally straight borehole, and when the boring head is oscillated, the boring head deviates the direction of the borehole.
The present invention further is directed to a method of steering a boring head through a material which is to be cut. The boring head comprises a roller cone and a deflection structure adapted to deflect the boring head. The boring head is operatively connectable to a boring machine. The method comprises the steps of rotating the boring head to bore a generally straight borehole and oscillating the boring head to deviate the direction of the borehole.
Still further, the present invention is directed to a directional boring machine comprising a drill string operatively connectable to a rotary machine for rotating the drill string and including an assembly for advancing the drill string and wherein the free end of the drill string is adapted to support a boring head for forming a borehole. The machine comprises a directional boring head attached to the free end of the drill string. The boring head comprises a body having a longitudinal axis and a roller cone mountable on the body. The position of the roller cone is offset with respect to the axis of the body, so that when the boring head is thrust forward and rotated, the boring head bores a generally straight borehole, and when the boring head is oscillated, the boring head deviates the direction of the borehole.
The present invention further is directed to a method of making an underground bore using a boring machine capable of axially advancing and rotating a drill string about an axis of rotation underground. The drill string has a first end operatively connectable to the boring machine and a second end terminating in a boring head. The boring head comprises a body having a longitudinal axis and a roller cone mountable on the body. The position of the roller cone is offset with respect to the axis of the body. The method comprises the steps of rotating the boring head to bore a generally straight borehole and oscillating the boring head to deviate the direction of the borehole.
Finally, the present invention is directed to a method of steering a boring head through a material which is to be cut. The boring head is operatively connectable to a boring machine and comprises a body having a longitudinal axis and a roller cone mountable on the body. The position of the roller cone is offset with respect to the axis of the body. The method comprises the steps of rotating the boring head to bore a generally straight borehole and oscillating the boring head to deviate the direction of the borehole.
Many boring heads have been designed which have such a steering feature. However, there is a continuing need to develop boring heads which have better directional control, operate in a variety of soil conditions effectively and provide enhanced cutting action.
SUMMARY OF THE INVENTION
The present invention is directed to a directional boring machine comprising a frame, a rotary machine supported on the frame, a drill string operatively connected to the rotary machine to drive the rotation of the drill string; and a directional multi-blade boring head attached to the end of the drill string. The boring head comprises a body having a central axis of rotation and a blade assembly mounted on the body.
In one embodiment the blade assembly has a first blade defining a deflecting surface at an oblique angle to the central axis of rotation of the body and a second blade defining a deflecting surface at an oblique angle to the central axis of rotation of the body. The first and second blades extend at an angle relative to each other. At least one additional blade extends from the blade assembly between the deflecting surface. The deflecting surfaces of a first and second blade deflect the boring head as the boring machine advances the drill string without rotation, and the directional multi-blade boring head drills a relatively straight borehole as the boring machine advances the drill string with rotation.
In another embodiment, the blade assembly a base and a blade extending from the base. The base is attached to the lower surface of the body of the boring head, and the base defines a first plane. The blade terminates in a forward end, and the blade defines a second plane intersecting the first plane of the base, so that the blade angles upward relative to the base. The blade has a thickness tapering gradually towards the forward end, and the forward end defines a plurality of teeth. Each tooth has a contact side and a back side, the contact side being the side that impacts the earth first as the boring head is rotated on the drill string, and the back side being the side opposite the contact side. The back side of each tooth is cut away forming a recess between the back side of the tooth and the surface being bored. Still further, the plurality of teeth includes a first set on a first side of the blade and a second set of teeth on the second side of the blade. The first set is substantially similar in size and configuration to the second set of teeth, but extends slightly forward of the second set of teeth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a boring machine as employed in practicing the method of the invention for drilling a borehole in the earth.
FIG. 2 is an elevational, enlarged scale view of the boring machine of FIG. 1.
FIG. 3 is a top plan view of the boring machine of FIGS. 1 and 2 taken along line 3--3 of FIG. 2.
FIG. 4 is an elevational, enlarged scale view of the boring machine of FIGS. 1 and 2 taken along line 4--4 of FIG. 2.
FIG. 5 is an elevational, cross-sectional, enlarged scale view taken along line 5--5 of FIG. 2 showing how the drill string is supported and rotationally oriented.
FIG. 6 is an enlarged, side elevational view of a boring head or downhole tool of FIG. 1 taken at (6) of FIG. 2.
FIG. 7 is top plan view of the boring head of FIG. 6.
FIG. 8 is an end view of the boring head of FIG. 6 taken along line 8--8 of FIG. 6.
FIG. 9 is a broken away perspective view of elements associated with a second alternative embodiment of a boring machine including a second alternative embodiment of a boring head.
FIG. 10 is a broken away perspective view of elements associated with the second alternative boring head of FIG. 9.
FIG. 11 is a side sectional view of the boring head of FIG. 10.
FIG. 12 is a cut-away view of the bottom flat surface of the boring head of FIGS. 10 and 11.
FIG. 13 is a front view of the boring head of FIGS. 10 and 11.
FIG. 14 is a top view of the boring head of FIGS. 10 and 11.
FIG. 15A is a broken away perspective view of elements associated with a frame of the second alternative embodiment of a boring machine.
FIG. 15B is a broken away partial perspective view of a connector link between a chain and a forward end of the frame of FIG. 15A
FIG. 15C is a broken away partial perspective view of a connector link between a chain and a thread of the frame of FIG. 15A.
FIG. 16 is a broken away perspective view of a saver sub and an adapter assembly for a drill string.
FIG. 17 is a bottom view of a dirt blade assembly of FIG. 10.
FIG. 18 is a side view of the dirt blade assembly of FIG. 17.
FIG. 19 is a bottom view of a sand blade assembly of FIG. 10.
FIG. 20 is a side view of the sand blade assembly of FIG. 19.
FIG. 21 is a bottom view of an alternative sand blade assembly.
FIG. 22 is a side view of the sand blade assembly of FIG. 21.
FIG. 23 is an enlarged elevational view of a third alternative embodiment of a boring head and of a portion of a drill string.
FIG. 24 is a top view of the boring head of FIG. 23.
FIG. 25 is a front view of the boring head of FIG. 23 take along line 25--25 of FIG. 23.
FIG. 26 is a fragmented section view of the blade of the boring head of FIG. 23 illustrating the wear resistant material on the blade.
FIG. 27 is an enlarged partial view of FIG. 24 showing a ball in a check valve assembly which is disposed inside the fluid passageway and adjacent the nozzle.
FIG. 27A is a perspective view of FIG. 24 showing a ball in a check valve assembly which is disposed inside the fluid passageway and adjacent the nozzle.
FIG. 28 is a partial view of the boring head of FIG. 23 including an alternative embodiment of a blade.
FIG. 29 is a top view of a hard soil/soft rock tapered blade assembly.
FIG. 30 is a side view of the hard soil/soft rock tapered blade assembly of FIG. 29.
FIG. 31 is an opposite side view of the hard soil/soft rock tapered blade assembly of FIG. 29.
FIG. 32 is a bottom view of a spade-like blade assembly.
FIG. 33 is a side view of the spade-like blade assembly of FIG. 32.
FIG. 34 is a bottom view of a relatively wide blade assembly.
FIG. 35 is a side view of the relatively wide blade assembly of FIG. 34;
FIGS. 36-59 illustrate various alternative boring heads that can be used;
FIG. 60 is a perspective view of another embodiment of the directional multi-blade boring head;
FIG. 61 is a front view of the boring head of FIG. 60;
FIG. 62 is a side view of the boring head of FIG. 60;
FIG. 63 is a perspective view of another embodiment of the directional multi-blade boring head;
FIG. 64 is a front view of the boring head of FIG. 63;
FIG. 65 is a side view of the boring head of FIG. 63;
FIG. 66 is a perspective view of another embodiment of the directional boring head;
FIG. 67 is an end view of the boring head of FIG. 66;
FIG. 68 is a side view of the boring head of FIG. 66;
FIG. 69 is a perspective view of a directional boring head forming a second embodiment of the present invention;
FIG. 70 is an end view of the boring head of FIG. 69;
FIG. 71 is a side view of the boring head of FIG. 69;
FIG. 72 is a plan view of an alternative blade assembly for the directional boring head;
FIG. 73 is a bottom view of the blade assembly shown in FIG. 72;
FIG. 74 is an elevational view of a first side of the blade assembly shown in FIG. 72;
FIG. 75 is an elevational view of the opposite side of the blade assembly shown in FIG. 72;
FIG. 76 is an elevational front end view of the blade assembly shown in FIG. 72; and
FIG. 77 is another side elevational view illustrating the angle of the blade portion of the assembly relative to the base portion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and first to FIG. 1, the environment in which the apparatus of this invention is used is illustrated. The boring machine is generally indicated by the numeral 10. The machine 10 is shown resting on earth's surface 12 and in position for forming a borehole 14 underneath an obstruction on the earth such as a roadway 16. As shown in FIG. 1, by using the extended range boring machine 10, the direction of the borehole can be changed as the borehole passes under the roadway 16. This illustrates how the machine 10 can be utilized to form a borehole 14 under an obstruction without first digging a deep ditch in which to place a horizontal boring machine, and also without having to dig a deep ditch on the opposite side of the obstruction where the borehole is to be received. While the method of drilling a borehole and the machine used therewith will be described as showing the borehole being drilled from the earth's surface 12, it can be appreciated that the machine 10 can be used in a shallow ditch if desired. It should be kept in mind, however, that the main emphasis of the method and machine of this invention is that of drilling a borehole in which the direction of the borehole can be changed during the drilling process. These methods could be applied on other types of drilling machines as well.
In conventional fashion, the drill string 44 is simultaneously rotated and advanced by means of the boring machine 10 to establish a borehole in the earth. The drilling operation, wherein the pipe 42 of FIG. 2 is simultaneously rotated and axially advanced, is continued until a change in direction of the borehole is desired. This typically occurs when the borehole is near a desired depth and when the borehole is to be moved substantially horizontal for a distance. In order to change the direction of the borehole, the following sequence is employed:
1. The rotation of the drill string 44 is stopped.
2. The rotational position of the drill string 44 is oriented so that the blade assembly 72, 172, 172', 272, 372, 472, 572, 672 or 772 of the boring head 58, 158 or 358 is inclined at an acute angle relative to the longitudinal axis of the drill string and towards the new direction of the borehole desired.
3. The drill string is axially advanced without rotation to axially advance the boring head 58, 158 or 358 a short distance such that the blade assembly moves the boring head in the earth towards the new desired direction.
4. Simultaneous rotation and axial advancement of the drill string is resumed for a short distance.
5. Sequentially repeating steps 1, 2, 3 and 4, until the direction of the borehole is in the new direction desired.
Thereafter, the boring head 58, 158 or 358 is axially advanced and simultaneously rotated until it is again desirable to change directions. This typically can occur when a borehole has reached a point adjacent the opposite side of the obstruction under which the borehole is being drilled. At this stage in the drilling of the borehole, it is desirable to have the direction of the borehole inclined upwardly so that the borehole will emerge at the surface of the earth on the opposite side of the obstruction.
To again change the direction of the borehole, the same sequence is repeated. That is, the rotation of drill string 44 is stopped, the orientation of the drill string is corrected so that the blade assembly of the boring head is inclined in the newly desired direction (that is, in this example, upwardly), the drill string is axially advanced without rotation a short distance, the drill string is then rotated and axially advanced a short distance, and the sequence is repeated until the new direction of drilling the borehole is attained. After the new direction is attained, the borehole is drilled by simultaneously rotating and advancing the drill string until the borehole is completed. Referring to FIGS. 2 and 3, more details of the boring machine are illustrated. In particular, the machine 10, which is utilized for practicing a method of this invention, includes a frame 18 having a forward end 18A and a rearward end 18B and supportable on the earth's surface. The frame 18 of FIGS. 2 and 3 and the frame 118 of FIGS. 15A-15C are preferably operated from a surface launch position which eliminates the need to dig a pit. Also, the frames 18 and 118 provide an elongated linear travel pathway. As best seen in FIGS. 4, 5 and 15A the linear pathway is preferably provided by spaced apart parallel channels 20 and 22 or 120 and 122.
Rotary machine 24 of FIGS. 2, 3 and 4 is supported on the frame and in the travel path. More specifically, rotary machine 24 is supported on wheels 26 of FIG. 4 which are received within channels 20 and 22.
The drill string 44 includes a plurality of drill pipes 42 each having a male thread at one end and a female threaded opening at the other end. Each pipe is attachable at one end to rotary machine 24 and to each other in series to form drill string 44. As seen in FIGS. 2 and 3, the rearward end of drill string 44 can be attached to the rotary machine 24. The drill string 44 can also include an adapter 230 and saver subs 232, as in FIGS. 9 and 16. Thread caps 234 and 236 are used to protect the drill pipe and are removed prior to insertion into the drill string.
The rotary machine 24 is supplied by energy such as by hydraulic pressure through hoses 28 and 30 of FIGS. 2 and 4. This hydraulic energy can be supplied by an engine driven trailer mounted hydraulic pump (not shown) which preferably is positioned on the earth's surface adjacent the drilling machine. The use of hydraulic energy is by example only. Alternatively, the rotary machine or drive 24 could be operated by electrical energy, an engine or the like. The use of hydraulic energy supplied by a trailer mounted engine driven pump is preferred, however, because of the durability and dependability of hydraulically operated systems. Third hose 32 of FIGS. 2 and 4, is used for supplying fluid for a purpose to be described subsequently.
By means of control levers 34 of FIG. 2, hydraulic energy can be controlled to cause rotary machine 24 to be linearly moved in the pathway provided by channels 20 and 22 of FIGS. 4 and 5 or 120 and 122 of FIG. 15A, and at the same time to cause a drill pipe to be axially rotated. The linear advancement or withdrawal of the rotary machine 24 is accomplished by means of the chain 36 of FIG. 2 or the chain 136 of FIG. 15A which is attached at one end to the frame front end 18A or 118A and at the other end to the frame rearward end 18B or 118B. The chain 36 passes over the cog wheel 38, the rotation of which is controlled by one of the levers 34 to connect hydraulic power to a hydraulic motor (not shown) which rotates the cog wheel 38 in the forward or in the rearward direction or which maintains it in a stationary position.
As seen in FIGS. 2 and 3, extending from the forward end of the rotary machine 24 is a drive spindle or shaft 40 which has means to receive the male or female threaded end of the drill pipe 42. Upper or uphole end 60 of the drill string is attached to shaft 40 (FIG. 2), that is, to the rotary machine 24. The saver sub 232, attached to the shaft 40 with a thread retaining compound such as Loctite® RC/680 is a replaceable protector ("saver") of the threads on the shaft 40.
A plurality of drill pipes 42 are employed and, when the drill pipes are assembled together, they form the drill string 44 as seen in FIG. 1. The drill pipes 42 are of lengths to fit a particular size drill frame 18 or 118, such as 5 feet, 10 feet, 12 feet and/or 20 feet. When sequentially joined the drill pipes 42 can form a drill string of a length determined by the length of the hole to be bored. The preferred embodiments generally have a distance capability of over 400 feet in many soil conditions.
As seen in FIGS. 2 and 5, adjacent the forward end 18A of the frame is a drill pipe support 46. The drill pipe support 46 maintains the drill pipe 42 in a straight line parallel to the guide path formed by the channels 20 and 22. The drill pipe support can include a sight 48, the purpose of which will be described subsequently.
Positioned adjacent the forward and rearward ends of the frames 18 or 118 are jacks 50 or 150 by which the elevation of the frame relative to the earth's surface 12 may be adjusted. In addition, at front end 18A of the frame are opposed stakes 52 and 54 which are slidably received by the frame front end. The stakes 52 and 54 may be driven in the earth's surface so as to anchor the machine during the drilling operation.
Also illustrated in FIG. 15A are a flange lock bolt 117 and a flange lock nut 119 for attaching the rearward end of the rear cross-member 118B of the frame 118 to the channels 120 and 122. Also, as seen in FIG. 15C, the thread 113 (attached to the rearward end 118B by nuts 111) adjustably engages the chain 136 via the connector link 137. In addition, as seen in FIG. 15B, the opposite end of the chain 136 also engages the forward end 118A of the frame 118 via the second connector link 137.
Affixed to the downhole end 56 of the drill string 44 is a bit or downhole tool generally indicated by the numeral 58 and referred to hereinafter as a boring head. The boring head is best seen in FIGS. 6, 7 and 8.
The boring head 58 includes body portion 62 which has rearward end portion 64 and a forward end portion 66. The rearward end portion 64 of the body 62 includes an internally threaded recess 68 which receives the external threads 70 of the drill string forward end 56.
The blades or blade assemblies 72, 172, 172', 272, 272', 372, 472, 572, 672 and 772 can be affixed to the bodies 62, 162 or 362 of the boring head 58. The plane of the blade assemblies 72, 172, 172', 272, 272', 372, 472, 572, 672 and 772 is inclined at an acute angle to the axis X--X of the boring head's internally threaded recess 68. Axis X--X is also the longitudinal axis of the drill string 44 or the forward most drill pipe 42. That is, the axis X--X is the axis of the portion of the drill string immediately adjacent and rearward of the boring head.
The blade assemblies are preferably sharpened at their outer forward ends 72A, 172A, 272A, 372A, 472A, 572A, 672A and 772A. When rotated, the blade assemblies cut a circular pattern to form walls 6 or 6' at end 4 of borehole 14 as illustrated in FIG. 6.
The boring head bodies 62, 162 and 362 have fluid passageway 78 therethrough connecting to jet or nozzle 76. The fluid passageway 78 is in turn connected to the interior of the tubular drill string 44. As previously stated with reference to FIG. 2, the hose 32 provides means for conveying fluid under pressure to the boring machine 24. This fluid is connected to the interior of the drill pipe 42 and thereby to the entire drill string 44, and, thus, to the interior of the bodies 62, 162 and 362. The fluid is ejected from the boring head bodies 62, 162 and 362 through the nozzle 76 to aid in the drilling action. That is, fluid is ejected from the nozzle 76 to cool and lubricate the blade assemblies 72, 172, 172', 272, 272', 372, 472, 572, 672 or 772 and flush away cuttings formed by the blade as it bores through the earth by forming a slurry of cuttings.
The nozzle 76 in this case refers to any of a plurality of fluid nozzles designed for different soil conditions. For example, one can use one nozzle for soft dirt or hard dirt and then interchange that with another nozzle for sand. Also, one can interchange nozzles to vary the flow rate.
As best seen in FIGS. 6 and 7, the blade assembly 72 includes an outer surface which is substantially flat. Also, the blade assembly 72 is rectangular as illustrated.
The preferred boring head improves the ability to make rapid steering corrections. The boring head bodies 62, 162 and 362 include a tapered portion, between the rearward end 64, 164 and 364, and the forward ends 66, 166 and 366, which tapers toward the forward end of the body. Also, this surface of the body defines an outer surface which is free of cutters, except for the blade.
Although not necessary, the body 62 has a substantially triangular cross-section defined by a converging flat top surface 90 and flat bottom surface 92. Also, the blade assembly 72 is fixed to the bottom flat surface of the boring head body and extends axially beyond forward end 66 of the body 62 at an acute angle. This angled extension, in conjunction with the converging top surface 90 of the boring head body, defines a relief space 8 in which a fluid nozzle 76 is positioned. In use, the relief space 8 will form a cavity in the borehole which will facilitate rapid steering corrections. Thus, the structure in FIG. 6 illustrates this acute angle of the blade assembly and the tapered portion of the body having the uniquely advantageous function of defining a relief area or space 8 of reduced axial resistance near the forward end 4 of borehole 14 to thereby allow for rapid deviation of the borehole from a straight line when the boring head 58 is thrust forward without rotation.
Although the invention provides an improved rapid steering correction function in a boring operation with both a blade assembly and a fluid jet or nozzle, it is not necessary in certain circumstances to have a fluid jet to achieve the desired advantageous functions. A preferred structure, however, is the blade assembly 72 having an outer surface which is substantially flat and a tapered portion which defines an outer surface of the body from which only the blade assembly 72 and nozzle 76 project.
When a change of direction of the drill pipe is desired, rotation is stopped and the drill pipe is advanced axially without rotation. However, in certain soils or ground conditions, it is very difficult to move the drill pipe forward without rotation. The relief area 8 shown in FIGS. 6 and 23, which is created by the structure of the boring head, allows for reduced axial resistance at least over the relief area when the drill string 44 is advanced without rotation. This relief area 8 of reduced axial resistance may be all that is needed to provide for rapid or sudden steering corrections. In some soil or boring situations, however, it may be necessary to incrementally repeat the rotation and push cycle to get the proper steering correction to form the walls 6 of the borehole 14 a along a curved path as in FIG. 1 or some other desired path. The present invention, thus, provides for improved rapid steering correction which is not available with known prior art devices.
An orientation directional indicator may be secured to the drill string adjacent the drill machine so that the angle of the plane of the boring head body can at all times be known. Referring back to FIGS. 2 and 4, a device which is utilized to indicate the rotational orientation of drill string 44, and thereby the rotational orientation of boring head 58, is shown. The ring member 80 is slidably and rotatably received on the drill pipe 42. The ring has a threaded opening therein receiving a set screw 82 having a handle 84. When the set screw 82 is loosened, the ring 80 can be slid on the drill pipe 42 and rotated relative to it.
Affixed to the ring 80 is a bracket 85 having a pointer 86. In addition to the pointer 86, the bracket 85 carries a liquid bubble level 88. The function of the ring 80 with its pointer and bubble level is to provide means of maintaining the known orientation of the drill string 44. When a drilling operation is to start, the first length of the drill pipe 42 is placed in the machine and the boring head 58 is secured tightly to it. At this juncture, the boring head is above ground and the operator can easily observe the orientation of blade assemblies 72, 172, 172', 272, 272', 372, 472, 572, 672 or 772. The operator can then affix the ring 80 so that it is in accurate orientation with the blade, that is, as an example, the ring 80 is affixed so that pointer 86 points straight up with the blade aligned so that a plane drawn perpendicular to the plane of the blade would be vertical. With the ring 80 so aligned, the set screw 82 is tightened by the handle 84. Thereafter, as the drill pipe 42 is rotated and advanced into the earth, the ring 80 remains in the same axial rotation orientation, rotating with the drill string. As the drill string is advanced by the advancement of the machine 24 towards the forward end 18A of the boring machine frame, the ring 80 moves with it. It can be seen that when the boring machine has been advanced so that the shaft 40 is adjacent the frame forward end, drilling must be stopped and a new length of pipe 42 inserted. With drilling stopped, the drill string 44 can be aligned with the pointer 86 in alignment with sight 48 affixed to drill pipe support 46. The ring 80 may then be removed and inserted on a new length of drill pipe 42 threadably secured to the drill string and the procedure continually repeated, each time tightening the set screw 88 so that the alignment of the blade is always known to the operator. To form a borehole 44 in the earth, the operator attaches the drill pipe and boring head as shown in FIG. 2, begins rotation of the drill pipe and at the same time, by means of control levers 34, causes rotary machine 24 to linearly advance in the travel path of the frame towards the forward end 18A or 118A of frame 18 or 118. The boring head 58, rotating and advancing, enters the earth and forms a borehole therein. As long as the boring head 58 is rotated as it is advanced, the borehole follows generally the axis of the drill pipe. That is, the borehole continues to go straight in the direction in which it is started.
In the most common application of the invention wherein the borehole is started at the earth's surface to go under an obstruction such as a highway, the borehole must first extend downwardly beneath the roadway. When the borehole has reached the necessary depth, the operator can then change the direction of drilling so as to drill horizontally. This can be accomplished in the following way: When it is time to change direction, the operator stops drilling and orients the drill string so that boring head blade assembly 72, 172, 172', 272, 272', 372, 472, 572, 672 or 772 is oriented in the direction desired. In the illustrated case of FIG. 1, the borehole is first changed in the direction so that instead of being inclined downwardly, it is horizontal. For this purpose the operator will stop drilling with drill string 44 having pointer 86 pointing straight up, that is, with bracket 85 in the vertical position. With rotation stopped and the drill string properly oriented, the operator causes rotary machine 24 to move forwardly without rotating the drill pipe. After forcing the boring head a foot or two (or as far as possible, if less), the operator begins rotation of the boring head and continues to advance the drill string for a short distance. After a short distance of rotary boring, the procedure is repeated. That is, the drill string is reoriented so that the operator knows the inclination of blade assembly 72, 172, 172', 272, 272', 372, 472, 572, 672 or 772 and then the tool is advanced a short distance as above described without rotation and the procedure is repeated. The procedure may be repeated sequentially for a number of times until the direction of drilling has changed to that which is desired. The opposite steering correction will have to be applied just prior to the bit reaching the desired path in order to prevent or minimize any overshooting of that path. After the borehole has been oriented in the desired direction, such as horizontal, the drilling can continue by simultaneous rotation and advancement of drill string 44, adding new links of drill pipe 42 as necessary until it is again time to change the direction of drilling, such as to cause the borehole to be inclined upwardly towards the earth's surface after the borehole has reached the opposite of the extremity of the obstruction under which the borehole is being placed. This is achieved as previously indicated; that is, by orienting the drill string 44 to thereby orient the blade assembly, advancing the boring head without rotation of drill string 44, rotating and advancing the drill string for a short distance, reorienting the boring head or tool and advancing without rotation and sequentially repeating the steps until the new direction of drilling is achieved. The experienced operator soon learns the number of sequences which are normally required in order to achieve a desired direction of drilling.
Thus, it can be seen that a method of drilling provided by the present disclosure is completely different than that of the typical horizontal boring machine. The necessity of digging ditches to the opposite sides of an obstruction in which to place a horizontal boring machine is avoided.
The structure of FIGS. 9-35, which disclose alternative embodiments for a boring system, will now be described in greater detail. Shown in FIGS. 9-22 is a second embodiment of a drill string assembly and a second embodiment of a boring head body. The boring head body 162 of FIGS. 10-14 at least differs from the body 62 of the embodiment of FIGS. 1-8 in that the jet is no longer at an acute angle to the centerline of the longitudinal axis of the drill string 44 and the blade assembly is now removable. If a difference is not identified between embodiments, the elements described herein to operate the boring machine 10 can be used in the latter discussed embodiments.
As seen from the combination of FIGS. 9-14 and 23-28, the boring head bodies 162 and 362 have fluid nozzle 76 fixed to the fluid passageway and positioned behind a forward end 72A, 172A, 272A, 372A, 472A, 572A, 672A and 772A of the blade assembly. The nozzle 76 can project from a nozzle receiving portion either on or adjacent top 190 and 390 of the outer surface of the bodies 162 and 362. The nozzle 76 can also be recessed into the nozzle receiving portion of the body.
The top surface 190 of the body 162 is preferably 20° to the longitudinal axis X--X of the drill pipe. It can be appreciated that other types of nozzles or jet orifices could be employed.
The nozzle 76 on bodies 162 and 362 has a centerline Y--Y substantially parallel to the longitudinal axis X--X of the drill pipe 42. Preferably, as most clearly seen in FIG. 28, the nozzle 76 is displaced laterally from the longitudinal axis X--X of drill pipe 42 so that a fluid stream is emitted above the blade. Also, the nozzle opening or orifice 77 size is governed by factors such as pump capacity, fluid viscosity and flow rate desired downhole. Blade assemblies 72, 172, 172', 272, 272', 372, 472, 572, 672 and 772 include an outer surface which is substantially flat. Blade assemblies 172, 172', 272, 272', 372, 472, 572, 672 and 772 are removably mounted on the tapered portion of the boring head body so that the blade assembly is at an acute angle to the longitudinal axis X--X of the drill pipe and the blade assembly is extending beyond the forward end 166 and 366 of the boring head bodies 162 and 362. Having removable blade assemblies means that the blades can be replaceable without having to replace the body. This results in substantially lower operating cost. Also, one obtains versatility, because one can use a variety of cutter blade assemblies for trenchless installations in various soil types without having to invest in a plurality of boring heads.
The means for mounting removable blade assemblies is especially important, because of the high stress which these blades undergo. A preferred mode for mounting a removable blade assembly includes having apertures on the blade assembly receiving surfaces 192 and 392 of the outer surface of the boring head body and having corresponding apertures on the blade assemblies. Also, the blade assemblies are preferably disposed directly adjacent and flush mounted with the shouldered sections 169 and 369 of the bodies 162 and 362. Furthermore, shouldered sections 169 and 369 are preferably at an angle 10° to a line perpendicular to the axis X--X.
Apertures on the body 162 are identified as elements 180-183 in FIGS. 11-14, and apertures on body 362 are identified as elements 380-83 in FIGS. 23 and 25. Apertures on the blade assembly 172 are identified as elements 175 and 177-79 in FIG. 17. Apertures on the blade assembly 272 are identified as elements 275 and 277-279 in FIG. 19. Also, apertures on the blade assembly 572 are identified as elements 575 and 577-9 in FIG. 29, apertures on the blade assembly 672 are identified as elements 675 and 677-79 in FIG. 32, and apertures on the blade assembly 772 are identified as elements 775, and 777-79 in FIG. 34. As seen in FIG. 10, each blade assembly is removably mounted on the boring head body by means of a plurality of bolts 194 mounted through the corresponding apertures and substantially flush with an outer surface of the blade. Preferably the bolts 194 are coated with a thread retaining compound, such as Loctite® 242, and torqued to 40 ft.-lbs. by wrench 199. Different types of removable blade assemblies are preferred. One blade type, represented by preferred blade assemblies 172 and 172' in FIGS. 10, 17 and 18, is for cohesive soils and soils that offer a reasonable amount of steering resistance. Thus, blade assemblies 172 and 172' are primarily for dirt/clay conditions. The blade assembly 172 is preferably 21/4 inches wide, 7 inches long and 1/2 inch thick and preferred for dry/hard clay. Alternative blade assembly 172', is slightly wider at 21/2 inches. The wider blade assembly 172' would be preferable for less resistant applications such as moist or soft dirt/clay conditions. The wider blade assembly is more advantageous in these softer dirt applications, because the wider the blade assembly the more steering force one obtains.
Even wider 3" blade assemblies 272 or 272' of FIGS. 19-22 are preferred for sandy soils and other loose soils of little resistance. In these sandy soils, a big surface area blade assembly is desired. The additional width provides improved steering response.
Wear resistant material is added in selective areas of the blade assemblies for additional durability. As seen in FIGS. 17 and 18, the blade assembly 172 includes wear resistant material 185 such as a carbide strip on the underside of forward portion 173 of the blade. The blade assembly 172 also includes wear resistant material 186 and 187 adjacent the underside rear portion of the blade as seen in FIGS. 17 and 18.
Alternatively, one can place a weld bead 289 (of harder surface material than the blade) on the forwardmost portion of the blade and down the edges of the blade as seen in FIGS. 19 and 20. Basically, it is preferred that all blade assemblies have either the weld bead or hard facing strips such as carbide on three edges as shown. It is not desired, though, that the carbide strips and weld beads be mixed on a blade assembly. Note, however, if the soil has any rock content, use of carbide strips on the blades is preferred.
Seen in the alternative 3" blade assembly 272' of FIGS. 21 and 22 is a more preferred location for hard surfacing on a forward portion of the blade. As seen in FIGS. 21 and 22, the forward portion of the blade includes strips 284 and 288 of harder surface material (i.e., carbide) than the blade which are disposed in recesses on portions of the surfaces of the blade. In particular, strip 288 is disposed on a right-hand side portion of the bottom or outer side of the blade when facing endwall 4 of borehole 14 and strip 284 is on a left-hand side portion of the top or inner side of the blade when facing endwall 4 of borehole 14. With clockwise rotating (when looking in the direction of boring) of the blade assembly, the preferred location of hard surfacing in FIGS. 21 and 22 is more effective in protecting both front corners of the blade assembly. Consequently, the strips are provided on the portions of the surfaces of the blade assembly which have the primary contact with the earth when the tool body is simultaneously rotated and axially advanced.
It is also preferred that the recesses and the strips of harder surface material in the recesses cross a centerline of the blade assembly as seen in FIG. 21. This double reinforcement at the centerline of the blade assembly is particularly advantageous where the blade and carbide strips 684 and 688 define a spade-like profile in the forward portion of the blade assembly 672 as seen in the blade of FIGS. 32 and 33.
In addition, as seen in FIGS. 21 and 22, the blade assembly 272' includes hard surface material 286 and 287 in the rear portion of the blade assembly, and FIGS. 32 and 33 show hard surface material 687 in the rear portion of blade assembly 672. This wear resistant material is preferably either brazed or welded onto the blade.
The boring head body 162 includes a forward end 166 and rearward end 164 having an aperture including threads for engaging a drill pipe. As seen in FIG. 11, an intermediate portion of boring head body 162 has cavity 165 for receiving a transmitter and first fluid passageway 163A.
As can be appreciated from FIGS. 10 and 11, transmitter 220 is disposed in cavity 165 of the intermediate portion of the body. Pulling tool or wrench 218 is preferably used to install transmitter 220 in cavity 165. Transmitter 220 produces an electromagnetic signal which allows the position and depth of boring head body 162 to be determined by use of an above ground receiver.
The rotational orientation of blade assembly 172 et al., must also be known when advancing without rotation to make course direction changes. An angle or roll sensor, such as those known in the art, can be used in conjunction with the above transmitter/receiver system to determine blade rotational orientation or aid in positioning the blade assembly at a particular desired orientation. Although downhole roll sensing is preferred, tophole drill string indicating means, such as described in the parent U.S. application Ser. No. 07/211,889, may be employed to determine blade orientation.
The removable plug 214 of FIG. 10 is disposed on a rearward portion of cavity 165 of the intermediate portion of the body. Plug 214 is also installed with pulling tool or wrench 218. The plug is waterproof and it is positioned in the body for diverting pressurized fluid from drill string 44 to first passageway 163A of the intermediate portion of the tool body. In other words, as the fluid comes down the center of fluid pipe (i.e., drilling cap) 210 in FIGS. 9 and 10, the fluid path is deviated as it hits plug 214. The fluid path is diverted downward through first passageway 163A of boring head body 162 of FIG. 11. An advantage of this arrangement is that plug 214 is removable. Thus, one can get into body 162 or 362 to replace battery 222 of transmitter 220. Also, while performing a fluid deviating function, the plug protects the transmitter from fluid. Consequently, an additional advantage of this structure is that it allows the on-board transmitter to be disposed very close to the boring head.
The boring head further comprises O-rings 212 and 216 adjacent each end of plug 214. Also, adjacent the forward end of the tool body is second fluid passageway 163B and third fluid passageway 163C. Second passageway 163B is in fluid communication with and substantially perpendicular to first passageway 163A. Third passageway 163C is in fluid communication with and substantially perpendicular to second passageway 163B. It would be understood by one of ordinary skill in the art that the passageway adjacent the connection of first passageway 163A with second passageway 163B would be tightly sealed at shouldered section 169 and at outer end 170. Also, as can be appreciated from FIGS. 9-11, fluid nozzle 76 is fixed to the fluid end 166 of body 162.
FIGS. 9, 10 and 16 illustrate elements for an arrangement wherein the nozzle 76 or the like is actually moved up the drill string and inside saver sub 232 or inside the adapter 230. In particular, the drill string 44 includes a channel for transferring fluid from the exterior of the borehole to the front of the drill string. In FIG. 10, fluid outlet 171 is fixed to the fluid passageway and associated with boring head body 162.
When boring in sandy situations, it is preferred to place the nozzle rearward of the boring head body and install it in saver sub 232 or adapter 230. As can be appreciated from FIG. 9, disposed adjacent drive spindle 40 and the back end of the drill string 44 is saver sub assembly 232. As shown in FIG. 16, within saver sub assembly 232 is filter seating plug 245 which is internally threaded to hold nozzle 76. If inserted in saver sub 232, inner nozzle 76 meters the amount of and controls the rate of fluid that the surface fluid pump discharges into borehole 16. Once ejected from that inner nozzle, 76 the fluid fills drill string 44 and exits out through outlet or bushing 171 in boring head body 62, 162 or 362. The hole in outlet or bushing 171 is large enough so that the downhole debris entering drill string 44 when the flow stops will likely be flushed back out when the flow resumes. In the preferred embodiments, outlet 171 has a diameter approximately the same as the diameter of the fluid passageway. This arrangement is particularly beneficial when drilling in sand or sandy soils where sand particles flowing back into a small orifice nozzle located at end 166 of body 162, could at least partially plug the opening when pressurized flow is resumed.
When installing the nozzle in saver sub 232, the operator must be careful. When the fluid pump is turned on, the pressure gauge will begin to show pressure before fluid ever reaches the boring head body. Even though the gauge shows pressure, the operator must wait until the fluid has reached the boring head body. This waiting time varies depending upon whether there are just a few feet or a few hundred feet of drill pipe in the ground. If the operator happens to thrust the boring head body forward before fluid reaches it, there is the possibility of plugging the boring head body. If drilling is continued while the boring head body is plugged, damage to the transmitter can occur.
To reduce the operator involvement in this process, one can alternatively install nozzle 76 in adapter 230. By installing nozzle 76 in adapter 230, the operator knows that when the gauge pressures up, the fluid is at the boring head body. This is true whether there are thirty feet or three hundred feet of pipe in the ground.
The saver sub 232 and adapter 230 both include filter and gasket combinations 240 and 242 as seen in FIG. 16. The filter and gasket combination 240 includes 30 mesh coarse screen filter for use with drilling fluids (bentonite, polymers, etc.). The fluid filter and gasket combination 242 includes 100 mesh fine screen for use with water or a water and antifreeze combination. If one uses 100 mesh filter with drilling fluid, the filter may collapse and stop the flow of fluid. The purpose of the filters is to remove any particles from the fluid flow which could obstruct nozzle 76.
FIGS. 23-27A illustrate an alternative boring head embodiment 362. As shown in FIGS. 23-26, some embodiments function to deflect fluid from nozzle 76 to an acute angle relative to the longitudinal axis X--X of the drill pipe. In particular, by having spray from nozzle 76 impinge upon removable cutting blade 372, the deflected jet stream should more easily allow redirecting of the body out of an existing borehole. This becomes important if an obstruction is encountered.
The deflecting portion of the blade assembly 372 comprises wear-resistant material 388 disposed in the blade as seen in FIGS. 24 and 26. Furthermore, the deflecting material 388 includes concave portion 389 for controlling the fluid spray pattern.
As soils become more difficult to drill, it is preferred to have the forward end of the blade assembly adjacent the longitudinal axis X--X of the drill pipe as in FIG. 28. This relationship of the blade assembly forward end to axis X--X is preferred, because if one happens to drill into a hard soil or soft rock, the boring head and its drill string will start rotating around the tip of the tool. If the blade assembly tip is not on or adjacent the centerline of the bore, this may cause the rear portion to wobble and rub against walls of the diameter of borehole 14 which are behind the bit. Thus, in these situations blade assembly 472 of FIG. 28 may be more advantageous. Therefore, in the embodiment of FIG. 28, a forward end 472A of blade assembly 472 is adjacent and in fact on the longitudinal axis X--X of the drill pipe. For example, when harder soils or soft rock formations are anticipated, a tapered (pointed) rather than straight leading edge on the blade assembly (as in the spade-like blade assembly of FIGS. 32 and 33 or the stepped-taper blade assembly of FIGS. 29-31) can further aid in causing the blade assembly to "pilot" into the end of the borehole and will also rotate more smoothly than a straight-edged bit in such hard conditions.
In soft soils, however, it is preferred to have the forward end of the blade assembly extend beyond the longitudinal aids X--X of the drill pipe as in FIGS. 23-26. In soft soils, the tool will not tend to pilot on the face of the bore but instead will slip across it. In fact, for such soils it is advantageous for the blade assembly to be above (i.e., beyond) the centerline of the borehole in order to provide more steering force. It should be recognized that the above principle would apply whether or not deflecting of the spray is employed. By varying the lateral displacement of the jet relative to the X--X axis, a deflecting of the spray can be accomplished for the various types of blades discussed herein.
Shown in FIGS. 24, 27 and 27A is ball check valve 394 to prevent sand or the like from plugging the nozzle opening. When boring a hole in a tight formation, there tends to be a head pressure in borehole 16 at front portion 166 or 366 of boring head 162 or 362. Therefore, when one shuts off fluid flow to drill string 44 in order to, for example, add another piece of drill pipe, external debris-laden fluid in the borehole can actually flow upstream and into the drill pipe. Cuttings such as grains of sand and the like which enter nozzle 76 may plug the relatively small nozzle orifice 77 and, after adding a new piece of drill pipe and beginning fluid pressure through the fluid passageway, restrict or prevent the start of flow again.
It is preferred, therefore, to have check valve 394, disposed in the passageway, for opening the passageway when fluid pressure in the passageway towards nozzle 76 and on valve 394 is greater than pressure from borehole 16 on valve 394, and for closing the passageway when pressure from borehole 16 on valve 394 is greater than fluid pressure in the passageway towards nozzle 76 and on valve 394. The preferred valve includes ball 395 for preventing external downhole particles from entering a portion of the fluid passageway which is upstream of the ball. Also, included in valve 394 is roll pin 397.
Even with an essentially horizontal drill string, there is a tendency for fluid to flow out of nozzle 76 during the addition to the drill string or other work stoppages. This tends to be wasteful of drilling fluid and also causes delays in re-initiating the drilling operation, because of the time required to refill the drill string and reach operating pressure. This factor can become significant when drilling longer boreholes. Thus, the check valve means also preferably includes spring 396 disposed in the passageway and on a front side of the ball. The spring provides little pressure. In fact, the spring only biases the check valve closed with sufficient force to hold fluid in the drill string when pump flow is stopped and another joint of pipe is added to the drill string. In particular, the light spring force only causes the ball to close the passageway when the pressure of fluid in the passageway towards nozzle 76 and on ball 395 is less than 10-20 PSI.
As discussed herein, as an alternative to using ball check valve 394 one can use nozzle 76 in saver sub assembly 232 in combination with outlet 171. If the nozzle 76 is moved to adapter 230 instead of saver sub 232 for operation in sand, however, the ball check valve may preferably be used in combination with the nozzle to prevent plugging since nozzle 76 is only about a foot behind forward portion 166 (containing bushing/outlet 171) of body 162. In fact, a further reason for having the nozzle in adapter 230 at the downhole end of the drill string is to make use of the spring-biased check valve method of keeping the drill string full.
When drilling with nozzle 76 in saver sub 232 or adapter 230 and with check valve 394 installed in place of the nozzle on the boring head body, one will reduce the chance of mud and fluid being sucked back into the housing while breaking loose drill pipe to add another joint. This should also reduce the chance of plugging the boring head body. In addition, it should reduce the possibilities of damaging the transmitter 220. Note, however, it is strongly suggested that one should not run nozzles in both the boring head body and adapter 230 at the same time.
Also, one can also utilize two or more jets instead of one. It is preferred that these jets also be displaced vertically from the centerline of the housing as in FIGS. 13 and 23 and side by side. In other words, the front of body 362 of FIG. 25 can be modified to include one or more nozzles 76 laterally displaced from longitudinal axis X--X of drill pipe 42.
Shown in FIGS. 29-31 is a removable blade assembly 572 for hard soil or soft rock cutting. In particular, the blade assembly 572 is for drilling harder formations such as soft sedimentary rocks (i.e., sandstone or even soft limestone). This stepped-taper blade assembly 572 is advantageous because it has improved steering control. The blade assembly 572 includes a forward portion including end 572A, which, when mounted on the boring head body, projects beyond a forward end of the body. The forward portion of the blade assembly 572 preferably, when viewed from its top as in FIG. 29, has a staggered profile which steps rearwardly from a forwardmost point 572A at a center of the blade to an outside of the forward portion of the blade.
As discussed with respect to the blade assembly 272' of FIGS. 21 and 22 and blade assembly 672 of FIGS. 32 and 33, the blade 572 also preferably includes a plurality of strips 584A-E which are disposed on recessed portions of the top and bottom surfaces of the substantially flat blade assembly. These strips have the primary contact with the earth when the blade assembly is simultaneously rotated and axially advanced.
The forward portion of the top of blade assembly 572 is a mirror image of a forward position of a bottom of the blade assembly 572. Furthermore, as discussed, it is preferred to have strips 584A on the top and bottom surfaces extend across the centerline of blade assembly 572 and to have these same strips extend forward of the forwardmost point of the blade as illustrated in FIGS. 30 and 31.
Forward portion of blade assembly 572 is wider than rear portions of the blade for smoother operation when rotated in hard soil or soft rock formations. Also, bottom edges 586 and 587 include wear resistant material such as carbide. Also, apertures 575 and 577-79 are for mounting the blade assembly on a tool body 162 or 362.
The blade assembly 572 has been shown to penetrate hard formations at a fast drilling rate, as well as enabling some corrective steering action in those formations. In this hard formation application, as was mentioned herein, it is desirable to have the forwardmost point on strip 584A on the longitudinal axis X--X of drill pipe 42 in order to prevent the tool body from being rotated eccentrically around the center of bit rotation. In order to steer in soft rock, it takes an operating technique of intermittent rotating and thrusting. With this technique, directional blade assembly 572 allows a selective chipping away of the face of the borehole in order to begin deviating in the desired direction.
The blade assembly 772 of FIGS. 34 and 35 is a 4" wide bit having hard facing carbide strips 784 and 788 at forward point or tip 772A and carbide strips 786 and 787 all functioning and having advantages as discussed herein. The 4" wide blade assembly is preferred for making a larger pilot hole so that backreaming is not necessary for a 3" to 4" conduit installation.
There can also be an assembly associated with the drill frame 18 or 118 of a boring machine for preventing rotation of a drill pipe 42 having wrench receiving slots 43 as shown in FIG. 9. The assembly includes wrench 238 of FIG. 15A having an open end for removably engaging wrench receiving slots 43 of a rearward portion of a lower or first drill pipe. Also, included is pin 237 received in apertures of both the wrench and the frame and disposed adjacent forward end 118A of the frame for attaching wrench 238 to the frame. When the wrench engages the drill pipe, the lower or first drill pipe is substantially prevented from rotation.
With this preferred structure, a method of breaking a joint between drill pipe 42 and rotary 24 with saver sub 232 can include the steps of moving saver sub 232, which is joined to drill pipe 42, to a forward portion in drill frame 18 or 118. This joint breaking method then includes placing lower joint wrench 238, which is attached to the frame and adjacent a forward end 118A of the frame, in wrench receiving slots 43 on drill pipe 42 to substantially prevent rotation of the drill pipe, and using rotary drive 24 to rotate saver sub 232 in a reverse direction to unscrew saver sub 232 from drill pipe 42.
The method of adding a second drill pipe between saver sub 232 and a first drill pipe 42 includes breaking a joint between first drill pipe 42 and saver sub 232 as discussed in the prior paragraph. The method further includes the steps of moving saver sub 232 to a rearward portion in drill frame 18 or 118, placing a second or intermediate drill pipe in the frame between saver sub 232 and the lower or first drill pipe, threading a male end of the second or intermediate drill pipe into the saver sub, aligning a female end of the second drill pipe with a male end of the first drill pipe, moving the second drill pipe forward until a female end of the second drill pipe fits around a male end of the first drill pipe and applying rotational torque to tighten the rotating second drill pipe, with the stationary first drill pipe. This method can further include the steps of a slight reversing rotation to relieve pressure on joint wrench 238 and removing the joint wrench from wrench receiving slots 43 of the first drill pipe 42.
Preferably an open end of wrench 238 is at a first end of the wrench and a pin receiving aperture 239 of the wrench is at an opposite second end of the wrench so that the wrench can be rotated into engagement with the wrench receiving slots of the drill pipe. In addition, it is preferable that the wrench can be slid on pin 237 in a direction parallel to a centerline of drill pipe 42 for easy alignment with drill pipe receiving slots 43.
A second wrench 238' is also preferred for removing a second drill pipe from between a first drill pipe and saver sub 232 as would be required when withdrawing the drill string from the borehole. The second wrench 238' also has aperture 239' for receiving pin 237' which attaches the second wrench to frame 18 or 118. The second wrench is closer to rearward end 18B or 118B of the frame than to forward end 18A or 118A of the frame. A preferred method for removing a second drill pipe from between a first drill pipe and saver sub 232 includes the steps of moving rotary drive 24 to a substantially rearward position in drill frame 18 or 118 so that wrench receiving slots on a rearward portion of the first drill pipe are adjacent a forward end of the frame and the second or intermediate drill pipe is disposed on the frame between the saver sub and the first or lower drill pipe. This method then includes placing a first joint wrench 238, which is attached to the frame and adjacent forward end 18A or 118A of the frame, in wrench receiving slots 43 of the first drill pipe to substantially prevent rotation of the first drill pipe. The next preferred step includes securing the second drill pipe to saver sub 232 to ensure that the joint of the second drill pipe to the first drill pipe will loosen before the joint of the second drill pipe to the saver sub when rotational torque is applied to the second drill pipe. It is preferred that a lock be applied between the saver sub and the second drill pipe so that this joint does not break before the joint between the second drill pipe and the lower first drill pipe is broken. One can, however, use additional torque applied by a hand held pipe wrench on the second drill pipe to accomplish this same function, i.e., to insure that the lower joint is broken first.
The method then includes applying a rotational torque to the second drill pipe which is sufficient to loosen the second drill pipe from the first drill pipe. After applying this rotational torque, one can then unsecure the second drill pipe from the saver sub. The method then includes rotating the saver sub and the second drill pipe in a reverse direction to unscrew the second or intermediate drill pipe from the first or lower drill pipe. Further steps include placing second joint wrench 238', which is attached to the frame, in wrench receiving slots on a rearward portion of the second drill pipe to substantially prevent rotation of the second uppermost drill pipe, and rotating the saver sub in a reverse direction to unscrew the saver sub from the second drill pipe.
Additional steps in removing a second drill pipe can include removing second joint wrench 238' from the wrench receiving slots of the second drill pipe and removing the second drill pipe from the frame. Further steps can include moving rotary drive 24 forward in the frame, rotating the saver sub to join it with the first drill pipe and, removing the first joint wrench from the wrench receiving slots of the first drill pipe. To remove additional drill pipes, these above recited steps can be repeated.
Having a joint wrench attached to the frame provides advantages in safety, simplicity and economy. Safety is attained because attaching the wrench to the frame alleviates the prior worry about the wrench being accidentally loosened if, for example, the drill pipe accidentally rotates in an opposite direction than desired. Also, by using this fixed wrench assembly, one eliminates the complex hydraulic systems and the need for another valve section as would be required for a powered breakout wrench.
All patents and applications mentioned in this specification are hereby incorporated by reference in their entireties. In addition, the structures described in this specification and claimed are preferably used with structures disclosed in U.S. patent application Ser. Nos. 07/539,851; 07/539,699; 07/539,551; 07/539,847; 07/539,616; 07/513,186; and 07/513,588, which are also hereby incorporated by reference in their entireties.
With reference now to FIGS. 36-55, a number of bits suitable for use with the boring machine will be described. These bits will be used for horizontal and near horizontal drilling as well as vertical drilling. FIGS. 36 and 37 illustrate a bit 600. The bit has a body 602 which defines a rearward end 604 for attachment to the drill string and a forward end 606 facing the ground to be bored.
The portion of the body adjacent the rearward end 604 can be seen to have a hexagonal cross-section perpendicular to the axis of rotation 608 of the bit. The body defines six parallel surfaces 610-620 which each extend parallel the axis 608. Outer edges 622-632 are defined at the intersection of the parallel surfaces as illustrated.
Three angled surfaces 634, 636 and 638 are defined on the body and extend from intermediate the rearward and forward ends to the forward end 606. Each of the surfaces 634, 636 and 638 are at an angle relative to the axis 608. The orientation of the angled surfaces can be defined relative to a hypothetical framework 640 (illustrated in FIG. 39) which is defined as if the parallel surfaces 610-620 of the body extended all the way to the forward end 606. The angled surfaces 634 and 638 can be seen each to intersect two of the hypothetical parallel surfaces, specifically parallel surfaces 610 and 612 in the case of angled surface 634 and parallel surfaces 618 and 620 in the case of angled surface 638. It is also helpful to define a plane of symmetry 601 (not shown) which contains axis 608 and divides the bit 600 into two mirror image halves. Each angled surface 634 and 638 is a mirror image of the other relative the plane of symmetry 601. Angled surface 636, in turn, will intersect a total of four parallel surfaces, specifically surfaces 612-618. Angled surface 636 also is bisected by the plane of symmetry 601. The intersection of the angled surfaces and the actual parallel surfaces will define a series of edges 642-660 between the various intersecting surfaces, each one of those edges being at an angle relative to the axis 608.
The bit 600 has numerous advantages in the drilling operation. Each of the edges 622-632 and 642-660 are potential cutting surfaces to cut the ground. The angled surfaces 634, 636 and 638 define an area as the drill bit is thrust forward which causes the bit to be deflected in a new direction. The area is a compaction area during thrust and simultaneous rotation. Further, the inclined surfaces 634-638 define incline planes that, as the bit is rotated and thrust forward simultaneously, permit the surfaces 634-638 to work in conjunction with cutting edges 642-660 to cut the periphery of the borehole and simultaneously compact the material into the bore wall or pass the cuttings through the relief areas defined by the borehole and surfaces 610-620. Further, the use of a hexagonal cross-section defined by the surfaces 610 through 620 will further define an additional relief area as the drill bit is rotated bounded by the surfaces and the cylindrical bore cut through the ground. This additional relief area will also assist steering of the bit. As the drill bit is rotated to form a borehole, the bit will define a cylindrical borehole of diameter determined by the radial dimension between the axis of rotation 608 and the edges 622-632. When the bit rotation is halted to steer the bit into a new direction, voids exist between the inner surface of the borehole and the surfaces 610-620, providing this additional area to more easily deflect the bit into the new direction of drilling. It also has a stabilizing effect to maintain a truer line (course) while; making corrections to a new base path.
With reference now to FIGS. 38 and 39, a bit 680 is illustrated which is in all respects identical to bit 600 with the exception of the addition of two carbide cutting tips 682 and 684. The carbide tip 682 is positioned to extend outwardly from about the center of surface 636 and near axis 608. The carbide tip 684 is at the forward end 606. As the bit 680 rotates, the carbide tips will define cutting circles established by the radial distance between the rotational axis 608 and the individual tip. Tip 682, being closer to axis 608, defines the inner cutting circle. Tip 684, at the outer portion of the bit, defines the outer cutting circle. The tips 682 and 684 assist in boring, particularly in cutting through hard soil conditions.
FIGS. 40 and 41 illustrate a bit 690 which is a modification of bit 600. In bit 690, angled surfaces 692, 694 and 696 are positioned on the bit with the surface 694 intersecting five of the six parallel surfaces. The plane of symmetry 698 bisects parallel surface 614 and the angled surface 694. The surfaces define angled outer edges 702-714. The distance between edges 702 and 714 and the edges 706 and 708 are greater in bit 690 than the corresponding distance in bit 600, which makes the surface 694 wider and the bit more appropriate for boring in softer soils. It is expected that bit 690 will be easier to direct in soft soils because of the width of the surface 694 and the greater surface area of the angled surface 694.
With reference to FIGS. 42 and 43, a bit 710 is illustrated which is a slight modification of bit 690. In bit 710, the angled surfaces 712 and 716 are at a slighter greater angle relative to the plane of symmetry 718 than those of bit 690. It would be expected that bit 710 would be more effective in medium soils than bit 690.
With reference now to FIGS. 44 and 45, a bit 720 is illustrated which is formed with angled surfaces 722-728. Angled surfaces 722 and 724 are on a first side of the plane of symmetry 730. Each of the surfaces 724 and 726 intersect three of the parallel surfaces, while angled surfaces 722 and 728 each intersect two of the parallel surfaces. The surfaces define angled outer edges 732-756. Bit 720 would be intended primarily for clay and harder soils.
FIGS. 46 and 47 illustrate a bit 780. Bit 780 has a body 782 with a circular cross-section perpendicular the axis 608. A plane of symmetry 784 passes through the bit, intersecting axis 608, to divide the bit into two equal mirror halves. Angled surfaces 786 and 788 are formed on the bit 780 on either side of the plane of symmetry. Because of the circular cross-section of the bit, the surfaces 786 and 788 will define curved edges 790 and 794, and linear edge 792. Bit 780 would also be intended primarily for clay and harder soils.
FIGS. 48 and 49 illustrate a bit 800 which is a modification of bit 780. Bit 800 includes a third angled surface 802 which bisects the plane of symmetry to form linear edges 804 and 806 and a curved edge 808.
FIGS. 50 and 51 illustrate a bit 820 which has a triangular cross-section perpendicular the axis of rotation 608. The bit defines parallel surfaces 822, 824 and 826. A plane of symmetry 828 is defined through the bit 820 which divides the bit into mirror image halves. Angled surface 830 is formed on one side of the plane while an angled surface 834 is formed on the other side the plane. An angled surface 832 bisects the plane of symmetry between the surfaces 830 and 834. The surfaces define slanted outer edges 836-850.
FIGS. 52 and 53 illustrate a bit 860 which has a generally square cross-section perpendicular the axis 608 defining parallel surfaces 862-868. Angled surfaces 870-880 are formed to define angled edges 882-900. It should be noted that bit 860 does not have a plane of symmetry, defining two parallel surfaces 902 and 904 on one side of the bit.
With reference to FIGS. 54 and 55, a bit 920 is illustrated which has a tapered wedged shape. The bit includes parallel surfaces 922, 924 and 926 and angled surface 928.
With reference to FIG. 59, a bit 980 is illustrated which has parallel surfaces 982, 984, 986 and 988 and an angled surface 990. The front end of the bit 992 is perpendicular to parallel surfaces 982-988 and is formed at the intersection of parallel surfaces 982 and 988 and angled surface 990. The angled surface 990 preferably extends at an angle of about 20° from the rotational axis of the bit.
With reference now to FIG. 56, a drill bit 950 is illustrated which has a body 952 with a circular cross-section perpendicular the axis 608. A curved surface 954 is formed on the drill bit which extends from near the rear end 604 to the forward end 606. Carbide cutting tips 956 and 958 are mounted along the drill bit to aid in cutting with the same cutting action as described in bit 680.
With reference to FIG. 57, a drill bit 960 is illustrated which has a prong 962 which extends outward from the curved surface 964. A carbide cutting tip 966 is mounted at the end of the prong 962 and a carbide cutting tip 968 is mounted at the end 606 of the drill bit to provide the same cutting action as described in bit 680.
With reference to FIG. 58, a drill bit 970 is disclosed which has a prong 972 extending from surface 974. A carbide cutting tip 976 is mounted at the end of prong 972, a carbide cutting tip 978 is mounted at the end 606 of the drill bit to provide the same cutting action as described in bit 680.
With reference now to FIGS. 60-62, a directional multi-blade boring head 1000 will be described. The head 1000 is mounted at the end of a drill string which is capable of selectively rotating the head about its central axis of rotation 1002 and advancing the head along the axis 1002. The head includes a body 1004 which is attached to the end of the drill string in a conventional manner. The body defines a first planar surface 1006 on a first side of the body and a second planar surface 1008 on the other side of the body. The planar surfaces are both angled in an oblique angle, preferably 13°, relative to the axis 1002. A jet recess 1010 is cut from the first planar surface 1006 and mounts a jet 1012 to discharge a fluid to assist in the boring action.
As can best be seen in FIG. 62, the body has internal passages 1014, 1016 and 1018 which direct the fluid from the drill string to the jet 1012. The fluid can be air, water, gas or any suitable drilling fluid. As can be seen, a check valve 1020 is provided within the passages which includes a check ball 1022 and a spring 1024 to urge the check ball into a closed position unless the fluid pressure in passage 1018 acting on the ball is sufficient to overcome the force of the spring 1024.
A blade assembly 1026 is mounted to the body at the second planar surface 1008. Preferably, the blade assembly 1026 is bolted to the body by bolts 1028 to permit the body assembly to be removed for repair or replaced by a new blade assembly when necessary.
The blade assembly 1026 is formed of at least three blades, including a first blade 1030, a second blade 1032 and at least one intermediate blade 1034.
The first blade 1030 defines a deflecting surface 1036 and the second blade defines a similar deflecting surface 1038. The deflecting surfaces extend at an oblique angle relative to the axis 1002, preferably 13°. These deflecting surfaces act to deflect the head when the drill string to which the head is attached is thrust forward without rotation. Thus, the head 1000 acts as a directional boring head in the manner of the bits and heads described previously.
The first and second blades 1030 and 1032 also define staggered cutting teeth 1040 to assist the boring action. The included angle θ between the first and second blades is preferably about 120°. The intermediate blade 1034 extends between the deflecting surfaces 1036 and 1038 at an angle θ 1 from the first blade and at an angle θ 2 from the second blade. With the single intermediate blade 1034, the angles θ 1 and θ 2 are preferable each 120°.
Each of the teeth 1040 are staggered in the direction of rotation of the head for more effective cutting. Also, carbide cutting elements 1041 form the part of the teeth exposed to the greatest wear to lengthen the service life of the blade assembly 1026.
With reference now to FIGS. 63-65, a directional multi-blade boring head 1050, forming a modification of the invention, is illustrated. A number of the elements of boring head 1050 are identical to those of multi-blade boring head 1000. These elements have been identified by the same reference numerals and have similar functions to those described with reference to head 1000.
However, the included angle θ between the blades 1030 and 1032 is 180°. A second intermediate blade 1042 extends between the blades 1030 and 1032 on the sides of the blades opposite the deflecting surfaces 1036 and 1038. The second intermediate blade 1042 in effect forms a continuation of the intermediate blade 1034 and is also provided with serrated teeth 1040 and carbide cutting elements 1041. It will be noted that the discharge of nozzle 1012 will strike a portion of the second intermediate blade 1042 and a recess 1054 has been formed in the blade 1042 to redirect the stream to assist in the cutting action. The four bladed bit 1050 will permit smoother, straighter bores in harder soil conditions while the inclined planes 1036 and 1038 provide the bit with directional capabilities.
Now with reference to FIGS. 66-68, a directional dual-cone boring head 1100 is illustrated. The dual cone boring head has rotary cutters or cones 1104 and 1105 similar to those used on prior art tri-cone drilling bits used in the oil field. The boring head 1100 is used to directionally drill in hard or semi-hard materials. The head 1100 is mounted at the end of a drill string which is capable of selectively rotating the head about its central axis of rotation 1002 and advancing the head along the axis 1002. The head includes a body 1004 which is attached to the end of the drill string in a conventional manner. The body defines a first planar surface 1006 on the first side of the body and a second planar surface 1008 on the other side of the body. The planar surfaces are both angled in an oblique angle, preferably 13 degrees, relative to the axis 1002. A jet recess 1010 is cut from the first planar surface 1006 and mounts a jet 1101 to discharge a fluid such as a liquid or a gas to assist in the boring. The jet 1101 is extended in length as compared to jet 1012 of the previous multi-blade bits to ensure fluid is directed at the dual cones to provide lubrication, cooling and assist in boring. All other aspects of the fluid delivery system are the same as boring heads 1000 and 1050.
The bit assembly 1102 is mounted to the body at the second planar surface 1008. Preferably, the bit assembly 1102 is bolted to the body by bolts 1103 to permit the body assembly to be removed for repair or install a new bit assembly when necessary.
The bit is formed of two roller cones and attachment body consisting of the center cut cone 1104 and adjacent cone 1105 from a standard tri-cone oil field bit. The rotational axis of each of the cones preferably intersects the axis 1002. The cones and bodies are welded to components 1106 and 1107 to form bit assembly 1102. A part of the bit assembly defines a deflecting surface 1108 extending at an oblique angle similar to and causing the bit to act as a directional boring head in the manner of the bits and heads described previously.
With reference now to FIGS. 69-71, a directional single cone boring head 1200 is illustrated. The single cone head has a single rotary cutter or cone 1202 similar to those used on prior art tri-cone drilling bits used in the oil field. The jet 1101 discharges against the side of the cutter 1202 to clean debris therefrom. In other aspects, the boring head 1200 is identical to boring head 1100 discussed previously, and identical elements on the figures are identified by the same reference numerals.
The roller cones described in this invention provide the same cutting action as in the oil field application of the tri-cone bits previously described. These tri-cone bits have one center cut cone and two adjacent cones. However, the addition of the deflecting surface and the removal of one of the adjacent roller cones permits the boring head 1100, when thrust forward without rotation, to be deflected from the axis of the bore thus permitting the direction of the bore to be altered. The addition of the deflecting surface and the removal of two of the adjacent roller cones permits the head 1200, when thrust forward without rotation, to be deflected from the axis of the bore thus permitting the direction of the bore to be altered. The continuous rotation of the boring head and application of thrust permits the borehole to be in a straight line relative to the drill string axis 1002. The hardness of the material being cut will dictate the amount of steering capable of being accomplished. Some semi-hard materials will permit the oscillating of the boring head and the drill string about the central axis of rotation 1002 while applying thrust to change the direction of the bore axis.
The boring heads 1000, 1050, 1100 and 1200 described have a number of significant advantages over previous known boring heads. The heads 1000, 1050, 1100 and 1200 bore a rounder, straighter hole than a one-sided slanted head which tends to drill more of a helical borehole. The heads 1000, 1050, 1100 and 1200 have proven particularly effective in boring productivity and direction accuracy through sand and rock. With previous one-sided slanted heads, the head could impact and catch on a hard object, causing the boring rods in the drill string to wind up in torsion until the head breaks free of the object with a sudden release. The heads 1000, 1050, 1100 and 1200 appear to alleviate this problem.
The additional advantages of the heads 1000, 1050, 1100, and 1200 include an improvement in the directional accuracy of the head through rock and other hard boring conditions. The boring head also uses less water to cool the bit which has significant advantages, as EPA regulations for disposal of drilling fluids are becoming more difficult to comply with. The presence of the blades also reduces a tendency for the head to roll when pushed forward without rotation to make a directional change. Finally, the head provides an improved ease of surface launch.
Turning now to FIGS. 72-77, another preferred blade assembly will be described. The blade assembly, designated generally by the reference numeral 1500, can be attached to and used with any of the boring head bodies 62 (FIGS. 6-8), 162 (FIG. 10), 362 (FIGS. 23-24) and 1004 (FIGS. 60-71), to form a boring head in accordance with the present invention.
The blade assembly 1500 comprises a flat base portion 1502 with a top surface 1504 and a bottom surface 1506. The base portion is adapted to removably attach the blade assembly 1500 to the bottom surface 92, 192, 392, 1008, of the boring head body 62, 162 and 362 (FIGS. 6, 11 and 23, 62, 65, 68 and 71), in the manner previously described. To this end, the top surface 1504 of the blade assembly 1500 is sized and shaped to conform closely to the bottom surface of the boring head body, and is provided with bolt holes only one of which is designated in the drawings as reference numeral 1508. The base has a thickness "T 1 " (FIGS. 74-75) and width "W 1 " (FIGS. 72-73). The width W 1 is selected to be about the width of the boring head body. The thickness may vary but should provide sufficient rigidity and strength.
Extending from the base 1502 is a blade portion 1510 which preferably is flat and broader than the base 1502. More preferably, the blade 1510 has a width "W 2 " which increases gradually from the point "P" where the blade joins the base 1502 to the forward end 1512. This provides a larger cutting surface on the blade and therefore a borehole slightly larger than the boring head body.
The blade 1510 is serrated, that is, the forward end 1512 of the blade terminates in a plurality of points or teeth, designated generally in the drawings by the numeral 1514. As best seen in FIGS. 72 and 73, in the preferred embodiment of the blade assembly 1500 the blade may be considered as having two halves 1516A and 1516B, joining at about the line "H." These halves are similarly formed, each having three teeth including a forward tooth 1520A and 1520B, a middle tooth 1522A and 1522B, and a rearward tooth 1524A and 1524B. The half 1516A extends slightly beyond the half 1516B. This provides good cutting action by allowing each of the teeth on each half to contact a different point (for a total of six points in this particular embodiment) on the surface through which the borehole is being made. Were the two halves 1516A and 1516 B perfectly symmetrical, rather than offset as taught herein, the tooth 1522B, for example, would follow in the cutting path of the tooth 1522A. This would be duplicative, providing in effect only three true cutting points on the end of borehole and being less efficient than the design herein with the offset halves.
With continuing reference to FIGS. 72 and 73, the front or primary contact surfaces of the teeth 1514 are provided with hardened strips, designated generally by the numeral 1530 of carbide or some other suitable material, as previously described herein.
With reference now to FIGS. 74-76, it will be seen that the teeth 1514 do not have a flat frontal surface parallel to the blade 1510. Rather, the back sides of the teeth 1514 are cut away at 1532. As used herein, the "back" of a tooth refers to the side of the tooth opposite the primary contact surfaces, such as those shown in the drawings covered with the hardened strips 1530, that is, behind or following the sharp edge that first contacts the surface to be cut. This cut away portion of the teeth 1514, when the boring head is penetrating the earth or rock through which the borehole is being drilled, forms a recess or cavity for the cuttings formed by the drilling action of the blade. This also provides a thinner frontal edge, which impacts the earth or rock, and improves the stabbing or penetration ability of the boring head when the head is not being rotated.
Still further, and now referring also to FIG. 76, there is slot or space 1534 between the two frontal teeth 1520A and 1520B. (See also FIGS. 72 and 73.) This serves as additional relief space for the cuttings as the blade pushes and rotates through the earth.
Referring still to FIGS. 74 and 75, it will be seen that the thickness "T 2 " of the blade 1510 tapers slightly from the point "P" where it joins the base 1502 to the forward end 1512. This provides a thinner profile to the blade and aids in piercing the earth when the blade is being axially, but not rotationally, advance.
Referring now to FIG. 77, both the base 1502 and blade 1510 are substantially planar. Thus, the plane of the base may be identified as B 1 and plane of the blade may be identified as B 2 . It will be seen that the plane B 1 is the center of the converging upper and lower planes of the tapered blade. The plane B 1 forms an angle "A" of about 170 degrees with the plane B 2 so that the blade 1510 is angled upwardly relative to the base when the base 1502 is attached to the boring head body. This angled configuration provides the boring head with better penetration and better steering capabilities.
Now it will be appreciated that the serrated or stepped, tapered blade 1500 provides many advantages. The relief areas provide space for cuttings being thrown back from the cutting surface. The angle and tapered configuration of the blade improves its ability to penetrate the earth and to steer the boring head, when the rotation is stopped but axial advancement continues.
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claims, including the full range of equivalency to which each element thereof is entitled.
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A method and apparatus for deviating the direction of a borehole. The method comprises the steps of rotating a boring head underground through a material which is to be cut and oscillates the boring head to achieve a desired direction change. The boring head has one or more roller cones and may further comprise a deflection structure. The deflection structure may be separately mountable to the boring head or may be integrally formed with the boring head. The boring head is rotated to bore a generally straight hole. To change direction, the roller cone is oriented to achieve the desired direction change and oscillated to deviate the direction of the borehole. Oscillation of the roller cone may be carried out by oscillating the drill string, the boring head and/or the roller cone.
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BACKGROUND OF THE INVENTION
This application is a continuation-in-part of application, Ser. No. 351,347, filed June 14, 1982 now abandoned and entitled THEFT PREVENTION STEP LADDER.
Recreational vehicles are usually provided with a permanent ladder mounted on its rear for providing access to its roof. These ladders have been used by thieves for entering the vehicle through roof vents.
Thus, a need exists for eliminating this illegal access to the roof and since most recreational vehicle users carry a step ladder with them, it is desirable to modify the step ladder and to mount it on the vehicle in a given way to prevent unauthorized access to the top of the vehicle along its permanent ladder.
DESCRIPTION OF THE PRIOR ART
No known prior art exists.
SUMMARY OF THE INVENTION
FIG. 1 is a front perspective view of a step ladder embodying the invention;
FIG. 2 is a back perspective view of FIG. 1;
FIG. 3 is an end view of the ladder shown in FIGS. 1 and 2 mounted on the permanent ladder of a recreational vehicle; and
FIG. 4 is an enlarged view of the circled area of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings by characters of reference, FIG. 1 and 2 disclose an ordinary wooden or aluminum step ladder 1; in this particular case, five feet in length, which is the most suitable length for use around a recreational vehicle and for the purpose hereinafter explained.
Ladder 1 comprises a pair of longitudinal frame members 2A and 2B which are hingedly connected at their top ends so as to pivotally move to their extended positions shown in FIGS. 1 and 2 where it is maintained erected by a pair of extended cross braces. These cross braces each comprise a pair of links 3 and 4 pivotally connected at one end to each other at 5 which their other ends connected one to each of the frame members 2A and 2B, as shown. One of the links of each of the pairs may be provided with a flange along one of its edges to prevent it from moving over center in its extended position in a manner well known in the art.
Frame member 2A is provided with a plurality of treads or steps 6 which are laterally spacedly positioned across the frame along its length.
Frame member 2B is provided with one or more laterally positioned cross braces 7 spacedly arranged across its frame for reinforcing the frame member.
In accordance with the teachings of this invention, a thin sheet or plate of fiber glass, aluminum or any other lightweight suitable skin like material 8 is fastened along substantially the full length of frame member 2B or any suitable portion thereof. This material is suitably fastened to the exposed surface of the frame member with either it or the frame member reinforced by a cross brace 9, as shown in FIG. 1.
As noted in FIG. 2, material 8 provides a smooth outer surface along the length of the back of the step ladder.
A pair of hooks 10 are fastened to the top end of step ladder 1 connected to either, or both, of frame members 2A and 2B to extend outwardly of the planar surface of frame member 2A for use in clamping the step ladder on the top rung of the permanent ladder mounted on the rear of a recreational vehicle.
A plate 11 is mounted to the inside, non-exposed, surface 12 of material 8 to which suitably attached a link chain 13.
FIG. 3 illustrates the rear of a recreational vehicle 14 to which is permanently attached a ladder 15 providing access to the top of the vehicle. This ladder is being used by thieves to climb the top of the vehicle for illegal entrance into the interior of the vehicle through its vents (not shown) mounted on the top of the vehicle.
Ladder 15 is provided with a plurality of rungs 16 spacedly positioned along its length.
In order to avoid unauthorized use of ladder 15, step ladder 1, modified in accordance with the teachings of this invention to include the skin like material 8 along its back surface, is mounted on the permanent ladder 15 with frame 2B and the flat, smooth surface of material 8 exposed.
As shown in FIG. 3, hooks 10 are hooked over the top rung 16 of the permanent ladder mounting and supporting step ladder 1 on permanent ladder 15. Chain 13 is then looped around a juxtapositioned rung 16 or ladder 15 and connected back through lug 11A of plate 11 with its ends connected together by a padlock 17, as shown in FIG. 4.
Thus, it should be noted that the back side of the step ladder with the smooth skin like surface of material 8 covering substantially all of the rungs of the permanent ladder 15 forming a part of the recreational vehicle 14 prevents the use of ladder 15 by an unauthorized user.
Although but one embodiment of the invention has been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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A step ladder for detachably mounting in a locked arrangement along the length of the permanent ladder of a recreational vehicle for preventing thieves from climbing to the top of the recreational vehicle, said step ladder having a smooth surface along its back support which is exposed when mounted on the permanent ladder to prevent use of the permanent ladder.
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CROSS REFERENCE TO RELATED APPLICATIONS
[1] 1. This application is a divisional application of copending U.S. Ser. No. 124,816, filed Jul. 29, 1998, for “Hydraulic Tubing Punch and Method of Use”.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[2] 2. Not Applicable
BACKGROUND OF THE INVENTION
[3] 3. 1. Field of the Invention
[4] 4. This invention is in the field of methods and apparatus used to punch holes through, or place fittings or markers in, downhole tubular elements, such as casing pipe.
[5] 5. 2. Background Information
[6] 6. In the completion of oil wells, and the production of oil from such wells, it can often become necessary or beneficial to punch one or more holes through, or perforate, the casing which lines the well bore, or the production tubing within the casing. These perforations can have several purposes, such as the creation of a gas lift flow path, the production of different zones or different formations from the well bore, the creation of a circulation path to kill the well, the loosening of sand or mud between the production tubing and the casing, or the placement of an orifice, check valve, or marker in the production tubing or casing. Further, such perforations can be used to create a circulation path to squeeze cement around a leaking packer element or perforation, or to create a circulation path for use in other remedial work, such as stimulation. A tool used for this purpose will ideally be able to be positioned within a highly deviated or even horizontal well bore, it will reliably and safely generate sufficient power to puncture thick walled tubing or casing, it will give the operator a positive indication of complete penetration of the tubing or casing, and it will reliably withdraw completely from the tubing or casing without hanging up.
[7] 7. Some tools are available for puncturing tubing, using either a burn-through technique, or a mechanical punch driven by a jarring tool, for creation of the penetration. These tools are typically carried by a wireline. None of the known tools exhibit the ideal attributes listed above. Wireline tools can not be positioned reliably in highly deviated holes. Bum-through tools and jar driven punches do not give reliable indications of complete and uniform penetration, and they are sometimes subject to hanging in the perforation, making withdrawal difficult or impossible.
BRIEF SUMMARY OF THE INVENTION
[8] 8. The present invention is a method for operating a hydraulically driven punch which generates sufficient, smoothly applied, power to penetrate thick walled tubing and casing. Conveyed on a tubular work string, the punch can be positively positioned at any desired location in a deviated or horizontal well bore before activation. Full penetration is positively signalled to the operator. Withdrawal is positive, and full withdrawal is achieve prior to lifting of the tool, virtually preventing hangup.
[9] 9. In the preferred embodiment, a drive assembly, consisting of two stacked pistons and a plunger, moves longitudinally to drive a penetrator element transversely into the production tubing or casing. The housing of the hydraulic tubing punch of the present invention consists of a piston housing and a plunger housing, connected by a releasable sub. The piston housing contains the two stacked hydraulic pistons. The upper piston applies force to the center of the lower piston by means of an upper piston rod. The lower piston is connected by a lower piston rod to the plunger, which is located in the plunger housing. The plunger incorporates a pair of oppositely facing ramped surfaces, angled slightly relative to the longitudinal axis of the tool. The ramped surfaces on the plunger mate with similarly angled surfaces on a penetrator element which can move transversely relative to the longitudinal axis of the tool. In the preferred embodiment, the oppositely facing ramped surfaces on the plunger comprise at least one groove, and the mating surfaces on the penetrator element comprise at least one ridge. The penetrator element incorporates an outwardly oriented punch of hard, durable material, capable of penetrating the production tubing or casing.
[10] 10. Application of high pressure drilling fluid or other hydraulic pressure to the upper surface of the upper piston drives it downwardly to cause its piston rod to exert downward force on the lower piston. Throughout this specification, the term “downward” will be used to mean “downhole”, and “upward” will mean “uphole”, even though in some applications the tool will be located in a highly deviated or horizontal well bore. Simultaneous application of hydraulic pressure to the upper surface of the lower piston also forces it downwardly. Downward travel of the lower piston is accompanied by downward travel of the plunger. As the ramped surfaces on the plunger move longitudinally downwardly, they cause the penetrator element to move transversely outwardly, which causes the punch portion of the penetrator element to exit through a window in the plunger housing and punch through the wall of a production tube or a casing surrounding the hydraulic tubing punch tool. A support dog, radially opposite the punch portion of the penetrator element, is forced radially outwardly, simultaneously with, or just prior to, the transverse travel of the penetrator element. The support dog bears against the opposite side of the production tubing or casing to maintain the tubing punch tool axially aligned with the tubing or casing. Additional support dogs can be used to further stabilize the axial alignment of the tool.
[11] 11. A bleed port is positioned in the piston housing, at a location just above the full travel position of the upper piston. As the upper piston reaches its full travel position, the bleed port is uncovered, allowing the hydraulic fluid to exit from the interior of the tubing punch to the annulus surrounding the tool. This reduces the hydraulic pressure applied to the pistons, and the pressure drop is seen by the operator at the surface of the well site, signalling full travel of the upper piston. Because of the rigid connection between the pistons and the plunger, full travel of the upper piston is accompanied by substantially full transverse travel of the penetrator element, thereby ensuring full penetration of the production tubing or casing.
[12] 12. The work string is then pulled upwardly, with the first upward movement of the work string causing the piston housing to separate from the plunger housing at the releasable sub. Release can be accomplished by shearing a shear pin in the releasable sub upon pulling up on the work string, or by releasing a release dog in the releasable sub upon full downward travel of the lower piston. In either case, pulling of the work string continues upwardly, pulling the piston housing, the pistons, and the plunger upwardly. This upward pulling of the plunger causes the ramped surfaces to pull the penetrator element transversely inward, withdrawing the punch from the tubing or casing. If desired, a fitting, such as an orifice, check valve, or marker tag, can be releasably mounted on the punch, to be left in the tubing or casing upon withdrawal of the punch into the plunger housing. After full retraction of the punch from the tubing or casing, a support profile on the plunger contacts a mating profile on the plunger housing, to enable withdrawal of the plunger housing from the well bore, along with the rest of the tool.
[13] 13. An anchor mechanism can be provided to anchor the tubing punch tool within the well bore at any selected location. The anchor mechanism can be hydraulically set, and mechanically released by upward pulling on the work string.
[14] 14. The novel features of this invention, as well as the invention itself, will be best understood from the attached drawings, taken along with the following description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[15] 15.FIG. 1 is a longitudinal section view of the piston housing of a first embodiment of the hydraulic tubing punch tool of the present invention, before longitudinal travel of the drive assembly;
[16] 16.FIG. 2 is a longitudinal section view of the releasable sub and plunger housing of the tool shown in FIG. 1, using a shearable release sub;
[17] 17.FIG. 3 is a transverse section view of the penetrator element and support dog of the tool shown in FIG. 2, before extension of the punch;
[18] 18.FIG. 4 is a transverse section view of the penetrator element and support dog of the tool shown in FIG. 2, after extension of the punch;
[19] 19.FIG. 5 is a transverse section view of the penetrator element and support dog of the tool shown in FIG. 2, showing optional side support dogs;
[20] 20.FIG. 6 is a longitudinal section view of the piston housing of the hydraulic tubing punch tool shown in FIG. 1, after full longitudinal travel of the drive assembly;
[21] 21.FIG. 7 is a longitudinal section view of the releasable sub and plunger housing of the tool shown in FIG. 6, showing full extension of the penetrator element;
[22] 22.FIG. 8 is a longitudinal section view of the lower end of the plunger housing of the tool shown in FIG. 6, showing full downward extension of the plunger;
[23] 23.FIG. 9 is a longitudinal section view of the piston housing of a second embodiment of the hydraulic tubing punch tool of the present invention, before longitudinal travel of the drive assembly;
[24] 24.FIG. 10 is a longitudinal section view of the releasable sub and plunger housing of the tool shown in FIG. 9, using a release dog in the releasable sub;
[25] 25.FIG. 11 is a longitudinal section view of the piston housing of the hydraulic tubing punch tool shown in FIG. 9, after full longitudinal travel of the drive assembly;
[26] 26.FIG. 12 is a longitudinal section view of the releasable sub and plunger housing of the tool shown in FIG. 11, showing full extension of the penetrator element; and
[27] 27.FIG. 13 is a longitudinal section of a hydraulically settable anchor mechanism for use with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[28] 28. As seen in FIG. 1, a first embodiment of the hydraulic tubing punch tool 10 of the present invention includes a piston housing 12 , which preferably consists of an upper piston housing 14 threaded to a lower piston housing 16 . An upper connector sub 18 is threaded to the upper end of the upper piston housing 14 , for connecting the hydraulic tubing punch tool 10 to a work string, such as a drill pipe or coiled tubing (not shown). An upper piston 20 is slidably mounted within the upper piston housing 14 for longitudinal movement. A lower piston 22 is slidably mounted within the lower piston housing 16 for longitudinal movement. A rigid, hollow, upper piston rod 24 extends downwardly from the upper piston 20 to contact the central portion of the upper surface of the lower piston 22 . The abutment between the upper piston rod 24 and the upper central surface of the lower piston 22 can be by means of a loose fit into a cavity within the lower piston 22 , as shown. The inner bore of a work string connected to the upper end of the tool 10 is in fluid flow communication with the upper surface of the upper piston 20 . Simultaneously, the inner bore of the work string is in fluid flow communication with the upper surface of the lower piston 22 via the inner bore of the upper piston rod 24 and via one or more side ports 25 in the upper piston rod 24 .
[29] 29. A rigid lower piston rod 26 extends downwardly from the lower piston 22 , with the lower piston rod 26 being pinned to the lower piston housing 16 by one or more shear pins 28 . A plurality of seals 30 provide a fluid seal between the upper piston 20 and the upper piston housing 14 , between the upper piston rod 24 and the upper piston housing 14 , and between the lower piston 22 and the lower piston housing 16 . One or more bleed ports 32 are provided in the wall of the upper piston housing 14 , connecting the interior of the upper piston housing 14 with the annulus surrounding the upper piston housing 14 . The longitudinal placement of the bleed ports 32 is just above the longitudinal position where the upper piston 20 will reach substantially full travel in the downward direction.
[30] 30.FIG. 2 shows a releasable sub 34 releasably attached to the lower end of the lower piston housing 16 , and a plunger housing 36 attached to the lower end of the releasable sub 34 . One or more shear pins 38 releasably attach the releasable sub 34 to the lower piston housing 16 . The plunger housing 36 is shown positioned at a selected longitudinal position within a production tubing or casing C. A plunger 40 is fixedly attached to the lower end of the lower piston rod 26 , for instance by means of threads as shown. As seen in FIGS. 2 and 3, a double faced ramp contour, in the form of at least one angled groove 42 , is seen on the interior wall of a longitudinal channel 43 formed in the plunger 40 . Each angled groove 42 includes an outwardly facing angled surface 44 and an inwardly facing angled surface 46 . Further, the ramp contour includes the outwardly facing angled surface 47 at the bottom of the longitudinal channel 43 .
[31] 31. A penetrator element 48 is slidably mounted for transverse movement in the lower end of the plunger housing 36 . The penetrator element 48 can consist of a sliding block 49 within which is affixed a hard, durable punch 50 . Various means known in the art can be used to affix the punch 50 to the sliding block 49 , including the use of a retainer plate 51 , which can be bolted to the sliding block 49 . The punch 50 can be fitted with any of several different types of fittings 52 , if desired, such as a marker tag, an orifice, or a check valve. This allows the fitting 52 to be left in the tubing or casing C after penetration by the punch 50 . Alternatively, the punch 50 can be used simply to create a hole in the tubing or casing C.
[32] 32. A support dog 54 is mounted for transverse movement within the lower end of the plunger housing 36 , substantially radially opposite the penetrator element 48 . The penetrator element 48 slides in and out of a penetrator window 56 in the lower end of the plunger housing 36 , and the support dog 54 slides in and out of a support dog window 58 in the lower end of the plunger housing 36 . As best seen in FIG. 3, one or more ridges 60 are formed on the lateral sides of the penetrator element 48 , with the ridges being formed at substantially the same angle as the grooves 42 in the plunger 40 . The ridges 60 fit into and mate with the grooves 42 . Further, the angled inside edge 53 of the penetrator element 48 abuts the angled surface 47 at the bottom of the longitudinal channel 43 in the plunger 40 .
[33] 33. When the plunger 40 is at the upward limit of its travel as shown in FIGS. 2 and 3, the support dog 54 can rest entirely within the plunger housing 36 , abutting an undercut surface 62 in the lower end of the plunger 40 . In this position, the ridges 60 on the penetrator element 48 follow the grooves 42 on the plunger 40 to cause the penetrator element 48 to be at the inward limit of its transverse travel, fully withdrawn within the plunger housing 36 . It can be seen in FIG. 4 that downward movement of the plunger 40 will cause the full diameter surface 64 of the plunger 40 to force the support dog 54 outward through the support dog window 58 to abut the casing C. Further, in this downward position of the plunger 40 , the ridges 60 on the penetrator element 48 slide in the grooves 42 in the plunger 40 to cause the penetrator element 48 to move transversely outwardly to exit the plunger housing 36 through the penetrator window 56 and penetrate the casing C. As seen in FIG. 5, one or more additional support dogs 66 can be mounted peripherally around the plunger housing 36 to further stabilize the axial alignment of the hydraulic tubing punch tool 10 with the casing C.
[34] 34.FIG. 6 shows the upper and lower pistons 20 , 22 substantially at the lower limit of their longitudinal travel within the upper and lower piston housings 14 , 16 . When hydraulic pressure is increased to a predetermined value, the shear pins 28 shear, releasing the upper and lower pistons to move downwardly. The pressure level at which the shear pins 28 will shear can be designed to provide an initial impulse to the drive assembly, to facilitate penetration of the tubing or casing C. Upon substantially full downward travel of the upper piston 20 , the bleed ports 32 are uncovered, allowing hydraulic pressure to bleed off from the interior of the upper piston housing 14 to the annulus surrounding the tool 10 . This signals the operator that the upper piston 20 has reached substantially full longitudinal travel, and that, consequentially, the penetrator element 48 has reached substantially full transverse travel. Downward travel of the pistons 20 , 22 can be stopped by abutment against seats 21 , 23 in the piston housing 12 . Alternatively, the size and number of the bleed ports 32 can also be designed to bleed off sufficient pressure to essentially stop the downward travel of the pistons 20 , 22 . The relative length of the upper piston rod 24 can be designed to allow the lower piston 22 to have some additional downward travel after the bleed ports 32 are uncovered by the downward travel of the upper piston 20 .
[35] 35.FIG. 7 shows the plunger 40 substantially at the downward limit of its longitudinal travel, with the support dog 54 abutting the casing C for axial alignment, and with the penetrator element 48 having fully penetrated the casing C. FIG. 8 illustrates the extension of the lower end of the plunger 40 from the lower end of the plunger housing 36 .
[36] 36. After the penetrator element 48 has fully penetrated the casing C, the operator can pull upwardly on the work string to shear the shear pins 38 , thereby releasing the piston housing 12 from the releasable sub 34 and the plunger housing 36 . During this shearing process, the upward pulling of the work string is resisted by the punch 50 of the penetrator element 48 , which is extended into the casing C. After shearing of the shear pins 38 to release the releasable sub 34 , the piston housing 12 moves upwardly, and the seat 23 abuts the lower piston 22 and pulls the pistons 20 , 22 , and the plunger 40 upwardly. As the plunger 40 is withdrawn longitudinally into the plunger housing 36 , it can be seen that the plunger 40 will return to the position shown in FIG. 2, within the plunger housing 36 . This withdraws the penetrator element 48 transversely into the plunger housing 36 . When the punch 50 has withdrawn from the casing C, the upper end 68 of the plunger 40 can abut the lower end 69 of the releasable sub 34 , to support the plunger housing 36 from the work string. The entire hydraulic tubing punch tool 10 can then be withdrawn from the well bore.
[37] 37.FIGS. 9 through 12 show a second embodiment of the hydraulic tubing punch tool 100 , which utilizes a release dog 138 , rather than the shear pins 38 used in the first embodiment, to release the piston housing 112 from the plunger housing 136 . As seen in FIG. 9, the piston housing 112 consists of an upper piston housing 114 threaded to a lower piston housing 116 . An upper connector sub 118 is threaded to the upper end of the upper piston housing 114 , for connecting the hydraulic tubing punch tool 110 to a work string, such as a drill pipe or coiled tubing (not shown). An upper piston 120 is slidably mounted within the upper piston housing 114 for longitudinal movement. A lower piston 122 is slidably mounted within the lower piston housing 116 for longitudinal movement. A rigid, hollow, upper piston rod 124 extends downwardly from the upper piston 120 to contact the central portion of the upper surface of the lower piston 122 .
[38] 38. A rigid lower piston rod 126 , having an undercut portion 127 and a full diameter portion 129 , extends downwardly from the lower piston 122 . A plurality of seals 130 provide a fluid seal between the upper piston 120 and the upper piston housing 114 , between the upper piston rod 124 and the upper piston housing 114 , and between the lower piston 122 and the lower piston housing 116 . One or more bleed ports 132 are provided in the wall of the upper piston housing 114 , connecting the interior of the upper piston housing 114 with the annulus surrounding the upper piston housing 114 .
[39] 39.FIG. 10 shows a releasable sub 134 releasably attached to the lower end of the lower piston housing 116 , and a plunger housing 136 attached to the lower end of the releasable sub 134 . The lower piston rod 126 is pinned to the releasable sub 134 by one or more shear pins 128 . One or more release dogs 138 releasably attach the releasable sub 34 to the lower piston housing 16 . The release dogs 138 are held in an outward position by abutment with the full diameter portion 129 of the lower piston rod 126 , when the lower piston 122 is near the upward limit of its travel.
[40] 40. A plunger 140 is fixedly attached to the lower end of the lower piston rod 126 . A double faced ramp contour, in the form of at least one angled groove 142 , is seen on the interior wall of a longitudinal channel 143 formed in the plunger 140 .
[41] 41. A penetrator element 148 is slidably mounted for transverse movement in the lower end of the plunger housing 136 . The penetrator element 148 includes a hard, durable punch 150 . A support dog 154 is mounted for transverse movement within the lower end of the plunger housing 136 , substantially radially opposite the penetrator element 148 . Similarly to the first embodiment, one or more ridges are formed on the lateral sides of the penetrator element 148 , with the ridges being formed at substantially the same angle as the grooves 142 in the plunger 140 .
[42] 42.FIG. 11 shows the upper and lower pistons 120 , 122 substantially at the lower limit of their longitudinal travel within the upper and lower piston housings 114 , 116 . When hydraulic pressure is increased to a predetermined value, the shear pins 128 shear, releasing the upper and lower pistons to move downwardly. Upon substantially full downward travel of the upper piston 120 , the bleed ports 132 are uncovered, allowing hydraulic pressure to bleed off from the interior of the upper piston housing 114 to the annulus surrounding the tool 110 .
[43] 43.FIG. 12 shows the plunger 140 substantially at the downward limit of its longitudinal travel, with the support dog 154 abutting the casing C for axial alignment, and with the penetrator element 148 having fully penetrated the casing C. The lower piston 122 has moved downward sufficiently to allow the release dogs 138 to fall into the undercut portion 127 of the lower piston rod 126 , thereby withdrawing the outermost portion of the release dog 138 from the recess 170 in the releasable sub 134 , into the hole 172 in the lower piston housing 116 . This releases the releasable sub 134 from the piston housing 112 .
[44] 44. After the penetrator element 148 has fully penetrated the casing C, the operator can pull upwardly on the work string to pull the piston housing 112 upwardly. This pulls the pistons 120 , 122 , and the plunger 140 upwardly. As the plunger 140 is withdrawn longitudinally into the plunger housing 136 , it can be seen that the plunger 140 will return to the position shown in FIG. 10, within the plunger housing 136 . This withdraws the penetrator element 148 transversely into the plunger housing 136 . When the punch 150 has withdrawn from the casing C, the upper end 168 of the plunger 140 can abut the lower end 169 of the releasable sub 134 , to support the plunger housing 136 from the work string. The entire hydraulic tubing punch tool 110 can then be withdrawn from the well bore.
[45] 45. In order to assist in the actuation of the hydraulic tubing punch tool 10 , 110 at any desired location in the casing C, an anchor mechanism can be used in conjunction with the tool. An example of such an anchor mechanism 200 is shown in FIG. 13. An upper connector sub 210 can be threadedly attached to the work string, and the hydraulic tubing punch tool 10 , 110 can be threadedly attached to the lower connector sub 214 . A hollow mandrel 212 is supported by the upper connector sub 210 , with a drive cone 216 formed on or attached to the outer surface of the mandrel 212 . A split finger collet 218 is slidably mounted on the outer surface of the mandrel 212 , below the drive cone 216 . A port 222 through the wall of the mandrel 212 provides fluid pressure from the work string to drive the collet 218 upwardly. A plurality of slip fingers 220 on the upper ends of the fingers of the collet 218 are driven outwardly by contact with the drive cone 216 . This forces the slip teeth 224 on the outer surfaces of the slip fingers 220 to forcibly contact the casing C, holding the anchor mechanism 200 and the tubing punch 10 , 110 in position.
[46] 46. The same hydraulic pressure that sets the anchor mechanism 200 can actuate the tubing punch 10 , 110 . After full travel of the drive assembly and the penetrator element 48 , 148 , pulling upwardly on the work string will cause the drive cone 216 to withdraw from contact with the slip fingers 220 , releasing the anchor mechanism 220 . Thereafter, continued upward pulling on the work string withdraws the penetrator element 48 , 148 from the casing C, as described above.
[47] 47. While the particular invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages hereinbefore stated, it is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended other than as described in the appended claims.
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A method for driving a ramped drive assembly longitudinally, to drive a penetrator transversely, to cause the penetrator to penetrate and withdraw from a downhole tubular element. An anchor holds the tubing punch assembly in place in the downhole tubular element. A double piston assembly drives the drive assembly hydraulically in the downhole direction, thereby driving the ramp downhole, to force the penetrator outwardly to penetrate the tubular element. Thereafter, pulling uphole on the work string shears a shear sleeve, separating the housing of the tubing punch assembly from the work string. Further pulling on the work string partially withdraws the ramped drive assembly from the tubing punch assembly, thereby withdrawing the penetrator into the tubing punch assembly.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S. provisional patent application Ser. No. 61/311,626, filed on Mar. 8, 2010.
FIELD OF THE INVENTION
[0002] The present invention relates generally to animal detection systems, and more particularly to roadside animal detection systems.
BACKGROUND OF THE INVENTION
[0003] Existing animal detection systems (“ADSs”) include sensor stations and warning stations. When an animal is detected by one of these sensor stations, the warning stations illuminate lights, which are intended to warn drivers of the presence of the detected animal.
[0004] There are only about 34 different locations in the world (12 in North America and 22 in Europe) where ADSs have been tested or permanently installed. Of those 34, only 8 are still in operation today. The majority of the ADSs that were removed had problems, which included (a) a high rate of false positives (providing a warning when an animal was not in the area), (b) a high rate of false negatives (providing no warning when an animal was in the area), (c) a wide variety of maintenance issues resulting from complex hardware that was difficult to fix and was not readily available, (d) an inability to accurately detect the direction in which an animal is moving, (e) large costs associated with the purchase and installation of ADSs, and (f) large bulky equipment that is not aesthetically pleasing. These problems have discouraged acceptance of ADSs installed along roadways.
SUMMARY OF THE INVENTION
[0005] The invention may be embodied as an animal detection system. Such a system may include at least one warning station and at least one sensor station arranged adjacent to a roadway. Each sensor station may include a first sensor attached to the sensor station at a first distance from the ground and at a first distance from the roadway, and a second sensor attached to the sensor station at a second distance from the ground and at a second distance from the roadway.
[0006] A processor may be in communication with the first sensor and the second sensor, and configured to determine the presence of an animal using information provided by the first sensor and the second sensor, and to cause transmission of a warning signal to the at least one warning station when the animal is detected.
[0007] Also, the invention may be embodied as a method of detecting an animal. In one such method, a plurality of sensor stations are arranged adjacent to a roadway. Each sensor station includes a first sensor attached to the sensor station at a first distance from the ground and at a first distance from the roadway, and a second sensor attached to the sensor station at a second distance from the ground and at a second distance from the roadway. Sensor information is transmitted from the plurality of sensor stations to a processor. Information provided by the plurality of sensor stations is analyzed by the processor to determine a condition of an animal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a fuller understanding of the nature and objects of the invention, reference should be made to the accompanying drawings and the subsequent description. Briefly, the drawings are:
[0009] FIG. 1A is a perspective view of a sensor station according to the invention;
[0010] FIG. 1B is similar to FIG. 1A , but a panel has been removed to show components of the sensor station;
[0011] FIG. 1C is another perspective view of the sensor station shown in FIG. 1B ;
[0012] FIG. 1D is a schematic showing two sensor stations and the beams which extend between them;
[0013] FIG. 2A is a perspective view of a warning station according to the invention;
[0014] FIG. 2B is a different perspective view of the warning station of FIG. 2A ;
[0015] FIG. 3A is a schematic showing an ADS according to the invention used in conjunction with a roadway; and
[0016] FIG. 3B shows four schematics and text describing how the system might operate to indicate the presence of an animal near a roadway.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The invention may be embodied as an ADS having two types of stations: (a) sensor stations 10 , and (b) localized warning stations 13 that may be placed at line-of-sight intervals along a road 16 . FIGS. 1A , 1 B and 1 C depict a sensor station 10 according to the invention, and FIGS. 2A and 2B depict a warning station 13 according to the invention. Each sensor station 10 may have at least two types of sensors. When an animal 19 is detected by a sensor station 10 , a warning signal is sent from the sensor station 10 to one or more of the warning stations 13 . Upon receiving such a warning signal, the warning station 13 provides an indication, which can be interpreted by drivers that an animal 19 has been detected.
[0018] Warning stations 13 may be spaced less than every quarter mile, and preferably are spaced every 250 feet, in order to provide drivers with sufficient advanced warning that an animal 19 has been detected in the area and to allow drivers more time to slow down. A small distance between warning stations 13 may reduce the rate of false negatives reported by drivers. A 250 foot spacing may coincide with the spacing of reflector poles found on many highways, and so it may be possible to mount the warning stations 13 on such reflector poles, thereby saving money during installation. By keeping the spacing of warning stations 13 small, the present invention may allow the location of an animal 19 to be more precisely identified to drivers, which in turn may allow for providing a more meaningful warning to drivers.
[0019] The sensor stations 10 may include at least two types of sensors. The two types of sensors may rely on electromagnetic energy with different frequency ranges. For example, in one embodiment of the invention, each sensor station 10 includes a laser break-beam sensor 22 and also an infrared break-beam sensor 25 . The emitters 28 , 31 corresponding to the sensors 22 , 25 may have different angles (i.e. varying areas) of coverage. For example, the first emitter/sensor 22 , 28 combination may have a smaller area of coverage than the second emitter/sensor 25 , 31 combination. FIG. 1D depicts the beams of two types of energy emitters 28 , 31 , one emitter 28 having an electromagnetic energy beam 34 that covers a narrow area, and the other having an electromagnetic beam 37 that covers a wide area. For example, the emitter 28 may be a laser and the emitter 31 may be an infrared emitter. By having sensors 22 , 25 with different areas of detection, the first combination of emitter 28 and sensor 22 may be selected to detect an animal 19 over a narrower area, than the second combination of emitter 31 and sensor 25 . This may be useful, for example, for avoiding false positives.
[0020] A programmed micro-processor/controller 40 (or logic circuit) may be in communication with the sensors 22 , 25 and the micro-processor/controller 40 may be used to intelligently differentiate an actual crossing event from a false positive or false negative, such as those created by snow thrown from snow plows. The micro-processor/controller 40 may be programmed according to algorithms that use data from the sensor stations 10 regarding which of the sensor stations 10 detected an interruption in both the first sensor 22 and the second sensor 25 , and the order in which those sensors were interrupted to identify an area where the animal 19 is located, and the direction in which the animal 19 is traveling. The micro-processor/controller 40 also may be programmed to use data from the sensor stations 10 to identify which of the warning stations 13 to activate or deactivate.
[0021] The two sensors 22 , 25 on a sensor station 10 may be spaced apart from each other. In a similar manner, the emitters 28 , 31 on an adjacent sensor station 10 may be similarly spaced apart from each other. By doing so, the micro-processor/controller 40 can determine the direction in which an animal 19 is moving by identifying the order in which the sensor beams 34 , 37 are broken. Also, the speed of the animal 19 can be calculated using the time which lapses between detection of the animal 19 by one of the sensors 22 or 25 and detection of the animal 19 by the other sensor 22 or 25 . The direction in which the animal 19 is moving can be used to determine if an animal 19 is moving toward or away from the roadway 16 . If the micro-processor/controller 40 determines that the animal 19 is moving away from the roadway 16 , the warning station 13 may be commanded by the micro-processor/controller 40 to deactivate.
[0022] The beams 34 , 37 of the sensor stations 10 define a boundary 43 . When one of the sensor stations 10 detects an animal crossing the boundary 43 and the direction in which the animal 19 is moving, the micro-processor/controller 40 may increment a counter in order to keep track of how many animals 19 are near the roadway 16 . For example, when an animal 19 is detected crossing the sensor boundary 43 toward the roadway 16 , the micro-processor/controller 40 may add to the counter, and when an animal 19 is detected crossing the sensor boundary 43 away from the roadway 16 , the micro-processor/controller 40 may subtract from the counter. The counter information may be transmitted to other sensor stations 10 , and in this manner, the ADS can accommodate a situation in which there are multiple animals 19 near the roadway 16 . When the counter returns to zero, the micro-processor/controller 40 may send a signal commanding that the warning lights 46 of the warning stations 13 be turned off.
[0023] The micro-processor/controller 40 may keep track of the length of time that one or more of the sensor beams 34 , 37 are broken. If a sensor beam 34 , 37 is broken for an extended period of time, that sensor station 10 can be turned off, thereby shutting down part of the ADS, and eliminating the possibility that drivers would receive a warning indication when there is no animal 19 . Such a condition might exist, for example, due to snow or brush residing in the sensor boundary 43 . By shutting down only a portion of the ADS, other portions of the ADS may continue to provide warnings to drivers.
[0024] Each sensor station 10 may include a warning signal transmitter 49 , which may emit an electromagnetic frequency signal (such as a radio signal) when an animal 19 has been detected. Each warning station 13 may include a warning signal receiver 52 , which may detect when the warning signal transmitter 49 has emitted a warning signal. Upon detection of a warning signal sent by a sensor station 10 , the warning station 13 may provide an indication, which can be interpreted by drivers as a warning that an animal 19 has been detected in the area. For example, the warning station 13 may include lights 46 which are illuminated to warn drivers that an animal 19 has been detected. The lights 46 may provide a message or illuminate a sign that provides a message urging drivers to slow down and/or be aware of the possible presence of an animal 19 .
[0025] FIGS. 1A and 1B depict a sensor station 10 that is in keeping with the invention. The sensor station 10 includes a solar energy collection panel 55 , which may be electrically connected to a rechargeable battery 58 . The solar energy collection panel 55 and battery 58 can be used to provide electricity to enable the sensors 22 , 25 to detect animals 19 , and send warning signals to one or more warning stations 13 . In this manner, electric power lines need not be installed, which provides for easy, quick and inexpensive installation of the sensor stations 10 .
[0026] An enclosure 61 protects components from the weather, and may be mounted to a post 64 . Transmitter 49 may extend from the enclosure 61 , and thereby provide a better means to emit an electromagnetic warning signal when an animal 19 has been detected. An accelerometer (not shown) may be included and connected to the micro-processor/controller 40 so that if a sensor station 10 is knocked over (e.g. by a car, snow plow, etc.), that sensor station 10 may be taken off-line. The enclosure 61 may be formed to have suitable shapes and openings to accommodate the sensors 22 , 25 and emitters 31 , 34 .
[0027] FIG. 1B shows additional detail of the sensor station 10 depicted in FIG. 1A . In FIG. 1B , a portion of the enclosure 61 has been removed in order to better illustrate that each sensor station 10 may include a micro-processor/controller circuit 40 , battery 58 , and charge controller 67 . The charge controller 67 may govern when and how the battery 58 is charged. A very simple and low cost micro-processor/controller circuit 40 , such as an ATmega 328 , can be used. Such a micro-processor/controller 40 is inexpensive and consumes little power.
[0028] The sensors 22 , 25 shown in the figures are at different heights above the ground, and differ in height by a distance “V.” While the sensors 22 , 25 are shown to be situated at different heights, they may be positioned at an equal distance from the ground. However, displacing the sensors 22 , 25 at different heights, may help protect against false positives. For example, if the system is configured for the detection of larger animals 19 , like a moose, placing the sensors 22 , 25 at different heights may help protect against the sensors 22 , 25 from being triggered by a bird flying horizontally past the sensor stations 10 . While the sensors 22 , 25 may be placed at any height above the ground, it may be advantageous to place the sensors 22 , 25 greater than two feet above the ground—in this manner, small animals are less likely to be detected by the sensors 22 , 25 . The emitters 28 , 31 may be similarly positioned at different heights above the ground.
[0029] Also, the sensors 22 , 25 shown in the figures are not vertically aligned. Instead, the non-vertical alignment results in a horizontal distance (shown in FIG. 1A as “H”) separating the sensors 22 , 25 . When the horizontal distance “H” is not equal to zero, the ADS obtains an ability to detect the direction in which an animal 19 is moving. For example, if an animal 19 crosses the sensor boundary 43 by tripping the laser sensor 22 prior to the infrared sensor 25 , the system will be able to determine whether the animal 19 is moving toward or away from the roadway 16 . In this manner, the warning signal may be sent when the animal 19 is detected moving toward the road 16 , and then the warning signal may be stopped when the animal 19 is detected moving away from the road 16 . Preferably, the horizontal distance “H” is greater than two inches. The emitters 28 , 31 may be similarly positioned at different distances from the road 16 .
[0030] FIGS. 2A and 2B depict a warning station 13 according to the invention. The warning station 13 may be equipped with a solar energy collection panel 70 , which may be electrically connected to a rechargeable battery. The solar collection panel 52 and battery of the warning station 13 can be used to provide electricity to enable components of the warning station 13 to receive warning signals from one or more sensor stations 10 , and provide a warning to drivers, for example, by illuminating the lights 46 . In this manner, electric power lines need not be installed, which provides for easy, quick and inexpensive installation of the warning stations 13 .
[0031] FIGS. 2A and 2B show that a warning station 13 may include a receiver 52 . Receiver 52 may be used to receive a warning signal from a sensor station 10 . The warning station 13 may include warning lights 46 , for example, in the form of an array of light emitting diodes, which may be used to provide drivers on the roadway 16 with a warning that an animal 19 has been detected. The warning station 13 may be mounted to a post 73 that is located near the roadway 16 .
[0032] FIGS. 3A and 3B describe how the system of break-beam sensor stations 10 might communicate with the warning stations 13 to provide a driver with a warning. FIG. 3A depicts a wild animal 19 breaching the boundary 43 . When the beams of the sensors 22 , 25 are broken, the presence of the animal 19 at the boundary 43 is determined by the micro-processor/controller 40 , and a warning signal is transmitted to one or more of the warning stations 13 . Upon receipt of the warning signal, warning stations 13 may then illuminate warning lights 46 to provide drivers on the roadway 16 with a warning that an animal 19 has been detected. FIG. 3B depicts the process of an animal 19 approaching boundary 43 and crossing the boundary 43 . Once the animal 19 has crossed boundary 43 , warning lights 46 are activated. After the sensor stations 10 detect that the animal 19 has exited boundary 43 , warning lights 46 are deactivated.
[0033] A sensor station 10 and a warning station 13 that are in keeping with the invention may be each made so as to use less power than an ordinary household flashlight. Since the ADS may need to operate only part of the day when animal 19 crossings are most likely, it is believed that a small (1′×1′ 12V) solar panel 55 , 70 and battery 14 (6″×3″×3″) can power the system for three days without supplemental sunlight.
[0034] Each sensor station 10 of the present invention may be relatively independent of the others. For example, if one sensor station 10 fails, the entire ADS system need not be rendered inoperable. Furthermore, using a predetermined radio frequency band, each of the sensor stations 10 can communicate with at least two other nearby devices (sensor stations 10 and/or warning stations 13 ), which may be within 500 feet of each other. Consequently, the present invention may identify more accurately where along the roadway 16 the animals 19 are located. Such a localized ADS system may allow for advanced warning while also reducing the number of false positives reported.
[0035] Each sensor station 10 may be equipped to send information about its activities to a recording station (not shown), which may be programmed to store information for use in determining how the ADS is operating, and how animals 19 are moving through the area.
[0036] The components of the sensor stations 10 and warning stations 13 may be selected from those currently available from vendors which provide electrical components through mail-order or the Internet. For example, the laser emitter may be laser diode model no. CA-3-4-650A, which is available from Creative Technology Lasers of Walnut Creek, Calif. The infrared emitter may be a photo-electric sensor model no. 1151E-6517, which is available from Eaton Cutler-Hammer of Cleveland, Ohio. Such emitters are inexpensive and consume little power. In doing so, the cost of the system may be kept low, and maintenance may be quickly and easily performed.
[0037] Although the present invention has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present invention may be made without departing from the spirit and scope of the present invention. Hence, the present invention is deemed limited only by the appended claims and the reasonable interpretation thereof.
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A system for detecting an animal proximate a roadway is disclosed. In one embodiment of the invention, there is at least one warning station, a plurality of sensor stations, and a processor. Each of the plurality of sensor stations may have a first sensor and a second sensor. The processor may be configured to detect an animal using information provided by the first sensor and the second sensor, and to cause transmission of a warning signal to the at least one warning station when the animal is detected.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of application Ser. No. 11/023,740, filed Dec. 28, 2004, entitled ELECTRONIC KITCHEN DISPENSING FAUCET. This application also claims benefit of provisional application Ser. No. 60/782,335, filed Mar. 14, 2006, entitled ELECTRONIC KITCHEN DISPENSING FAUCET, and also claims benefit of provisional application Ser. No. 60/791,352, filed Apr. 12, 2006, entitled ELECTRONIC KITCHEN DISPENSING FAUCET. The entire content of each of the above applications is incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to liquid measuring and dispensing devices, and more particularly relates to devices for accurate and easy dispensing of adjustable amounts of liquid and/or at adjustable desired temperatures.
[0003] Liquid measuring and dispensing devices exist for use in industrial applications and beverage dispensing devices. An industrial dispenser is typically set up or calibrated for dispensing a consistent volume of liquid and is operated in repetitive batch mode. The calibrated settings may be stored in the industrial dispenser and used again at a later time for consistently producing the same product. However, these devices are not sufficiently accurate for small volumes that are desired in many kitchens, nor are they sufficiently controlled for accurate temperatures as needed in many kitchens, especially consumer kitchens where recipes are relatively small.
[0004] Thus, there is a need to improve the accuracy and ease of dispensing liquids in industrial, commercial, and consumer kitchens while preparing recipes and pre-packaged food products. Further, known liquid-dispensing devices are not configured to be conveniently located within smaller kitchens and do allow for dispensing precise volumes of liquid, or more specifically water, into a container for reconstituting pre-packaged food or mixing with other recipe ingredients.
[0005] Still further, known systems are not configured to automatically adjust the flow rate of liquid based on the volume of liquid to be dispensed. This automatic adjustment of the flow rate is necessary to compensate for the anticipated container size and will prevent the ensuing mixture from gushing out of the container when the liquid is added.
[0006] Still further, known liquid-dispensing devices cannot accurately dispense a precise volume of liquid at specific temperatures. One such example would be for activating yeast for use in baking. Yeast requires a specific volume of liquid at a very narrow temperature range to effectively promote the yeast to produce carbon dioxide necessary for proper rising of flour during baking. If the liquid is too hot, the yeast is instantly killed. If the liquid is too cool, the yeast will cake or not produce sufficient quantities of carbon dioxide for proper rising.
[0007] There are many additional needs not presently met in the industry. For example, there is also a need for accurately dispensing an exact volume of water at extremely elevated temperatures as required when mixing beverages like coffee, tea, or cocoa. Likewise, there is a need for the apparatus to limit the volume of extremely hot liquid that is dispensed in a single dispensing cycle to prevent overflowing the container and to prevent scalding of the operator.
[0008] There is a need to allow normal or manual operation of a “standard” kitchen faucet. Numerous other kitchen tasks require the use of the faucet to dispense liquid at varying flow rates and temperatures. These include tasks such as washing pots, pans, and utensils or rinsing food during preparation of recipes. These tasks require the operator to manually adjust the liquid flow rate and temperature for the task undertaken. There is a further desire by the commercial or consumer chef for the kitchen faucet to be quickly converted to allow dispensing of precise volumes, temperature, and flow rates of liquids.
[0009] There is a need for the kitchen faucet to control a garbage disposal unit. As the kitchen faucet senses liquid flowing, the garbage disposal may be operated by the operator. Should the kitchen faucet not have sufficient liquid flowing, the garbage disposal unit would not operate, even when requested by the operator.
[0010] Furthermore, there is a need for a kitchen faucet that disables or turns off the garbage disposal when the flow of liquid from the kitchen faucet is stopped. This prevents damage to the garbage disposal when insufficient liquid is flowing.
[0011] While some manufacturers have attempted to solve the dispensing of specific volumes of liquid for industrial baking or processing, known devices are typically too big and cumbersome to be retrofitted to a commercial or consumer kitchen sink. One such device is available from Hass Manufacturing Company and sold under the product name of Intellifaucet BC375 Batch Controller. While this device may be useful for dispensing a large volume of liquid for batch processing, it is inadequate for dispensing small volumes of liquid and/or for dispensing precise volumes of liquid, which items are needed in preparing recipes in the commercial or consumer kitchen.
[0012] Other products like the one shown in U.S. Pat. No. 5,431,302 entitled Dispensing Liquid Volume Control by Tulley et al. describes a specialty dispenser for dispensing beer or other expensive carbonated beverages. This apparatus improves the volumetric accuracy by compensating for the liquid spilled from the container. This spillage compensation method would not work for kitchen recipes or food preparation. If used in preparing cooking recipes or other food preparation, the results would be disastrous as the outcome of the recipe would be compromised by the spillage of the liquid and the ensuing mixture.
[0013] Therefore, there exists a need, both for households and restaurants, and also for consumers and chefs, a device configured to accurately measure and dispense water or other liquids in the kitchen for use in preparing recipes, while making instant hot or cold beverages, or in the preparation of pre-packaged foods. There is also a need for flexibility of use to satisfy the wide variety of needs in such applications.
[0014] Accordingly, a kitchen dispensing faucet apparatus is desired that provides the advantages noted above and that solves the disadvantages.
SUMMARY OF THE INVENTION
[0015] The present invention relates to an apparatus and method for accurately dispensing an operator-selected volume of liquid from a kitchen faucet for use in preparing food recipes or general food preparation. In another aspect, the present invention relates to an apparatus and method for dispensing liquids at accurate selected temperatures. In still another aspect, the present invention relates to an apparatus and method for controlling a garbage disposal based on the flow of water through a faucet while performing food preparation.
[0016] In one aspect of the present invention, a liquid-dispensing apparatus includes a first circuit adapted for connection to a first source of liquid to dispense liquid from the first source at a first flow rate, the first circuit including a first valve for controlling the flow of the liquid from the first source through the first circuit. The apparatus further includes a second circuit also adapted for connection to the first source of liquid and being constructed to dispense liquid from the first source at a second flow rate different than the first flow rate, the second circuit including a second valve for controlling the flow of the liquid from the first source through the second circuit. At least one flow meter is provided for measuring the volume of the liquid dispensed through the first and second circuits. A programmable controller is operably connected to at least one flow meter and to the first and second valves, the controller being programmed and adapted to receive first signals from the at least one flow meter and being programmed and adapted to generate second signals to control the first and second valves to dispense a variable amount and also an accurate total amount of dispensed liquid.
[0017] In another aspect of the present invention, a kitchen faucet apparatus adapted to dispense a selected amount of liquid includes a base, a faucet supported on the base, a first circuit having a first flow rate and adapted to connection to a source of liquid, and a second circuit having a second flow rate and adapted to connection to a source of liquid. The first and second circuits are connected to the faucet and include valves for controlling the first and second flow rates to accurately deliver a total flow amount of as little as ½ teaspoon and as great as at least 1 gallon. A controller is programmed to variably control the flow-controlling devices of the first and second circuits to output a selected quantity of liquid.
[0018] In yet another aspect of the present invention, a liquid-dispensing apparatus includes a first circuit adapted for connection to a first source of liquid to dispense liquid from the first source at a variable flow rate, the first circuit including at least one variable-rate device for automatically controlling the flow of the liquid from the first source through the first circuit. A programmable controller is operably connected to the variable-flow-rate device and being programmed and adapted to generate signals to control the variable-flow-rate device to dispense an accurate total amount of dispensed liquid down to within at least 10% of a ½ teaspoon of liquid.
[0019] In another aspect of the present invention, a kitchen faucet apparatus adapted to dispense a selected amount of liquid includes a base, a faucet supported on the base, and a circuit having a flow rate of at least 0.5 gallons per minute and adapted to connection to a source of liquid. The circuit is connected to the faucet and includes a variable-flow-rate device for controlling the flow rate to accurately deliver a total flow amount of as little as ½ teaspoon and as great as at least 1 gallon.
[0020] In another aspect of the present invention, a kitchen faucet apparatus adapted to dispense a selected amount of liquid includes a base with an input device, and an outlet with a faucet supported on the base and including a temperature sensor. First and second circuits are connected to first and second sources of liquid at different temperatures, respectively, and include first and second variable-flow-rate control devices; the first and second circuits being connected to the outlet. A controller is operably connected to the input device, to the sensor and to the first and second variable-flow-rate control devices; the controller being programmed to output a selected quantity of liquid at a selected temperature.
[0021] An object of the invention is to provide a liquid-dispensing apparatus comprising a base adapted for mounting to a kitchen sink. A spout extends from the base for dispensing the total amount of liquid. A first circuit is constructed and adapted for connection to a first source of liquid. The first circuit includes a valve to control the flow of liquid from the first source through the circuit. A first flow meter is adapted to measure the volume of the first source liquid flowing through the liquid-dispensing apparatus. A programmable controller is operably connected to the first flow meter and to the first valve contained within the first circuit. The programmable controller is adapted to receive first signals from the flow meter representing the volume of liquid flowing through the meter and dispensed from the liquid-dispensing apparatus. The programmable controller also is adapted to generate second signals to control the first valve to dispense an accurate total amount of dispensed liquid from the spout.
[0022] Another object of the invention is to provide a liquid-dispensing apparatus comprising a first and second circuit constructed and adapted for connection to a first source of liquid. The first and second circuits each include a valve to control the flow of liquid from the first source through their respective circuit. A first flow meter is adapted to measure the volume of the first source liquid flowing through the liquid-dispensing apparatus. A programmable controller is operably connected to the first flow meter and to the first and second valves contained within the first and second circuits. The programmable controller is adapted to receive first signals from the flow meter representing the volume of liquid flowing through the meter and dispensed from the liquid-dispensing apparatus. The programmable controller also is adapted to generate second signals to control the first and second valves to dispense an accurate total amount of dispensed liquid.
[0023] Another object of the invention is to provide a liquid-dispensing apparatus comprising a base adapted for mounting to a kitchen sink. A spout extends from the base for dispensing the total amount of liquid. A first circuit is constructed and adapted for connection to a first source of liquid. The first circuit includes a positive-displacement pump to control the flow of liquid from the first source through the circuit. The first positive-displacement pump is capable of measuring the volume of the first source liquid flowing through the liquid-dispensing apparatus. A programmable controller is operably connected to the first positive-displacement pump within the first circuit. The programmable controller is adapted to provide first signals to the positive-displacement pump representing the volume of liquid flowing through the positive-displacement pump and dispensed from the liquid-dispensing apparatus.
[0024] Another object of the invention is to provide a liquid-dispensing apparatus comprising a positive-displacement pump connected to a variable-speed control device. The variable-speed control device provides the means of changing the flow rate of the first source of liquid through the device. It is therefore an object of the invention to provide a liquid-dispensing apparatus comprising a base adapted for mounting to a kitchen sink. A spout extends from the base for dispensing the total amount of liquid.
[0025] Another object of the invention is to provide a liquid-dispensing apparatus comprising a measuring flow-restrictor apparatus with shut-off capability connected to a control device capable of varying the flow of first pressurize source liquid through the first circuit based on the desired volume to be dispensed. A first circuit is constructed and adapted for connection to a first pressurized source of liquid. The first circuit includes a measuring flow-restrictor apparatus with shut-off capability which is capable of measuring the volume of liquid that flows through the circuit using a measurement apparatus that is in fluidic contact with the first circuit. The measuring flow-restrictor apparatus with shut-off capability varies the flow rate of the liquid flowing through the circuit by varying an externally applied load resistance placed on the measurement apparatus. The measuring flow-restrictor apparatus with shut-off capability may increase the flow rate of the liquid flowing through the first circuit by varying an externally applied pumping action applied to the measurement apparatus. The measuring flow-restrictor apparatus with shut-off capability may terminate the flow of liquid flowing through the circuit by restricting the movement of the measurement apparatus.
[0026] Another object of the invention is to provide a means within the control device to measure the volume of first pressurized source liquid dispensed while also providing a means of increasing or decreasing the flow rate by reducing or increasing the flow resistance on the first pressurized source liquid by varying a load resistance applied to the measurement apparatus.
[0027] Another object of the invention is to provide a device that is readily available in the kitchen near the sink, cooking, or food preparation areas that would dispense an operator-selected volume of liquid with the accuracy required by recipes or pre-packaged foods. The device rapidly dispenses the desired volume of liquid into a container, and is programmed to limit the liquid flow rate based on the volume of liquid desired to prevent splashing or loss of the ensuing mixture. The device also dispenses a wide range of volumes ranging from a fractional teaspoon to gallons of liquid with sufficient accuracy and consistency required by cooking recipes and food preparation.
[0028] Another object of this invention for this new device is to dispense a measured volume of extremely hot water for preparing instant or hot beverages, and for reconstituting pre-packaged foods. The measured volumes are programmed and stored in the memory contained within the device and may be adjusted by the operator. These predefined measured volumes are typical for such foods and beverages and provide the operator a margin of safety by reducing the risk of scalding or overflowing the container as the hot liquid is dispensed.
[0029] It is a further object of this invention for this new device to provide for changing the temperature of the liquid to be dispensed across a range of temperatures. The dispensed liquid temperature may be adjusted on demand by the consumer throughout the temperature range of below room temperature but above freezing to a temperature near boiling. The device may include preset temperatures for dispensing liquids at temperature commonly needed within the kitchen for recipes and food preparation.
[0030] It is a further object of the invention to provide a method of dispensing a desired volume wherein the operator dispenses several arbitrary volumes of liquid, followed by a final dispensing of liquid to the desired preset volume.
[0031] It is a further object of the invention to provide a method of rapidly dispensing the desired volume of liquid while controlling the flow of liquid through the faucet into a container filled with ingredients, thereby preventing the liquid splashing out or a loss of mixture from the container while the liquid is being added.
[0032] In one of its aspects, the present invention may be retrofitted to a kitchen faucet assembly for measuring and dispensing a desired volume of water by controlling the hot and cold water supply sources to the existing faucet or sprayer.
[0033] Another aspect of this device is a control device attached to a kitchen sink garbage disposal. The control device provides a signal for activating the garbage disposal only when the liquid flow sensor detects a sufficient volume of water flowing through the faucet. The garbage disposal would turn off when the flow of water through the faucet is interrupted; thereby preventing damage to the garbage disposal.
[0034] These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is an electrical and plumbing diagram of an All-in-One dispensing faucet with auxiliary water heater and garbage disposal controller using the valve method.
[0036] FIG. 2 is a block diagram of an All-in-One kitchen dispensing faucet.
[0037] FIG. 3 is an illustration of an All-in-One electronic kitchen dispensing faucet with control panel and including a manual liquid temperature and volume control handle.
[0038] FIG. 4 is an illustration of an All-in-One electronic kitchen dispensing faucet with control panel and including a manual liquid temperature and volume control handle.
[0039] FIGS. 5A and 5B are block diagram of the control sequence used to control an All-in-One kitchen dispensing faucet using the valve method.
[0040] FIG. 6 is an electrical and plumbing diagram of a typical kitchen sink retrofitted with an Auxiliary design dispensing faucet using the valve method.
[0041] FIG. 7 is a block diagram of a typical kitchen sink modified with an Auxiliary design dispensing faucet.
[0042] FIG. 8 is an electrical and plumbing diagram of a typical kitchen faucet retrofitted with an Add-on dispensing faucet using the valve method.
[0043] FIG. 9 is a block diagram of a typical kitchen sink faucet retrofitted with an Add-on dispensing apparatus and control module.
[0044] FIGS. 10A , and 10 B is a block diagram of the control sequence used to control a typical kitchen sink retrofitted with an Add-on dispensing apparatus and control module.
[0045] FIG. 11 is a table of flow rate settings used while dispensing an operator-desired volume of liquid.
[0046] FIGS. 12, 13A , 13 B, 14 , 15 , 16 A, and 16 B are diagrams of a second embodiment incorporating a positive-displacement pump, the diagrams being similar to FIGS. 1, 5A , 5 B, 6 , 8 , 10 A, and 10 B, respectively and being usable in the apparatus shown in FIGS. 2-4 , 7 , 9 , and 11 .
[0047] FIGS. 17, 18A , 18 B, 19 , 20 , 21 A, and 21 B are diagrams of a third embodiment incorporating a measuring flow-restrictor apparatus with shutoff, the diagrams being similar to FIGS. 1, 5A , 5 B, 6 , 8 , 10 A, and 10 B, respectively and being usable in the apparatus shown in FIGS. 2-4 , 7 , 9 , and 11 .
[0048] FIG. 22 is a diagram of a fourth embodiment, the diagram being similar to but simplified from that of FIG. 17 .
DETAILED DESCRIPTION
[0049] This invention is described using three (3) different faucet designs: All-in-One design, Auxiliary design, and Add-on design. The All-in-One design replaces the standard faucet as shown in FIGS. 2, 3 , and 4 . The Auxiliary design is installed adjacent to a standard faucet as shown in FIG. 7 . The Add-on design is added to a standard faucet as shown in FIG. 9 . Each of these designs could use any one of the control methods described below.
[0050] This invention is controlled by one of three (3) methods: valves, positive-displacement pump, and measuring flow-restrictor. The valve method is shown in FIGS. 1, 6 and 8 . The positive-displacement pump method is shown in FIGS. 12, 14 , and 15 . The measuring flow-restrictor is shown in FIGS. 17, 19 , 20 and 22 . Each of these methods could be used on any one of the designs described above.
[0051] The apparatus 1 ( FIGS. 1 and 2 ) for an electronic dispensing kitchen faucet includes a base 48 , a spout 49 , a first circuit 50 , a first flow meter 7 , and a programmable controller 3 . The base 48 is adapted for mounting to a kitchen sink 45 . The spout 49 extends from the base 48 for dispensing the total amount of liquid. The first circuit being adapted for connection to a first source of liquid 15 to dispense liquid from the first source at a first flow rate 51 . The first circuit 50 includes a first valve 9 for controlling the flow of the liquid from the first source through the first circuit 50 .
[0052] The first flow meter 7 measures the volume of liquid dispensed through the first circuit 50 . The first flow meter 7 is shown in FIG. 1 in the circuit after the first circuit 50 . However, it should be understood by those skilled in the art that the first flow meter 7 may be positioned before the first circuit 50 or it may be positioned within the first source liquid circuit. In either of these positions, the first flow meter 7 will accurately measure the amount of first source liquid flowing through the faucet exit 29 .
[0053] The programmable controller 3 is operably connected to the first flow meter 7 and to the first valve 9 . The controller 3 is programmed and adapted to receive first signals from the first flow meter 7 . The controller 3 generates control signals to actuate and de-actuate the first valve 9 to dispense an accurate total amount of liquid from the spout 49 .
[0054] The apparatus 1 for an electronic dispensing kitchen faucet includes a first circuit 50 , a second circuit 52 , a first flow meter 7 , and a programmable controller 3 as shown in FIG. 1 . The first circuit being adapted for connection to a first source of liquid 15 to dispense liquid from the first source at a first flow rate 51 . The first circuit 50 includes a first valve 9 for controlling the flow of the liquid from the first source through the first circuit 50 .
[0055] The second circuit 52 is adapted for connection to a first source of liquid 15 to dispense liquid from the first source at a second flow rate 53 . The second circuit 52 includes a second valve 10 for controlling the flow of the liquid from the first source through the second circuit 52 .
[0056] The first flow meter 7 measures the volume of liquid dispensed through the first and second circuits 50 , 52 . The first flow meter 7 is shown in FIG. 1 in the circuit after the first and second circuits 50 and 52 are joined together. However, it should be understood by those skilled in the art that the first flow meter 7 may be positioned before the first and second circuits 50 , 52 or it may be positioned within the first source liquid circuit. In either of these positions, the first flow meter 7 will accurately measure the amount of first source liquid flowing through the faucet exit 29 .
[0057] The programmable controller 3 is operably connected to the first flow meter 7 and to the first and second valves 9 and 10 , respectively. The controller 3 is programmed and adapted to receive first signals from the first flow meter 7 . The controller 3 generates control signals to actuate and de-actuate the first and second valves 9 , 10 to dispense an accurate total amount of liquid.
[0058] Another embodiment of the apparatus 1 for an electronic dispensing kitchen faucet includes a first circuit 50 , a second circuit 52 , a common outlet circuit 26 , and a programmable controller 3 . The first circuit 50 is adapted for connection to a first source of liquid 15 to dispense liquid from the first source at a first flow rate 51 . The first circuit 50 includes a first valve 9 for controlling the flow of the liquid from the first source through the first circuit 50 .
[0059] The second circuit 52 is adapted for connection to a first source of liquid 15 to dispense liquid from the first source at a second flow rate 53 . The second circuit 52 includes a second valve 10 for controlling the flow of the liquid from the first source through the second circuit 52 .
[0060] The first and second circuits 50 , 52 are connected together to form a common outlet circuit 26 . The first flow meter 7 measures the volume of liquid dispensed through the common outlet circuit 26 .
[0061] The programmable controller 3 is operably connected to the first flow meter 7 and to the first and second electric solenoid valves 9 and 10 , respectively. The controller 3 is programmed and adapted to receive first signals from the first flow meter 7 . The controller 3 generates control signals to actuate and de-actuate the first and second valves 9 , 10 to dispense an accurate total amount of liquid.
[0062] Another embodiment of the apparatus 1 for an electronic dispensing kitchen faucet includes a first flow meter 7 , a first and second electric solenoid valves 9 and 10 respectively, an operator input device 2 , a start input switch 31 , and a programmable controller 3 .
[0063] The first flow meter 7 connects to a first source of liquid 15 and produces a first flow signal indicating the volume of liquid flowing through the flow meter and a faucet exit 29 . The first electric solenoid valve 9 is connected to a first source of liquid 15 and to the first flow meter 7 and controls the liquid flow rate at a first flow rate 51 . The second electric solenoid valve 10 is connected to the first source of liquid 15 and to the first flow meter 7 and controls the liquid flow rate at a second flow rate 53 . The second flow rate 53 is typically 3-5 times greater than the first flow rate 51 .
[0064] The operator input device 2 allows the operator to specify the volume of liquid desired, as well as other parameters, settings, and values useful for liquid dispensing. The operator input contains a display 30 for communicating information to the operator such as volume dispensed, volume to be dispensed, temperature of the liquid being dispensed, and other parameters or settings. The parameters and settings are stored in memory 36 and used by the programmable controller 3 while operating the faucet apparatus 1 .
[0065] The start input switch is used to initiate liquid dispensing through the electronic kitchen dispensing faucet apparatus. When the start input switch 31 is depressed, the apparatus initiates dispensing. If the start input switch 31 is depressed while the apparatus is dispensing, the apparatus will pause the liquid dispensing pending further action by the operator. The liquid dispensing will complete the dispensing operation if the start input switch 31 is depressed while the apparatus 1 is paused.
[0066] The programmable controller 3 receives input from the operator input 2 and start input switch 31 and contains an audible signal generator 4 for alerting the operator of errors or when the liquid dispensing cycle is complete. The programmable controller 3 communicates with the operator by displaying information on the display 30 . The programmable controller 3 generates control signals to initiate liquid flowing from the first source of liquid 15 . These control signals actuate the first and second electric solenoid valves to achieve the desired flow rate through the faucet apparatus 1 .
[0067] The programmable controller 3 receives input signals from the first flow meter 7 representing the volume of liquid flowing. The controller 3 sums the first flow signals and compares the total volume dispensed to the desired operator volume input. The controller 3 generates control signals to the first and second electric solenoid valves 9 , 10 to stop the flow of liquid when the desired volume of liquid has been dispensed from the faucet apparatus 1 into the container 44 .
[0068] An example of such a flow meter is produced by Omega Engineering and sold as the FTB2000 Series Economical Flowrate Sensor. The Omega Engineering flow rate sensor is available in several flow rate resolutions and flow capacities. It should be noted that other flow meter designs may be equally substituted for measuring the volume of liquid flowing through the faucet outlet. These flow meters may generate pulsed signals or frequency output signals representative of the finite volume of liquid flowing through them.
[0069] The first electric solenoid valve 9 controls the flow of the first source liquid 15 at a first flow rate 51 . The second electric solenoid valve 10 controls the flow of the first source liquid 15 at a second flow rate 53 . The cumulative volume of first source liquid 15 flowing through the first and second electric solenoid valves 9 , 10 flows through the first flow meter 7 and is dispensed from the faucet exit 29 .
[0070] The first flow meter 7 generates first flow signals representative of the volume of liquid flowing through the first flow meter 7 . The first flow signals are connected to the programmable controller 3 for processing. The programmable controller 3 sums the first flow signals and stores the resulting total volume of first source liquid dispensed from the faucet exit 29 in memory 36 for later use.
[0071] The operator input 2 provides a means for the operator to specify the volume of first source liquid 15 to be dispensed from the faucet apparatus 1 . The operator may select from volumetric units typical of recipes or volumes of liquid used in the kitchen which would be displayed to the operator on a display 30 . These volumetric units may be either English or metric. English volumetric units include teaspoon (tsp), tablespoon (Tbsp), ounces (oz), cups (c), pints (pt), quarts (qt), or gallons (gal). Metric volumetric units include milliliters (ml) or liters (l). Once the operator selects the volumetric units for input, the quantity is specified by the operator using the operator input 2 . The operator may specify the quantity of the specified volumetric unit in either decimal or fractional increments. As an example, English units are typically required in fractional increments of the selected volumetric unit. (e.g., ⅔ teaspoon, ¼ cup, ½ gallon, etc.) The present apparatus 1 will automatically accurately and repeatedly dispense selected volumes of liquid input into the input device 2 , including amounts as small as ½ teaspoon, and do so to at least about 10% accuracy, and more preferably to within about 5% accuracy, and even to within about 2% accuracy, depending on the system components selected for use.
[0072] The operator input 2 includes an audible signal generator 4 . Numerous audible signal generators are known within the industry. These include audio speakers of various designs and manufacturing styles; some are designed for direct exposure to high moisture environments which may include direct contact with liquids. Other audible signal generators include fixed frequency generators that may be controlled in duration or intensity. The programmable controller 3 audible output signal connects to the audible signal generator 4 for frequency, intensity, and duration control. The programmable controller 3 outputs the appropriate signal to alert the operator of various conditions while dispensing liquid. These operator alerts may include feedback that operator input 2 has been acknowledged, errors have occurred while dispensing liquid, or to alert the operator prior to dispensing elevated or hot temperature liquids from the faucet to prevent scalding the operator.
[0073] An alternative operator input device 2 can include individual increment and decrement input buttons for each volumetric unit and parameter to be dispensed as shown in FIG. 4 , item 37 . The operator would press the increment or decrement switch input means to select between the available fractional or decimal volume for each unit.
[0074] Another operator input device would include a traditional keypad that includes the numeric digits 0-9 and additional keys for each volumetric unit. The operator would input the desired numeric or fractional value before or after specifying the units.
[0075] More specifically, the electronic kitchen dispensing faucet 1 as shown in FIG. 3 includes a rotary switch 32 that is rotated by the operator in the forward direction 34 or reverse direction 35 . Using the rotary switch 32 , the operator increments or decrements the decimal or fractional unit volume of liquid to be dispensed from the faucet apparatus 1 . As the rotary switch 32 is moved in the forward direction 34 , the value selected is incremented. Likewise, as the rotary switch 32 is moved in the reverse direction 35 , the value selected is decremented. It is well understood in the industry that the forward and reverse directions 34 , 35 are interchangeable in incrementing and decrementing the value selected and is primarily an operator preference. The rotary switch 32 also contains a perpendicular input switch 33 that is actuated when the operator presses the rotary switch 32 in the direction perpendicular to its rotation.
[0076] The perpendicular input switch 33 selects the volumetric unit or other parameter to be input by the operator. Each press of the perpendicular input switch 33 selects the next volumetric unit or parameter to be adjusted by the operator. As an example when operating in the English volumetric mode, the operator may select between the English units of tsp, Tbsp, oz, pt, qt, and gal. The perpendicular input switch 33 may select between other non-numeric input parameters such as temperature, garbage disposal, and country.
[0077] When non-numeric input parameters are selected by the perpendicular input switch 33 , the rotary switch 32 would be used to select between the possible values. The possible values may be numeric or specific non-numeric settings. As an example, when the COUNTRY parameter is selected, the rotary switch would allow the operator to select between ENGLISH or METRIC values by rotating the rotary switch 32 in either the forward or reverse direction 34 , 35 .
[0078] A start input switch 31 creates a start signal to the programmable controller 3 indicating the operator's desire to operate the electric kitchen dispensing faucet apparatus 1 . The start input switch 31 may be any style switch known within the industry. This switch could be of a mechanical actuator, capacitive sensing, magnetic sensing, or optical switch input means that generates a signal to the programmable controller indicating the operator's intent to operate the faucet apparatus 1 .
[0079] The programmable controller 3 receives input signals from the first flow meter 7 , operator input 2 , and start input switch 31 . The programmable controller 3 produces control signals to the first and second electric solenoid valves 9 and 10 , respectively, and display 30 . The programmable controller 3 monitors the start input switch signal to initiate, pause, or stop the flow of liquid through the faucet as shown in FIGS. 5A and 5B . The programmable controller 3 generates a first and second control signal in sequence which actuates the first and second electric solenoid valves 9 and 10 , respectively, as needed to control the flow rate of the first source liquid flowing through the first flow meter 7 and dispensed from the faucet exit 29 .
[0080] Continuing to refer to FIG. 1 , the electronic kitchen dispensing faucet apparatus 1 may also include a third circuit 54 , a fourth circuit 56 , and a temperature sensor 19 . The third circuit 54 is adapted for connection to a second source of liquid 16 to dispense liquid from the second source at a third flow rate 55 . The third circuit 54 includes a valve 11 for controlling the flow of liquid from the second source through the third circuit 54 . The fourth circuit 56 is adapted for connection to a second source of liquid 16 to dispense liquid from the second source at a fourth flow rate 57 . The fourth circuit 56 includes a valve 12 for controlling the flow of liquid from the second source through the fourth circuit 56 . The fourth flow rate 57 is typically 3-5 times greater than the third flow rate 55 .
[0081] The second source of liquid 16 is typically available in residential or commercial kitchens providing an elevated temperature water source. This elevated temperature water source is typically at a temperature between 130 and 190 degrees Fahrenheit.
[0082] The first, second, third, and fourth circuits 50 , 52 , 54 , 56 are connected together to form a common outlet circuit. The first flow meter 7 generates signals representing the volume of liquid flowing through the flow meter 7 and common outlet circuit 26 and dispensed from the faucet exit 29 .
[0083] The temperature sensor 19 may be selected from several temperature sensors known within the industry. The temperature sensor may be any of a variety of thermocouple sensor styles (J, K, T, E, R, S) which use different bimetal junctions to create an electrical voltage which increases or decreases proportionally as the temperature increases or decreases. Other temperature sensors use various materials to create a change in resistance as the temperature changes. The temperature sensor is positioned within the liquid conduit between the first flow meter outlet and the faucet exit 29 . The temperature sensor measures the resulting temperature of the liquids flowing through the faucet exit 29 .
[0084] The temperature sensor 19 is capable of sensing liquid temperatures between 32 and 212 degrees Fahrenheit. The temperature sensor 19 measures the resulting temperature of the first and second source liquids 15 , 16 and the reservoir liquid flowing through the faucet apparatus 1 .
[0085] The operator input 2 allows the operator to define the resultant liquid temperature dispensed from the faucet exit 29 . The operator input 2 allows the operator to select a temperature to be dispensed from commonly used temperatures, or the operator may enter the temperature directly into the operator input 2 . The present apparatus 1 will automatically accurately and repeatedly dispense liquids at selected temperatures from as low as the normal cold water source of a household (e.g. about 60 degrees) to as high as the normal hot water source of a household (e.g. about 200 degrees), and will do so within at least about 5 degrees Fahrenheit of the selected temperature input into input device 2 , or more preferably within about 2 degrees Fahrenheit of the selected temperature, or even to within about 1 degree Fahrenheit of the selected temperature.
[0086] The programmable controller 3 generates control signals that actuate the first, second, third, and fourth electric solenoid valves 9 , 10 , 11 , 12 , resulting in liquid flowing through the corresponding valve and circuit. The programmable controller 3 receives an electric voltage signal from the temperature sensor 19 representative of the liquid temperature dispensed from the faucet exit 29 . The programmable controller 3 converts the temperature sensor electrical voltage into a dispensed liquid temperature. The programmable controller 3 then compares the dispensed liquid temperature to the desired operator temperature. The programmable controller calculates the pulse rate for the first, second, third, and fourth electric solenoid valves 9 , 10 , 11 , 12 to adjust the temperature and volume of liquid flowing from the faucet exit 29 . The programmable controller 3 determines the magnitude of temperature error in the resultant liquid dispensed from the faucet and increases the flow rate in the temperature direction of adjustment required. The solenoid pair attached to the opposing temperature liquid source may be reduced if the flow rate exceeds the maximum flow rate for the volume being dispensed or if a greater temperature error exists.
[0087] Continuing to refer to FIG. 1 , the electronic kitchen dispensing faucet apparatus 1 may also include a fifth circuit 58 , a sixth circuit 60 , and a heated liquid reservoir 6 . The heated liquid reservoir 6 has an inlet and outlet, the inlet connected to the first source liquid 15 , the heated liquid reservoir 6 maintaining the temperature of the liquid in the reservoir at a temperature between 180 and 205 degrees Fahrenheit. The reservoir 6 heats the first source liquid 15 flowing into the reservoir. The reservoir 6 contains a heating element and temperature regulating means to maintain the liquid within the reservoir at an elevated temperature between 180 and 205 degrees Fahrenheit. The liquid stored within the reservoir becomes a third source liquid for dispensing from the electronic kitchen dispensing faucet.
[0088] The fifth circuit 58 is adapted for connection to the outlet of the heated liquid reservoir 6 to dispense hot liquid from the heated reservoir 6 at a fifth flow rate 59 . The fifth circuit 58 includes a valve 13 for controlling the flow of hot liquid from the heated liquid reservoir 6 through the fifth circuit 58 . The sixth circuit 60 is adapted for connection to the outlet of the heated liquid reservoir 6 to dispense hot liquid from the heated liquid reservoir 6 at a sixth flow rate 61 . The sixth circuit 60 includes a valve 14 for controlling the flow of hot liquid from the heated liquid reservoir 6 through the sixth circuit 60 . The sixth flow rate 61 is typically 3-5 times greater than the fifth flow rate 59 .
[0089] The first, second, third, fourth, fifth, and sixth circuits 50 , 52 , 54 , 56 , 58 , 60 are connected together to form a common outlet circuit 26 . The first flow meter 7 generating signals representing the volume of liquid flowing through the first flow meter 7 and common outlet circuit 26 and dispensed from the faucet exit 29 .
[0090] The programmable controller 3 generates control signals connected to the first, second, third, fourth, fifth, and sixth electric solenoid valves 9 - 14 for actuating the corresponding valve resulting in liquid flowing through the valve and dispensed from the faucet exit 29 . The programmable controller 3 receives an electric voltage signal from the temperature sensor 19 proportional to the liquid temperature dispensed from the faucet. The programmable controller 3 converts the temperature sensor electrical voltage into a dispensed liquid temperature. The programmable controller 3 then compares the dispensed liquid temperature to the operator desired liquid temperature. The programmable controller 3 calculates the pulse rate needed for actuating the first, second, third, fourth, fifth, and sixth electric solenoid valves 9 - 14 to adjust the temperature and volume of liquid flowing through the faucet exit 29 . The programmable controller 3 determines the magnitude of temperature error in the resultant liquid dispensed from the faucet and increases the flow rate in the temperature direction of adjustment required. The solenoid pair attached to the opposing temperature liquid source may be reduced if the flow rate exceeds the maximum flow rate for the volume being dispensed.
[0091] The programmable controller 3 determines the initial flow rate 71 by comparing the operator input volume 75 to a table of volumes 70 with corresponding output flow rate parameters stored in memory 36 . The programmable controller 3 selects the appropriate initial flow rate 71 . The initial flow rate 71 limits the flow rate of liquid dispensed from the faucet exit 29 to insure the liquid does not splash or gush out of the container 44 used to capture the dispensed liquid. The output flow rate is also determined and limited by the total volume of liquid to be dispensed, and the actual volume of liquid dispensed from the faucet exit 29 into the container 44 .
[0092] The flow rate through the electric solenoid valves is reduced to a termination flow rate 73 when the actual volume dispensed is near the total volume desired by the operator to insure volumetric accuracy. The programmable controller 3 determines the termination flow rate 73 by comparing the operator input volume 75 to a table of volumes 70 with corresponding output flow rates stored in memory 36 . The programmable controller 3 selects the appropriate terminating flow rate 73 . The flow rate through the faucet exit 29 may be abruptly terminated as the total volume dispensed increases above a predefined volume. By abruptly terminating the flow of liquid, liquid volumes above this predefined volume are rapidly dispensed without compromising volumetric accuracy dispensed into the container.
[0093] The flow rate through the electric solenoid valve is maintained at an average flow rate 72 while dispensing the source liquids when the volume dispensed is greater than the initial volume but less than the operator input volume less the termination volume. The programmable controller 3 determines the average flow rate 72 by comparing the operator input volume to a table of volumes 70 with corresponding output flow rates stored in memory 36 . The programmable controller 3 selects the appropriate average flow rate 72 .
[0094] The flow rate through the faucet exit 29 is limited to a maximum flow rate 74 whenever dispensing a measured volume of liquid. This maximum flow rate 74 is determined by the maximum first flow meter characteristics. By limiting the flow rate through the faucet exit 29 to the maximum flow rate 74 , the volumetric accuracy is insured.
[0095] Once the operator-specified volume has been dispensed through the kitchen faucet or the dispensing operation suspended by the operator, the programmable controller 3 remains idle waiting for additional operator input. If no operator input is received within a selected time interval, the electronic kitchen dispensing faucet apparatus 1 will turn power off to the unit to conserve electricity and to turn off the operator display illumination source which could be annoying to the operator during the nighttime.
[0096] Now referring to FIG. 5A , the operator initially turns the electronic kitchen dispensing faucet apparatus 1 to the ON position which initializes an On-Delay timer value to zero and starts a timing sequence within the programmable controller 3 . The current value of the On-Delay timer is then compared to a preset value as shown in step 100 to see if the On-Delay timer has exceed the preset value. If so, the start input switch 31 signal is tested in step 101 and if activated, the liquid temperature is measured 102 and compared to an operator desired temperature 103 . If the current temperature measured in step 102 is not at the desired value, the electric solenoid pulse rate is adjusted 104 prior to the electric solenoids being actuated and de-actuated 105 based on a pulse rate calculated to maintain the average flow rate 72 and to regulate the liquid temperature flowing from the faucet exit 29 at the operator desired temperature. As long as the operator continues to hold the start input switch 31 depressed maintaining the start input signal activated 101 , the flow of liquid through the faucet exit 29 continues. This cycle allows the operator to prime or preheat the faucet components with elevated temperature liquid to insure the desired liquid temperature is dispensed in a subsequent dispensing cycle.
[0097] The operator activates the On/Off switch signal 108 to retrieve the previous dispensed volume stored in memory 107 . The operator input 2 then displays the current value and allows the operator to adjust the units and values to the desired volume and temperature for dispensing 120 . When the desired volume has been selected by the operator, the start input switch 31 is depressed by the operator which generates a start input switch signal activation 121 which starts a timing sequence by initializing a start timer value to zero. The start timer value measures the duration the start input switch 31 is activated. The start timer value is compared to a preset value. If the start timer exceeds the preset value, the electric solenoid valves will be actuated while the start input switch 31 remains depressed, activating the start input signal as shown in FIG. 5B , which will dispense liquid while the start input switch 31 is activated 243 or until the dispensed volume equals the dispensed volume 210 .
[0098] If the start input switch 31 is de-activated before the start timer exceeds the preset value 241 , the dispensing process continues as shown in FIG. 5B step 242 , which dispenses liquid until the operator desired volume has been dispensed 210 ; or the start input switch 31 is activated 242 . If the start input switch 31 signal is activated while liquid is flowing 242 , the electric solenoid valves are de-actuated which suspends liquid flowing through the faucet exit 29 . When the operator depresses the start input switch 31 signal as shown in step 246 , the liquid dispensing continues until the dispensed volume is dispensed 210 or the operator activates the On/Off input switch signal 240 .
[0099] Now referring to FIG. 5B , the operator input stored volume of liquid to be dispensed is retrieved 201 from memory 36 . The programmable controller 3 compares the volume to be dispensed to a predefined volume 202 to adjust the liquid flow rate based on the operator desired volume of liquid. If the dispensed volume is above the predefined volume, the electric control valves are actuated at a pulse rate to dispense at a high flow rate. If the dispensed volume is below the predefined volume, the electric control valves are actuated at a pulse rate to dispense at a lower flow rate as shown in step 203 .
[0100] The first flow meter signals are added to the accumulated pulses and calculations performed to determine the total volume of liquid dispensed in step 204 . The accumulated total volume dispensed is stored in memory as shown in step 207 . The temperature sensor 19 is read by the programmable controller 3 in step 205 . The average flow rate through the faucet exit 29 is calculated by dividing the total volume of liquid dispensed by the time elapsed while dispensing as shown in step 206 .
[0101] The current dispensed liquid temperature is compared to the desired operator input temperature in step 208 . Each electric solenoid valve pulse rate is adjusted based on the difference between the current temperature and desired temperature. The flow rate through each electric solenoid is factored into the new pulse rates stored in memory.
[0102] The actual dispensed volume is then compared to the desired operator requested volume in step 210 ; if the electronic kitchen dispensing faucet apparatus 1 has dispensed the desired volume of liquid, an audible alarm is signaled 220 and the electric solenoid valves are de-actuated 221 . A courtesy delay is provided in step 222 for the operator to review the liquid dispensing information shown on the display 30 before the electronic kitchen dispensing faucet apparatus is turned off to conserve electricity.
[0103] If all liquid has not been dispensed, the On/Off switch signal is tested by the programmable controller 3 to determine if the operator has decided to turn the kitchen dispensing faucet Off 240 . The programmable controller 3 then tests to determine if the start timer has exceeded a preset value to determine if the operator is holding the start input switch depressed 241 . If so, the faucet apparatus 1 dispenses the volume of liquid while the operator continues to press and hold the start input switch 31 depressed 243 and will stop dispensing when the start input switch 31 is released.
[0104] If the start input switch 31 signal is momentarily pressed, the liquid is dispensed without further intervention by the operator as shown in step 242 . If while dispensing the liquid the operator presses the start input switch 31 signal, the programmable controller 3 will stop the flow of liquid through the faucet exit 29 and store the present volume dispensed as shown in step 244 . If the operator fails to complete the dispensing before the non-use timer is exceeded 245 , power to the electronic kitchen dispensing faucet apparatus 1 is turned off 230 . The operator can continue dispensing liquid by pressing the start input switch 31 signal as shown in step 246 .
[0105] The programmable controller 3 may determine the maximum volume of heated liquid that may be dispensed from the liquid reservoir 6 during a single dispensing. The operator input volume is compared to this maximum heated liquid volume prior to dispensing. If the operator input volume is greater that the maximum heated liquid volume, the programmable controller 3 will alert the operator by controlling the signal connected to the audible signal generator 4 .
[0106] A table of frequently dispensed heated liquid volumes may be maintained in the memory 36 . This table would include the predefined liquid volume and temperature. The operator input 2 will allow the operator to select a predefined volume and temperature of heated liquid for measured dispensing from the electronic kitchen dispensing faucet apparatus 1 . These frequently dispensed volumes and temperatures are typical of pre-packaged food products like instant soups, tea, coffee, cocoa, or other hot beverages. The table of volumes and temperatures may be preprogrammed from the manufacturer or input by the operator and stored in memory 36 for future use.
[0107] To use the table of frequently dispensed heated liquid volumes and temperatures, the operator input would enable the selection from the table of heated volumes and temperatures. The operator would then scroll through each entry stored in memory 36 . When the desired table entry is located by the operator, the operator would then select this entry for subsequent dispensing when the start input switch 31 is activated.
[0108] Now referring to FIG. 1 , the electronic kitchen dispensing faucet apparatus 1 may also include a manual mixing valve 8 , a second and third flow meter 17 and 18 respectively for measuring the volume of the first and second source of liquids flowing through the faucet exit 29 as a result of the manual mixing valve actuation. The manual mixing valve 8 provides the means for the operator to infinitely adjust the flow rates of the first and second source liquids 15 , 16 through the manual mixing valve 8 and to be dispensed from the faucet exit 29 .
[0109] The second flow meter 17 inlet is in fluid connection with the first source of liquid 15 and the outlet being in fluid connection with the first inlet of the manual mixing valve 8 . The third flow meter 18 inlet is in fluid connection with the second source of liquid 16 and the outlet is in fluid connection with the second inlet of the manual mixing valve 8 . The manual mixing valve 8 outlet is in fluid connection with the liquid conduit connected to the first flow meter 7 outlet, temperature sensor 19 , and faucet exit 29 .
[0110] The second and third flow meters 17 , 18 generate signals representative of the volume of liquid flowing through their respective flow meter, these signals are connected to the programmable controller 3 which sums the discrete volumes represented by each signal pulse and accumulating the total volume flowing of the first and second source liquid 15 , 16 in its memory 36 for future processing.
[0111] The programmable controller 3 may display the accumulated volume of liquid flowing through the second and third flow meters 17 , 18 , and the average temperature dispensed from the faucet into a container on the display of the operator input 2 while the manual mixing valve 8 is actuated by the operator.
[0112] The operator can close the manual mixing valve 8 , and using the operator input 2 select a total volume and temperature for dispensing by the electronic kitchen dispensing faucet apparatus 1 . The programmable controller 3 will calculate the remaining volume of liquid by subtracting the volume of liquid dispensed through the manual mixing valve from the desired volume selected from the operator input 2 . The programmable controller 3 will then actuates the electric solenoid valves in sequence to dispense the remaining volume of liquid from the faucet exit 29 .
[0113] The programmable controller 3 may also sequence the electric solenoid valves to complete the dispensing of liquid at the average temperature set by the operator using the manual mixing valve position. The programmable controller 3 may also sequence the electric solenoid valves to complete the dispensing of liquid at the same flow rate established by the operator while operating the manual mixing valve 8 .
[0114] Referring to FIG. 6 , a garbage disposal input switch 22 is provided for the operator to initiate the operation of a garbage disposal 20 by the programmable controller 3 generating a garbage disposal control signal to an actuator means 21 . The garbage disposal input switch 22 may be an electromechanical relay or solid-state relay or other means for converting the programmable controller low voltage signal into a high-voltage, high-current signal sufficient for operating the garbage disposal. The programmable controller 3 detects the operator's desire to operate the garbage disposal by sensing the operator activating the garbage disposal input switch 22 . The programmable controller 3 then verifies sufficient liquid is flowing from the faucet exit 29 by reading the flow meter values indicating the volume of liquid flowing through the faucet exit 29 . It is know within the industry that garbage disposal units should be operated with sufficient water flowing through the garbage disposal unit 20 to prevent damage.
[0115] The programmable controller 3 continues to monitor the flow meter values and will de-activate the garbage disposal control signal when the volume of liquid flowing through the faucet exit 29 is insufficient to prevent damage to the garbage disposal unit 20 .
[0116] The programmable controller 3 may also be operated in a mode where the operator enables the garbage disposal. The programmable controller 3 will then activate and de-activate the garbage disposal control signal as the flow of liquid through the faucet exit 29 is of sufficient volumes to prevent damage to the garbage disposal unit 20 . This allows the operator to control the garbage disposal unit 20 by operating the manual mixing valve 8 . The programmable controller 3 may include a delay in the garbage disposal control signal after sufficient liquid is flowing to allow the liquid to travel through the sink and into the garbage disposal unit 20 . A different delay interval may be used by the programmable controller 3 when de-activating the garbage disposal unit 20 once the liquid flow is terminated through the faucet exit 29 .
[0117] The Auxiliary-design electronic kitchen dispensing faucet apparatus 1 as shown in FIGS. 6 & 7 retrofits onto an existing kitchen sink and faucet assembly. An auxiliary faucet spigot 46 is attached to the sink assembly 45 . The auxiliary faucet spigot 46 is attached to the first flow meter 7 and temperature sensing means 19 . The first source of liquid 15 may be dispensed through the electronic kitchen dispensing faucet apparatus 1 or heated in the reservoir 6 and dispensed. The electronic kitchen dispensing faucet 1 may mix the first source liquid and heated reservoir liquid to achieve the desired operator dispensed liquid temperature.
[0118] Referring to FIG. 6 , an Auxiliary-design electronic kitchen dispensing faucet 1 is shown with a first source of liquid 15 , a heating reservoir 6 , a programmable controller 3 , an operator input 2 , a first flow meter 7 , a temperature sensor 19 , and first, second, third, and fourth electric solenoid valves 9 , 10 , 13 , and 14 respectively. The faucet shown dispenses an operator-defined volume of a first liquid at an operator-defined temperature by actuating the valves 9 , 10 , 13 , 14 in sequence, measuring the volume of liquid flowing through the first flow meter 7 and faucet exit 29 , de-actuating the valves in sequence when the desired volume has been dispensed into the container 44 .
[0119] The Add-on electronic dispensing kitchen faucet shown in FIG. 8 may be used to retrofit a typical kitchen faucet and sink to allow dispensing of an operator-defined volume of liquid at an operator-specified temperature by actuating the electric solenoid valves 9 ′- 12 ′ in sequence. The plumbing modifications to the typical kitchen sink 45 are shown in FIG. 9 .
[0120] Continuing to refer to FIG. 8 , the electronic dispensing kitchen faucet apparatus for converting a typical kitchen faucet into a dispensing faucet includes a first circuit 90 , a second circuit 91 , a programmable controller 3 , and a operator input 2 . The first circuit 90 being adapted for connection between a first source of liquid 15 to dispense liquid from the first source at first and second flow rates 51 and 53 , respectively and adapted for connection to the typical kitchen faucet cold water source inlet 15 . The first circuit 90 includes a first and second valve 9 ′ and 10 ′, respectively, for controlling the flow of the liquid from the first source through the first circuit 90 , and a first flow meter 92 for measuring the volume of first source liquid flowing through the first circuit 90 and into the typical kitchen faucet cold water source inlet 15 .
[0121] The second circuit 91 being adapted for connection between a second source of liquid 16 to dispense liquid from the second source at third and fourth flow rates 55 and 57 , respectively and adapted for connection to the typical kitchen faucet hot water source inlet 16 . The second circuit 91 includes a third and fourth valve 11 ′ and 12 ′, respectively, for controlling the flow of the liquid from the second source through the second circuit 91 , and a second flow meter 93 for measuring the volume of second source liquid through the second circuit 93 and into the typical kitchen faucet hot water source inlet 16 .
[0122] The first, second, third and fourth valves 9 ′, 10 ′, 11 ′, and 12 ′ are of a normally open design which allows liquid to flow from the inlet to the outlet port without a signal applied. When the signal is applied to the normally open valve, the valve flow path is blocked, restricting liquid from flowing between the inlet and outlet ports.
[0123] The outlet ports of the first and second valves 9 ′, 10 ′ are connected together and in fluid connection with the inlet of the first flow meter 92 . The first flow meter 92 outlet is in fluid connection with the typical kitchen faucet cold water source inlet 15 , typically referred to as the cold water source. The inlet ports of the first and second electric solenoid valves are connected together and in fluid connection with the first source liquid 15 .
[0124] The outlet ports of the third and fourth valves 11 ′, 12 ′ are connected together and in fluid connection with the inlet of the second flow meter 91 . The second flow meter 91 outlet is in fluid connection with the typical kitchen faucet hot water source inlet 16 . The inlet ports of the third and fourth valves 11 ′, 12 ′ are connected together and in fluid connection with the second source liquid 16 .
[0125] The programmable controller 3 generates output signals to control the first, second, third, and fourth valves 9 ′- 12 ′. The operator input 2 includes an on/off input switch 47 which turns the electronic kitchen dispensing faucet on and off. When the on/off input switch 47 is depressed, the electronic kitchen faucet apparatus 1 is turned on. The first, second, third, and fourth electric solenoid valves 9 ′- 12 ′ are actuated as shown in FIG. 10A step 600 , terminating flow of the first and second liquid 15 and 16 , respectively, through the faucet exit 29 , thereby enabling the dispensing of an operator desired volume of liquid as shown in step 610 . The programmable controller 3 generates an audible control signal which activates the audible signal generator 4 to inform the operator the electronic kitchen dispensing faucet apparatus 1 has closed the electric solenoid valves thereby stopping the flow of the first and second source liquid through the faucet exit 29 . The programmable controller 3 also displays a message to the operator on the operator display 30 indicating the operator must open the manual mixing valve to allow the measured volume of liquid to flow from the faucet exit 29 .
[0126] When the start input switch is actuated as shown in FIG. 10A step 620 , the desired volume of liquid is dispensed from the faucet exit 29 . The programmable controller 3 calculates the pulse rate of the first, second, third, and fourth valves 9 ′- 12 ′ needed to flow the desired volume of liquid desired by the operator.
[0127] If no activity occurs on the operator input within the non-use timer interval as shown in FIG. 10A step 630 , the programmable controller 3 will generate an audible control signal to the audible signal generator 4 to inform the operator that the faucet apparatus 1 will be turned off and the valves 9 ′- 12 ′ will be de-actuated. If the operator left the manual mixing valve in the open position, the first and second source liquids 15 , 16 would flow through the faucet exit 29 .
[0128] The operator input 2 allows the operator to select the desired volume of liquid to be dispensed as shown in FIG. 10A step 610 .
[0129] The liquid flow rate through the faucet exit 29 is increased slowly to insure the liquid does not splash out of the container 44 or result in the containers ensuing mixture gushing out as the liquid begins to flow into the container 44 . Referring to FIG. 11 , the programmable controller 3 locates the desired volume of liquid 75 within a flow rate table of volumes 70 stored in memory 36 . The values for the initial, terminating, average, and maximum flow rates 71 , 72 , 73 , 74 , respectively, are extracted from the flow rate table 70 stored in memory 36 . The initial, terminating, average, and maximum flow rates 71 - 74 are based on the dispensed volume 75 and the anticipated container size to be used in collecting the volume dispensed. The flow rate table 70 also contains the initial and terminating flow rate volumes 71 and 73 , respectively. The initial flow rate 71 is used when the programmable controller 3 initiates liquid flowing through the faucet exit 29 . The initial flow rate 71 will be allowed to flow for up to the initial flow volume before increasing the flow rate to the average flow rate 72 . The terminating flow rate 73 is used when the dispensed volume is within the terminating flow volume. The flow rate will be reduced to the terminating flow rate 73 while dispensing the terminating flow volume and therefore dispense the total operator input volume desired.
[0130] Once the initial flow volume has been dispensed, the programmable controller 3 increases the liquid flow rate to the average flow rate 72 . The programmable controller 3 sequences the first, second, third, and fourth electric solenoid valves 9 ′- 12 ′ to maintain the flow rate at approximately the average flow rate 72 ; but below the maximum flow rate 74 . The first, second, third, and fourth electric solenoid valves 9 ′- 12 ′ are actuated and de-actuated in sequence to maintain the liquid temperature at the desired operator temperature.
MODIFICATION
[0131] Modified apparatus and systems are shown in FIGS. 12-16B , 17 - 21 B, and FIG. 22 . In the modified apparatus and systems, identical and similar components and features are identified using the same numbers . . . and substituted components are also identified using the same numbers but with the addition of a letter “A”, “B”, or “C”. This is done to reduce redundant discussion. It is noted that these modified apparatus and systems perform with the accuracy and repeatability of the previously described system.
First Modification
[0132] The apparatus 1 A ( FIG. 12 ) for an All-in-One electronic dispensing kitchen faucet includes a base 48 , a spout 49 , a first circuit 50 A, a first positive-displacement pump 10 A, and a programmable controller 3 . The base 48 is adapted for mounting to a kitchen sink 45 . The spout 49 extends from the base 48 for dispensing the total amount of liquid. The first circuit is adapted for connection to a first source of liquid 15 to dispense liquid from the first source through the first circuit 50 A.
[0133] The first positive-displacement pump 10 A ( FIG. 12 ) is connected to a first motor 9 A. The first positive-displacement pump 10 A generates a specific volume output for a given input. By activating the first positive-displacement pump 10 A with the first motor 9 A for a controlled number of rotations, it will accurately dispense a measured amount of first source liquid flowing through the faucet exit 29 . Those skilled in the art will understand that a pump can be driven in different manners such as electric motor or electric solenoid and a scope of the present invention is believed to include these concepts.
[0134] The programmable controller 3 ( FIG. 12 ) is operably connected to the first positive-displacement pump 10 A through the first motor 9 A. The controller 3 is programmed and adapted to output first signals to the first motor 9 A. The controller 3 generates control signals to activate the first motor 9 A, driving the first positive-displacement pump 10 A to dispense an accurate total amount of liquid from the spout 49 .
[0135] The first motor 9 A is capable of operating at a varying rotational velocity in response to the control signal from the controller 3 . The controller 3 generates a control signal to activate the first motor 9 A at a given speed to control the first flow rate 51 .
[0136] Another embodiment of the apparatus 1 A for an electronic dispensing kitchen faucet includes a first motor 9 A, a first positive-displacement pump 10 A, an operator input device 2 , a start input switch 31 , and a programmable controller 3 .
[0137] The operator input device 2 allows the operator to specify the volume of liquid desired, as well as other parameters, settings, and values useful for liquid dispensing. The operator input contains a display 30 for communicating information to the operator such as volume dispensed, volume to be dispensed, temperature of the liquid being dispensed, and other parameters or settings. The parameters and settings are stored in memory 36 and used by the programmable controller 3 while operating the faucet apparatus 1 A.
[0138] The start input switch is used to initiate liquid dispensing through the electronic kitchen dispensing faucet apparatus. When the start input switch 31 is depressed, the apparatus initiates dispensing. If the start input switch 31 is depressed while the apparatus is dispensing, the apparatus will pause the liquid dispensing pending further action by the operator. The liquid dispensing will complete the dispensing operation if the start input switch 31 is depressed while the apparatus 1 A is paused.
[0139] The programmable controller 3 receives input from the operator input 2 and start input switch 31 and contains an audible signal generator 4 for alerting the operator of errors or when the liquid dispensing cycle is complete. The programmable controller 3 communicates with the operator by displaying information on the display 30 . The programmable controller 3 generates control signals to initiate liquid flowing from the first source of liquid 15 . These control signals actuate the first positive-displacement pump 10 A to achieve the desired flow rate through the faucet apparatus 1 A.
[0140] The programmable controller 3 generates a signal representing the volume of liquid flowing. The controller 3 sums the signals and compares the total volume dispensed to the desired operator volume input. The controller 3 generates control signals to the first positive-displacement pump 10 A to stop the flow of liquid when the desired volume of liquid has been dispensed from the faucet apparatus 1 A into the container 44 .
[0141] Many examples of positive-displacement pumps are commercially available. A positive-displacement pump of type used in this application is any pump that has an expanding cavity on the inlet side of the pump and a decreasing cavity on the outlet side. Liquid flows into the inlet as the cavity is expanding and the liquid is forced out the outlet side as the cavity collapses. Some types include: peristaltic, diaphragm, piston, rotary lobe, screw, flexible impeller, gear, or vane. It should be noted that any of these types of pump designs may be equally substituted for producing the volume of liquid flowing through the faucet outlet. Those skilled in the art will also understand that a pump can be driven in different manners such as electric motor or electric solenoid and a scope of the present invention is believed to include these concepts.
[0142] The operator input 2 provides a means for the operator to specify the volume of first source liquid 15 to be dispensed from the faucet apparatus 1 A, as discussed above. The operator input 2 also includes an audible signal generator 4 , as discussed above. The input device 2 and its operation with the system 1 A were previously described and the description of its operation need not be repeated.
[0143] The programmable controller 3 receives input signals from the operator input 2 and start input switch 31 . The programmable control 3 produces control signals to the first motor 9 A and display 30 . The programmable controller 3 monitors the start input switch signal to initiate, pause, or stop the flow of liquid through the faucet as shown in FIGS. 5A and 5B . The programmable controller 3 generates a first control signal which actuates the first motor 9 A driving the first positive-displacement pump 10 A as needed to control the flow rate of the first source liquid dispensed from the faucet exit 29 .
[0144] Continuing to refer to FIG. 12 , the electronic kitchen dispensing faucet apparatus 1 A may also include a second circuit 52 A, a third circuit 54 A, and a temperature sensor 19 . The second circuit 52 A is adapted for connection to a second source of liquid 16 to dispense liquid from the second source at a second flow rate 53 A. The second circuit 52 A includes a second motor 11 A connected to a second positive-displacement pump 12 A for controlling the flow of liquid from the second source through the second circuit 52 A. The second motor 11 A is capable of operating at a varying rotational velocity in response to the control signal from the controller 3 . The controller 3 generates a control signal to activate the second motor 11 A at a given speed to control the second flow rate 53 A.
[0145] In apparatus 1 A, the programmable controller 3 generates control signals that activate the first motor 9 A, driving the first positive-displacement pump 10 A and the second motor 11 A, driving the second positive-displacement pump 12 A resulting in liquid flowing through the corresponding circuit. The programmable controller 3 receives an electric voltage signal from the temperature sensor 19 representative of the liquid temperature dispensed from the faucet exit 29 . The programmable controller 3 converts the temperature sensor electrical voltage into a dispensed liquid temperature. The programmable controller 3 then compares the dispensed liquid temperature to the desired operator temperature. The programmable controller calculates the rate for the first and second motors 9 A, 11 A to adjust the temperature and volume of liquid flowing from the faucet exit 29 . The programmable controller 3 determines the magnitude of temperature error in the resultant liquid dispensed from the faucet and increases the flow rate in the temperature direction of adjustment required. The rate of the positive-displacement pump attached to the opposing temperature liquid source may be reduced if the flow rate exceeds the maximum flow rate for the volume being dispensed or if a greater temperature error exists.
[0146] Continuing to refer to FIG. 12 , the electronic kitchen dispensing faucet apparatus 1 A may also include a third circuit 54 A and a heated liquid reservoir 6 . The heated liquid reservoir 6 has an inlet and outlet, the inlet connected to the first source liquid 15 A, the heated liquid reservoir 6 maintaining the temperature of the liquid in the reservoir at a temperature between 180 and 205 degrees Fahrenheit. The reservoir 6 heats the first source liquid 15 flowing into the reservoir. The reservoir 6 contains a heating element and temperature regulating means to maintain the liquid within the reservoir at an elevated temperature between 180 and 205 degrees Fahrenheit. The liquid stored within the reservoir becomes a third source liquid for dispensing from the electronic kitchen dispensing faucet.
[0147] The third circuit 54 A is adapted for connection to the outlet of the heated liquid reservoir 6 to dispense hot liquid from the heated reservoir 6 at a third flow rate 55 A. The third circuit 54 A includes a third motor 13 A, driving the third positive-displacement pump 14 A for controlling the flow of hot liquid from the heated liquid reservoir 6 through the third circuit 54 A. The third motor 13 A is capable of operating at a varying rotational velocity in response to the control signal from the controller 3 . The controller 3 generates a control signal to activate the second motor 13 A at a given speed to control the third flow rate 54 A.
[0148] The first, second, and third circuits 50 A, 52 A, 54 A are connected together to form a common outlet circuit 26 and dispensed from the faucet exit 29 .
[0149] The programmable controller 3 generates control signals that activate the first motor 9 A to drive the first positive-displacement pump 10 A, and the second motor 11 A to drive the second positive-displacement pump 12 A, and the third motor 13 A to drive the third positive-displacement pump 14 A, which results in liquid flowing through the circuit and being dispensed from the faucet exit 29 . The programmable controller 3 receives an electric voltage signal from the temperature sensor 19 proportional to the liquid temperature dispensed from the faucet. The programmable controller 3 converts the temperature sensor electrical voltage into a dispensed liquid temperature. The programmable controller 3 then compares the dispensed liquid temperature to the operator desired liquid temperature. The programmable controller 3 calculates the rate needed for actuating the first, second, and third motors 9 A, 11 A, 13 A to adjust the temperature and volume of liquid flowing through the faucet exit 29 . The programmable controller 3 determines the magnitude of temperature error in the resultant liquid dispensed from the faucet and increases the flow rate in the temperature direction of adjustment required. The rate of the positive-displacement pump attached to the opposing temperature liquid source may be reduced if the flow rate exceeds the maximum flow rate for the volume being dispensed.
[0150] The programmable controller 3 determines the initial flow rate 71 (see FIG. 11 ) by comparing the operator input volume 75 to a table of volumes 70 with corresponding output flow rate parameters stored in memory 36 . The programmable controller 3 selects the appropriate initial flow rate 71 . The initial flow rate 71 limits the flow rate of liquid dispensed from the faucet exit 29 to insure the liquid does not splash or gush out of the container 44 used to capture the dispensed liquid. The output flow rate is also determined and limited by the total volume of liquid to be dispensed, and the actual volume of liquid dispensed from the faucet exit 29 into the container 44 .
[0151] The flow rate through the positive-displacement pumps is reduced to a termination flow rate 73 when the actual volume dispensed is near the total volume desired by the operator to insure volumetric accuracy. The programmable controller 3 determines the termination flow rate 73 by comparing the operator input volume 75 to a table of volumes 70 with corresponding output flow rates stored in memory 36 . The programmable controller 3 selects the appropriate terminating flow rate 73 . The flow rate through the faucet exit 29 may be abruptly terminated as the total volume dispensed increases above a predefined volume. By abruptly terminating the flow of liquid, liquid volumes above this predefined volume are rapidly dispensed without compromising volumetric accuracy dispensed into the container.
[0152] The flow rate through the positive-displacement pumps is maintained at an average flow rate 72 while dispensing the source liquids when the volume dispensed is greater than the initial volume but less than the operator input volume less the termination volume. The programmable controller 3 determines the average flow rate 72 by comparing the operator input volume to a table of volumes 70 with corresponding output flow rates stored in memory 36 . The programmable controller 3 selects the appropriate average flow rate 72 .
[0153] The flow rate through the faucet exit 29 is limited to a maximum flow rate 74 whenever dispensing a measured volume of liquid. This maximum flow rate 74 is determined by the maximum flow rate of the positive-displacement pump. By limiting the flow rate through the faucet exit 29 to the maximum flow rate 74 , the volumetric accuracy is insured.
[0154] Once the operator specified volume has been dispensed through the kitchen faucet or the dispensing operation suspended by the operator, the programmable controller 3 remains idle waiting for additional operator input. If no operator input is received within a selected time interval, the electronic kitchen dispensing faucet apparatus 1 A will turn power off to the unit to conserve electricity and to turn off the operator display illumination source which could be annoying to the operator during the nighttime.
[0155] The flow chart of FIGS. 13A-13B are sufficiently similar to that of FIGS. 5A-5B , such that a detailed description is not required. It is noted that if the current temperature measured in step 102 is not at the desired value, the pump rate is adjusted in step 104 a prior to the positive-displacement pumps being actuated 105 a based on a rate calculated to maintain the average flow rate 72 and to regulate the liquid temperature flowing from the faucet exit 29 at the operator desired temperature. As long as the operator continues to hold the start input switch 31 depressed maintaining the start input signal activated 101 , the flow of liquid through the faucet exit 29 continues. This cycle allows the operator to prime or preheat the faucet components with elevated temperature liquid to insure the desired liquid temperature is dispensed in a subsequent dispensing cycle. Also, if the start timer exceeds a preset value, the positive-displacement pumps will be actuated while the start input switch 31 remains depressed, activating the start input signal as shown in FIG. 13B , which will dispense liquid while the start input switch 31 is activated 243 or until the dispensed volume equals the dispensed volume 210 .
[0156] If the start input switch 31 is de-activated before the start timer exceeds the preset value 241 , the dispensing process continues as shown in FIG. 13B step 242 , which dispenses liquid until the operator desired volume has been dispensed 210 ; or the start input switch 31 is activated 242 . If the start input switch 31 signal is activated while liquid is flowing 242 , the positive-displacement pumps are de-actuated which suspends liquid flowing through the faucet exit 29 . When the operator depresses the start input switch 31 signal as shown in step 246 , the liquid dispensing continues until the dispensed volume is dispensed 210 or the operator activates the On/Off input switch signal 240 .
[0157] Now referring to FIG. 13B , the operator input stored volume of liquid to be dispensed is retrieved 201 from memory 36 . The programmable controller 3 compares the volume to be dispensed to a predefined volume 82 to adjust the liquid flow rate based on the operator desired volume of liquid. If the dispensed volume is above the predefined volume, the positive-displacement pumps are actuated at a rate to dispense at a high flow rate. If the dispensed volume is below the predefined volume, the positive-displacement pumps are actuated at a rate to dispense at a lower flow rate as shown in step 84 .
[0158] The accumulated total volume dispensed is stored in memory as shown in step 207 . The temperature sensor 19 is read by the programmable controller 3 in step 205 .
[0159] The current dispensed liquid temperature is compared to the desired operator input temperature in step 208 . Each positive-displacement pump rate is adjusted based on the difference between the current temperature and desired temperature.
[0160] A table of frequently dispensed heated liquid volumes may be maintained in the memory 36 . This table would include the predefined liquid volume and temperature, and optimal control information for controlling the pumps. The operator input 2 will allow the operator to select a predefined volume and temperature of heated liquid for measured dispensing from the electronic kitchen dispensing faucet apparatus 1 A. These frequently dispensed volumes and temperatures are typical of pre-packaged food products like instant soups, tea, coffee, cocoa, or other hot beverages. The table of volumes and temperatures may be preprogrammed from the manufacturer or input by the operator and stored in memory 36 for future use.
[0161] To use the table of frequently dispensed heated liquid volumes and temperatures, the operator input would enable the selection from the table of heated volumes and temperatures. The operator would then scroll through each entry stored in memory 36 . When the desired table entry is located by the operator, the operator would then select this entry for subsequent dispensing when the start input switch 31 is activated.
[0162] FIG. 12 also illustrates that the electronic kitchen dispensing faucet apparatus 1 A may also include a manual mixing valve 8 , a first and second flow meter 17 and 18 respectively for measuring the volume of the first and second source of liquids flowing through the faucet exit 29 as a result of the manual mixing valve actuation. The manual mixing valve 8 provides the means for the operator to infinitely adjust the flow rates of the first and second source liquids 15 , 16 through the manual mixing valve 8 and to be dispensed from the faucet exit 29 . This was previously discussed in regard to FIG. 1 and the discussion need not be repeated.
[0163] Notably, the operator can close the manual mixing valve 8 , and using the operator input 2 , select a total volume and temperature for dispensing by the electronic kitchen dispensing faucet apparatus 1 A. The programmable controller 3 will calculate the remaining volume of liquid by subtracting the volume of liquid dispensed through the manual mixing valve from the desired volume selected from the operator input 2 . The programmable controller 3 will then actuate the positive-displacement pumps to dispense the remaining volume of liquid from the faucet exit 29 .
[0164] The programmable controller 3 may also sequence the positive-displacement pumps to complete the dispensing of liquid at the average temperature set by the operator using the manual mixing valve position. The programmable controller 3 may also sequence the positive-displacement pumps to complete the dispensing of liquid at the same flow rate established by the operator while operating the manual mixing valve 8 .
[0165] Referring to FIGS. 12 and 14 , a garbage disposal input switch 22 may be connected to apparatus 1 A ( FIG. 12 ) as described above for apparatus 1 ( FIG. 1 ).
[0166] FIG. 14 shows an Auxiliary-design electronic kitchen dispensing faucet 1 A with a first source of liquid 15 , a heating reservoir 6 , a programmable controller 3 , an operator input 2 , a first positive-displacement pump 10 A, a first motor 9 A, a temperature sensor 19 , a second positive-displacement pump 14 A, and a second motor 13 A. The faucet shown dispenses an operator-defined volume of a first liquid at an operator-defined temperature by activating the first motor 9 A driving the first positive-displacement pump 10 A and the second motor 13 A driving the second positive-displacement pump 14 A, measuring the volume and temperature of the liquid flowing through the faucet exit 29 , and de-activating the pumps when the desired volume has been dispensed into the container 44 .
[0167] The Add-on electronic dispensing kitchen faucet shown in FIG. 15 may be used to retrofit a typical kitchen faucet and sink to allow dispensing of an operator-defined volume of liquid at an operator-specified temperature by activating the positive-displacement pumps 10 A and 14 A. The plumbing modifications for a typical kitchen sink 45 are shown in FIG. 9 .
[0168] Continuing to refer to FIG. 15 , the electronic dispensing kitchen faucet apparatus for converting a typical kitchen faucet into a dispensing faucet includes a first circuit 90 A, a second circuit 91 A, a programmable controller 3 , and an operator input 2 . The first circuit 90 A is adapted for connection between a first source of liquid 15 to dispense liquid from the first source at a flow rate 51 A and is adapted for connection to the typical kitchen faucet cold water source inlet 15 . The first circuit 90 A includes a first motor 9 A and positive-displacement pump 10 A for controlling the flow of the liquid from the first source through the first circuit 90 A, and into the typical kitchen faucet cold water source inlet 15 . A first pressure switch 92 A is installed between the first positive-displacement pump 10 A and the faucet outlet 29 , and is monitored to disable the flow 51 A if the faucet outlet 29 is obstructed.
[0169] The second circuit 91 A being adapted for connection between a second source of liquid 16 to dispense liquid from the second source at a flow rate 55 A and adapted for connection to the typical kitchen faucet hot water source inlet 16 . The second circuit 91 A includes a second motor 13 A and positive-displacement pump 14 A for controlling the flow of the liquid from the second source through the second circuit 91 A, and into the typical kitchen faucet hot water source inlet 16 . A second pressure switch 93 A is installed between the second positive-displacement pump 14 A and the faucet outlet 29 , and is monitored to disable the flow 55 A if the faucet outlet 29 is obstructed.
[0170] A first solenoid-operated directional control valve 94 A ( FIG. 15 ) is installed between the first circuit 90 A and the cold water inlet 15 . The first solenoid-operated directional control valve 94 A is of a design that allows liquid to flow from the inlet port to either of two outlet ports. The first outlet port is installed to bypass the first circuit 90 A when the electronic dispensing kitchen faucet apparatus 1 A is off. When a signal is applied to the valve, the flow from the inlet port is directed to the second outlet port and through the first circuit 90 A. A second solenoid-operated directional control valve 95 A is installed between the second circuit 91 A and the hot water inlet 16 . The second solenoid-operated directional control valve 95 A is of a design that allows liquid to flow from the inlet port to either of two outlet ports. The first outlet port is installed to bypass the first circuit 91 A when the electronic dispensing kitchen faucet apparatus 1 A is off. When a signal is applied to the valve, the flow from the inlet port is directed to the second outlet port and through the second circuit 91 A. The programmable controller 3 generates output signals to control the first motor 9 A, driving the first positive-displacement pump 10 A and the second motor 13 A, driving the second positive-displacement pump 14 A. The operator input 2 includes an on/off input switch 47 which turns the electronic kitchen dispensing faucet on and off. When the on/off input switch 47 is depressed, the electronic kitchen faucet apparatus 1 A is turned on. The first and second solenoid-operated directional control valves 94 A and 95 A are actuated as shown in FIG. 16A step 600 A, terminating flow of the first and second liquid 15 and 16 , respectively, through the faucet exit 29 , thereby enabling the dispensing of an operator desired volume of liquid as shown in step 610 . The programmable controller 3 generates an audible control signal which activates the audible signal generator 4 to inform the operator the electronic kitchen dispensing faucet apparatus 1 A has activated the electric solenoid valves thereby stopping the flow of the first and second source liquid through the faucet exit 29 . The programmable controller 3 also displays a message to the operator on the operator display 30 indicating the operator must open the manual mixing valve to allow the measured volume of liquid to flow from the faucet exit 29 .
[0171] When the start input switch is actuated in step 620 ( FIG. 16A ), the desired volume of liquid is dispensed from the faucet exit 29 . The programmable controller 3 calculates the rate of the positive-displacement pumps needed to flow the desired volume of liquid desired by the operator.
[0172] The liquid flow rate through the faucet exit 29 is controlled to slowly increase to insure that the liquid does not splash out of the container 44 or result in the containers ensuing mixture gushing out as the liquid begins to flow into the container 44 . The programmable controller 3 locates the desired volume of liquid 75 within a flow rate table of volumes (see FIG. 11 ) stored in memory 36 . The values for the initial, terminating, average, and maximum flow rates are extracted from the flow rate table stored in memory 36 . The initial, terminating, average, and maximum flow rates are based on the dispensed volume and the anticipated container size to be used in collecting the volume dispensed.
[0173] Once the initial flow volume has been dispensed, the programmable controller 3 increases the liquid flow rate to the average flow rate. The programmable controller 3 generates control signals that activate the first motor 9 A, driving the first positive-displacement pump 10 A and the second motor 13 A, driving the second positive-displacement pump 14 A to maintain the flow rate at approximately the average flow rate; but below the maximum flow rate. The rate of the positive-displacement pumps 10 A and 14 A is controlled to maintain the liquid temperature at the desired operator temperature.
Second Modification
[0174] The apparatus 1 B ( FIG. 17 ) for an All-in-One electronic dispensing kitchen faucet includes a base 48 , a spout 49 , a first circuit 50 B, a first flow meter 10 B, a first flow-restrictor apparatus 9 , and a programmable controller 3 . The base 48 is adapted for mounting to a kitchen sink 45 . The spout 49 extends from the base 48 for dispensing the total amount of liquid. The first circuit being adapted for connection to a first pressurized source of liquid 15 to dispense liquid from the first source through the first circuit 50 B.
[0175] The first flow meter 10 B ( FIG. 17 ) is connected to a first flow-restrictor apparatus 9 B. The first flow meter 10 B generates a first signal as a specific volume of liquid flows through the flow meter. By summing the signals generated by the flow meter 10 B, the total volume flowing through circuit 50 B and the faucet exit 29 may be calculated. After the Operator specified quantity of liquid is dispensed from the faucet exit, the first flow-restrictor apparatus 9 B is signaled to terminate flow of the first pressurized source liquid 15 through the flow meter 10 B.
[0176] The programmable controller 3 ( FIG. 17 ) is operably connected to the first flow-restrictor apparatus 9 B. The controller 3 is programmed and adapted to output first signals to the first flow-restrictor apparatus 9 B. The controller may generate signals to the first flow-restrictor apparatus 9 B to vary the resistance load to the flow meter 10 B, thereby limiting the flow rate of the liquid flowing through the first circuit 50 B. The controller may also generate signals to the first flow-restrictor apparatus 9 B to restrict the movement of the flow meter 10 B, thereby terminating the flow of liquid through the first circuit 50 B.
[0177] The first pressurized source liquid 15 exerts pressure on the first flow meter 10 B as it attempts to flow through the flow meter to the outlet port of the flow meter and to the dispensing faucet exit 29 . Without a resistance load attached to the first flow meter, the source liquid would flow at a maximum free flow rate. The programmable controller 3 varies the resistance load to the flow meter 10 B by increasing or decreasing the load placed on the flow-restrictor apparatus 9 B. As the load is increased, the resistance to the flow meter is likewise increased, thereby causing the flow rate of the liquid flowing through the first circuit to be reduced. The programmable controller 3 may reduce the load placed on the flow-restrictor apparatus to increase the flow rate of liquid in the first circuit. Once the programmable controller reduces the load to zero, the maximum free flow rate of liquid through the first circuit is achieved.
[0178] In some variations of the invention, the programmable controller 3 may include the ability to increase the flow rate through the first circuit above the maximum free flow rate by changing the signals to the flow-restrictor apparatus 9 B to create a pumping action. The flow-restrictor apparatus 9 B would then force the flow meter 10 B to operate as a pump, thereby increasing the pressure of the first source liquid and resulting in a higher flow rate through the first circuit. As the programmable controller 3 increases the signal rate to the flow-restrictor apparatus 9 B, the flow rate through the flow meter 10 B increases.
[0179] In some variations of the invention, the common output liquid circuit includes a solenoid valve 56 B for terminating the flow of liquid through the flow meter 10 B and dispensed from the faucet exit 29 . The solenoid valve may be used on flow meters that may not completely terminate the flow of liquid once the flow meter is restricted from movement. Certain styles of flow meter designs allow a slight leakage due to the incomplete sealing surfaces, while other designs provide a complete seal thereby terminating the flow of liquid and slight leakage while the flow meter is restricted from operating.
[0180] By monitoring and summing the signals received from the flow meter 10 B, the programmable controller 3 may determine the total volume of liquid dispensed from the faucet 29 .
[0181] The first flow meter 10 B may be one of several flow meter designs known within the industry. The flow meter may be of a lobe, gear, nutating disk, single or dual-action piston, single or double screw, vane or progressive cavity design. Each of these designs is capable of measuring a known volume of liquid based on a mechanical reaction to the liquid flowing though the flow meter. This mechanical movement may be measured or controlled external to the flow meter fluidic cavity. By attaching the flow-restrictor apparatus to the mechanical movement within the flow meter, a load may be applied that resists movement and subsequent flow of liquid through the circuit. The attachment of the flow-restrictor apparatus may be either a direct or indirect attachment means. Several means for indirect attachment exist; however, the preferred method is by electromagnetic coupling between the external load restrictor apparatus and the flow meter's moving parts.
[0182] In some variations, the flow-restrictor apparatus may be attached to the mechanical action within the flow meter and controlled so that a pumping action is applied to the flow meter and increases the flow rate of liquid within the flow meter and connected circuit. The attachment of the flow-restrictor apparatus for operating the flow meter as a pump may be either direct or indirect attachment means. Several means for indirect attachment exist; however, the preferred method is by electromagnetic coupling between the external flow-restrictor apparatus and the flow meter's moving parts.
[0183] The first flow-restrictor apparatus 9 B may be one of several known variable and adjustable designs. A variable, adjustable mechanical friction brake or governor device may be used to adjust the flow of liquid through the first flow meter. However, the preferred embodiment is an electronic or electromechanical design. These electronic or electro-mechanical designs are more easily adapted to allow for the instantaneous switching between a variable load applied to the flow meter and for creating a more variable and dynamic load that is responsive to the signals received from the flow meter indicating the amount of liquid flowing within the circuit. These electronic and electromechanical designs are also more suitable for operating the flow-restrictor apparatus as a pump motor when attached to the flow meter. There are several electric motor arrangements that may be operated as a load and then switched to a pump motor arrangement. These motor types include stepper motors, DC voltage motors, synchronous or servo motors.
[0184] The programmable controller 3 is operably connected to the first flow meter 10 B through the first flow-restrictor apparatus 9 B. The controller 3 is programmed and adapted to output first signals to the first flow-restrictor apparatus 9 B. The controller 3 generates control signals to activate the first flow-restrictor apparatus 9 B, restricting the flow of liquid through the first flow meter 10 B to dispense an accurate total amount of liquid from the spout 49 .
[0185] The first flow-restrictor apparatus 9 B is capable of operating at a varying rotational velocity in response to the control signal from the controller 3 . The controller 3 generates a control signal to activate the first flow-restrictor apparatus 9 B at a given speed to control the first flow rate 51 B.
[0186] Another embodiment of the apparatus 1 B for an electronic dispensing kitchen faucet includes a first flow meter 10 B, a first flow-restrictor apparatus 9 B, an operator input device 2 , a start input switch 31 , and a programmable controller 3 .
[0187] The operator input device 2 allows the operator to specify the volume of liquid desired, as well as other parameters, settings, and values useful for liquid dispensing. The operator input contains a display 30 for communicating information to the operator such as volume dispensed, volume to be dispensed, temperature of the liquid being dispensed, and other parameters or settings. The parameters and settings are stored in memory 36 and used by the programmable controller 3 while operating the faucet apparatus 1 B.
[0188] The start input switch is used to initiate liquid dispensing through the electronic kitchen dispensing faucet apparatus. When the start input switch 31 is depressed, the apparatus initiates dispensing. If the start input switch 31 is depressed while the apparatus is dispensing, the apparatus will pause the liquid dispensing pending further action by the operator. The liquid dispensing will complete the dispensing operation if the start input switch 31 is depressed while the apparatus 1 B is paused.
[0189] Now continuing to refer to FIG. 17 , the programmable controller 3 receives input from the operator input 2 and start input switch 31 and contains an audible signal generator 4 for alerting the operator of errors or when the liquid dispensing cycle is complete. The programmable controller 3 communicates with the operator by displaying information on the display 30 . The programmable controller 3 generates control signals to initiate liquid flowing from the first source of liquid 15 . These control signals to the flow-restrictor apparatus reduce the load on the flow meter 10 B, allowing liquid to flow within the first circuit 50 B. The control signals are adjusted to the flow-restrictor apparatus 9 B to achieve the desired flow rate through the faucet apparatus 1 B.
[0190] The first flow meter 10 B generates a signal representing the volume of liquid flowing. The controller 3 sums the signals and compares the total volume dispensed to the desired operator volume input. The controller 3 generates control signals to the flow-restrictor apparatus 9 B to stop the flow of liquid when the desired volume of liquid has been dispensed from the faucet apparatus 1 B into the container 44 .
[0191] The operator input 2 provides a means for the operator to specify the volume of first pressurized source liquid 15 to be dispensed from the faucet apparatus 1 B, as previously described. The operator input 2 also includes an audible signal generator 4 , as discussed above. The input device 2 and its operation with the system 1 B were previously described and the description of its operation need not be repeated.
[0192] The programmable controller 3 receives input signals from the, operator input 2 and start input switch 31 . The programmable control 3 produces control signals to the first flow-restrictor apparatus 9 B and display 30 . The programmable controller 3 monitors the start input switch signal to initiate, pause, or stop the flow of liquid through the faucet as shown in FIGS. 18A and 18B . The programmable controller 3 generates a first control signal which actuates the first flow-restrictor apparatus 9 B allowing liquid to flow through the first flow meter 10 B. The controller adjusts the first control signal as needed to control the flow rate of the first pressurized source liquid 15 dispensed from the faucet exit 29 .
[0193] An alternative start input signal may initiate liquid dispensing through the electronic kitchen dispensing faucet apparatus as shown in FIG. 22 . The controller 3 receives a signal from the flow meter 10 B when liquid is allowed to flow through a manual mixing valve 8 when the operator opens the manual mixing valve indicating they are ready to dispense the desired volume of liquid into the container 44 . The controller uses the flow meter 10 signal to initiate a dispensing cycle of the desired liquid. The controller 3 may detect the ratio of the flow rates 51 B and 52 B to compensate for the operators desired flow rate. The controller 3 may also detect if the operator terminates the flow of liquid prior to the desired volume of liquid being dispensed from the faucet exit.
[0194] Continuing to refer to FIG. 17 , the electronic kitchen dispensing faucet apparatus 1 B may also include a second circuit 52 B, a third circuit 54 B, and a temperature sensor 19 . The second circuit 52 B is adapted for connection to a second pressurized source of liquid 16 to dispense liquid from the second pressurized source at a second flow rate 53 B. The second circuit 52 B includes a second flow-restrictor apparatus 11 B connected to a second flow meter 12 B for controlling the flow of liquid from the second source through the second circuit 52 B.
[0195] The second flow-restrictor apparatus 11 B is capable of operating at a varying rotational velocity in response to the control signal from the controller 3 . The controller 3 generates a control signal to activate the second flow-restrictor apparatus 11 B at a given speed to control the second flow rate 53 B. The controller 3 may operate the flow-restrictor apparatus 11 B in several ways so that the flow of liquid dispensed is at the desired flow rate and produces the desired total volume dispensed. The controller 3 may produce a signal to the flow-restrictor apparatus that results in a resistive load placed on the flow meter, thereby limiting the flow of liquid through the circuit. The controller 3 may produce a signal to the flow-restrictor apparatus that restricts the flow meter from operating, thereby terminating the flow of liquid through the circuit. In some variations of the invention, the controller 3 may produce a signal to the flow-restrictor apparatus that creates a pumping action to the flow meter, thereby increasing the flow of liquid through the circuit.
[0196] In apparatus 1 B, the programmable controller 3 generates control signals that activate the first flow-restrictor apparatus 9 B and second flow-restrictor apparatus 11 B, allowing liquid to flow through the first flow meter 10 B and second flow meter 12 B respectively and through the corresponding circuit. The programmable controller 3 receives an electric voltage signal from the temperature sensor 19 representative of the liquid temperature dispensed from the faucet exit 29 . The programmable controller 3 converts the temperature sensor electrical voltage into a dispensed liquid temperature. The programmable controller 3 then compares the dispensed liquid temperature to the desired operator temperature. The programmable controller calculates the rate for the first and second flow-restrictor apparatus 9 B, 11 B to adjust the temperature and volume of liquid flowing from the faucet exit 29 . The programmable controller 3 determines the magnitude of temperature error in the resultant liquid dispensed from the faucet and increases the flow rate in the temperature direction of adjustment required. The rate of flow through the flow meter attached to the opposing temperature liquid source may be reduced if the flow rate exceeds the maximum flow rate for the volume being dispensed or if a greater temperature error exists.
[0197] Continuing to refer to FIG. 17 , the electronic kitchen dispensing faucet apparatus 1 B may also include a third circuit 54 B and a heated liquid reservoir 6 . The heated liquid reservoir 6 has an inlet and outlet, the inlet connected to the first pressurized source liquid 15 , the heated liquid reservoir 6 maintaining the temperature of the liquid in the reservoir at a temperature between 180 and 205 degrees Fahrenheit. The reservoir 6 heats the first pressurized source liquid 15 flowing into the reservoir. The reservoir 6 contains a heating element and temperature regulating means to maintain the liquid within the reservoir at an elevated temperature between 180 and 205 degrees Fahrenheit. The liquid stored within the reservoir becomes a third pressurized source liquid for dispensing from the electronic kitchen dispensing faucet.
[0198] An alternative start input signal may initiate liquid dispensing through the electronic kitchen dispensing faucet apparatus as shown in FIG. 17 . The controller 3 receives a signal from the first or second flow meters 17 B, 18 B when liquid is allowed to flow through a manual mixing valve 8 when the operator opens the manual mixing valve indicating they are ready to dispense the desired volume of liquid into the container 44 . The controller uses the signals from the flow meters 17 B, 18 B to initiate a dispensing cycle of the desired liquid. The controller 3 may detect the ratio of the flow rates 51 B and 53 B to compensate for the operators desired flow rate. The controller 3 may also detect if the operator terminates the flow of liquid prior to the desired volume of liquid being dispensed from the faucet exit.
[0199] The third circuit 54 B is adapted for connection to the outlet of the heated liquid reservoir 6 to dispense hot liquid from the heated reservoir 6 at a third flow rate 55 B. The third circuit 54 B includes a third flow-restrictor apparatus 13 B connected to a third flow meter 14 B for controlling the flow of hot liquid from the heated liquid reservoir 6 through the third circuit 54 B. The third flow-restrictor apparatus 13 B is capable of operating at a varying rotational velocity in response to the control signal from the controller 3 . The controller 3 generates a control signal to activate the third flow-restrictor apparatus 13 B at a given speed to control the third flow rate 54 B. The controller 3 may operate the flow-restrictor apparatus 13 B in several ways so that the flow of liquid dispensed is at the desired flow rate and produces the desired total volume dispensed. The controller 3 may produce a signal to the flow-restrictor apparatus that results in a resistive load placed on the flow meter, thereby limiting the flow of liquid through the circuit. The controller 3 may produce a signal to the flow-restrictor apparatus that restricts the flow meter from operating, thereby terminating the flow of liquid through the circuit. In some variations of the invention, the controller 3 may produce a signal to the flow-restrictor apparatus that creates a pumping action to the flow meter, thereby increasing the flow of liquid through the circuit.
[0200] The first, second, and third circuits 50 B, 52 B, 54 B are connected together to form a common outlet circuit 26 .
[0201] The programmable controller 3 generates control signals that activate the first, second, and third flow-restrictor apparatus 9 B, 11 B, and 13 B, respectively, allowing liquid to flow through the first, second, and third flow meters 10 B, 12 B, and 14 B, respectively and through the corresponding circuit. The programmable controller 3 receives an electric voltage signal from the temperature sensor 19 representative of the liquid temperature dispensed from the faucet exit 29 . The programmable controller 3 converts the temperature sensor electrical voltage into a dispensed liquid temperature. The programmable controller 3 then compares the dispensed liquid temperature to the desired operator temperature. The programmable controller calculates the rate for the first, second, and third flow-restrictor apparatus 9 B, 11 B, and 13 B, respectively to adjust the temperature and volume of liquid flowing from the faucet exit 29 . The programmable controller 3 determines the magnitude of temperature error in the resultant liquid dispensed from the faucet and increases the flow rate in the temperature direction of adjustment required. The rate of flow through the flow meter attached to the opposing temperature liquid source may be reduced if the flow rate exceeds the maximum flow rate for the volume being dispensed or if a greater temperature error exists.
[0202] The programmable controller 3 determines the initial flow rate 71 (see FIG. 11 ) by comparing the operator input volume 75 to a table of volumes 70 with corresponding output flow rate parameters stored in memory 36 . The programmable controller 3 selects the appropriate initial flow rate 71 . The initial flow rate 71 limits the flow rate of liquid dispensed from the faucet exit 29 to insure the liquid does not splash or gush out of the container 44 used to capture the dispensed liquid. The output flow rate is also determined and limited by the total volume of liquid to be dispensed, and the actual volume of liquid dispensed from the faucet exit 29 into the container 44 .
[0203] The flow rate through the flow meters is reduced to a termination flow rate 73 when the actual volume dispensed is near the total volume desired by the operator to insure volumetric accuracy. The programmable controller 3 determines the termination flow rate 73 by comparing the operator input volume 75 to a table of volumes 70 with corresponding output flow rates stored in memory 36 . The programmable controller 3 selects the appropriate terminating flow rate 73 . The flow rate through the faucet exit 29 may be abruptly terminated as the total volume dispensed increases above a predefined volume. By abruptly terminating the flow of liquid, liquid volumes above this predefined volume are rapidly dispensed without compromising volumetric accuracy dispensed into the container.
[0204] The flow rate through the flow meters is maintained at an average flow rate 72 while dispensing the source liquids when the volume dispensed is greater than the initial volume but less than the operator input volume less the termination volume. The programmable controller 3 determines the average flow rate 72 by comparing the operator input volume to a table of volumes 70 with corresponding output flow rates stored in memory 36 . The programmable controller 3 selects the appropriate average flow rate 72 .
[0205] The flow rate through the faucet exit 29 is limited to a maximum flow rate 74 whenever dispensing a measured volume of liquid. This maximum flow rate 74 is determined by the maximum first flow meter characteristics. By limiting the flow rate through the faucet exit 29 to the maximum flow rate 74 , the volumetric accuracy is insured.
[0206] Once the operator specified volume has been dispensed through the kitchen faucet or the dispensing operation suspended by the operator, the programmable controller 3 remains idle waiting for additional operator input. If no operator input is received within a selected time interval, the electronic kitchen dispensing faucet apparatus 1 B will turn power off to the unit to conserve electricity and to turn off the operator display illumination source which could be annoying to the operator during the nighttime.
[0207] The flow chart of FIGS. 18A and 18B are sufficiently similar to that of FIGS. 5A-5B such that a detailed description is not required. It is noted that if the current temperature measured in step 102 is not at the desired value, the flow rate is adjusted 104 B prior to the flow-restrictor apparatus being actuated 105 B based on a rate calculated to maintain the average flow rate 72 and to regulate the liquid temperature flowing from the faucet exit 29 at the operator desired temperature. As long as the operator continues to hold the start input switch 31 depressed maintaining the start input signal activated 101 , the flow of liquid through the faucet exit 29 continues. This cycle allows the operator to prime or preheat the faucet components with elevated temperature liquid to insure the desired liquid temperature is dispensed in a subsequent dispensing cycle. Also, if the start timer exceeds the preset value, the positive-displacement flow meters will be actuated while the start input switch 31 remains depressed, activating the start input signal as shown in FIG. 18B , which will dispense liquid while the start input switch 31 is activated 243 or until the dispensed volume equals the dispensed volume 210 .
[0208] If the start input switch 31 is de-activated before the start timer exceeds the preset value 241 , the dispensing process continues as shown in FIG. 18B step 242 , which dispenses liquid until the operator desired volume has been dispensed 210 ; or the start input switch 31 is activated 242 . If the start input switch 31 signal is activated while liquid is flowing 242 , the flow-restrictor apparatus are de-actuated which suspends liquid flowing through the corresponding flow meter and the faucet exit 29 . When the operator depresses the start input switch 31 signal as shown in step 246 , the liquid dispensing continues until the dispensed volume is dispensed 210 or the operator activates the On/Off input switch signal 240 .
[0209] Now referring to FIG. 18B , the operator input stored volume of liquid to be dispensed is retrieved 201 from memory 36 . The programmable controller 3 compares the volume to be dispensed to a predefined volume 82 to adjust the liquid flow rate based on the operator desired volume of liquid. If the dispensed volume is above the predefined volume, the flow-restrictor apparatus are actuated at a rate to dispense at a high flow rate. If the dispensed volume is below the predefined volume, the flow-restrictor apparatus are actuated at a rate to dispense at a lower flow rate as shown in step 83 .
[0210] The accumulated total volume dispensed is stored in memory as shown in step 207 . The temperature sensor 19 is read by the programmable controller 3 in step 205 .
[0211] The current dispensed liquid temperature is compared to the desired operator input temperature in step 208 . Each flow-restrictor apparatus is adjusted to achieve the desired flow rate through the corresponding flow meter based on the difference between the current temperature and desired temperature.
[0212] A table of frequently dispensed heated liquid volumes may be maintained in the memory 36 . This table would include the predefined liquid volume and temperature. The operator input 2 will allow the operator to select a predefined volume and temperature of heated liquid for measured dispensing from the electronic kitchen dispensing faucet apparatus 1 B. These frequently dispensed volumes and temperatures are typical of pre-packaged food products like instant soups, tea, coffee, cocoa, or other hot beverages. The table of volumes and temperatures may be preprogrammed from the manufacturer or input by the operator and stored in memory 36 for future use.
[0213] To use the table of frequently dispensed heated liquid volumes and temperatures, the operator input would enable the selection from the table of heated volumes and temperatures. The operator would then scroll through each entry stored in memory 36 . When the desired table entry is located by the operator, the operator would then select this entry for subsequent dispensing when the start input switch 31 is activated.
[0214] Now referring to FIG. 17 , the electronic kitchen dispensing faucet apparatus 1 B may also include a manual mixing valve 8 , a first and second flow meter 17 and 18 respectively for measuring the volume of the first and second source of liquids flowing through the faucet exit 29 as a result of the manual mixing valve actuation. The manual mixing valve 8 provides the means for the operator to infinitely adjust the flow rates of the first and second pressurized source liquids 15 , 16 through the manual mixing valve 8 and to be dispensed from the faucet exit 29 .
[0215] The first flow meter 17 inlet is in fluid connection with the first source of liquid 15 and the outlet being in fluid connection with the first inlet of the manual mixing valve 8 . The second flow meter 18 inlet is in fluid connection with the second source of liquid 16 and the outlet is in fluid connection with the second inlet of the manual mixing valve 8 . The manual mixing valve 8 outlet is in fluid connection with the liquid conduit connected to the outlet, temperature sensor 19 , and faucet exit 29 .
[0216] The first and second flow meters 17 , 18 generate signals representative of the volume of liquid flowing through their respective flow meter, these signals are connected to the programmable controller 3 which sums the discrete volumes represented by each signal pulse and accumulating the total volume flowing of the first and second pressurized source liquid 15 , 16 in its memory 36 for future processing.
[0217] The programmable controller 3 may display the accumulated volume of liquid flowing through the first and second flow meters 17 , 18 , and the average temperature dispensed from the faucet into a container on the display of the operator input 2 while the manual mixing valve 8 is actuated by the operator.
[0218] The operator can close the manual mixing valve 8 , and using the operator input 2 select a total volume and temperature for dispensing by the electronic kitchen dispensing faucet apparatus 1 B. The programmable controller 3 will calculate the remaining volume of liquid by subtracting the volume of liquid dispensed through the manual mixing valve from the desired volume selected from the operator input 2 . The programmable controller 3 will then actuate the flow-restrictor apparatus to dispense the remaining volume of liquid from the faucet exit 29 .
[0219] The programmable controller 3 may also sequence the flow-restrictor apparatus to complete the dispensing of liquid at the average temperature set by the operator using the manual mixing valve position. The programmable controller 3 may also sequence the flow-restrictor apparatus to complete the dispensing of liquid at the same flow rate established by the operator while operating the manual mixing valve 8 .
[0220] Referring to FIGS. 17 and 19 , a garbage disposal input switch 22 may be connected to apparatus 1 B ( FIG. 17 ) as described above for apparatus 1 ( FIG. 1 ).
[0221] Referring to FIG. 19 , an Auxiliary-design electronic kitchen dispensing faucet 1 B is shown with a first pressurized source liquid 15 , a heating reservoir 6 , a programmable controller 3 , an operator input 2 , a first flow-restrictor apparatus 9 B, a first flow meter 10 B, a temperature sensor 19 B, a second flow-restrictor apparatus 13 B, and a second flow meter 14 B. The faucet shown dispenses an operator-defined volume of a first pressurized source liquid at an operator-defined temperature by activating the first flow-restrictor apparatus 9 B controlling the rate of first pressurized source liquid flowing through the first flow meter 10 B and the second flow-restrictor apparatus 13 B controlling the rate of second pressurized source liquid flowing through the second flow meter 14 B, measuring the volume and temperature of each liquid flowing through the faucet exit 29 , and de-activating the flow-restrictor apparatus when the desired volume has been dispensed into the container 44 .
[0222] The Add-on electronic dispensing kitchen faucet shown in FIG. 20 may be used to retrofit a typical kitchen faucet and sink to allow dispensing of an operator-defined volume of liquid at an operator-specified temperature by activating the positive-displacement flow meters 10 B and 14 B. The plumbing modifications to the typical kitchen sink 45 are shown in FIG. 9 .
[0223] Continuing to refer to FIG. 20 , the electronic dispensing kitchen faucet apparatus for converting a typical kitchen faucet into a dispensing faucet includes a first circuit 90 B, a second circuit 91 B, a programmable controller 3 , and an operator input 2 . The first circuit 90 B being adapted for connection between a first pressurized source liquid 15 to dispense liquid from the first source at a flow rate 51 B and adapted for connection to the typical kitchen faucet cold water source inlet 15 . The first circuit 90 B includes a first flow-restrictor apparatus 9 B and flow meter 10 B for controlling the flow of the liquid from the first source through the first circuit 90 B, and into the typical kitchen faucet cold water source inlet 15 .
[0224] The second circuit 91 B being adapted for connection between a second pressurized source liquid 16 to dispense liquid from the second source at a flow rate 55 B and adapted for connection to the typical kitchen faucet hot water source inlet 16 . The second circuit 91 B includes a second flow-restrictor apparatus 13 B and flow meter 14 B for controlling the flow of the liquid from the second source through the second circuit 91 B, and into the typical kitchen faucet hot water source inlet 16 .
[0225] Continuing to refer to FIG. 20 , the first flow meter 10 B is allowed to operate freely when the electronic kitchen dispensing faucet is not dispensing a desired volume of liquid. The second flow meter 14 B is also allowed to operate freely when the electronic kitchen dispensing faucet is not dispensing a desired volume of liquid.
[0226] The programmable controller 3 generates output signals to control the first flow-restrictor apparatus 9 B connected to the first flow meter 10 B and the second flow-restrictor apparatus 13 B connected to the second flow meter 14 B. The operator input 2 includes an on/off input switch 47 which turns the electronic kitchen dispensing faucet on and off. When the on/off input switch 47 is depressed, the electronic kitchen faucet apparatus 1 B is turned on. The first and second flow-restrictor apparatus are actuated as shown in FIG. 21A step 600 B, terminating flow of the first and second liquid 15 and 16 , respectively, through the faucet exit 29 , thereby enabling the dispensing of an operator desired volume of liquid as shown in step 610 . The programmable controller 3 generates an audible control signal which activates the audible signal generator 4 to inform the operator the electronic kitchen dispensing faucet apparatus 1 B has completed dispensing the desired volume of liquid. This audible signal also indicates to the operator to close the manual mixing valve.
[0227] The programmable controller 3 may also generates an audible control signal which activates the audible signal generator 4 to inform the operator the electronic kitchen dispensing faucet apparatus 1 B is monitoring the flow through the flow meters and is ready to control the flow-restrictor apparatus thereby controlling the flow rate and volume of liquid dispensed from the first and second pressurized source liquid through the faucet exit 29 . The programmable controller 3 also displays a message to the operator on the operator display 30 indicating the operator must open the manual mixing valve to allow the measured volume of liquid to flow from the faucet exit 29 .
[0228] When the start input switch is actuated as shown in FIG. 21A step 620 , the desired volume of liquid is dispensed from the faucet exit 29 . The programmable controller 3 calculates the rate of the flow-restrictor apparatus control signals needed to flow the desired volume of liquid desired by the operator.
[0229] If no activity occurs on the operator input within the non-use timer interval as shown in FIG. 21A step 630 , the programmable controller 3 will generate an audible control signal to the audible signal generator 4 to inform the operator that the faucet apparatus 1 B will be turned off. If the operator left the manual mixing valve in the open position, the first and second pressurized source liquids 15 , 16 would flow through the faucet exit 29 .
[0230] The operator input 2 allows the operator to select the desired volume of liquid to be dispensed as shown in FIG. 21A step 610 .
[0231] The liquid flow rate through the faucet exit 29 is increased slowly to insure the liquid does not splash out of the container 44 or result in the containers ensuing mixture gushing out as the liquid begins to flow into the container 44 . The programmable controller 3 locates the desired volume of liquid 75 within a flow rate table of volumes 70 ( FIG. 11 ) stored in memory 36 . The values for the initial, terminating, average, and maximum flow rates 71 , 72 , 73 , 74 , respectively, are extracted from the flow rate table 70 stored in memory 36 . The initial, terminating, average, and maximum flow rates 71 - 74 are based on the dispensed volume 75 and the anticipated container size to be used in collecting the volume dispensed. The flow rate table 70 also contains the initial and terminating flow rate volumes 71 and 73 , respectively. The initial flow rate 71 is used when the programmable controller 3 initiates liquid flowing through the faucet exit 29 . The initial flow rate 71 will be allowed to flow for up to the initial flow volume before increasing the flow rate to the average flow rate 72 . The terminating flow rate 73 is used when the dispensed volume is within the terminating flow volume. The flow rate will be reduced to the terminating flow rate 73 while dispensing the terminating flow volume and therefore dispense the total operator input volume desired.
[0232] Once the initial flow volume has been dispensed, the programmable controller 3 increases the liquid flow rate to the average flow rate 72 . The programmable controller 3 generates control signals that activate the first flow-restrictor apparatus 9 B connected to the first flow meter 10 B and the second flow-restrictor apparatus 13 B connected to the second flow meter 14 B to maintain the flow rate at approximately the average flow rate 72 ; but below the maximum flow rate 74 . The rate of flow through the flow meters 10 B and 14 B is controlled to maintain the liquid temperature at the desired operator temperature.
[0233] It should be recognized that the above-described embodiments of the invention are intended to be illustrative only. A latitude of modification, change, and substitution is intended in the foregoing disclosure, and in some instances, some features of the invention will be employed without a corresponding use of other features.
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An electronic kitchen faucet dispensing apparatus capable of dispensing measured operator-selectable quantities of hot or cold liquid into a container with a flow rate suitable to prevent splashing and loss of the ensuing mixture while maintaining a rapid flow rate to quickly fill larger containers. The dispensing faucet can be used for measuring liquids required for preparing recipes, making instant beverages, or in the preparation of pre-packaged foods, and may be retrofitted to an existing faucet. The apparatus may utilize various controls to automatically control liquid flow, including 1) flow sensors and control valving; 2) positive-displacement pumps; and 3) flow-restrictors with shut-off valves. Also, it can be connected to a garbage disposal to prevent damage to the disposal.
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BACKGROUND
The present invention relates generally to the construction of a roofing shingle. In particular, the present invention relates to the construction of an asphalt roofing shingle utilizing a unique combination of exposure dimension and arrangement of color striations thereon to create a greater visual impact than existing asphalt shingles.
Asphalt shingles (sometimes also often referred to as composite shingles) are one of the most commonly used roofing materials. Asphalt shingles typically comprise an organic felt or fiberglass mat base on which is applied an asphalt coating. The organic felt or fiberglass mat base gives the asphalt shingle the strength to withstand manufacturing, handling, installation and servicing, and the asphalt coating provides resistance to weathering and stability under temperature extremes. An outer layer of mineral granules is also commonly applied to the asphalt coating to form a weather surface which shields the asphalt coating from the sun's rays, adds color to the final product, and provides fire resistance.
Asphalt shingles are typically manufactured as strip shingles, laminated shingles, interlocking shingles, and large individual shingles in a variety of weights and colors. Even though asphalt shingles offer significant cost, service life, and fire resistance advantages over wood shingles, wood shingles are often preferred due to their pleasing aesthetic features, such as their greater thickness as compared to asphalt shingles, which results in a more pleasing, layered look for a roof.
Various asphalt shingles have been developed to provide an appearance of thickness comparable to wood shingles. Examples of such asphalt shingles are shown in U.S. Pat. No. 5,232,530 entitled “Method of Making a Thick Shingle”; U.S. Pat. No. 3,921,358 entitled “Composite Shingle”; U.S. Pat. No. 4,717,614 entitled “Asphalt Shingle”; and U.S. Pat. Des. No. D309,027 entitled “Tab Portion of a Shingle.” Each of these patents is incorporated by reference herein in its entirety.
In addition to these patents, significant improvements in the art of roofing shingles have been disclosed and patented in U.S. Pat. Nos. 5,369,929; 5,611,186; and 5,666,776; each entitled “Laminated Roofing Shingle”, issued to Weaver et al. and assigned to the Elk Corporation of Dallas. These patents disclose laminated roofing shingles having a color gradient or gradation thereon to create the illusion of thickness or depth on a relatively flat surface. These patents are also incorporated by reference herein in their entireties. The present invention substantially improves on the roofing shingles described in the above-identified patents.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a roofing shingle that includes a unique combination of exposure dimension and arrangement of color striations thereon to provide a greater visual impact than existing asphalt shingles. In accordance with one aspect of the present invention, there is provided a laminated roofing shingle having a first shingle sheet and a second shingle sheet. The first shingle sheet has a headlap section and a buttlap section, the buttlap section being about 7 inches or greater in height and including a plurality of tabs which are spaced apart to define one or more openings between the tabs. Each of the tabs has a relatively uniform color throughout the tab. The relatively uniform color throughout the tab may very in contrast between each of the tabs. The second shingle sheet is attached to the underside of the first shingle sheet and has portions exposed through the openings between the tabs. The second shingle sheet has at least first, second, third, and fourth horizontal striations thereon across at least partial portions of the second sheet which are exposed through the openings between the tabs. The first striation has a substantially uniform dark color throughout a first quadrilateral area. The second striation includes a second elongated quadrilateral area below the first striation. The second striation has a substantially uniform color throughout the second quadrilateral area. The third striation includes a third elongated quadrilateral area below the second striation. The third striation has a substantially uniform color throughout the third quadrilateral area, which is lighter than the color of the second striation. The fourth striation includes a fourth elongated quadrilateral area below the third striation. The fourth striation has a substantially uniform color throughout the fourth quadrilateral area, which is lighter than the color of the third striation. At least the second, third, and fourth striations provide a color gradation on at least partial portions of the second sheet which are exposed through the openings between the tabs. The color of the first striation may be selected to be consistent with (i.e., to continue) the color gradation of the second through fourth striations.
Other aspects of the present invention include methods for manufacturing the above-described laminated shingle.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a laminated shingle incorporating one embodiment of the present invention;
FIG. 2 is a top plan view of the shingle of FIG. 1;
FIG. 3 is a front plan view of the shingle of FIG. 1;
FIG. 4 is a left side view of the shingle of FIG. 1;
FIG. 5 is a perspective view of a partial roofing section covered with shingles incorporating one embodiment of the present invention;
FIG. 6 is an isometric, schematic drawing of a sheet of roofing material incorporating one embodiment of the present invention from which components for the shingle of FIG. 1 may be obtained;
FIG. 7 is an exploded isometric view showing shingle components taken from the sheet of roofing material in FIG. 6 which may be used to form the shingle of FIG. 1;
FIG. 8A is an exploded isometric view showing shingle components taken from a sheet of roofing material according to another embodiment of the present invention; and
FIG. 8B is an enlarged drawing of a portion of a backer strip of FIG. 8A with transition stripes disposed between adjacent horizontal striations.
FIG. 9 is a top plan view of a laminated shingle wherein the tabs have different color contrasts from one another.
DETAILED DESCRIPTION OF THE INVENTION
A laminated shingle 20 according to an exemplary embodiment of the present invention is shown in FIGS. 1 to 4 . The laminated shingle 20 preferably comprises a first shingle sheet 30 attached to a second shingle sheet 50 . First shingle sheet 30 has a generally rectangular configuration defining a headlap section 32 of the laminated shingle 20 , with a plurality of tabs 36 extending therefrom to define a buttlap section 34 of the laminated shingle 20 . Tabs 36 may also be referred to as “dragon teeth.” A plurality of openings 38 are formed between adjacent tabs 36 . The second shingle sheet 50 also has a generally rectangular configuration and is disposed beneath tabs 36 with portions of the second shingle sheet 50 exposed through the plurality of openings 38 .
Various techniques such as glueing or self-sealing adhesive strips (not shown) may be used to attach the second shingle sheet 50 to the underside of the first shingle sheet 30 . The resulting laminated shingle 20 has a generally rectangular configuration defined in part by longitudinal edges 22 and 24 with lateral edges 26 and 28 disposed therebetween. Longitudinal edge 22 is defined by an end of headlap section 32 and constitutes the upper edge of the laminated shingle 20 . Longitudinal edge 24 is defined by an end of buttlap section 34 and constitutes the lower (or leading) edge of laminated shingle 20 . A plurality of self sealing adhesive strips 40 are preferably disposed on the exterior of first shingle sheet 30 between headlap section 32 and buttlap section 34 .
First shingle sheet 30 may sometimes be referred to as a “tab sheet” or a “dragon tooth sheet,” and second shingle sheet 50 may sometimes be referred to as a “backer strip” or “shim.” In addition, openings 38 formed between adjacent tabs 36 with portions of backer strip 50 disposed thereunder may sometimes be referred to as “valleys.” Depending upon the desired application and appearance of each laminated shingle 20 , tabs 36 may have equal or different widths and may have a square, rectangular, trapezoidal, or any other desired geometric configuration. In the same respect, openings 38 may have equal or different widths and may have a square, rectangular, trapezoidal or any other desired geometric configuration. As will be explained later in more detail, laminated shingles 20 may be formed from a sheet 80 of roofing material shown in FIG. 6 with tabs 36 and opening 38 formed as a “reverse image” of each other.
For one embodiment of the present invention, laminated shingle 20 may be formed from a fiberglass mat (not shown) with an asphalt coating on both sides of the mat. If desired, the present invention may also be used with shingles formed from organic felt or other types of base material. The present invention is not limited to use with shingles having a fiberglass mat.
The exposed outer surface or weather surface 42 for shingle 20 is defined in part by tabs 36 and the portions of backer strip 50 which are exposed through openings 38 between adjacent tabs 36 . Weather surface 42 of laminated shingle 20 may be coated with various types of mineral granules to protect the asphalt coating, to add color to laminated shingle 20 and to provide fire resistance. For some applications, ceramic coated mineral granules may be used to form the outer layer comprising weather surface 42 . Also, a wide range of mineral colors from white and black to various shades of red, green, brown and any combination thereof may be used to provide the desired color for shingle 20 . The underside of shingle 20 may be coated with various inert minerals with sufficient consistency to seal the asphalt coating.
According to the present invention, the buttlap section 34 (the exposed section of the shingle when it is laid up on a roof) is made about 7 inches or greater and four or more horizontal striations are provided on the surface of backer strip 50 which is exposed through openings 38 . The horizontal striation nearest the headlap section of the shingle is made a uniformly dark color. Other horizontal striations are each made of a uniform color which together provide a color gradient or gradation according to the teachings of U.S. Pat. Nos. 5,369,929; 5,611,186; and 5,666,776, which are incorporated herein by reference in their entireties. The color of the striation nearest the headlap section may be selected to be consistent with (i.e., to continue) the color gradation of the other horizontal striations.
Using the foregoing unique combination of buttlap section (exposure) dimension and arrangement of color striations, the laminated shingle according to the present invention provides a significantly greater visual appearance than existing laminated shingles. While the improvement in visual appearance is applicable to all types of roofs, it is especially significant on low-sloped roofs (i.e., those roofs having less than six feet of rise for every twelve feet of run).
While many different shingle dimensions may be utilized with the present invention, the following exemplary dimensions and number of shingles per square are suitable for easy handling and packaging of the shingles:
1. 38 inch length, 7.9 inch exposure height, 17.8 inch overall height, and 48 shingles/square;
2. 36 inch length, 8 inch exposure height, 18 inch overall height, and 50 shingles/square;
3. 36 inch length, 8.3 inch exposure height, 18.6 inch overall height, and 48 shingles/square; and
4. 36 inch length, 9 inch exposure height, 20 inch overall height, and 44 shingles/square.
Returning to FIGS. 1 through 4, the exemplary embodiment shown includes a backer strip 50 with four horizontal striations 52 , 54 , 56 , and 58 . Striation 58 , the striation adjacent the headlap section of the shingle, is a uniformly dark-colored striation. The horizontal striations 52 , 54 , and 56 are colored striations that provide a color gradient or gradation from a light color near the leading edge 24 to a dark color near the upper portion of each opening 38 . The color of the horizontal striation 58 may be selected to be consistent with (i.e., to continue) the color gradient or gradation of the other striations (so that striations 52 through 58 altogether provide a color gradient or gradation). Preferably, the height of each striation is approximately equal. In addition, for aesthetic reasons it is preferred that the height of each striation be in the range of one to two inches.
The number of horizontal striations and the width of each striation on backer strip, 50 may be varied depending upon the desired aesthetic appearance of the resulting laminated shingle 20 . It is preferred, however, for a shingle to have an exposure height of 7 to 9 inches and four to six horizontal striations thereon.
Each striation may have a different color to establish the desired amount of contrast. For the purposes of this patent application, a different color may include a different tone. In addition, contrast for purposes of this patent application is defined as the degree of difference in the tone or shading between areas of lightest and darkest color. For some applications, a gradual change in contrast associated with a large number of striations may provide the appearance of depth or thickness associated with wood or other natural products. Also, the amount or degree of contrast in the color gradient exposed in each opening 38 may be varied depending upon the desired aesthetic appearance. An important feature of the present invention is the ability to vary the color gradient and the amount of contrast to provide the desired illusion or appearance of thickness on the finished roof.
As shown in FIG. 5, a plurality of laminated shingles 20 may be installed on a roof or other structure (not shown) to provide protection from the environment and to provide an aesthetically pleasing appearance. The normal installation procedure for laminated shingles 20 includes placing each shingle 20 on a roof in an overlapping configuration. Typically, buttlap section 34 of one shingle 20 will be disposed on the headlap section of another shingle 20 . Self-sealing adhesive strips 40 are used to secure the overlapping shingles 20 with each other. Also, a limited lateral offset is preferably provided between horizontally adjacent rows of shingles 20 to provide an overall aesthetically pleasing appearance for the resulting roof.
FIGS. 6 and 7 show one procedure for fabricating a laminated shingle 20 from a sheet 80 of roofing material. Various procedures and methods may be used to manufacture sheet 80 from which shingles incorporating the present invention may be fabricated. Examples of such procedures are contained in U.S. Pat. No. 1,722,702entitled “Roofing Shingle”; U.S. Pat. No. 3,624,975 entitled “Strip Shingle of Improved Aesthetic Character”; U.S. Pat. No. 4,399,186 entitled “Foam Asphalt Weathering Sheet for Rural Roofing Siding or Shingles”; and U.S. Pat. No. 4,405,680 entitled “Roofing Shingle.” Each of these patents is incorporated by reference herein in its entirety.
Sheet 80 is preferably formed from a fiberglass mat placed on a jumbo roll (not shown) having a width corresponding to the desired sheet 80 . Laminated shingles 20 are typically fabricated in a continuous process starting with the jumbo roll of fiberglass mat. As previously noted, laminated shingle 20 may also be fabricated using organic felt or other types of base material.
Sheet 80 shown in FIG. 6 preferably comprises a fiberglass mat with an asphalt coating which both coats the fibers and fills the void spaces between the fibers. A powdered mineral stabilizer (not shown) may be included as part of the asphalt coating process. A smooth surface of various inert minerals of sufficient consistency may be placed on the bottom surface of sheet 80 to seal the asphalt coating.
Top surface 82 is preferably coated with a layer of mineral granules such as ceramic coated stone granules to provide the desired uniform color portions and the color gradient portions associated with weather surface 42 of shingle 20 . Typically, the mineral granules are applied to the sheet 80 while the asphalt coating is still hot and forms a tacky adhesive.
FIG. 6 shows a schematic representation of a roller 86 and mineral granule hopper 90 which may be used to provide the desired granular surface coating to sheet 80 . The hopper 80 , which may be any hopper which is well known in the art, includes a plurality of partitions 91 which divide the hopper 90 into three sets of compartments: a set of compartments 92 , 94 , 96 and 98 at each end of the hopper and a central compartment 99 between the ends. The central compartment 99 of hopper 90 contains a uniform mixture of the mineral granules which will produce the desired color on dragon teeth or tabs 36 and the other portions of first shingle sheet 30 which will be exposed to the environment. This transfer of mineral granules is sometimes referred to as a “color drop.” The rotation of roller 86 and the movement of sheet 80 are coordinated to place the desired color drop on each shingle 20 .
For the embodiment of the present invention shown in FIGS. 6 and 7, each first shingle sheet 30 will have the same uniform mixture of mineral granules on both the headlap section and the buttlap section. For the embodiment shown in FIGS. 1 to 4 , headlap section 32 may have the same layer of mineral granules as buttlap section 34 or headlap section 32 may have a neutral or non-colored layer of mineral granules. The surface layer on headlap section 32 may be varied as desired for each application.
Different colored mineral granules corresponding to the desired color of horizontal striations 52 , 54 , 56 , and 58 are preferably placed in the appropriate compartments 92 , 94 , 96 , and 98 , respectively. As sheet 80 passes under roller 86 , mineral granules from the appropriate compartment in hopper 90 will fall onto roller 86 and will be transferred from roller 86 to top surface 82 of sheet 80 . The volume or pounds per square foot of mineral granules placed on surface 82 is preferably the same throughout the full width of sheet 80 . However, by dividing the hopper 90 into compartments, the color of various portions of sheet 80 may be varied including providing horizontal striations 52 , 54 , 56 , and 58 for backer strip 50 .
It is important to note that conventional procedures for fabricating shingles having an exterior surface formed by mineral granules include the use of granule blenders and color mixers, along with other sophisticated equipment to ensure a constant uniform color at each location on the exposed portions of the shingles. Extensive procedures are used to ensure that each color drop on a sheet of roofing material is uniform. The color drop between shingles may be varied to provide different shades or tones in color. However, within each color drop, concerted efforts have traditionally been made to insure uniformity of the color on the resulting shingle associated with each color drop.
Once the color drop process is complete, the sheet 80 is allowed to cool. After the sheet 80 is cooled, it is then cut. As shown by dotted lines 84 , 86 , and 88 in FIG. 6, sheet 80 may be cut into four horizontal lengths or lanes 60 , 62 , 64 , and 66 . The width of lanes 62 and 64 corresponds with the desired width for first shingle sheet 30 . The width of lanes 60 and 66 corresponds with the desired width for second shingle sheet 50 .
The cut along dotted line 86 corresponds with the desired pattern for dragon teeth 36 and associated openings 38 . For some applications, more than four lanes may be cut from a sheet of roofing material similar to sheet 80 . The number of lanes is dependent upon the width of the respective sheet of roofing material and the desired width of the resulting shingles.
Sheet 80 may also be cut laterally to correspond with the desired length for the resulting first shingle sheet 30 and second shingle sheet 50 . As shown in FIG. 7, each lateral cut of sheet 80 results in two backer strips 50 and two first shingle sheets 30 which may be assembled with each other to form two laminated shingles 20 . The resulting laminated shingles 20 may be packaged in a square for future installation on a roof as is well known in the art.
The cutting of sheet 80 and the assembly of laminated shingles 20 may be performed in a number of ways. For example, the laminated shingles 20 may be produced through an off-line lamination process in which the sheet 80 is cut both longitudinally and laterally and then the tab sheets and backer sheets which are produced are matched and attached together. Alternatively, and more preferably, the laminated shingles 20 may be produced in a continuous in-line lamination process in which the sheet 80 is cut longitudinally by a rotary die cutter, producing horizontal lengths (such as lanes 60 , 62 , 64 , and 66 ) which consist of continuous tab sheet strips and backer sheet strips. The tab sheet strips and backer sheet strips are joined and adhered together to produce laminated shingle strips through means well known in the art. The laminated shingle strips may then be passed through a cutting cylinder, which cuts the strips into individual shingles. After discrete shingles are formed, they can be processed with commonly used apparatus for handling shingles, such as a shingle stacker to form stacks of shingles and a bundle packer to form shingle bundles.
It is important to note that a color gradient of the present invention may be placed on shingles using various procedures and various types of materials. The present invention is not limited to shingles formed by the process shown in FIGS. 6 and 7.
FIG. 8A is an exploded isometric view showing shingle components taken from a sheet of roofing material according to another embodiment of the present invention. In the embodiment of FIG. 8A, as better shown in FIG. 8B which is an enlarged drawing of a portion of a backer strip of FIG. 8A, transition stripes 152 and 154 are disposed between adjacent pairs 52 / 54 and 54 / 56 of the horizontal striations 52 , 54 and 56 . Each transition stripe has a color value that is a mixture of the colors associated with the two horizontal striations adjacent to the transition stripe. The transition stripes may be used when the difference in contrast between adjacent horizontal striations is sufficiently great that a shingle would present a confused or disjointed appearance without the transition stripes. The transition stripes may be applied as described in U.S. Pat. No. 5,611,186, which is incorporated by reference herein in its entirety.
FIG. 9 illustrates a laminated shingle according to the present invention wherein the backer strip 50 has four horizontal striations 52 , 54 , 56 and 58 , and wherein each of the tabs 36 has a relatively uniform color throughout each tab and different color contrasts between each tab.
Although the present invention has been described with reference to certain preferred embodiments, various modifications, alterations, and substitutions will be apparent to those skilled in the art without departing from the spirit and scope of the invention, as defined by the appended claims.
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There is provided a laminated roofing shingle having a first shingle sheet and a second shingle sheet. The first shingle sheet has a headlap section and a buttlap section, the buttlap section being about 7 inches or greater in height and including a plurality of tabs which are spaced apart to define one or more openings between the tabs. Each of the tabs has a relatively uniform color throughout the tab. The second shingle sheet is attached to the underside of the first shingle sheet and has portions exposed through the openings between the tabs. The second shingle sheet has at least first, second, third, and fourth horizontal striations thereon across at least partial portions of the second sheet which are exposed through the openings between the tabs. The first striation includes a first elongated quadrilateral area with a substantially uniform dark color throughout the first quadrilateral area. The second striation includes a second elongated quadrilateral area below the first striation. The second striation has a substantially uniform color throughout the second quadrilateral area. The third striation includes a third elongated quadrilateral area below the second striation. The third striation has a substantially uniform color throughout the third quadrilateral area, which is lighter than the color of the second striation. The fourth striation includes a fourth elongated quadrilateral area below the third striation. The fourth striation has a substantially uniform color throughout the fourth quadrilateral area, which is lighter than the color of the third striation. There are also provided methods for manufacturing the above-described laminated shingle.
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CROSS REFERENCE TO RELATED PROVISIONAL APPLICATION
This application is based on Provisional Application Ser. No. 60/231,788 filed on Sep. 12, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is generally related to methods and processes for analyzing well production data and maximizing efficiency of reservoir production therefrom and is specifically directed to the evaluation of multilayer commingled reservoirs using commingled production data and production logging information.
2. Discussion of the Prior Art
Field production performance data and multiple pressure transient tests over a period of time for oil and gas wells in geopressured reservoirs have been found to often exhibit marked changes in reservoir effective permeability over the producing life of the wells. Similarly, the use of quantitative fractured well diagnostics to evaluate the production performance of hydraulically fracture wells have clearly shown that effective fracture half-length and conductivity can be dramatically reduced over the producing life of the wells. A thorough investigation of this topic may be found in the paper presented by Bobby D. Poe, the inventor of the subject application, entitled: “Evaluation of Reservoir and Hydraulic Fracture Properties in Geopressure Reservoir,” Society of Petroleum Engineers, SPE 64732.
Some of the earliest references to the fact that subterranean reservoirs do not always behave as rigid and non-deformable bodies of porous media may be found in the groundwater literature, see for example, “Compressibility and Elasticity of Artesian Aquifers,” by O. E. Meinzer, Econ. Geol. (1928) 23, 263–271. and “Engineering Hydraulics,” by C. E. Jacob, John Wiley and Sons, Inc. New York (1950) 321–386.
The observations of early experimental and numerical studies of the effects of stress-dependent reservoir properties demonstrated that low permeability formations exhibit a proportionally greater reduction in permeability than high permeability formations. The stress-dependence of reservoir permeability and fracture conductivity over the practical producing life of low permeability geopressured reservoirs has resulted in the following observations:
1. Field evidence of reservoir effective permeability degradation with even short production time can often be observed in geopressured reservoirs. 2. Quantitative evaluation of the field production performance of hydraulic fractures in both normal and geopressured reservoirs have resulted in the observation that the fracture conductivity of hydraulically fractured wells commonly decreases with production time. 3. Multiphase fracture flow has been demonstrated to dramatically reduce the effective conductivity of fractures. 4. Pre-fracture estimates of formation effective permeability derived from pressure transient tests or production analyses are often not representative of the reservoir effective permeability exhibited in the post-fracture production performance.
The analysis of production data of wells to determine productivity has been used for almost fifty years in an effort to determine in advance what the response of a well will be to production-stimulation treatment. A discourse on early techniques may be found in the paper presented by R. E. Gladfelter, entitled “Selecting Wells Which Will Respond to Production-Simulation Treatment,” Drilling and Production Procedures, API (American Petroleum Institute), Dallas, Tex., 117–129 (1955). The pressure-transient solution of the diffusivity equation describing oil and gas flow in the reservoir is commonly used, in which the flow rate normalized pressure drops are given by:
( P i −P wf )/ q o , and
{ P p ( P i )− P p ( P wf )}/ q g ,
for oil and gas reservoir analyses, respectively, wherein:
P i is the initial reservoir pressure (psia), P wf is the sandface flowing pressure (psia) q o is the oil flow rate (STB/D) P p is the pseudopressure function, psia 2 /cp and q g is the gas flow rate (Mcsf/D).
While analysis of production data using flow rate normalized pressures and the pressure transient solutions work reasonably well during the infinite-acting radial flow regime of unfractured wells, boundary flow results have indicated that the production normalization follows an exponential trend rather than the logarithmic unit slope exhibited during the pseudosteady state flow regime of the pressure-transient solution.
Throughout most of the production history of a well, a terminal pressure is imposed on the operating system, whether it is the separator operating pressure, sales line pressure, or even atmospheric pressure at the stock tank. In any of these cases, the inner boundary condition is a Dirichlet condition (specified terminal pressure). Whether the terminal pressure inner boundary condition is specified at some point in the surface facilities or at the sandface, the inner boundary condition is Dirichlet and the rate-transient solutions are typically used. It is also well known that at late production times the inner boundary condition at the bottom of the well bore is generally more closely approximated with a constant bottomhole flowing pressure rather than a constant rate inner boundary condition.
An additional problem that arises in the use of pressure-transient solutions as the basis for the analysis of production data is the quantity of noise inherent in the data. The use of pressure derivative functions to reduce the uniqueness problems associated with production data analysis of fractured wells during the early fracture transient behavior even further magnifies the effects of noise in the data, commonly requiring smoothing of the derivatives necessary at the least or making the data uninterpretable at the worst.
There have been numerous attempts to develop more meaningful production data analyses in an effort to maximize the production level of fractured wells. One such example is shown and described in U.S. Pat. No. 5,960,369 issued to B. H. Samaroo, describing a production profile predictor method for a well having more than one completion wherein the process is applied to each completion provided that the well can produce from any of a plurality of zones or in the event of multiple zone production, the production is commingled.
From the foregoing, it can be determined that production of fractured wells could be enhanced if production performance could be properly utilized to determine fracture efficiency. However, to date no reliable method for generating meaningful data has been devised. The examples of the prior art are at best speculative and have produced unpredictable and inaccurate results.
SUMMARY OF THE INVENTION
The subject invention is a method of and process for evaluating reservoir intrinsic properties, such as reservoir effective permeability, radial flow steady-state skin effect, reservoir drainage area, and dual porosity reservoir parameters omega (dimensionless fissure to total system storativity) and lambda (matrix to fissure crossflow parameter) of the individual unfractured reservoir layers in a multilayer commingled reservoir system using commingled reservoir production data, such as wellhead flowing pressures, temperatures and flow rates and/or cumulatives of the oil, gas, and water phases, and production log information (or pressure gauge and spinner survey measurements). The method and process of the invention also permit the evaluation of the hydraulic fracture properties of the fractured reservoir layers in the commingled multilayer system, i.e., the effective fracture half-length, effective fracture conductivity, permeability anisotropy, reservoir drainage area, and the dual porosity reservoir parameters omega and lambda. The effects of multiphase and non-Darcy fracture flow are also considered in the analysis of fractured reservoir layers.
The subject invention is directed to a method of and process for fractured well diagnostics for production data analysis for providing production optimization of reservoir completions via available production analysis and production logging data. The method of the invention is a quantitative analysis procedure for reservoir and fracture properties using commingled reservoir production data, production logs and radial flow and fractured interval analyses. This permits the in situ determination of reservoir and fracture properties for permitting proper and optimum treatment placement and design of the reservoir. The invention provides a rigorous analysis procedure for multilayer commingled reservoir production performance. Production logging data is used to correctly allocate production to each completed interval and defined reservoir zone. This improves the stimulation and completion design and identifies zones to improve stimulation.
The subject invention is a computational method and procedure for computing the individual zone production histories of a commingled multi-layered reservoir. The data used in the analysis are the commingled well production data, the wellhead flowing temperatures and pressures, the complete wellbore and tubular goods description, and production log information. This data is used to construct the equivalent individual layer production histories. The computed individual completed interval production histories that are generated are the individual layer hydrocarbon liquid, gas, and water flow rates and cumulative production values, and the mid-completed interval wellbore flowing pressures as a function of time. These individual completed interval production histories can then be evaluated as simply drawdown transients to obtain reliable estimates of the in situ reservoir effective permeability, drainage area, apparent radial flow steady-state skin effect and the effective hydraulic fracture properties, namely, half-length and conductivity.
Typically, an initial production log is run soon after a well is put on production and the completion fluids have been produced back from the formation. Depending on the formation, the stimulation/completion operations performed on the well and the size and productive capacity of the reservoir, a second production log is run after a measurable amount of stabilized production has been obtained from the well. Usually, additional production logs are run at periodic intervals to monitor how the layer flow contributions and wellbore pressures continue to vary with respect to production time. The use of production logs in this manner provides the only viable means of interpreting commingled reservoir production performance without the use of permanent downhole instrumentation.
The subject invention is directed to the development of a computational model that performs the production allocation of the individual completed intervals in a commingled reservoir system using the fractional flow rates of the individual completed intervals, determined from production logs and the commingled system total well fluid phase flow rates. The individual completed interval flow rate histories generated include the individual completed interval fluid phase flow rates and cumulative production values as a function of production time, as well as the mid-zone wellbore flowing pressures. The computed mid-zone flowing wellbore pressures at the production time levels of the production log runs are then compared with the actual measured wellbore pressures at those depths and time level to ascertain which wellbore pressure traverse model most closely matches the measured pressures.
The identified wellbore pressure traverse model is then used to model the bottom hole wellbore flowing pressures for all of the rest of the production time levels for which there are not production log measurements available. This use of the identified pressure traverse model to generate the unmeasured wellbore flowing pressure is the only assumption required in the entire analysis. It is fundamentally sound unless there are dramatic changes in the character of the produced well fluids or in the stimulation/damage of the completed intervals which is not reflected in the composite production log history, primarily due to inadequate sampling of the changes in the completed intervals producing fractional flow rates. With an adequate sampling of the changing fractional flow rate contributions of the individual completed intervals in a commingled reservoir, this analysis technique is superior to other multi-layer testing and analysis procedures.
The method and process of the subject invention provide a fully-coupled commingled reservoir system analysis model for allocating the commingled system production data to the individual completed intervals in the well and constructing wellbore flowing pressure histories for the individual completed intervals in the well. No assumptions are required to be made as to the stimulation/damage steady-state skin effect, effective permeability (or formation conductivity), initial pore pressure level, drainage area extent, or intrinsic formation properties of the completed intervals in a commingled reservoir system. The method of the invention considers only the actual measured response of the commingled system using production logs and industry accepted wellbore pressure traverse computational models.
The fundamental basis for the invention is a computationally rigorous technique of computing the wellbore pressure traverses to the midpoints (or other desired points) of each completed interval using one or more of a number of petroleum industry accepted wellbore pressure traverse computational methods in combination with the wellbore tubular configuration and geometry, wellbore deviation survey information, completed interval depths and perforation information, wellhead measured production rates (or cumulatives) and the wellhead pressures and temperatures of the commingled multilayer reservoir system performance. The computed pressure traverse wellbore pressures are compared with the measured wellbore pressures of either a production log or a wellbore pressure survey. This permits the identification of the pressure traverse computational method that results in the best agreement with the physical measurements made.
The invention permits the use of information from multiple production logs run at various periods of time over the producing life of the well. The invention also permits the specification of crossflow between the commingled system reservoir layers in the wellbore. The invention evaluates the pressure traverse in each wellbore segment using the fluid flow rates in that wellbore section, the wellbore pressure at the top of that wellbore section, and the temperature and fluid density distributions in that section of the wellbore traverse. The method and process of the invention actually uses downhole physical measurements of the wellbore flowing pressures, temperatures, fluid densities, and the individual reservoir layer flow contributions to accurately determine the production histories of each of the individual layers in a commingled multilayer reservoir system. The results of the analysis of the individual reservoir layers can be used with the commingled reservoir algorithm to reconstruct a synthetic production log to match with the actual recorded production logs that are measured in the well. The invention has an automatic Levenberg-Marquardt non-linear minimization procedure that can be used to invert these production history records to determine the individual completed interval fracture and reservoir properties. The invention also has the option to automatically re-evaluate the initially specified unfractured completed intervals that indicate negative radial flow steady-state skin effects as finite-conductivity vertically fractured completed intervals.
The method and process of the subject invention permits for the first time a reliable, accurate, verifiable computationally rigorous analysis of the production performance of a well completed in a multilayer commingled reservoir system using physically measured wellbore flow rates, pressures, temperatures, and fluid densities from the production logs or spinner surveys and pressure gauges to accomplish the allocation of the flow rates in each of the completed reservoir intervals. The combination of the production log information and the wellbore traverse calculation procedures results in a reliable, accurate continuous representation of the wellbore pressure histories of each of the completed intervals in a multilayer commingled reservoir system. The results may then be used in quantitative analyses to identify unstimulated, under-stimulated, or simply poorly performing completed intervals in the wellbore that can be stimulated or otherwise re-worked to improve productivity. The invention may include a full reservoir and wellbore fluids PVT (Pressure-Volume-Temperature) analysis module.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of the process of the subject invention.
FIG. 2 is an illustration of the systematic and sequential computational procedure in accordance with the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The subject invention is directed to a computational model for computing the wellbore pressure traverses and individual layer production contributions of the individual completed intervals in a commingled reservoir. Direct physical measurements of the individual layer flow contributions to the total well production and the actual wellbore flowing pressures are recorded and included in the analysis. There are numerous wellbore pressure traverse models available for computing the bottom hole flowing and static wellbore pressures from surface pressures, temperatures and flow rates, as will be well known to those skilled in the art. The selection of the appropriate pressure traverse model is determined by comparison with the actual wellbore pressure measurements. In a commingled reservoir the layer fractional flow contribution to the total well production rate also commonly varies with respect to time. There are many factors that govern the individual layer contributions to the total well production rate with respect to time. Among these are differences in the layer initial pressures, effective permeability, stimulation or damage steady-state skin effect, drainage area, net pay thickness, and the diffusivity and storativity of the different layers. Other factors that are not directly reservoir-controlled that affect the contribution of each of the layers to the commingled reservoir well production are the changing wellbore pressures, completion losses and changing gas and liquid produced fluid ratios with respect to time.
Production logs (PLs) provide a direct means of measuring the wellbore flowing pressures, temperatures, and actual reservoir layer flow contributions at specific points in time, with which to calibrate the computed pressure traverse models. It is preferable to run multiple production logs on wells producing commingled reservoirs to track the variation in the individual completed interval contributions with respect to production time.
It is known that the commingled system total production rate commonly does not equal or even come close to equaling the sum of the individual completed interval isolated flow rates when each interval is tested in isolation from the other completed intervals in the well. There are several factors causing this, including but not limited to (1) invariably higher flowing wellbore pressures present in the commingled system across each of the completed intervals than when they were measured individually, and (2) possible crossflow between the completed intervals.
As more particularly shown in the flowchart of FIG. 1 , the subject invention is directed to a computational model that performs the production allocation of the individual completed intervals in a commingled reservoir system using the fractional flow rates of the individual completed intervals, determined from the production logs and the commingled system total well fluid phase flow rates. This depicts the analysis process for a reservoir with three completed reservoir layers in which the upper and lower reservoir layers have been hydraulically fractured. The middle reservoir completed interval has not been fracture stimulated. The wellbore pressure traverse is computed using the total well commingled production flow rates to the midpoint of the top completed interval. Then the fluid flow rates in the wellbore between the midpoint of the top and middle completed intervals are evaluated using the total fluid phase flow rates of the commingled system minus the flow rates from the top completed interval. The pressure traverse in the wellbore between the midpoints of the middle and lower completed intervals is evaluated using the fluid phase flow rates that are the difference between the commingled system total fluid phase flow rates and the sum of the phase flow rates from the top and middle completed intervals. The individual completed interval flow rate histories generated in this analysis include the individual completed interval fluid flow rates and cumulative production values as a function of production time, as well as the mid-zone wellbore flowing pressures. The computed mid-zone flowing wellbore pressures at the production time levels of the production log runs are then compared with the actual measured wellbore pressures at those depths and time level to ascertain which wellbore pressure traverse model most closely matches the measured pressures.
The identified wellbore pressure traverse model is then used to model the bottomhole wellbore flowing pressure for all of the rest of the production time levels for which there are not production log measurements available. This use of the identified pressure traverse model to generate the unmeasured wellbore flowing pressures is the only major assumption made in the process. It is fundamentally sound unless there are dramatic changes in the character of the produced well fluids or in the stimulation/damage of the completed intervals which is not reflected in composite production log history, primarily due to inadequate sampling of the changes in the completed intervals producing fractional flow rates. With an adequate sampling of the changing fractional flow rate contributions of the individual completed intervals in a commingled reservoir, this analysis technique produces accurate results.
FIG. 2 is an illustration of the systematic and sequential computational procedure in accordance with the subject invention. Beginning at the wellhead 10 , the pressure traverses to the midpoint of each completed interval are computed in a sequential manner. The fluid flow rates in each successively deeper segment of the wellbore are decreased from the previous wellbore segment by the production from the completed intervals above that segment of the wellbore. The mathematical relationships that describe the fluid phase flow rates (into or out) of each of the completed intervals in the wellbore are given as follows for oil, gas, and water production of the j th completed interval, respectively:
q oj ( t )= q ot ( t ) f oj ( t ), q gi ( t )= q gt ( t ) f gj ( t ), q wj ( t )= q wt ( t ) f wj ( t ),
where:
q oj is the j th completed interval hydrocarbon liquid flow rate, STB/D, q of is the composite system hydicarbon liquid flow rate, STB/D, f oj is the j th completed interval hydrocarbon liquid flow rate liquid contribution of the total well hydrocarbon liquid flow rate, fraction, q gi is the j th interval gas flow rate, Mcsf/D j is the index of completed intervals, q gt is the composite system total well gas flow rate, Mscf/D, f gj is the j th completed interval gas flow rate fraction of total well gas flow rate, fraction, q wj is the j th interval water flow rate, STB/D q wt is the composite system total well water flow rate, STB/D f wj is the j th completed interval water flow rate fraction of total well water flow rate, fraction.
The corresponding fluid phase flow rates in each segment of the weilbore are also defined mathematically with the relationships as follows for oil, gas and water for the n th wellbore pressure traverse segment, respectively.
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The flow rate and pressure traverse computations are performed in a sequential manner for each wellbore segment, starting at the surface or wellhead 10 and ending with the deepest completed interval in the wellbore, for both production and injection scenarios. The wellbore flow rate and pressure traverse calculation procedures employed permit the evaluation of production, injection or shut in wells.
The fundamental inflow relationships that govern the transient performance of a commingled multi-layered reservoir are fully honored in the analysis provided by the method of the subject invention. Assuming that accurate production logs are run in a well, when a spinner passes a completed interval without a decrease in wellbore flow rate (comparing wellbore flow rates at the top and bottom of the completed interval, higher or equal flow rate at the top than at the bottom), no fluid is entering the interval from the wellbore (no loss to the completed interval, i.e., no crossflow). Secondly, once the minimum threshold wellbore fluid flow rate is achieved to obtain stable and accurate spinner operation, all higher flow rate measurements are also accurate. Lastly, the sum of all of the completed interval contributions equals the commingled system production flow rates for both production and injection wells.
In the preferred embodiment of the invention, two ASCII input data files are used for the analysis. One file is the analysis control file that contains the variable values for defining how the analysis is to be performed (which fluid property and pressure traverse correlations are uses, as well as the wellbore geometry and production log information). The other file contains commingled system wellhead flowing pressures and temperatures, and either the individual fluid phase flow rates or cumulative production values as a function of production time.
Upon execution of the analysis two output files are generated. The general output file contains all of the input data specified for the analysis, the intermediate computational results, and the individual completed interval and defined reservoir unit production histories. The dump file contains only the tabular output results for the defined reservoir units that are ready to be imported and used in quantitative analysis models.
The analysis control file contains a large number of analysis control parameters that use can be used to tailor the production allocation analysis to match most commonly encountered wellbore and reservoir conditions.
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A method for providing production optimization of reservoir completions having a plurality of completed intervals via available production analysis and production logging data provides a quantitative analysis procedure for reservoir and fracture properties of a commingled reservoir system, that includes the steps of measuring pressure for specific zones in a reservoir; selecting a pressure traverse model; computing midzone pressures using the traverse model; comparing the computed midzone pressures with the measured pressures; and modeling the bottomhole pressure of the reservoir based on the traverse model.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a construction apparatus designed with an extendable mast having an upper mast element and a lower mast element, whereby the upper mast element is longitudinally displaceable relative to the lower mast element, a linear drive for displacement of the two mast elements relative to each other, wherein the linear drive has an upper drive part which can be actuated in a linear manner relative to a lower drive part of the linear drive, and a locking device for locking the two mast elements in an extended mast position.
The invention further relates to a method for operating a construction apparatus, in particular a construction apparatus according to the invention, in which the linear drive is extended and in doing so the upper mast element is extended, afterwards the two mast elements are locked in an extended mast position, afterwards the lower drive part is released from the lower mast element and the lower drive part is moved longitudinally of the lower mast element and in doing so a workload arranged on the lower drive part is lifted.
2. Description of Related Art Including Information Disclosed Under 37 CFR §§1.97 and 1.98
A generic construction apparatus is known from JP 2002-285775. This printed publication discloses a construction apparatus with a two-part extendable mast. For the extension of the mast a mast cylinder is provided. This mast cylinder is connected on its piston rod to the lower mast element. On its cylinder housing the mast cylinder has a contact-pressure surface that takes along the upper mast element during the extension of the mast cylinder. In addition to the mast cylinder also a feed cylinder for displacement of a drilling carriage is present.
In accordance with JP 2002-285775 the cylinder housing of the feed cylinder is connected to the cylinder housing of the mast cylinder. Due to this connection the drilling carriage also has to be lifted during the extension of the upper mast element so that correspondingly high power needs to be applied for the extension.
BRIEF SUMMARY OF THE INVENTION
The object of the invention is to provide a construction apparatus and a method for operating a construction apparatus, which permit particularly high efficiency whilst ensuring high reliability and versatility of use.
The object is achieved in accordance with the invention by a device having an extendable mast having an upper mast element and a lower mast element, wherein the upper mast element is longitudinally displaceable relative to the lower mast element, and a linear drive for displacement of the two mast elements relative to each other, wherein the linear drive has an upper drive part which can be actuated in a linear manner relative to a lower drive part of the linear drive, and a locking device for locking the two mast elements in an extended mast position, wherein the upper drive portion of the linear drive is attached to the upper mast element, the lower drive portion of the linear drive along the lower mast element can slide, and a fixing device is provided at the lower pole element, with which the lower drive unit for moving the upper mast element detachably at the lower pole element is fixed. The object of the invention is further achieved by a method in which the linear drive is extended and in doing so the upper mast element is extended, afterwards the two mast elements are locked in an extended mast position, afterwards the lower drive part is released from the lower mast element and the lower drive part is moved longitudinally of the lower mast element and in doing so a workload arranged on the lower drive part is lifted.
A construction apparatus according to the invention is characterized in that the upper drive part of the linear drive is fixed to the upper mast element, in that the lower drive part of the linear drive can be displaced longitudinally of the lower mast element and in that on the lower mast element a securing device is provided with which the lower drive part of the linear drive can be secured in a releasable manner to the lower mast element for displacement of the upper mast element.
In accordance with the invention a mast consisting of at least two parts is provided, whose two mast parts can be extended and, by preference, can also be retracted again by means of a linear drive. Here, the linear drive is fixed at its upper side to the upper mast element. A central idea of the invention can be considered to reside in the fact that on its opposite-lying lower side the linear drive is only secured temporarily to the lower mast element, namely at that time when the two mast elements are to be extended or retracted relative to each other by means of the linear drive. The temporary fixing of the lower drive part to the lower mast element, which is brought about by means of the securing device, renders it possible that the compressive forces that act in the linear drive during the retraction and extension of the mast elements are transmitted to the lower mast element.
However, once the displacement process of the two mast elements is completed, the mast elements can be fixed relative to each other by means of the locking device, which means that the upper mast element is from then on supported by the locking device. The invention is based on the finding that after completion of the locking the linear drive is no longer needed for supporting the upper mast element and can therefore be used for other drive purposes. Consequently, in the construction apparatus according to the invention the lower drive part of the linear drive can be cleared by the securing device after the locking of the mast elements and can therefore be released from the lower mast element so that the lower drive part can again be displaced longitudinally of the lower mast element. The linear drive, which was initially used for the extension of the mast and is suspended on the upper mast element of the now-locked mast, can now serve other lifting purposes. In particular, by means of the linear drive loads can be lifted and lowered longitudinally of the lower mast element. For example, by means of the lower drive part of the linear drive it is possible to lift and lower a drilling carriage with a drill drive longitudinally of the mast.
According to the invention the extension of the mast and the displacement of the drilling carriage longitudinally of the mast can therefore be achieved with one and the same linear drive so that a separate drive for the movement of the carriage relative to the mast is not required. Consequently, according to the invention an especially efficient and at the same time versatile construction apparatus is obtained.
According to the invention provision is made for the linear drive to be positioned on the mast base only temporarily, namely in particular for the extension of the mast. When the mast is extended to the desired height, in particular fully extended, the upper mast part is locked with respect to the lower mast part. The linear drive can then be used for lifting tasks and can be connected for this purpose with its lower drive part to the carriage for example.
Advantageously, the construction apparatus has a control which is adapted such that, in particular when the mast is extended, a connection established via the securing device between the lower drive part and the lower mast element for the transmission of compressive forces from the lower drive part to the lower mast element is only cleared, if the two mast elements are locked by means of the locking device.
By preference, the construction apparatus according to the invention can be a soil working apparatus, such as a drilling apparatus for example.
The linear drive according to the invention is used in particular for the extension of the upper mast element, i.e. for distance enlargement. However, it can also be employed for the retraction of the upper mast element. For the retraction provision can be made for the lower drive part to be secured initially again by means of the securing device to the lower mast element, for the locking device to be cleared subsequently and for the linear drive to be finally retracted together with the upper mast element. Hence, the displacement of the mast elements and the linear drive can be understood as both an extension and a retraction. The upper mast element can be understood in particular as the one of the two mast elements which is located further away from the ground.
The upper drive part can also be fixed in an articulated manner to the upper mast element, i.e. it can be linked to the upper mast element. In order to be able to lift loads by means of the linear drive, the upper drive part is suitably fixed to the upper mast element in such a way that tensile forces can be transmitted via the fixing from the linear drive to the upper mast element. For especially high operating safety provision can be made on the lower and/or upper mast element for a guide device, which guides the lower drive part that is displaceable relative to the lower mast element. In accordance with the invention such a guide can still be present, when the lower drive part is cleared by the securing device.
Advantageously, the locking device is remote-controlled, for example remote-controlled hydraulically, and can be designed in particular in a form-fitting manner. For instance it can have a lock, more particularly a bolt, which, for the purpose of locking, is guided through corresponding recesses located in the upper mast element and in the lower mast element. In particular the locking device can be provided on the lower mast element. Alternatively or in addition to the form-fitting locking device a force-fitting locking device can basically be provided.
In particular, to achieve an especially great stroke of the linear drive the securing device is advantageously provided in the area of the mast base, i.e. in an end portion of the lower mast element facing away from the upper mast element and directed towards the ground.
It can be sufficient if the securing device secures the lower drive part only in one spatial direction to the lower mast element. Since normally only compressive forces occur in the linear operation during the displacement of the upper mast element, it can be sufficient if the securing device secures the lower drive part against a displacement directed away from the upper mast element, i.e. directed downwards.
It is especially preferred that the securing device has a stop which suitably limits a displacement path of the lower drive part away from the upper mast element, i.e. which limits, in particular, the displacement path in the downward direction. In such case the securing device can be designed in an entirely passive way without any active setting elements so that a construction apparatus is obtained that is particularly simple and reliable from a constructional viewpoint. For especially high operating safety the stop can also be combined with active securing means. According to the invention the stop is designed such that it is able to take up at least the forces acting in the linear drive during the extension of the two mast elements and to transfer these forces to the lower mast element. The stop can also be adjustable. More particularly, it can be moved out of the path of the lower drive part and moved back into the path again. In addition, the stop can also be height-adjustable. In accordance with the invention the stop is arranged on the lower mast element.
The securing device can also have e.g. an adjustable lock or a clamping device, with which the lower drive part can be connected temporarily to the lower mast element for displacement of the mast elements. In this way the lower drive part can be secured in several spatial directions to the lower mast element, which may be of advantage even if tensile forces have to be reckoned with.
A preferred embodiment of the invention resides in the fact that the linear drive is a hydraulic cylinder. As a result, high efficiency accompanied with high reliability is achieved. In this case the drive parts of the linear drive can be constituted by a piston rod and respectively a cylinder housing of the hydraulic cylinder. In principle, other types of linear drive, such as a rack-and-pinion drive, are conceivable, too. For best suitability, the hydraulic cylinder is double-acting allowing for both a controlled extension and a controlled retraction. With regard to the transport dimensions and the operating reliability it is especially advantageous that the linear drive, in particular the hydraulic cylinder, extends in the inside of the two mast elements.
It is especially preferred that the linear drive is a hydraulic cylinder with two opposite lying piston rods. In this case the upper drive part can be a first piston rod and the lower drive part can be a second piston rod, with a cylinder housing being arranged between the two piston rods. Due to the design with two piston rods an especially high buckling strength can be achieved at a low weight. If two piston rods are provided, it is suitable for the cylinder housing to be longitudinally displaceable both relative to the upper mast element and relative to the lower mast element.
Another advantageous embodiment of the invention resides in the fact that on the mast a carriage is provided, which can be displaced longitudinally of the mast and has a drill drive, in particular. The drill drive can be a rotary drive, a roto-percussive drive and in general also a regular vibrator. It is especially advantageous that the drill drive can be pivoted on the carriage about an axis that preferably extends in the horizontal direction. In this way it is possible to arrange the output shaft of the drill drive in an approximately horizontal manner for a simple attachment of a drill rod section and to then pivot the output shaft together with the drill rod attached thereto into the vertical for drilling purposes. For best suitability, the carriage can be displaced both longitudinally of the lower mast element and longitudinally of the upper mast element.
If a carriage is provided it is of advantage in accordance with the invention that on the lower drive part of the linear drive a connecting part is provided for connecting the lower drive part to the carriage. This connecting part makes it possible to connect the lower drive part of the linear drive to the carriage and the rotary drive after the locking of the two mast elements so that the linear drive which was originally employed for extension can now serve for lifting and lowering the carriage. The connecting part is suitably provided at the lower end of the lower drive part. The connecting part can be designed for example for a bolt connection to the carriage.
If a connecting part is provided for connecting the lower drive part to the carriage, the stop of the securing device that limits the displacement path of the lower drive part is suitably arranged in the path of the connecting part. According to this embodiment the lower drive part rests through the connecting part on the stop and is thus secured temporarily through the connecting part to the lower mast element.
Furthermore, according to the invention it is of advantage that on the mast an auxiliary carriage is provided which can be displaced longitudinally of the mast, and that means are provided for connecting the auxiliary carriage to the carriage. By means of this auxiliary carriage the carriage can be moved longitudinally of the mast even if the carriage is not connected to the lower drive part of the linear drive. However, by means of the auxiliary carriage it is also possible to apply additional force onto the carriage that acts in addition to the force of the linear drive. This may be especially advantageous during the extraction of a drill rod.
For instance provision can be made for the carriage to be connected to the auxiliary carriage during the displacement, in particular during the extension of the upper mast element, because in this case the linear drive is needed for actuation of the upper mast element and is not available for actuation of the carriage. However, the auxiliary carriage can also be connected to the carriage during the extraction of a drill rod. In such case the carriage can be connected at the same time to the lower drive part of the linear drive so that the auxiliary carriage can assist the linear drive or the carriage can be separate from the lower drive part so that the auxiliary carriage applies the tensile forces alone.
Advantageously, the means for connecting the auxiliary carriage to the carriage are provided for a bolt connection. For best suitability, the means for connecting the auxiliary carriage to the carriage can be remote-controlled hydraulically for example so that a reliable operation is on hand even when the carriage is difficult to access.
An especially compact type of construction can be attained in that the auxiliary carriage is arranged above the carriage. In principle, an arrangement below the carriage is conceivable, too.
In addition, it is particularly advantageous that the auxiliary carriage can be displaced both longitudinally of the upper mast element and longitudinally of the lower mast element. As a result, an especially great stroke of the auxiliary carriage, but also of the carriage that can be connected thereto and therefore of the drill drive, is given which permits e.g. a very time-saving extraction of the drill rod.
If an auxiliary carriage is provided, it is especially preferred that a drive, especially a winch drive, is provided for displacement of the auxiliary carriage.
To attain an especially simple construction the winch drive can be designed for the lifting of the auxiliary carriage, whereas the lowering of the auxiliary carriage takes place through gravity.
Furthermore, it is useful for the winch drive to have a rope winch. By preference, the rope winch is arranged on a frame, on which the lower mast element is arranged. The frame concerned can be a vehicle superstructure for example. In particular, the lower mast element can be linked in a pivotable manner to the frame about a horizontal axis so that the mast can be folded for transport purposes. On the frame a ground-facing mast extension can also be provided, which is located below the lower mast element when the mast is erected.
It is particularly preferred that a winch rope of the winch drive is guided around at least one deflection roller arranged on the upper mast element. The deflection roller is suitably provided in the portion of the mast head. With such a deflection roller an especially compact and reliable type of construction can be obtained. By preference, two deflection rollers having parallel, spaced axes are provided for the winch rope on the upper mast element in the portion of the mast head.
Moreover, provision can be made for the winch rope to be guided around a deflection roller arranged on the auxiliary carriage and/or for the winch rope to be guided around a deflection roller provided on the frame. As a result of this deflection, which can be of multiple type where applicable, a tackle mechanism can be created that reduces the force to be applied by the rope winch, which proves to be of advantage for the extraction of a heavy drill rod for example.
Another advantageous embodiment of the invention resides in the fact that the two mast elements can be telescoped. According to this embodiment the retracted mast elements are arranged inside each other, in which case it is useful for the upper mast element to be arranged inside the lower mast element. Through a telescopic design particularly compact transport dimensions can be obtained. In principle, however, the two mast elements can also be provided in a laterally offset manner. For best suitability, the two mast elements have an aligned guide, as for example a guide rail, for the carriage and/or the auxiliary carriage so that the carriage or respectively the auxiliary carriage can be moved longitudinally of both mast elements.
The method according to the invention is provided for operating a construction apparatus with an extendable mast, which has an upper mast element and a lower mast element, whereby the upper mast element is longitudinally displaceable relative to the lower mast element. In particular, the method can be provided for operating a construction apparatus according to the invention.
Pursuant to the method in accordance with the invention a linear drive is provided, which has an upper drive part and a lower drive part, whereby the upper drive part can be actuated in a linear manner relative to the lower drive part, and whereby the upper drive part of the linear drive is fixed to the upper mast element, the lower drive part is secured to the lower mast element for the transmission of compressive forces from the linear drive into the lower mast element, and the linear drive is extended and in doing so the upper mast element is extended. Afterwards, pursuant to the method in accordance with the invention, the two mast elements are locked in an extended mast position. Afterwards, pursuant to the method in accordance with the invention, the lower drive part is released from the lower mast element and the lower drive part is moved longitudinally of the lower mast element and, in doing so, a workload arranged on the lower drive part is lifted.
The aspects of the invention set out in conjunction with the method can equally be applied to the device according to the invention, just as the aspects of the invention mentioned in conjunction with the device can be applied to the method.
It can be sufficient if, for the purpose of transmitting the compressive forces, the lower drive part is secured to the lower mast element in one spatial direction only, more particularly if the lower drive part is secured against a movement in the downward direction. If tensile forces are also likely to occur, though the lower drive part can also be secured in two opposite spatial directions.
The securing of the lower drive part to the lower mast element can be effected in particular by means of a stop which is provided on the lower mast element and on which the lower drive part rests in the secured state. Then, the release of the lower drive part can take place through a simple lifting of the lower drive part from the stop.
A particularly preferred further development of the method resides in the fact that after the locking of the two mast elements the lower drive part is connected to a drill drive and that the lower drive part is moved together with the drill drive longitudinally of the lower mast element. In this case the workload is constituted at least in part by the drill drive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the following the invention will be described in greater detail by way of preferred embodiments shown schematically in the accompanying Figures, wherein:
FIG. 1 to FIG. 11 show an embodiment of a construction apparatus according to the invention in different operating stages.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of a construction apparatus according to the invention is shown in FIGS. 1 to 11 . As shown in FIG. 1 in particular, the construction apparatus has a horizontally extending frame 70 which can be moved onto a trailer, not shown here, for transport purposes and which rests on the ground by means of four hydraulically actuated supports 75 .
Through a pivot joint 77 a mast 1 is linked to the frame 70 . The mast 1 can be pivoted about the pivot joint 77 between an approximately vertical operating position shown in the Figures and a horizontal transport position, not shown, in which the mast 1 extends approximately parallel to the frame 70 . For the active pivoting of the mast 1 about the pivot joint 77 a hydraulic cylinder arrangement 76 is provided, which is linked on the one hand to the frame 70 and on the other hand to the mast 1 .
The mast 1 has an upper mast element 2 and a lower mast element 3 , the upper mast element 2 being displaceable longitudinally of the drilling axis 100 relative to the lower mast element 3 and the frame 70 . Through displacement of the two mast elements 2 and 3 relative to each other the mast 1 can be retracted and extended. For example FIG. 1 shows the mast 1 in a retracted position, whereas FIG. 4 , for example, shows the mast 1 in an extended position. In the retracted state depicted in FIG. 1 the upper mast element 2 rests on the lower mast element 3 so that a further movement of the upper mast element 2 in the downward direction is restrained by the lower mast element 3 .
For the active displacement of the two mast elements 2 and 3 relative to each other, i.e. for the extension and retraction of the mast 1 , a linear drive 10 is provided. The linear drive 10 has an upper drive part 12 as well as a lower drive part 13 , wherein during the operation of the linear drive 10 the two drive parts 12 and 13 are displaced actively with respect to each other in the longitudinal direction of the drilling axis 100 .
The linear drive 10 is designed as a hydraulic cylinder with a twin piston rod. As such the linear drive 10 has a central cylinder housing 11 , on the upper side of which an upper piston rod 16 and on the underside of which a lower piston rod 17 can be extended and retracted. Here, the upper drive part 12 is constituted by the upper piston rod 16 and the lower drive part 13 is constituted by the lower piston rod 17 .
The linear drive 10 designed as a hydraulic cylinder extends in the inside of the mast longitudinally of the drilling axis 100 . On its upper end facing away from the cylinder housing 11 the upper drive part 12 (the upper piston rod 16 ) is linked to the upper mast element 2 in the upper area thereof. In this way the linear drive 10 is suspended on the upper mast element 2 .
The lower drive part 13 , i.e. the lower piston rod 17 , is in turn supported in a displaceable manner longitudinally of the lower mast element 3 and in parallel to the drilling axis 100 . However, the displacement path is limited at least temporarily by a securing device 30 described below in more detail.
The construction apparatus has a carriage 40 provided on the mast 1 by being displaceable longitudinally of the mast 1 , in particular longitudinally of both mast elements 2 and 3 . On the carriage 40 a drill drive 41 is arranged. The drill drive 41 can serve for the rotating operation of a drill rod 44 , shown e.g. in FIG. 9 , about the drilling axis 100 .
The carriage 40 is connected in a releasable manner to an auxiliary carriage 60 , which is also provided on the mast 1 by being displaceable longitudinally of the mast 1 , in particular longitudinally of both mast elements 2 and 3 . The auxiliary carriage 60 is arranged above the carriage 40 . For the releasable connection of the carriage 40 to the auxiliary carriage 60 a connecting device 61 is provided, which is constituted in the illustrated embodiment by a bolt on the carriage 40 and a corresponding recess on the auxiliary carriage 60 .
For the active movement of the auxiliary carriage 60 and of the carriage 40 that is optionally connected thereto a winch drive is provided. The winch drive has a rope winch 72 that serves for winding up a winch rope 73 . The winch rope 73 runs from the rope winch 72 in succession to two deflection rollers 9 , 9 ′ provided paraxially on the upper end of the upper mast element 2 . From the deflection rollers 9 , 9 ′ the winch rope 73 runs longitudinally of the drilling axis 100 in the downward direction to another deflection roller 69 arranged on the auxiliary carriage 60 . The winch rope 73 is guided around the deflection roller 69 of the auxiliary carriage 60 and from there it runs upwards again back to the upper area of the upper mast element 2 . There the winch rope 73 is deflected by a deflection device not shown in detail, from which it runs downwards again to another deflection roller 79 provided on the frame 70 . The winch rope 73 coming from the auxiliary carriage 60 is guided around this deflection roller 79 of the frame 70 and runs from the deflection roller 79 upwards again to the upper end of the upper mast element 2 , where the winch rope 73 is eventually fixed with its end. By the described multiple deflection of the winch rope 73 , into which the auxiliary carriage 60 is suspension-mounted through its deflection roller 69 , a tackle mechanism is created which renders it possible to apply by means of the rope winch 72 especially high tensile forces onto the auxiliary carriage 60 and therefore onto the carriage 40 with the drill drive 41 and which permits at the same time a simple folding of the mast 1 for transport purposes.
On its upper drive part 12 the linear drive 10 is suspended on the upper mast element 2 . At the lower end of the lower drive part 13 a block-shaped connecting part 50 is fixed to the lower drive part 13 , the said connecting part being guided on the lower mast element 3 in a longitudinally displaceable manner. As shown in FIG. 2 for example, the connecting part 50 is provided for producing a releasable connection to the carriage 40 . Hence, by means of the connecting part 50 the carriage 40 can be connected in a releasable manner to the lower drive part 13 . For connection to the carriage 40 the connecting part 50 can have e.g. means for producing a bolt connection.
As is furthermore shown in FIG. 1 , the construction apparatus has a securing device 30 . This securing device 30 is designed as a stop 31 that restrains a movement of the lower drive part 13 relative to the lower mast element 3 . In the illustrated embodiment the stop 31 is arranged in the path of the connecting part 50 so that the movement of the lower drive part 13 is restrained through the connecting part 50 .
The securing device 30 permits a temporary securing of the lower drive part 13 to the lower mast element 3 , namely at those times when the lower drive part 13 and/or the connecting part 50 rests on the stop 31 . In this temporarily secured state the linear drive 10 is in operative connection with both the upper mast element 2 and the lower mast element 2 so that the mast elements 2 and 3 can be extended through the actuation of the linear drive 10 .
In order to lock the mast elements 2 and 3 in an extended position a remote-controlled locking device 20 is provided in the upper area of the lower mast element 3 . The locking device 20 has a locking element which, for the purpose of locking, can be introduced into a corresponding recess in the upper mast element 2 .
FIG. 1 shows the construction apparatus in a state immediately after the mast 1 has been brought into the vertical operating position by means of the hydraulic cylinder arrangement 76 . In this state the auxiliary carriage 60 is connected to the carriage 40 and is located together with the carriage 40 in an upper area of the mast 1 on the upper mast element 2 . The upper mast element 2 is retracted and rests on the lower mast element 3 . The linear drive 10 is almost fully retracted, in which case the lower drive part 13 rests via the connecting part 50 on the stop 31 of the securing device 30 .
For the extension of the mast 1 the auxiliary carriage 60 is initially lowered together with the carriage 40 through actuation of the rope winch 72 . Then the carriage 40 is connected to the connecting part 50 and therefore to the lower drive part 13 and in doing so the connecting device 61 releases the carriage 40 from the auxiliary carriage 60 . This state is shown in FIG. 2 .
As shown in FIG. 3 , through actuation of the rope winch 72 the auxiliary carriage 60 is then raised to an upper area of the mast 1 and is thereby lifted from the carriage 40 . The carriage 40 remains connected through the connecting part 50 to the lower drive part 13 in a lower area of the mast 1 .
As shown in FIG. 4 , the mast 1 is then extended. To this end the linear drive 10 is actuated so that the opposite lying piston rods 16 and 17 , which constitute the upper drive part 12 and the lower drive part 13 respectively, move out of the cylinder housing 11 . The lower drive part 13 rests through the connecting part 50 on the stop 31 of the securing device 30 . Hence, via the stop 31 arranged on the lower mast element 3 compressive forces from the linear drive 10 , and in particular the weight force of the upper mast element 2 , can be introduced into the lower mast element 3 so that an upward directed reaction force can be applied to the upper mast element 2 in order to extend the upper mast element 2 . Therefore the linear drive 10 , together with the upper mast element 2 , pushes itself upwards and away from the stop 31 so that the upper mast element 2 moves upwards relative to the lower mast element 3 .
When the upper mast element 2 is extended to a desired height, in particular when fully extended, as shown in FIG. 4 , the locking device 20 is actuated, i.e. a locking element of the locking device 20 is introduced into a corresponding recess on the upper mast element 2 . From then on the weight force of the upper mast element 2 can be introduced via the locking device 20 into the lower mast element 3 so that the linear drive 10 is then available for lifting tasks, especially for lifting the carriage 40 relative to the mast 1 . The use of the linear drive for lifting the carriage 40 is illustrated in FIG. 5 . Since the upper mast element 2 is supported by the locking device 20 , the linear drive 10 can be retracted without the upper mast element 2 being retracted thereby. Due to the fact that the upper drive part 12 is suspended on the upper mast element 2 , the lower drive part 13 is moved upwards relative to the lower mast element 3 during the retraction of the linear drive 10 . As a result, the connecting part 50 and the carriage 40 fixed thereto are also lifted and the carriage 40 is thus moved along the lower mast element 3 .
During its lifting the connecting part 50 is raised from the stop 31 and in this way the temporary securing, brought about by the securing device 30 , of the lower drive part 13 to the lower mast element 3 is released.
As depicted in FIGS. 5 and 6 , when the mast 1 is extended and the locking device
is secured the carriage 40 can be displaced together with the drill drive 41 longitudinally of the mast 1 in the upward and downward direction through actuation of the same linear drive 10 that was employed initially for the extension of the mast 1 .
FIGS. 7 to 9 show the installation of a drill rod 44 on the drill drive 41 . As shown in FIG. 7 , the drill drive 41 is linked to the carriage 40 in a pivotable manner about a horizontally extending axis. In particular, the drill drive can thus be pivoted into the horizontal position shown in FIG. 7 , in which the drill rod 44 can be introduced horizontally into the drill drive 41 . Here, for reason of better accessibility the carriage 40 is moved with the drill drive 41 into a lower area of the mast 1 through extension of the linear drive 10 .
Afterwards, as shown in FIG. 8 , the linear drive 10 is retracted and the carriage 40 is lifted thereby. The drill drive 41 , together with the drill rod 44 arranged therein, can thus be pivoted from the horizontal back to the vertically extending drilling axis 100 .
As shown in FIG. 9 , through retraction of the linear drive 10 the carriage 40 is lifted up to such a height that the drill drive 41 with the drill rod 44 is finally able to pivot into the drilling axis 100 . For connection of the drill rod 44 to a further section of the drill rod 44 ′, a holding device 80 can be provided on the frame 70 for example, with which device the drill rod 44 ′ can be held temporarily. The holding device 80 can have e.g. at least one releasable clamping claw.
If an especially great stroke of the carriage is required, use can also be made of the auxiliary carriage 60 with the rope winch 72 for actuation of the carriage 40 . For this purpose the carriage 40 is connected through the connecting device 61 to the auxiliary carriage 60 and the carriage 40 is released from the connecting part 50 . As depicted in FIGS. 10 and 11 , when the mast 1 is extended the carriage 40 can then be moved along both the lower mast element 3 and the upper mast element 2 . If the connecting part 50 is arranged in the path of the carriage 40 and thereby limits the stroke of the carriage 40 , the connecting part 50 is suitably arranged in a lower position through extension of the linear drive 10 , as shown in FIGS. 10 and 11 , so that the stroke of the carriage is not restricted.
If particularly high tensile forces are required it is also conceivable to connect the carriage 40 through the connecting device 61 to the auxiliary carriage 60 and at the same time through the connecting part 50 to the lower drive part 13 of the linear drive 10 , in which case an upward directed tensile force can be applied to the carriage 40 by means of both the rope winch 72 and the linear drive 10 .
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A construction apparatus having an extendable mast with an upper mast element longitudinally displaceable relative to a lower mast element. A linear drive displaces the mast elements relative to each other, and has an upper drive part linearly actuable relative to a lower drive part of the linear drive, and a locking device for locking the two mast elements in an extended mast position. The upper drive part is fixable to the upper mast element, the lower drive part of the linear drive is displaceable longitudinally of the lower mast element and a securing device is provided on the lower mast element, with which the lower drive part is releasably securable to the lower mast element for displacement of the upper mast element. A method for operating a construction apparatus with an extendable mast can be carried out with a construction apparatus in accordance with the invention.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD
[0001] The present invention relations to installation of building panels and, more particularly, to a support apparatus to temporarily support a drywall or other panel until an installer can secure the panel in place.
BACKGROUND
[0002] Installation of panels such as drywall is known in the art. Installation of drywall is particularly cumbersome, labor intensive and tiring, particularly for installation overhead on a ceiling. Drywall sheets are heavy and somewhat fragile if not handled and installed carefully. A drywall sheet is typically lifted by two persons, and supported in place by one person against the overhead joists or against wall studs while the second person secures the drywall in place with nails or screws. Drywall sheets are typically 48 or 54 inches wide and eight to 14 feet long. The standard thickness of drywall is one-half inch and five-eighths inch, but other thicknesses may be used such as one-quarter inch or three-eighths inch.
[0003] To properly install a sheet of drywall, the sheet should be held snug against the ceiling joists or wall studs and screwed or nailed in place starting from the center of the sheet and fanning out. If the sheet is not against or close to the studs or joists the screws or nails may pull through the drywall. If the corners or edges of the sheet are nailed or screwed first the edges or corners may break, or the middle of the sheet may bow resulting in an uneven or sagging installation or nail pop as the bow is pulled to the stud or joist and the nail or screw head pulls through the drywall. Additionally, supporting heavy sheets of drywall overhead throughout the day is tiring while trying to hold a sheet against the ceiling joists it is difficult to adjust, align reposition the heavy sheet.
[0004] There is a need for a support apparatus that is easy to use, quickly repositionable, can be used for both wood and metal studs, holds the sheet in close proximity to the stud or joist and is adaptable for various thicknesses of drywall.
SUMMARY
[0005] The present invention provides a panel installation support apparatus that is versatile and convenient for attachment of the panel to a frame member. The support apparatus includes an adjustable support surface for accommodating various panel thicknesses, a sloped surface to support the leading edge of the panel when positioning in place, and an alignment support shelf to properly align an edge of the panel with the joist or stud while supporting the edge of the panel. An accessory block may be used when standing a panel against a wall or when hanging drywall on sloped ceilings.
DETAILED DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a front elevation perspective view of the panel support apparatus of the present invention.
[0007] FIG. 2 is a right side elevation perspective view of FIG. 1 .
[0008] FIG. 3 is a bottom perspective view of FIG. 1 .
[0009] FIG. 4 is an overhead installation view showing three panel support apparatuses clamped to ceiling joists.
[0010] FIG. 5 is a bottom view looking up at one of the panel support apparatuses of FIG. 4 .
[0011] FIG. 6 is an overhead installation view showing a drywall sheet being supported by the panel support apparatuses.
[0012] FIG. 7 is an overhead installation view showing a drywall sheet being supported by the panel support apparatus.
[0013] FIG. 8 is an end view of the panel support apparatus.
[0014] FIG. 9 is an overhead installation view showing a drywall sheet being supported along a longitudinal edge by the panel support apparatus.
[0015] FIG. 10 is a wall installation view showing two panel support apparatuses clamped to wall studs supporting a drywall panel.
[0016] FIG. 11 is a perspective view of an accessory block for use with the panel support apparatus.
[0017] FIG. 12 is a perspective view of the accessory block of FIG. 11 engaged with the panel support apparatus.
[0018] FIG. 13 is an overhead installation view showing two panel support apparatuses clamped to wall studs with engaged accessory blocks supporting a drywall sheet.
[0019] FIG. 14 is an overhead installation view showing two panel support apparatuses clamped to wall studs with engaged accessory blocks supporting a drywall panel for installation on a sloped ceiling.
[0020] FIG. 15 is a side perspective view of the panel support apparatus clamped to a longitudinal metal stud.
[0021] FIG. 16 is a back perspective view of the panel support apparatus clamped to a lateral metal stud.
[0022] FIG. 17 is a back perspective view of the panel support apparatus secured to a joist with double-headed nails.
DETAILED DESCRIPTION
[0023] 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 that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0024] Moreover, except where otherwise expressly indicated, all numerical quantities in this description and in the claims are to be understood as modified by the word “about” in describing the broader scope of this invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary, the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures or combinations of any two or more members of the group or class may be equally suitable or preferred.
[0025] Referring initially to FIGS. 1-3 , a panel support apparatus of the present invention is generally indicated by reference numeral 30 . Panel support apparatus 30 has a generally L-shaped body 32 with a lateral supporting arm 34 extending rearwardly from and generally perpendicularly to the L-shaped body 32 . The U-shaped body 32 includes right 36 and left 38 back members, an alignment ledge 40 for engaging a ceiling joist or wall stud, a panel support ledge 42 and sloped support members 44 , 46 and 48 separated by clamping channels 50 and 52 . The lateral supporting arm 34 includes a lateral back member 54 with a clamping window 56 and a lower leg 55 . Right 36 and left 38 longitudinal back members include clamping windows 58 and 60 vertically aligned with channels 50 and 52 , respectively. The back members 36 , 38 and 54 include raised surface indicia to press into wood framing to keep the panel support apparatus from slipping and twisting.
[0026] The alignment ledge 40 has a width of approximately one-half inch. The height of the right 36 and left 38 back members may be two to three inches, for example. The panel support ledge 42 may be one-half inch wide and have a height of 11/16 to support a five-eighths inch drywall sheet. Generally, the height of panel support ledge 42 may be one-sixteenth inch more than the thickness of the drywall sheet to be hung. In the preferred embodiment, a thickness adjustment spacer 62 may be used to accommodate different drywall thicknesses. The spacer 62 includes two or more posts 64 spaced to engage apertures 66 in ledge 42 . For example, if the panel support ledge 42 is eleven-sixteenths inch high, a five-eighths inch thick drywall panel may be supported with a one-sixteenth inch clearance between the drywall sheet and the joists or studs without a spacer 62 . A one-half inch drywall panel may be hung by inserting a one-eighth inch thickness adjustment spacer 62 to maintain the one-sixteenth inch clearance.
[0027] An alignment window 68 is included through the panel support ledge 42 and sloped support member 46 . Adjustment spacer 62 may also include an alignment window 70 aligned with the alignment window 68 .
[0028] Referring to FIGS. 4-9 , panel support apparatuses 30 are illustrated secured via C-clamp vice grips 72 to ceiling joists 74 . To properly align the panel support apparatuses 30 , a pencil or other mark is made across the ceiling joists 74 a distance from the wall header 76 equaling the length (or width) of the drywall sheet 78 to be hung. For example, if the drywall sheet is four feet wide, a mark 80 is made using a framing square perpendicularly across the joists 74 four feet from the wall header 76 . Looking through the alignment window 70 , the installer can align the mark 80 with alignment indicia 82 on the bottom surface 84 of the panel support apparatus 30 .
[0029] Once the panel support apparatuses 30 are aligned and secured to the ceiling joists 74 , the front edge 86 of the drywall sheet 78 is brought into contact with the sloped support members 44 , 46 and 48 . The panel 78 may now be pushed up the sloped surfaces until the front edge 86 comes to rest on the panel support ledges 42 . The drywall sheet 78 may now be adjusted as desired while fully supported along the front edge 86 . The widths of the alignment ledge 40 and the panel support ledge 42 provide adjustment space 88 for the drywall sheet 78 . Once the installer is satisfied with the alignment of the drywall sheet 78 , the sheet 78 may be screwed or nailed to the ceiling joists 74 . When the drywall sheet 78 is secured to the ceiling joists 74 , the C-clamp vice grips 72 may be released and the panel support apparatuses 30 may be moved to the next position to install another drywall sheet.
[0030] Referring to FIGS. 5 and 10 , when installing a drywall sheet 90 to wall studs 92 , the panel support apparatuses 30 may be secured to the wall studs 92 via C-clamp vice grips 72 . To properly align the panel support apparatuses 30 a pencil or other mark 80 is made across the wall studs 92 an equal distance from the ceiling 94 or other reference point equal to the length or width of the drywall sheet 90 depending on the orientation of the sheet 90 to be hung. Looking through the alignment window 70 , the installer can align the mark 80 with the alignment indicia 82 on the bottom surface 84 of the panel support apparatus 30 .
[0031] Once the panel support apparatuses 30 are aligned and secured with the C-clamp vice grips 72 to the wall studs 92 , the bottom edge 96 of the drywall sheet 90 is brought into contact with the sloped support members 44 , 46 and 48 . The drywall sheet 90 is now supported along the bottom edge 96 and may be pivoted flat against the wall studs 92 . The drywall sheet 90 may then be aligned as desired and secured to the wall studs 92 .
[0032] Referring to FIGS. 11-14 , an accessory block for use in combination with the panel support apparatus 30 is generally indicated by reference numeral 100 . Accessory block 100 includes a beveled profile 102 , which matches the profile of the sloped support members 44 , 46 and 48 , the panel support ledge 42 and alignment ledge 40 . A lip 104 fits over the leading tip of the sloped support members 44 , 46 and 48 to the lower surface 84 of the panel support apparatus 30 . The accessory block includes a sloped support surface 106 extending from a top surface 108 in a plane which intersects a lower surface 84 plane. The top surface 108 lies in a plane parallel to the front surfaces 37 and 39 of right 36 and left 38 back members and surface 43 of panel support ledge 42 .
[0033] When installing the last sheet of drywall 110 where the panel support apparatus 30 cannot be secured to the ceiling joists, the accessory blocks 100 may be used in combination with the panel support apparatuses 30 . The panel support apparatuses 30 may be secured to the wall studs 92 with C-clamp vice grips 72 . With the accessory block 100 in place, the drywall sheet 110 may be lifted and the front edge 112 placed on the sloped support surface 106 . The drywall sheet 110 can then be raised and slid against the wall header 76 , aligned as desired and secured to the ceiling joists 74 with screws or nails. When the drywall sheet 110 is being held against the ceiling joists 74 , the front edge 112 rests on and is supported by the top surface 108 of the accessory block 100 .
[0034] Similarly, when installing drywall sheets 120 on a vaulted ceiling 122 , the panel support apparatuses 30 with the accessory blocks 100 may be secured to the wall studs 92 with C-clamp vice grips 72 . With the accessory block 100 in place, the drywall sheet 120 may be lifted and the front edge 124 placed on the sloped support surface 106 . The drywall sheet 120 can then be raised and held against the vaulted ceiling 122 , aligned as desired and secured in place. When the drywall sheet 120 is being held against the vaulted ceiling 122 , the front edge 124 rests on and is supported by the top surface 108 of the accessory block 100 .
[0035] Referring to FIG. 15 , the panel support apparatus 30 is illustrated secured by a C-clamp vice grips 72 longitudinally to a steel stud or joist 130 . The upper jaws 73 of the vice grips 72 passes through the clamping window 60 in the left back member 38 to clamp the lower flange 132 of the steel stud 130 . The lower jaw 75 of the vice grips 72 is placed in the aligned clamping channel 52 to engage the panel support apparatus 30 .
[0036] Referring to FIG. 16 , the panel support apparatus 30 is illustrated secured by a C-clamp vice grips 72 laterally to a steel stud or joist 130 . The upper jaw 73 of the vice grips 72 clamps the lower flange 132 of the steel stud 130 to the lower lea 55 of the supporting arm 34 opposite the lower jaw 75 . For an orientation with the open channel of the steel stud 130 facing the lateral back member 54 of the lateral supporting arm 34 , the upper jaw 73 passes through the clamping window 56 to clamp the lower flange 132 of the steel stud to the lower leg 55 opposite the lower jaw 75 .
[0037] Referring to FIGS. 1-3 and 17 , the panel support apparatus 30 may be temporarily secured longitudinally to a stud or joist 140 using double-headed nails 142 or screws passing through apertures 144 to support a drywall sheet 146 . Similarly, for a lateral application (not shown), double-headed nails 142 or screws may be driven into a joist or stud through apertures 148 to temporarily secure the panel support apparatus 30 to the joist or stud to support a dry-wall sheet 146 .
[0038] It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims and allowable equivalents thereof.
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A panel installation support apparatus versatile and convenient for temporary attachment of the panel to a frame member includes an adjustable support surface for accommodating various panel thicknesses, a sloped surface to support the leading edge of the panel when positioning in place, and an alignment support shelf to properly align an edge of the panel with the joist or stud while supporting the edge of the panel. An accessory block may be used when standing a panel against a wall or when hanging drywall on sloped ceilings.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] In one embodiment, this invention relates generally to a top drive system for a drilling rig.
[0002] Top drive is the oilfield definition of a power swivel in combination with certain additional features which facilitate torque reaction and pipe handling.
[0003] A power swivel is a hydraulic or electric powered rotating device which is suspended in or on the derrick, and which drives the drill pipe from above the rig floor, thus the name top drive. It replaces the rotary table, which drives the pipe from lower down, at the rig floor level.
[0004] The power swivel generates torque which is reacted by vertical track member(s) in the derrick in which the power swivel rides up and down. That is, this track is arranged such that the swivel torque is restrained no matter where the power swivel is vertically positioned in the derrick.
[0005] For lower torque levels, the vertical track members have historically been 1 or 2 wire ropes, tensioned between the top of the derrick and the rig floor. Torque reaction arm(s) mounted to the swivel are attached to the rope(s) by either common U-shaped fittings called shackles which slide up and down against the rope(s), or sheaves (pulleys) which provide rolling contact against the rope(s). This approach is low cost, fairly quick to rig up, and the loads imparted to the derrick by power swivels rated at lower torque levels are generally not significant. This is good for the rental tool business which rents the lower torque range of portable power swivels and cannot afford to be concerned with generating stresses in the customer's derrick.
[0006] For torque levels in the higher ranges, some form of rigid steel track members have been used, either attached to the derrick from top to bottom, or attached only at the top and bottom. In either of these cases, significant loads resulting from the swivel torque are transmitted to the derrick, and the derrick stress levels must be examined for safety.
[0007] The portable rental tool industry needs top drives which can be installed in any derrick without adding any torque loading whatsoever.
[0008] It is an object of this invention to provide a top drive system which can be installed in any derrick without adding any torque loading whatsoever.
[0009] It is a further object of this invention to provide a device which permits measurement of the torque being generated by the top drive.
[0010] It is another object of this invention to provide a top drive system which accomplishes multiple purposes, including torque reaction, torque measurement, and pipe handling, in a simple and low cost system.
SUMMARY OF THE INVENTION
[0011] In one embodiment, the invention provides an arrangement of a torque absorber unit, a track unit, a carriage unit, a power swivel, and linkage arms, for use on a drilling rig comprising a drilling rig floor structure and a mast structure positioned on the drilling rig floor structure.
[0012] For brevity, the arrangement is described in its installed configuration. The track unit comprises a track having an upper end and a lower end and a longitudinal axis. The track is mounted in the mast structure and to the drilling rig floor structure in a manner which permits limited rotational movement around the longitudinal axis of the track. The torque absorber unit is connected to the lower end of the track unit and to the drilling rig floor structure and limits rotation of the track. The carriage unit is mounted for vertical travel on the track and is capable of exerting torque to the track around the longitudinal axis of the track. The power swivel is for rotating the drill pipe and is suspended in the mast structure. At least one pair of linkage arms extends from opposite sides of the power swivel to opposite sides of the carriage unit. The linkage arms are mounted to both the power swivel and the carriage unit for pivoting movement in a horizontal plane. Torque generated by the power swivel can be transmitted from the power swivel to the drilling rig floor structure via the at least one pair of linkage arms, the carriage unit, the track unit and the torque absorber unit.
[0013] In another embodiment of the invention, there is provided a method for absorbing torque generated by power swivel in a drilling rig. The method is preferably carried out using the above described apparatus. The method is carried out by rotating a drill pipe with the power swivel, which results in the generation of reaction torque. The reaction torque is transmitted from the power swivel to the drilling rig floor structure via the at least one pair of linkage arms, the carriage unit, the track unit and the torque absorber unit.
[0014] In a preferred embodiment, the torque output from the power swivel is further measured. This is easily accomplished where the torque absorber unit is the form of a hydraulic cylinder coupled to a pressure gauge which has been calibrated to measure torque output from the power swivel.
[0015] In a further embodiment of the invention, there is provided a method for rotationally manipulating, with respect to a vertical axis, a power swivel in a drilling rig. The method is preferably carried out in the above described apparatus in an embodiment wherein the torque absorber unit comprises a hydraulic cylinder and piston mechanically connected at one end to the track and at the other end to the drilling rig floor structure. The apparatus further comprises a hydraulic actuator means in operable association with the torque absorber unit for selectively positioning the piston in a desired position. The hydraulic actuator means, preferably a pump and control valve, is employed to position the piston in a desired location, which in turn manipulates the rotational orientation of the power swivel via the track unit, the carriage unit, and the at least one pair of linkage arms. Thus, the same hydraulic cylinder that is used for torque reaction and torque measurement can be used for torque track manipulation as well. By providing pipe handling means facing outwardly from the power swivel, the same hydraulic cylinder can be further employed to perform top drive pipe handling functions.
[0016] The invention thus provides a drilling rig with top drive functions using a simple, low cost machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a frontal view schematically illustrating certain features of the top drive system of the invention as deployed in a drilling rig, the drill pipe, cables, control lines, and portions of the derrick structure not being shown for the sake of clarity.
[0018] [0018]FIG. 2 is a top view of a portion of the device shown in FIG. 1 illustrating the pivot and linkage arrangement of elements used to absorb torque generated by the power swivel.
[0019] [0019]FIG. 3 is a schematic illustration of a hydraulic control system useful with the invention as illustrated in FIG. 2.
[0020] [0020]FIG. 4 is a side view of the device shown in FIG. 2, after having been rotated to a neutral position, the elevator arms having been moved from position A (illustrated in FIG. 2) to position B.
[0021] [0021]FIG. 5 is a frontal view of a portion of the device shown in FIG. 1, to illustrate certain features in greater detail.
DETAILED DESCRIPTION OF THE INVENTION
[0022] With reference to the Figures, the track unit 2 comprises a rigid track 4 having an upper end and a lower end and a longitudinal axis. The track is for mounting to, generally in, a mast structure 6 positioned on a drilling rig floor structure 8 in a manner to permit rotational movement of the track unit around the longitudinal axis of the track. The torque absorber unit 10 is for connecting the lower end of the track unit with the drilling rig floor structure. The carriage unit 12 is mountable for vertical travel on the track and is capable of transmitting torque to the track around the longitudinal axis of the track. The power swivel 13 is for rotating the drill pipe. At least one pair of linkage arms 14 , 14 ′ extend from opposite sides of the power swivel to opposite sides of the carriage unit. The linkage arms are mounted to both the power swivel and the carriage unit for rotational movement in a horizontal plane. Torque generated by the power swivel is transmitted from the power swivel to the drilling rig floor structure via the at least one pair of linkage arms, the carriage unit, the track unit and the torque absorber unit.
[0023] Preferably, the track unit extends vertically upwardly from the drilling rig floor structure, and is pivotally mounted to an upper portion of the mast structure and pivotally mounted to the drilling rig floor structure for limited rotational movement around the longitudinal axis of the track unit. Preferably, the track is mounted in bearing assemblies top and bottom and is located in the mast structure between the mast crown structure and the drilling rig floor. The track may further be longitudinally tensioned by a cable connecting the upper end of the track to the mast crown structure. By drilling rig floor structure is meant the deck or strong structures mounted to or supporting the deck, such as the base of the mast structure or the substructures supporting the deck. The term mast crown structure is intended to include the gear including the crown sheaves at the top or crown of the mast. By employing this mounting technique and employing freely pivoting linkage arms, it is impossible for the track to impart torque to the mast.
[0024] The track unit preferably further comprises a base plate 16 connected to the lower end of the track unit and extending laterally from the track unit. The torque absorber unit preferably comprises at least one hydraulic cylinder 18 horizontally mounted to the drilling rig floor structure. The cylinder contains a movable piston 20 and a horizontal piston shaft 22 connecting the piston to the base plate. The piston shaft is preferably pivotally connected to the base plate. More preferably, the at least one hydraulic cylinder is mounted to the drilling rig floor structure for pivotal movement in the horizontal plane, and the horizontal piston shaft is pivotally connected to an outer end of the base plate for pivotal movement in the horizontal plane.
[0025] The piston divides the hydraulic cylinder into a first chamber and a second chamber. The apparatus preferably further comprises a fluid supply means 24 operatively connected to the hydraulic cylinder for driving the piston to a desired location in the hydraulic cylinder. See FIG. 3. The hydraulic cylinder applies rotational torque to the track unit which is transmitted to the power swivel via the track, the carriage unit, and the at least one pair of linkage arms, so that the power swivel is selectively rotatable from a first rotational position to a second rotational position in a variable manner. The same apparatus is thus useful for both torque reaction and pipe handling, i.e., it has dual functionality.
[0026] Additional functionality can be achieved by providing a pressure indication means 26 operatively connected with the fluid supply means to provide an indication of fluid pressure in the hydraulic cylinder. This enables the torque being generated by the power swivel to be easily determined. Over-torquing and possible pipe twist-off can thereby be prevented. Thus, triple functionality, and the system is easily automated.
[0027] The apparatus preferably further includes an elevator unit 28 for latching attachment to an upper end of a drill pipe string. A pair of elevator links 30 , 30 ′ extend from opposite sides of the power swivel to opposed sides of the elevator unit. A pair of actuator means 32 , 32 ′ connect the power swivel with an outer end portion of each elevator link for selectively moving the elevator unit from a lowered position to an extended position to lay down or pick up pipe.
[0028] The power swivel can be described as having a front side 34 and a back side 36 . The linkage arms extend generally away from the back side of the power swivel and the elevator links are mounted for movement generally on the front side of the power swivel from the lowered position (“B” in FIG. 4) to the extended position (“A” in FIG. 4).
[0029] Each actuator means preferably comprises a hydraulic cylinder unit 38 , 38 ′ having a first end and a second end pivotally connected by its first end to a rigid support structure 40 , 40 ′ extending from the power swivel alongside its respective elevator link and pivotally connected by its second end to a bracket structure 42 , 42 ′ extending transversely from the elevator link.
[0030] The power swivel is preferably suspended via hanger links 44 , 44 ′ from a traveling block which is in turn suspended from the mast crown structure and selectively movable up and down.
[0031] Preferably, the track has a generally rectangular cross section, having a length and a width, is of hollow construction, and is provided with generally cylindrical, axially-extending shafts at its ends for rotational mounting. The carriage unit has a passage therethrough of generally rectangular cross section to match the track, and a width which is preferably on the order of the length of the linkage arms. The carriage unit has an upper end and a lower end and a length as measured between the upper end and the lower end and the linkage arms are attached at both the upper end and the lower end of the carriage unit. In the illustrated embodiment, the linkage arms are formed from plates and the length of the carriage unit is about the same as the width of the track, to provide pitch stability.
[0032] In another embodiment of the invention, there is provided a method for absorbing torque generated by a power swivel in a drilling rig. The drilling rig comprises a mast structure mounted to a drilling rig floor structure. A track unit comprising a rigid track having an upper end and a lower end and a longitudinal axis is mounted in the mast structure and the drilling rig floor structure to permit rotational movement of the track unit around the longitudinal axis of the track. A torque absorber unit is provided connecting the lower end of the track unit with the drilling rig floor structure and permitting limited rotational movement of the track unit. A carriage unit is mounted for vertical movement on the track. The carriage unit is capable of transmitting torque to the track around the longitudinal axis of the track. A power swivel is provided for rotating a drill pipe. The power swivel is suspended in the mast structure. At least one pair of linkage arms extending from opposite sides of the power swivel to opposite sides of the carriage unit is provided. The at least one pair of linkage arms is mounted to both the power swivel and the carriage unit for pivoting movement in a horizontal plane. A drill pipe is then rotated with the power swivel which results in the generation of reaction torque. The reaction torque is transmitted from the power swivel to the drilling rig floor structure via the at least one pair of linkage arms, the carriage unit, the track unit and the torque absorber unit.
[0033] In a preferred embodiment, the torque absorber unit comprises a hydraulic cylinder and piston mechanically connected at one end to the track and at the other end to the drilling rig floor structure. Torque is hydraulically transmitted from the track to the drilling rig floor structure via the torque absorber unit.
[0034] In a further preferred embodiment, a pressure sensor is operatively associated with the torque absorber unit. An electrical signal is produced with the pressure sensor which is representative of a fluid pressure in the torque absorber unit. This pressure can be correlated with the torque being applied by the power swivel, and the signal can be further used to trigger an alarm or reduce (or increase) the power applied by the power swivel.
[0035] In a further embodiment of the invention, there is provided a method for rotationally manipulating, with respect to a vertical axis, a power swivel in a drilling rig. The drilling rig comprises a mast structure mounted to a drilling rig floor structure. The method comprises providing a track unit comprising a rigid track having an upper end and a lower end and a longitudinal axis mounted in the mast structure and to the drilling rig floor structure to permit rotational movement of the track unit around the longitudinal axis of the track. A torque absorber unit is provided connecting the lower end of the track unit with the drilling rig floor structure and permitting limited rotational movement of the track unit. The torque absorber unit comprises a hydraulic cylinder and piston mechanically connected at one end to the track and at the other end to the drilling rig floor structure. A carriage unit is mounted for vertical movement on the track. The carriage unit is capable of transmitting rotational torque to the track around the longitudinal axis of the track. A power swivel is provided for rotating a drill pipe. The power swivel is suspended in the mast structure. At least one pair of linkage arms is provided extending from opposite sides of the power swivel to opposite sides of the carriage unit. The linkage arms are mounted to both the power swivel and the carriage unit for rotational movement in a horizontal plane. A hydraulic actuator means is provided in association with the torque absorber unit for selectively positioning the piston in a desired position. The hydraulic actuator means is employed to position the piston in a desired location and manipulate the rotational orientation of the power swivel via the track unit, the carriage unit, and the at least one pair of linkage arms.
[0036] In a further preferred embodiment, an elevator unit is provided for latching attachment to an upper end of a drill pipe string. A pair of elevator links is provided extending from opposite sides of the power swivel to opposed sides of the elevator unit. A pair of actuator means for the elevator links is provided, each actuator means being mechanically connected at one end to the power swivel and at the other end to an elevator link for selectively moving the elevator unit from a lowered position to an extended position. The pair of actuator means is employed to selectively move the elevator unit between the lowered position and the extended position. By manipulating the position of the traveling block, the rotational orientation of the power swivel, and the extension and retraction of the elevator arms, drill pipe can be moved at will from the drill string to storage and back.
[0037] Further Description of Preferred Embodiments
[0038] The following three sections further explain the novel method in which the torque track and links are used to effect multiple purposes previously requiring much more involved and more costly equipment.
[0039] Torque Reaction Purpose of Torque Track and Links
[0040] Typical top drives on the market transmit power swivel torque to the tracks, imparting torque and at least some side loads to the derrick. My invention imparts only torque to the track assembly, and no side loads to the derrick. Torque in the track is reacted only by a base plate assembly at the floor level. To initially raise the track to vertical during installation, a hoist cable is attached to a lifting point on top of the track. The track is free to rotate in bearings, top and bottom, being restrained from rotating only by the torque absorber unit mounted to the drilling rig structure at the bottom end.
[0041] The torque reaction mechanism includes two link plates which are arranged with bearings in a parallelogram linkage. These link plates connect each side of the power swivel to each side of a carriage which is free to travel up and down the track with the power swivel. As the power swivel generates torque and tries to rotate, one link is in tension, the other in compression. Through this mechanism, only torque can be applied to the track, which is restrained from rotating only at the floor. No side loads are imparted to the center bearing at the top of the track, even when the power swivel is supplying drilling torque near the top of the track. All other known power swivel top drives, because their torque transmitting links are rigid, not frictionless bearing-mounted, inherently transmit a side load to the track along with torque.
[0042] Torque Measurement Purpose of Torque Track and Links
[0043] The invention also provides a unique mechanism for accurate torque measurement. As has been discussed, the torque imparted to the track is reacted by a base plate assembly which is arranged as follows. The vertical torque track is actually supported between top and bottom bearings. It is seen, then, that during rigup, before the power swivel and links are attached, and before the torque absorbing hydraulic cylinder is attached, the vertical track is free to spin on its axis between its top and bottom bearings. In operation, the track is restrained from rotating by a hydraulic cylinder(s), a common torque measuring device, but one which has never been used in this manner to measure torque of a power swivel. Historically, power swivel torque has been measured by a hydraulic pressure gauge which is calibrated in foot-pounds of torque. This method always lacks accuracy as there are considerable losses which are quite variable, and therefore which cannot be accurately taken into account. These losses occur between the power swivel hydraulic motor input and the actual torque output to the drill pipe, and include gear train losses, seal and bearing frictions which vary with speed and temperature, and packing grip on the washpipe which varies with mud pump pressure and packing lubrication. Another major inaccuracy is due to the considerable pressure drop due to high flow rates in the hoses at high speed. This embodiment of the invention accurately measures the true output torque of the power swivel, because only the torque available to rotate the pipe is reacted by the torque track. For the first time, actual power swivel torque output will be accurately measured.
[0044] Pipe Handling Purpose of Torque Tracks and Links
[0045] The invention further provides a pipe handling function, normally required in a top drive, using the torque track, parallelogram links, and the torque measuring hydraulic cylinder(s).
[0046] When pipe is not attached to the power swivel, such as between connections when drilling, an oilfield elevator attached to the swivel must be remotely manipulated to pick up the next joint of pipe from a variety of positions including the mousehole or the v-door at the bottom of power swivel travel, and the racking position at the top. As is seen, additional hydraulic cylinders are used to extend the reach of the elevators, and rotation (lateral elevator swing) is provided by the same hydraulic cylinder(s) used otherwise for measuring torque. During this pipe handling function, the power swivel is not drilling or providing torque, so the hydraulic cylinder is not measuring torque. Instead, the cylinder is now being powered by a hydraulic power source through a conventional directional control valve to provide power rotational movement of the bearing-mounted torque track as required to manipulate the elevator. The simple hydraulic circuit is arranged to allow independent dual purposes of either the torque measurement pipe handling.
[0047] While certain preferred embodiments of the invention have been described herein, the invention is not to be construed as being so limited, except to the extent that such limitations are found in the claims.
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A torque track in conjunction with parallelogram links and a hydraulic cylinder is used for multiple purposes in a drilling rig top drive system. The torque track is rotationally mounted within the mast between the crown and the rig floor and pivotally mounted by the parallel linkages to the sides of a power swivel. The hydraulic cylinder is mounted to an arm at the lower end of the track and it's other end is connected to the fixed rig structure. When the power swivel is supplying torque during drilling, the linkage transmits the torque to the track which is restrained from rotating by the hydraulic cylinder. The torque is thereby transmitted via the hydraulic cylinder to the fixed rig structure rather than the mast. The hydraulic cylinder can also be used as a load cell to allow torque measurement as well as to pivot the power swivel when needed for pipe handling purposes. The arrangement thus provides triple top drive functionality.
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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 a method and apparatus for separating solids from liquids in general and in particular to a method and apparatus for separating solids from liquids in an oil well drilling operation.
[0003] 2. Description of Related Art
[0004] Wells for recovering oil, gas and the like are typically created by drilling into an underground source using a hollow drill string supported by a drilling rig. The drill string includes a drill bit at the lower end that is rotated into the ground to create a well bore. As the drill bit is rotated, drilling fluid is pumped down through the interior of the drill string to pass through the bit and return to the surface in the well bore external to the drill string. The drilling fluid acts to lubricate the drill bit and carries the loose solids or cuttings created by the drill bit to the surface. At the surface, the used drilling fluid is collected and recycled by removing some or all of the cuttings. The composition of the cuttings content in the drilling fluid can be varied depending on the state of the drilling process and the location of the drill bit below the surface.
[0005] Presently, a mud storage tank to hold drilling fluid and a shale shaker to perform screening of larger cuttings tend to be standard equipment for a drilling rig. In normal well site operation, drilling fluid is circulated out of the borehole and passed over a shale shaker which is a screen to separate large solid particles from the drilling fluid. The shale shaker is generally positioned directly above the mud storage tank and the large particles are collected in a shale bin. The resulting collected large particles typically still have at least some drilling fluid on them after being deposited in the shale bin and are typically in the form of a slurry. A rotational particle separator such as for example a centrifuge or cyclonic separator is typically used to remove the smaller particles remaining in the drilling fluid in the storage tank.
[0006] Drilling fluids are typically either water based or oil based. Regulations in many countries require that when an oil based drilling fluid is used, the cuttings in the shale bin be hauled away for disposal or blended with sawdust and canola for land spreading. This is because the remaining drilling fluid on the cuttings discussed above would contaminate any site at which the cuttings were disposed unless the drilling fluid was removed beforehand. Blending of the cuttings prior to land spreading increases the cost to dispose of cuttings as compared to the cost of disposal of dry cuttings alone. In addition, the resulting wet cuttings composition is greater in volume and weight than dry cuttings alone. This increased weight and volume of the wet cuttings further increases transportation and disposal costs.
[0007] While the smaller particles in the drilling fluid are typically separated from the drilling fluid by a centrifuge, the larger particles removed by the shale shaker are not. The wet cuttings resulting from not centrifuging the larger particles results in the aforementioned problems with disposal of such wet cuttings. Previous attempts to pass all of the cuttings through a centrifuge have not been successful.
[0008] Heretofore, it has been impractical to pass all of the solid materials removed by the shale shaker through a centrifuge to further remove any drilling fluid from the solid material. The larger particles removed by the shale shaker would constitute too dry of a composition to properly pass through a centrifuge or cyclonic separator without plugging the same.
[0009] In addition, it has not been practical to pass all of the used drilling fluid through a centrifuge without first separating the drilling fluid from the larger particles with a shale shaker. Because of the relatively large volume of the mud storage tank, the velocity and agitation of the drilling fluid in this tank is relatively low. The lack of agitation of the mud storage tank allows the small and large particles to accumulate on the bottom of the tank. Because of the settling of the particles on the bottom of the tank, the larger particles would accumulate in the tank and thereby would not be removed quickly enough from the mud storage tank by the centrifuge. This allows for solids carry over between chambers of the mud storage tank and eventually allows for recirculation of the solids in the mud storage tank down the drill string which is undesirable.
[0010] What is desirable is a solid separation system that produces a drier solid product that does not require blending prior to disposal. Specifically, a method and apparatus that enables all of the solid material to be passed through a centrifuge or cyclonic separator so as to produce a drier solid is desirable.
SUMMARY OF THE INVENTION
[0011] The present invention provides a method and apparatus that enables all of the solid material in a drilling fluid to be passed through a centrifuge or cyclonic separator to remove all excess drilling fluid from the solid material. Specifically, the present invention permits the solid material removed from the drilling fluid by a shale shaker or screen to be passed through a centrifuge or cyclonic separator to further remove any drilling fluid from the solid material.
[0012] According to a first embodiment of the present invention, there is provided an apparatus for separating solids from liquids in a drilling operation. In the drilling operation, used drilling fluid is screened into a substantially solid portion and a substantially liquid drilling fluid whereby the drilling fluid is stored in a storage tank. The apparatus comprises a recirculation tank having a second liquid for receiving the solid portion, and a first rotational particle separator for separating the solid portion from the second liquid. The apparatus further includes a pump for pumping the solid portion and the second liquid from the recirculation tank to the first rotational particle separator and a bin region to receive and retain the separated solids from the first rotational particle separator, wherein the separated second liquid is returned to the recirculation tank.
[0013] The rotational particle separator may comprise a centrifuge. The rotational particle separator may comprise a cyclonic separator. The apparatus may be further mounted on a field transportable skid. The skid may include a raised platform for mounting the rotational particle separator. The apparatus may further comprise a second rotational particle separator for removing particles from the drilling fluid supplied from the storage tank wherein the particles are deposited in the bin region wherein the drilling fluid is returned to the storage tank.
[0014] The recirculation tank may include an angled bottom having a high end and a low end relative to each other. The pump may draw the solid portion and the second liquid proximate to the low end. The recirculation tank may further include a closable top. The second liquid may comprise drilling fluid. The apparatus may further include at least one tank for supplying a particle separation assisting agent to the input of the second rotational particle separator when said drilling fluid is a water based drilling fluid.
[0015] According to a further embodiment of the present invention, there is provided a method for separating solids from liquids in a drilling operation. In the drilling operation, used drilling fluid is screened into a substantially solid portion and a substantially liquid drilling fluid, wherein the drilling fluid is stored in a storage tank. The method comprises depositing the solid portion in a recirculation tank having a second liquid and drawing off the solid portion and the second liquid from the recirculation tank for delivery to a first rotational particle separator. The method further comprises separating the solid portion from the second liquid in a first rotational particle separator and collecting the separated solids in a bin region and deposing the second liquid back in the recirculation tank. The method may further include removing solid particles from a portion of the screened drilling fluid in a second rotational particle separator and returning the liquid portion to a collection tank, wherein the solids are deposited in a bin region.
[0016] 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
[0017] In drawings which illustrate embodiments of the invention,
[0018] FIG. 1 is a schematic view of a drilling system incorporating the drilling fluid cleaning system of the present invention.
[0019] FIG. 2 is a perspective view of a preferred embodiment of the drilling fluid cleaning system according to the present invention.
[0020] FIG. 3 is a top plan view of the drilling fluid cleaning system of FIG. 2 .
[0021] FIG. 4 is cross sectional view of the recirculation tank of FIG. 2 taken along the line 4 - 4 of FIG. 3 .
[0022] FIG. 5 is cross sectional view of the shale bin and two polymer tanks of FIG. 2 as taken along the line 5 - 5 of FIG. 3 .
[0023] FIG. 6 is cross sectional view of the shale bin of FIG. 2 as taken along the line 6 - 6 of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring to FIG. 1 , there is shown a schematic view of a well drilling system 10 , which includes a drill rig 12 , and a transportable drilling fluid cleaning system 40 . The drilling rig includes a drill derrick 14 supporting a drill string 16 , which is rotated to drill a well bore into the ground. A mud storage tank 20 is associated with the drilling rig and stores drilling fluid 18 . The composition of the drilling fluid 18 can be adjusted depending on the stage to which the well bore is drilled. The apparatus of the present invention can be used to remove undesirable solids from the drilling mud and to recycle the drilling fluid to the tank 20 at a desired viscosity.
[0025] The drilling fluid is pumped in a conventional manner from the tank 20 through a conduit 22 into drill string 16 . Drilling fluid 18 flows downwardly through the drill string to exit from the lower end of the string at bit 17 . The drilling fluid 18 acts to lubricate the drill bit and collect cuttings created by the drilling action of the bit. The drilling fluid with additional solids flows upwardly in the well bore externally to the drill string to be collected near the surface. The collected drilling fluids/solids mixture passes through conduit 24 to be delivered to a shale shaker 26 . Shale shaker is a vibrating screen positioned above the tank 20 that removes larger solids from the drilling fluid and delivers cleaned drilling fluid back to the tank 20 . The larger solids are delivered to the apparatus for further removal of drilling fluid for collection. Drilling fluid from the tank 20 may also be pumped by conventional means to the cleaning system 40 for further removal of smaller particles via conduit 28 wherein cleaned drilling fluid is returned to the tank 20 via conduit 30 .
[0026] FIG. 2 shows a side elevation view of a preferred embodiment of the drilling fluid cleaning system 40 . The system includes a recirculation tank 50 , a shale bin 70 , a first centrifuge 92 and a pump house 100 . The system may also include a second centrifuge 94 and a plurality of strip tanks and polymer tanks 102 and 104 respectively. The above components may be arranged on a platform, preferably in the form of a skid 42 , to permit loading of the system onto a trailer towable by a truck for transport of all of the components as a unit in a single trip by roads between drilling sites. In the province of Alberta, Canada, where the inventors are based, skid 42 can be dimensioned to a maximum size of 63 feet long, 12.5 feet wide and 17.5 feet high in order to be transportable on roads and highways as a non-divisible load. A skid of this size requires a special permit for oil field hauling, however, a pilot vehicle to lead the truck is not required. Skids of different sizes may be permitted in other jurisdictions.
[0027] The centrifuges 92 and 94 may be located on a secondary platform 96 above the shale bin and recirculation tank. The secondary platform 96 may also be moveable between a stored position during transportation and an operating position. The secondary be located above the shale bin 70 and recirculation tank 50 by means of telescoping arms 98 wherein the telescoping arms facilitate movement between the stored and operating positions. It will be appreciated that other means of moving the secondary platform between the stored and operating positions, such as, for example, by means of supporting the secondary platform on rotatable arms, will also be acceptable.
[0028] FIG. 3 shows a plan view of the fluid cleaning system 40 with the centrifuges removed showing details primarily of recirculation tank 50 , shale bin 70 and strip tanks and polymer tanks 102 and 104 , respectively. The recirculation tank and shale bin are located at a first end 44 of the skid 42 . The pump house 100 is located at a second end 46 of the skid 42 and includes various pumps and ancillary equipment for use in the fluid cleaning operation including pump 48 . The strip tanks and polymer tanks 102 and 104 , respectively, are located intermediate the pump house 100 and the shale bin 70 and recirculation tank 50 .
[0029] In the preferred embodiment shown in FIG. 3 , the recirculation tank 50 is located longitudinally along the skid 42 adjacent to the first end 44 of the skid. The shale bin 70 is located adjacent to the recirculation tank 50 and is substantially coterminous along the longitudinal length of the skid 42 . The recirculation tank 50 comprises a substantially rectangular container region defined by first and second longitudinal walls 52 and 54 respectively, first and second end walls 56 and 58 , respectively, and a bottom 60 .
[0030] Turning now to FIG. 4 , a cross sectional view of the recirculation tank is shown along the line 4 - 4 from FIG. 3 . As shown in FIG. 4 , the recirculation tank includes an opening 62 which may be connected to a conduit 47 as shown in FIG. 5 . The conduit connected to the opening 62 may be further connected to a pump 48 of conventional means which serves to supply a flow of the solid particles and drilling fluid in the recirculation tank to the first centrifuge 92 . In a preferred embodiment as shown in FIG. 4 , the bottom 60 may be angled so as to direct any particles settling on the bottom to the opening 62 for pickup and processing by the centrifuges. The recirculation tank 50 may also include a cover 64 that is positionable over the recirculation tank as shown in FIG. 6 . Cover 64 may be connected to the recirculation tank by a hinge or other suitable pivot 66 so that the cover may be opened to permit depositing of solid material in the recirculation bin or closed so as to aid in depositing of solid material directly into the shale bin 70 . In a preferred emobidment as shown in FIG. 6 , the cover 64 opens inwardly into the recirculation tank 50 . The cover 64 may be retained in a closed position over the recirculation tank 50 by any suitable means, such as, for example, by a chain (not shown) suspended from the secondary platform 96 connected to the free end 67 of the cover 64 at an appropriate position to substantially cover the recirculation tank. It will be appreciated by those of skill in the art that other methods of retaining the cover in a closed position may also be applied to the present apparatus.
[0031] The recirculation tank 50 is sized such that the addition of solid particles and cleaned drilling fluid at the top and the removal of the same from the bottom produces a sufficient agitation as to prevent the settling of a large quantity of particles before being drawn into the opening 62 . In practice, the applicant has found that a distance of approximately about 18 inches or less between the first and second longitudinal walls 52 and 54 , respectively, is sufficient to prevent excessive settling of any solid particles in the recirculation tank with a distance of 12 inches being preferred.
[0032] Referring back to FIG. 1 , drilling fluid pumped out of the recirculation tank 50 is directed to the first centrifuge 92 for further solids separation. The first centrifuge separates the solids from the drilling fluid/solid particles mixture and deposits the solid particles in the shale bin 70 . The cleaned drilling fluid is then returned to the recirculation tank 50 . Furthermore, in a preferred embodiment, the system also includes a second centrifuge for separating the solids from the drilling fluid in the mud storage tank 20 of the drilling rig. The solid/drilling fluid in the mud storage tank 20 is pumped by a conventional pump to the centrifuge. The centrifuge separates the solids from the liquids and deposits the solids in the shale bin 70 . The cleaned drilling fluid is then returned to the mud storage tank 20 .
[0033] Solids removed from the drilling fluid by centrifuges 92 and 94 as well as solids not requiring centrifuging are preferably stored in a shale bin 70 adjacent to the first end 44 of the skid 42 . Bin 70 is defined by four walls and floor 80 at a region of the skid adjacent to the recirculation tank 50 . The first and second walls 72 and 74 respectively of the bin 70 are transverse to the longitudinal length of the skid 42 while the third and fourth walls 76 and 78 are substantially parallel the longitudinal length of the skid. Preferably, as shown in FIGS. 5 and 6 , the bottom of each of the walls of the bin 70 may be offset towards the center of the bin so as to angled the wall. Alternatively, the walls of the bin 70 may be substantially vertical or the fourth wall 78 may alternatively include a hinged bottom to facilitate access for removing solid particles from the bin 70 .
[0034] In certain circumstances during drilling, for example when the drilling fluid is being changed from a water based drilling fluid to an oil based drilling fluid, it may be desirable to use a flocculating agent to promote the removal of solids from the drilling fluid. To address this need, the system of the present invention may include a flocculent source for adding a flocculating agent to the drilling fluid. Preferably, the flocculent source comprises at least one compartment for holding and mixing a flocculating agent and a delivery system to deliver flocculating agent to the centrifuges. Preferably, flocculating agent is added to the drilling fluid at the inlets of pumps supplying the centrifuges so the agent is mixed with the drilling fluid prior to centrifuging. Flocculating agents are conventional and may include a calcium water solution or a polymer based flocculating agent. According to a preferred embodiment, the fluid cleaning system 40 of the present invention includes two strip tanks 102 for holding a calcium water solution and two polymer tanks 104 for holding a polymer flocculating agent.
Operation
[0035] In use, the drilling fluid cleaning system 40 of the present invention is operated according to different schemes depending on the drilling stage.
[0036] During drilling of the “surface hole” (the first portion of the borehole), water based drilling fluid is commonly used to protect groundwater aquifers. During drilling of the surface hole, larger particles may be deposited directly into the shale bin 70 and the cover 64 of the recirculation tank positioned over the recirculation tank. The large particles may thereby slide over the cover 64 and into the shale bin 70 . The second centrifuge 94 may also be used to remove smaller particles from the drilling fluid 18 from the mud storage tank 20 whereby the particles are deposited in the shale bin 70 and the cleaned drilling fluid returned to the mud storage tank 20 .
[0037] During changeover of the drilling fluid from a water based drilling fluid to an oil based drilling fluid, the recirculation tank 50 may remain covered by cover 64 . The drilling fluid 18 in the mud storage tank 20 may be pumped into the second centrifuge 94 to remove any particles in the drilling fluid. In addition, calcium water from the strip tanks 102 or a polymer flocculating agent from the polymer tanks 104 may be added to the inlet of the centrifuge 94 along with the drilling fluid to enhance the separation of the solid particles from the drilling fluid. Thereafter the solid particles may be deposited in the shale bin 70 while the drilling fluid is returned to one or more of the strip tank 102 , polymer tank 104 or mud storage tank 20 . When the water based drilling fluid is sufficiently cleaned of particles it may be disposed of in a sump on or off site.
[0038] During drilling with oil based drilling fluid, the cover 64 to the recirculation tank 50 may be positioned off of the recirculation tank and the larger particles from the shale shaker 26 may be deposited in the recirculation tank. As previously indicated, the recirculation tank 50 contains a second fluid, which may be a drilling fluid similar to the drilling fluid as is used to drill the well. The drilling fluid and solid particles are drawn out of the recirculation tank 50 at opening 62 and passed through the first centrifuge 92 . The centrifuge removes the solids and deposit them into shale bin 70 and returns the drilling fluid to the recirculation tank 50 . The second centrifuge 94 draws the drilling fluid 18 from the mud storage tank 20 , removes the solids from the drilling fluid and returns the drilling fluid to the tank 20 . The solids are thereafter deposited in the shale bin 70 . The solids in the shale bin may thereafter be removed for land spreading or disposal by other means.
[0039] It will be appreciated that as the foregoing equipment is located on a field transportable skid, transportation to and from a drilling site is greatly simplified as compared to the transportation of various equipment separate from each other. In addition, the close proximity of all of the equipment set out above will greatly facilitate the switch over between different types of drilling fluid as well as switching over from removing solids from the drilling fluid to removing the water based drilling fluid from the drilling system.
[0040] 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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In a drilling operation, where used drilling fluid is screened into a substantially solid portion and a substantially liquid drilling fluid and the drilling fluid is thereafter stored in a storage tank. A method and apparatus for of separating solids from liquids. The apparatus comprises a recirculation tank having a second liquid for receiving the solid portion, and a first rotational particle separator for separating the solid portion from the second liquid. The apparatus further includes a pump for pumping the solid portion and the second liquid from the recirculation tank to the first rotational particle separator and a bin region to receive and retain the separated solids from the first rotational particle separator, wherein the separated second liquid is returned to the recirculation tank.
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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. 595,335, filed July 14, 1975.
BACKGROUND OF THE INVENTION
The present invention relates generally to the production of coal in situ into combustible gases, synthetic crude oils, coal chemicals and an underground system for production of industrial steam.
The civilized world is highly dependent on sources of energy for the necessities and amenities of life. In early times wood provided the energy for heat and light. With a growing world population and with forests denuded around the populated areas, coal gained favor as a source of heat and light, and later provided a source of energy for mechanized transportation and a host of other mechanical devices. Coal, of course, is more compact than wood and, therefore, contains more energy per unit weight or unit volume, and from that point of view is more desirable than wood.
As sources of energy, both wood and coal involve a series of batch operations. For wood, the tree is found and felled, useless parts such as twigs and leaves separated and disposed of, then lengths are cut to appropriate sizes, loaded on conveyances, carted to the point of use, off-loaded, stacked, picked up a few pieces at a time and cast into the fire, ashes are then removed and disposed of, and so on. Similarly, coal is found, grubbed out, obvious extraneous matter separated and disposed of, then broken down or crushed to desired sizes, loaded, transported to the point of use, off-loaded, piled, picked up and cast into the fire, then ashes and clinkers are removed and disposed of, and so on.
The discovery of commercial quantities of curde oiland natural gas led to massive displacements of wood and coal as sources of energy. Petroleum, of course, compared to wood or coal contains more energy per unit weight. Petroleum is fluid, clinker free, and is or can be made ash free. Further, pertroleum can serve as a source of energy in a series of continuous operations from the oil field to the end use. Batch operations, by nature costly, are essentially eliminated and messy cleanup as an aftermath of use is also eliminated. For decades petroleum discoveries were so prolific that supplies substantially exceeded demands with resultant abnormally low prices compared to other commodities in commerce.
Like the denuded forest of old, times today have changed. The easy to find oil fields of the world have been found. New discoveries of oil fields in recent years have tended to be located vast distances from population centers. The laws of supply and demand have been supplanted with international politics in the setting of market prices. Thus coal has been reinstated as a major source of furture energy supplies.
Coal has retained its advantages of being more favorably located in relation to the population centers of the world. Worldwide reserves of coal dwarf the known worldwide reserves of petroleum. For almost 100 years petroleum has been available in copious quantities at abnormally low prices. As a consequence, worldwide technical development was focused on petroleum to the virtual exclusion of technical development in coal. A look at the coal industry today reveals only token improvements over the old batch operations of grub, sort, crush, load, cart, off-load, pile, pick up, stoke and clean up. While it is true that individual operations have become highly mechanized with mammoth devices, the elements of batch operations remain. Batch operations, no matter what size, have great difficulty in competing with continuous operations of similar size.
The state of the art in the coal industry requires a lot of catching up to match the state of the art in the petroleum industry. First, coal should be brought to the surface as a fluid. A review of the prior art in coal shows that most of the work to fluidize coal has been performed after the coal was brought to the surface as a solid. This arrangement, of course, retains the batch operations of grub, sort, crush, load, cart, off-load, pile and pick up. After these batch operations have been performed and coal is transported to suitable above ground pressure vessels, it is well known in the art how to fluidize coal into combustible gases, into coal chemicals, and into synthetic crude oil. Unfortunately these operations also tend to be batch or semi-batch types.
Since the preponderance of the prior art of the above ground fluidization of coal begins after the coal has been mined by conventional methods, the feedstock is delivered with its two principal impurities -- moisture and ash contents -- intact. Moisture may be substantially removed in a separate batch operation, but the ash content is normally introduced into the pressure vessel fro removal at a later step in the fluidizing process. It should be obvious that a vast improvement would be made if the moisture content and the ash content were separated before the coal is brought to the surface.
Some prior art has dealt with fluidizing coal in situ. The preponderance of this work has been involved with in situ gasification of coal with the objective of producing combustible gases. Large scale operations were undertaken in Russia with lesser projects of shorter duration undertaken in the United States, England, Morrocco and other localities. All have been plagued with problems of underground burning consuming the combustible gases before they could be delivered to the surface. All have produced low BTU gases (in the range of 85 to 300 BTU per standard cubic foot) compared to natural gas of petroleum origin containing approximately 1000 BTU per standard cubic foot. These low BTU gases, while not suited to long distance pipe-lining, are quite satisfactory for nearby use if the BTU content can be stabilized at a reasonably constant level.
All in situ gasification projects heretofore seem to have overlooked a significant fact in their quest to generate combustible gases. The purpose of combustible gases as fuel is to generate heat. It, therefore, follows that it may not make too much difference whether the gas is burned below ground or above ground as long as the heat is captured to perform the useful work intended. If the heat is captured underground and brought to the surface, then the bothersome problem of preventing unplanned burning of combustible gases underground is eliminated. Methods of capturing heat underground will be apparent later in this disclosure.
A search of the prior art has revealed a meager amount of meaningful work in attempting to subject coal to pyrolysis in situ. Methods of pyrolizing coal in situ will be apparent later in this disclosure.
There has been a limited amount of work in the art of in situ liquefaction of coal. Methods have been described in U.S. Pat. No. 3,595,979 of Pevere et al, beginning with coal at ambient temperatures. No projects are known to applicant where coal has been liquefied in situ, using coal that is already hot. Methods of liquefying coal in situ, using hot coal as the raw material, will become more apparent later.
In order to understand the problems of producing coal in situ, it is helpful to understand some of the characteristics of coal. Coal had its origin in ancient geological times when large areas of the earth were relatively flat and swampy, and plant life grew in profusion. Over and over plants sprouted, grew, matured, died, fell in the water, then were replaced by many generations of other plants which repeated the cycle. Severe rotting occurred to dead plant parts protruding above the water, while submerged plant parts were substantially preserved. The accumulated plant debris, often many feet thick, contained a variety of components including roots, trunks, bark, limbs, leaves, moss, reeds, grasses, and mineral matter deposited by dust laden winds. Later in geological time the areas were inundated and deposits of mud, sands and clays sank to the bottom. These sediments ultimately formed the shales, sandstones, and limestones that overlie coal deposits today. The sediments, of course, provided the weight to compact the plant debris and thus began the evolution into coal. With the variety in the plant debirs it is easy to understand why today some coal is hard, some soft, some difficult to crush, some easy to crush, some highly permeable, some with hardly any permeability, and so on. With buckling of the earth's crust, such as occurred when mountains were formed or during earthquakes, it is also easy to understand how some coal deposits underground contain an extensive pattern of fractures and cracks that permit the passage of fluids.
For purposes of illustration, subbituminous coals as found in the western part of the United States are used in describing the processes herein, although coals of higher or lower rank are also applicable. These coals contain carbon, hydrogen, moisture and mineral matter. The carbon and hydrogen are combined into hydrocarbons that are similar to those found in crude petroleum, although the total hydrogen content in coal is only about half that of similar units of crude petroleum. It is this hydrogen deficiency in coal compared to petroleum, that prevents coal from being a ready substitute for petroleum. A proper planning of processes and projects, as will be described hereinafter, can produce products from coal that are readily interchangeable with products from crude petroleum.
The most prevalent use of hydrocarbons is as a fuel, whether the source be from petroleum or coal. In the combination process hydrogen (H 2 ) is burned with oxygen (O 2 ) to form water vapor (H 2 O), carbon is burned with oxygen to form carbon dioxide (CO 2 ), and any sulfur present forms sulfur dioxide (SO 2 ). These are the reactions when there is sufficient oxygen present to yield an oxidizing environment. With a shortage of oxygen and thus a reducing environment, substantially all of the carbon burns to carbon monoxide (CO) and sulfur combines to form hydrogen sulfide (H 2 S). In the combustion zone it is possible to have both oxidizing and reducing environments which will result in products of combustion containing water vapor, carbon dioxide, carbon monoxide, sulfur dioxide, hydrogen sulfide, free hydrogen, free oxygen and free carbon. As a practical matter in commercial operations it is desirable to control combustion either to a predominantly oxidizing or to a predominantly reducing environment.
In an oxidizing environment, the water vapor and carbon dioxide have contributed the maximum to the generation of heat from the fire. The sulfur dioxide can be further oxidized with a catalyst into sulfur trioxide (SO 3 ) which combines with water vapor to form a sulfuric acid mist (H 2 SO 4 ). Thus the oxidizing environment yields the most heat but in the presence of sulfur vields objectionable sulfur dioxide, sulfur trioxide or sulfuric acid, all of which are troublesome in the exit gases.
In the reducing environment, the carbon monoxide that is produced can be further oxidized and thus has a useful calorific content (approximately 315 BTU/cu ft) as a pipeline gas. The presence of sulfur yields hydrogen sulfide, which is relatively simple to separate from the exit gases. The reducing environment generates substantial quantities of heat, but much less than the oxidizing environment. In the predominantly reducing environment carbon dioxide (CO 2 ) reacts with incandescent carbon to form additional carbon monoxide (CO). As is well known in the art practiced above ground, incandescent carbon in the presence of water (or steam) reacts to form produces gas as follows:
H.sub.2 O + C = H.sub.2 + CO
this reaction absorbs considerable heat, but at the same time releases two valuable gases, hydrogen and carbon monoxide. Both of these gases, when properly redirected as described herein, serve as feedstocks to upgrade nearby coal in situ. The hydrogen generated underground is particularly useful in remedying the hydrogen deficiency of a portion of the coal in situ and also can be used as a feedstock for commercial facilities above ground.
A survey of the coal research and development shows that the preponderance of effort is directed to work above ground in gasification and liquefaction. All projects are plagued with a common problem; the hydrogen deficiency of coal. To understand the magnitude of the problem, consider the manufacture of fuel gases from coal. As previously mentioned, it is well known in the art how to derive producer gas (sometimes called blue water gas) by reacting steam with incandescent carbon to form hydrogen and carbon monoxide. Both hydrogen and carbon monoxide are good fuel gases, each containing slightly over 300 BTU cubic foot. Both fall woefully short in heat values; however, when compared to natural gas of petroleum origin which contains approximately 1000 BTU per cubic foot. It is well known in the art how to upgrade producer gas into gases with higher BTU content, but if upgrading is expected to be compatible with natural gas (principally methane, CH 4 ), makeup hydrogen is required in substantial quantities. For a typical coal to be upgraded into methane, almost three times as much hydrogen is required as is contained in the original coal. For liquefaction of coal, makeup hydrogen is also required because synthetic crude oil from coal contains approximately twice as much hydrogen as the original coal contained. Coal chemicals, however, can be extracted from raw coal without makeup hydrogen, simply by subjecting the coal to heat in the absence of air and capturing expelled gases and oozing tars.
Most underground coal deposits contain a certain amount of trapped gas in the pore space and in channels of permeability. The most common entrained gas is methane (sometimes called fire damp) which often is found in quantities of 50 to 300 standard cubic feet per ton of coal in place. This gas is a first hazard and a health hazard to underground workmen. Since the processes described herein require no manpower underground, entrained methane is readily captured for commercial use.
Referring again to producer gas generated from coal, either above ground or in situ, it is easy to understand the commercial desirability of upgrading. First is the problem of transportation. Cross country pipelines experience about the same amount of costs whether the gas transported be producer gas at 320 BTU per cubic foot or natural gas at 1000 BTU per cubic foot. It, therefore, follows that a million BTU's of producer gas at the destination will cost approximately three times as much in transportation charges as the same amount of BTU's delivered as natural gas. Second, while producer gas is an excellent fuel, it is not compatible with natural gas at the burner tip. Heating devices must be designed for one or the other, and substantial mechanical modifications normally must be made to convert from one gas to another.
With the worldwide reawakening to the importance of coal as a source of energy, both as a direct source of fuel and as a source of feedstocks for synthetic fuels, considerable outcry has been advanced regarding the environmental impact of coal production. In the United States, for example, powerful lobbying groups have joined forces to stop or severely restrict some of the mining methods practiced in the past. Gutting of the countryside, no doubt, will be a practice of the past, both in the United States and elsewhere. Coal production operations of the future must be designed to minimize damage to the environment as well as provide for restoration to proper aesthetic values upon termination of operations. Gutting of the countryside, in itself a costly operation, is overshadowed in terms of cost by the effort required in restoration. Restoration, no matter how well planned, leads to virtually endless differences of opinions as to the effectiveness of the job.
A minimum environmental impact occurs when coal is consumed in situ. Surface disturbance is kept to a minimum by drilling wells into the coal deposit. Then the coal can be subjected to in situ gasification, pyrolysis and liquefaction. By proper planning, subsidence can be controlled over a wide area, resulting in minor lowering of the landscape, the surface of which remains virtually intact.
INTRODUCTION
A major coal deposit underground can be consumed in situ resulting in the production of hydrogen, carbon monoxide, methane, steam, electricity, synthetic crude oil, sulfur, fertilizers, solvents, coal chemicals and a host of other useful products. Preferably the coal deposit is located several hundred feet underground, is composed of several strata of coal overlying each other with each stratum separated by a thin stratum of shale, and with one or more strata of coal being an aquifer. In this arrangement the overburden serves as a seal and source of pressure, so that each coal stratum may be pressurized with injected fluids without fear of blow-outs to the surface. The coal strata that are aquifers serve as a source of water for the processes described herein. Since in situ combustion is required, the water bearing coal stratum also serves as a deterrent to runaway burns underground.
Recognizing the many valuable products that may be derived from coal, those skilled in the art will be able to visualize product sequences not specifically described herein, but within the spirit and scope of those processes described for illustrative purposes. Further, no particular novelty is claimed for such well known processes as combining hydrogen with carbon monoxide to yield methane, converting hydrogen sulfide to elemental sulfur, distillation of coal derived from volatiles into various coal chemicals, and others. Novelty is claimed, however, in various series of methods and arrangements to accomplish the overall results described herein.
OBJECTS OF INVENTION
It is an object of the present invention to provide a new and improved method and apparatus for consuming coal in situ in order to derive a series of commercial products therefrom.
It is another object of the present invention to eliminate substantially the numerous batch type operations inherent in prior art applications of coal production and coal derivatives.
It is another object of the present invention to provide a method and apparatus for capturing sensible heat from underground burning of coal for further useful work above ground.
It is another object of the present invention to provide a new and improved method and apparatus for separating the useful components of the products of combustion and the products of chemical reaction underground of coal, and to use these components in commercial application.
It is still another object of the present invention to provide a new and improved method and arrangements of apparatus resulting in the integrated use of raw materials generated from coal in situ to create a host of finished products above ground.
Other objects of the invention will be apparent to those skilled in the art as the description proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic layout showing the various feed streams, the complex of processing and manufacturing plants above ground, and some of the finished products.
FIG. 2 is a diagrammatic sketch showing the surface of the earth, the overburden, the coal strata and the separating shale strata.
FIG. 3 is a diagrammatic sketch showing the coal and shale sequences underground and is divided into zones that are subjected to the phase processes described herein.
FIG. 4 is a diagrammatic shetch showing a well used for in situ gasification, including the underground heat exchange apparatus.
FIG. 5 is a diagrammatic sketch showing a well used for in situ pyrolysis.
FIG. 6 is a diagrammatic sketch showing wells used for in situ liquefaction.
FIG. 7 is a diagrammatic sketch showing a solids removal device in the gas exit tube of a production well.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The first steps of this invention involve reconnaissance of a coal deposit itself. Evaluation wells are drilled from the surface of the ground through the overburden and to the bottom of the lower coal stratum. It is desirable to take cores of the overburden above the uppermost coal stratum to ascertain the competentness of the rock. It is desirable to take oriented cores in each of the coal strata to determine the pattern of permeability. It is also desirable to test each coal stratum to determine the water bearing capabilities. Examination of the oriented cores in the first few evaluation wells will assist in determining the locations of subsequent evaluation wells. It is desirable to drill the evaluation wells in such a way that they may be used later as production, injection, or service wells. It is important that all wells drilled into the coal section be completed in such a way as to maintain a hermetic seal from the surface through the coal strata.
From the data derived from the evaluation wells, it is possible to plan the overall project. Sequence of production cycles can be established, zones of production can be identified, individual plants in the complex of plants above ground can be sized for compatibility with the overall project, utilities and service roads can be planned, and the wells can be equipped for the first series of production sequences.
The phases of production identified hereinafter are used for purposes of facilitating an understanding of the invention; however, it is to be recognized that the same production phases could be performed simultaneously in several nearby mining areas in order to yield desired production volumes to feed optimum sized plants at the surface. The phases of production described in detail hereinafter can be summarized as including:
Phase 1, gasification in a reducing environment;
Phase 2, gasification in an oxidizing environment;
Phase 3, production of producer gas;
Phase 4, pyrolysis; and
Phase 5, liquefaction.
The order of the phases could be changed or certain phases could be omitted to fit the desired plan. Detailed descriptions of some of the steps and of the apparatus for carrying out the steps in the various phases can be found in my later referenced copending applications which are hereby incorporated by reference.
Referring first to FIG. 3, coal strata No. 1, 2 and 3 are shown separated by layers of shale. Each coal stratum can be divided into one or more blocks of coal which can be subjected to one or more production phases as described herein. In FIG. 3, these blocks are identified as Blocks 1 through 9. In accordance with a preferred method, in Phase 1, carried out in coal block 7, a well 201, FIG. 1 or a plurality of such wells possibly of the type shown in FIG. 4 are subjected to gasification with the objectives of generating combustible gases, generating heat for conversion into steam, driving off coal tar mists for condensation at the surface, and converting the sulfur to hydrogen sulfide. This method is described in detail in my copending applications Ser. Nos. 510,409 and 531,453. The production plan calls for a reducing environment underground in the wells in block 7 and injection of an oxidizer in such a way as to prevent unplanned burning of the exit gases. In order to avoid dilution of the exit gases, the preferred oxidizer is oxygen from a conventional oxygen supply Plant 101, FIG. 1, provided for this purpose. A suitable mine pressure is selected, for example the pressure necessary to balance the hydrostatic head. Wells into coal block 7 are equipped for the purpose intended. Wells to be ignited are pumped free of water, ignition material, such as hot ceramic balls 10, are positioned in the coal strata, and oxygen is injected into the coal formation through an injection conduit 12 as the formation is set on fire. Mine pressure is stabilized by controlling oxidizer injection rates in consonance with gas withdrawl rates. The manner of ignition and stabilizing mine pressure is set forth in the aforementioned application Ser. No. 531,453. Hot exit gases are withdrawn through a heat exchanger 14, FIG. 4, installed in the well bore which is also disclosed in detail in application Ser. No. 531,453. Purified water from a conventional water treating Plant 104, FIG. 1, is circulated through the heat exchanger wherein a portion of the sensible heat in the hot exit gases is transferred to the water converting the water into steam. The steam from the heat exchanger is delivered to a conventional electrical generating Plant 105, FIG. 1, where a portion of its energy is converted into electricity. Steam is condensed in Plant 105 and the condensate is returned to the water Plant 104 to repeat the cycle.
Exit gases from production well 201, FIG. 1, in coal block 7 are delivered to a conventional gas clean-up Plant 103, FIG. 1, where the components of the gas are segregated by conventional means of scrubbing, absorption, adsorption, condensation, and the like. From Plant 103, water vapor is condensed and sent to the water Plant 104, hydrogen is sent to a conventional ammonia Plant 106 and to a conventional methane converter Plant 107. Mists derived from volatile coal tar are condensed and sent to a conventional distillation Plant 108. Hydrogen sulfide is separated and sent to a conventional sulfur conversion Plant 109. Carbon monoxide is sent via a gas pipeline (not shown) to a conventional methane converter Plant 107. Fly ash in the exit gases from production wells, for example well 201, is removed in the gas clean-up Plant 103 and sent to a concrete aggregate plant (not shown). Also, in gas clean-up Plant 103, free carbon particles are separated and recovered as carbon black. A multiplicity of production wells may be drilled into coal zone 7 to increase the volume of hot exit gases produced.
For the preferred method, Phase 2, carried out in coal block 9, a well 202, FIG. 1, or a plurality of such wells which may be similar or identical to the well 201 shown in FIG. 4 are subjected to gasification in accordance with the method and with the apparatus described in my copending applications Ser. Nos. 510,409 and 531,453. The objectives of the wells in block 9 are generating heat for conversion into steam, driving off coal tar mists for condensation at the surface, and converting sulfur to sulfur dioxide. This production plan calls for an oxidizing environment underground and injection of oxidizers in such a way as to burn the coal completely in this zone. The preferred oxidizer is air from a Plant 102 having air compressors therein. A suitable mine pressure is selected, for example the pressure necessary to balance the hydrostatic head. Wells in coal block 9 are of the aforedescribed type as shown in FIG. 4 and are equipped for the purpose intended to include a heat exchanger. Wells to be ignited are pumped free of water. Ignition material, such as the ceramic balls 10, are positioned in the coal strata and air is injected to set the coal on fire. Mine pressure is stabilized by controlling oxidizer injection rates in consonance with gas withdrawal rates. Hot exit gases are withdrawn through the heat exchanger 14 installed in the well bore. Purified water from the water Plant 104 is circulated through the heat exchanger so that a portion of the sensible heat in the hot exit gases is transferred to the water converting the water into steam. Steam is delivered to the electrical generating Plant 105 where a portion of its energy is converted into electricity. Steam is condensed in Plant 105 and the condensate is returned to water Plant 104 to repeat the cycle.
Exit gases from production wells 202 in coal block 9 are delivered to the gas clean-up Plant 103 where the components of the gas are segregated as previously discussed in regard to well 201. From clean-up Plant 103, water vapor is condensed and sent to the water Plant 104 and carbon dioxide is sent to a conventional purification Plant 115, or may be reinjected into a gasification well to react with incandescent coal to form carbon monoxide. Minor amounts of exit gases, such as tar mists, are segregated in the clean-up Plant 103 as described in Phase 1.
For the preferred method, in Phase 3, carried out in coal block 2, the zone is in the latter stages of an in situ gasification process having wells 203, FIG. 1, which may be similar or identical to the well 201 shown in FIG. 4, completed therein. By way of example, half of the coal in place may have been consumed, using the plan of either Phase 1 or Phase 2. Oxidizer injection is terminated and raw water injection from the water Plant 104 is begun through the injection conduit 12 previously used for oxygen injection. As an alternate, if the coal in block 2 is an aquifer, mine pressure can be lowered to permit encroachment of surrounding formation water. The incandescent coal in block 2 reacts with injected water to form producer gas (H 2 + CO) as described in more detail in my copending application Ser. No. 558,423. The producer gas can be further processed to adjust the ratio of H 2 to CO to form synthesis gas. Producer gas and steam are delivered to the gas clean-up Plant 103 for segregation, for use as described in Phase 5 later, or for other purposes. Phase 3 is a cool down phase that is continued until the remaining coal is cooled down to the desired temperature, for example at least as low as 800° F. Upon reaching the desired temperature, water injection is stopped and the remaining coal in block 2 is ready for liquefaction as described in Phase 5 later. If it is desirable to prolong the cool down, steam may be injected instead of water.
In the preferred method, in Phase 4, carried out in coal blocks 4 and 6, the gases are subjected to pyrolysis as described in my copending application Ser. No. 750,714 with the objectives of driving off volatile matter as gases and oozing tars. This phase is begun after coal blocks 7 and 9 have been under gasification for a period of time, for example, three months. The gasification projects in blocks 7 and 9 have generated a substantial amount of heat underground, a portion of which has been transferred through the overlying layer of shale 16 into the coal in blocks 4 and 6. Wells 204, FIG. 1, are drilled into blocks 4 and 6 and are equipped as shown in FIG. 5, so that gases may be withdrawn and delivered to the gas clean-up Plant 103 and so that oozing tars may be collected and delivered to the distillation Plant 108. A complete description of the wells 204 as shown in FIG. 5 can be found in the aforementioned application Ser. No. 570,714. Produced gases are segregated in clean-up Plant 103 for uses as described in Phases 1 and 2 above. Produced tars are distilled into coal chemicals and solvents, with a residue of pitch. Production in Phase 4 continues as long as heat is being added or until substantially all of the volatiles are driven off. Upon completion of Phase 4, the remaining coal may be further produced by gasification as described in Phases 1 and 2 above.
In the preferred method, in Phase 5, carried out in coal block 2, the zone has been cooled down in accordance with the production plan described in Phase 3 above. Water injection is terminated and solvent injection is begun from a chemical and solvent storage Plant 112. In addition producer gas from the gas clean-up Plant 103 is also injected to percolate through the solvent. Thus the remaining coal in block 2 is subjected to liquefaction by depolymerization and hydrogenation in accordance with the procedures and apparatus disclosed in my copending application Ser. No. 558,423. An example of an injection well 18 and a production well 20 for this purpose are shown in FIG. 6 and described more fully in the aforementioned application Ser. No. 558,423. Injection rates and withdrawl rates are balanced to maintain the desired mine pressure, for example, substantially in equilibrium with hydrostatic head. Excess solvent in the circulating fluids is delivered to the distillation Plant 108 for clean-up and recycling. Excess producer gas in the circulating fluids is delivered to the gas clean-up plant 103 for clean-up -and recycling. Liquefied coal, which is a synthetic crude oil, is delivered to the storage Plant 113 and to a conventional refinery 114 where it is processed into a variety of hydrocarbons and residual coke. Production continues until the residual coal is substantially consumed.
Referring to FIG. 3 and the production phases described above, block 3 can be subjected to gasification (Phases 1 or 2), followed by cool down and production of producer gas (Phase 3), followed by liquefaction (Phase 5). block 4 can produce first by pyrolysis (Phase 4), followed by gasification (Phases 1 or 2), followed by cool down and production of producer gas (Phase 3), followed by liquefaction (Phase 5). Likewise block 1 can be subjected to the same production sequences as block 4. Other zones in the coal formation such as blocks 5 and 8, can be subjected to one or more production phases described herein.
Referring to FIG. 1, in reviewing the various plants illustrated, those skilled in the art will be able to visualize other processing plants or modifications of the functions described for the plants listed without departing from the spirit of the disclosure presented herein. For example, consider electrical generation Plant 105. Should there be a requirement for higher temperature steam than is delivered from Wells 201 and 202, a superheater may be added to Plant 105 to bring the steam up to planned temperature and pressure. The superheater can be fueled from pipeline gas produced on site. Further, steam can be generated in Plant 105 from water or returned condensate by firing a suitable boiler with pipeline gas produced on site, and the like. Also, the electrical generation Plant 105 can be a combined cycle generating plant utilizing gas and steam.
Referring to FIG. 7, hot exit gases from production Wells 201 and 202 (FIG. 1) contain a certain amount of particulate matter including fly ash from the mineral matter in the coal and free carbon that was not completely consumed in the combustion process. Gases being withdrawn through the heat exchanger, FIG. 4, are being reduced in temperature on the way to the surface. This temperature drop tends to cause some of the particulate matter to stick to the cooler walls of the heat exchanger. To remove this particulate matter and thereby avoid a build up of the matter on the walls which would restrict gas flow, a suitable scraper 22 suspended from the well head extends through the gas exit tubes 24, only one being shown in FIG. 7, in the heat exchanger to the bottom of each tube. A sonic generator 26 is attached to the scraper support plate 28 and sound waves are transmitted to the scrapers. In the preferred embodiment sonic waves are transmitted at the resonant frequency of the scrapers, causing the scrapers to vibrate. In other embodiments, harmonics of the resonant frequency may be preferred. This vibration causes a scouring action that loosens the particulate matter which is then carried to the surface in the exit gas stream. In severe cases where hot tar mists are condensed and tend to form a sticky plug blocking the exit gas stream, gas flow can be reversed temporarily at the surface by higher pressure oxidizer injection into the exit gas tubes, causing the tars to burn to noncondensible gases, thus purging the exit gas tubes of sticky tars and permitting resumption of normal prodution.
In the preferred embodiment, the scrapers 22 are in the form of elongated augers, which impart a swirling motion to the exit gases and thus provide for a more efficient heat transfer to the circulating water in the heat exchanger.
In addition to the functions of the heat exchanger 14 described in the foregoing processes, the heat exchanger also serves a useful purpose in protecting the well bore. Referring to FIG. 4 it can be appreciated that the protective casing 30 is subjected to a substantial amount of heat from the hot exit gases, particularly in the lower part of the casing. Without the heat exchanger the casing would ultimately be heated cherry red, with resultant expansion and damage to the surrounding concrete seal. The heat exchanger removes heat from the casing area and thus prevents overheating and damage to the concrete seal.
While the above methods, descriptions of apparatus and arrangements of apparatus have been described with a certain degree of particularity, it is to be 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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A method of producing combustible gases, synthetic crude oils, coal chemicals and heat from coal in situ utilizes the combined teachings of in situ gasification, liquefaction and pyrolysis.
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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 swimming pools, and, more particularly, to an automatic pool cover box lid support bracket.
2. Description of the Related Art
Swimming pools are commonly covered to prevent debris from entering the pool, to preserve chemical treatments in the water and to heat the pool in the case of a solar cover. An automatic pool cover provides convenience for a user by allowing the cover to be easily extended over the pool during periods of non-use, and retracted during periods of use. Typically, a box is placed in the decking surrounding the swimming pool at a location opposite from the walk-in steps (usually at the deep end of a pool). The box extends across the width of the swimming pool, and houses an electric motor and reel on which the cover is wound.
A problem with conventional automatic pool cover boxes is that the lid which covers the box is typically installed without sufficient support under the body of the lid. If a person steps on a pool cover box lid the pool cover box lid may deform and may cause damage to the pool cover box lid.
Another problem with conventional automatic pool cover boxes is that angular adjustment of the pool cover box lid entails the bending of supports.
What is needed in the art is an automatic pool cover box lid which is adequately supported and easy to angularly adjust.
SUMMARY OF THE INVENTION
The present invention provides an automatic pool cover box lid support bracket assembly having a lid support, an angular adjustment and a wall mount assembled from modular components which may be easily connected together on-site and adjusted relative to each other to provide an optimum installation.
The invention comprises, in one form thereof, a lid support bracket assembly for supporting a pool cover box lid including a wall mount and a bracket adjustably coupled to the wall mount.
The invention comprises, in another form thereof, a pool cover box assembly for housing a swimming pool cover, including a plurality of vertical walls, including a rear wall, a lid having a rear edge, the rear edge being removably engaged with the rear wall and a plurality of lid support bracket assemblies supporting the lid. Each lid support bracket assembly including a wall mount attached to the rear wall and a bracket adjustably coupled to the wall mount.
An advantage of the present invention is that the pool cover box lid support bracket provides support to the pool cover lid.
A further advantage is the pool cover lid support bracket provides an angular adjustment to allow a pool cover box lid to be properly adjusted relative to a swimming pool deck resulting in an aesthetically pleasing look.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a swimming pool including an embodiment of an automatic pool cover box assembly of the present invention;
FIG. 2 is a partially sectioned perspective view of the automatic pool cover box assembly shown in FIG. 1 ;
FIG. 3 is an end, sectional view of the automatic pool cover box assembly of FIGS. 1 and 2 ;
FIG. 4 is a perspective view of the lid support bracket of FIGS. 2 and 3 ; and
FIG. 5 is an end, sectional view of another embodiment of a lid support bracket of the present invention.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to FIG. 1 , there is shown an embodiment of swimming pool 10 with deck 12 , coping 14 , cover 16 , leading edge bar 18 and pool cover box assembly 20 of the present invention.
Deck 12 is generally horizontal and is preferably constructed from concrete. Coping 14 connects to deck 12 in a substantially coplanar fashion along the edge of deck 12 facing the interior of swimming pool 10 .
Coping 14 is connected to deck 12 and provides a track allowing leading edge bar 18 to slide therein. The general shape of the exposed portion of coping 14 is generally curved such that there are no exposed sharp corners. Coping 14 may include a provision to retain a fiber optic light along the length of coping 14 and above the level of leading edge bar 18 and cover 16 . Coping 14 also includes a liner bead slot similar to liner bead slot 62 ( FIG. 3 ) from which vinyl liner 64 is suspended.
Cover 16 is attached to leading edge bar 18 which pulls cover 16 from pool cover box assembly 20 , through an opening existing between pool cover box assembly 20 and a top edge of swimming pool 10 , across the length of swimming pool 10 . To prepare swimming pool 10 for use, cover 16 retracts into pool cover box assembly 20 pulling leading edge bar 18 to the previously described opening.
Leading edge bar 18 is connected to cover 16 and provides support along the leading edge of cover 16 . Each end of leading edge bar 18 is connected to at least one cable (not shown) and is slideably connected to a track in coping 14 . Leading edge bar 18 is shaped in a manner to be unobtrusive and aesthetically pleasing when located at either end of swimming pool 10 .
Now additionally referring to FIGS. 2 and 3 , pool cover box assembly 20 includes a rear wall 22 , a bottom 24 , a front wall 26 , a coupling 28 , lid 30 , lid edge support 32 and a plurality of lid support bracket assemblies 34 . Pool cover box assembly 20 houses cover 16 , reel 36 and a drive mechanism (not shown) which drives reel 36 and a rope and pulley system for the extension and retraction of cover 16 . When cover 16 is retracted from swimming pool 10 , cover 16 is wrapped around reel 36 a number of times corresponding to the length of swimming pool 10 .
Rear wall 22 , bottom 24 and front wall 26 are arranged to form three sides of pool cover box assembly 20 adjacent and generally parallel to one end of swimming pool 10 . The top edge of front wall 26 is parallel to a plane formed by deck 12 and is disposed therebelow. End cap coping 38 rests on and finishes the top edge of front wall 26 .
Coupling 28 has protrusions along a back side to engage the concrete of deck 12 and has an L-shaped upper portion, extending from a front side, to accommodate a portion of lid 30 . The top edge of coupling 28 is substantially coplanar with deck 12 and forms part of rear wall 22 . Coupling 28 may be formed as an extrusion of metal or plastic.
Lid 30 is composed of two substantially identical extrusions having a coupling mechanism to engage the two extrusions. The rear edge of lid 30 is shaped to engage coupling 28 so that lid 30 does not slide from its intended position. The front edge of lid 30 has a C-shaped channel 40 to accommodate latching projections 42 of lid edge support 32 . As an alternative to the two piece construction of lid 30 , lid 30 may be made of one or more than two piece construction.
Lid edge support 32 is fastened to lid 30 and is disposed above end cap coping 38 forming an opening therebetween. This opening is generally parallel with the plane of deck 12 and is such that cover 16 may be freely extended over swimming pool 10 and retracted into pool cover box assembly 20 . Lid edge support 32 provides support to the front edge of lid 30 reducing the amount of deformation along the front edge of lid 30 .
According to an aspect of the present invention, and additionally referring to FIG. 4 , lid support bracket assemblies 34 include bracket 44 and wall mount 46 . Lid support bracket assembly 34 extends over the top of reel 36 and provides support to lid 30 . Lid support bracket assemblies 34 are vertically positioned such that bracket 44 accommodates the thickness of lid 30 . Lid support bracket assemblies 34 are adjustable such that lid 30 can be positioned at a desired angle to deck 12 or such that lid 30 is substantially coplanar with deck 12 .
Bracket 44 includes a load bearing portion 48 , supports 50 , female threaded coupling and bolt 54 . Bolt 54 engages female threaded coupling 52 of bracket 44 and slot 58 of wall mount 46 . This arrangement allows lid support bracket assembly 34 to resist downward force conveyed thereto, yet be easily removed by lifting bracket 44 and disengaging the head of bolt 54 from slot 58 of wall mount 46 .
Load bearing portion 48 is generally flat on the top portion and is connected on the underneath side to two supports 50 . Female threaded coupling 52 is attached between supports 50 to the underneath side of load bearing portion 48 . Alternatively, load bearing portion 48 may be an extrusion and female threaded coupling 52 may be integral thereto.
Supports 50 are generally parallel to each other and the top edges of supports 50 are connected to the bottom side of load bearing portion 48 . The rear edges of supports 50 are shaped and positioned to engage wall mount 46 and to rest on support pins 56 .
Bolt 54 , is threadably engaged with female threaded coupling 52 . The rotational position of bolt 54 is used to adjust the angle of bracket 44 to accommodate the positioning of lid 30 and provide support thereto. The head of bolt 54 couples with wall mount 46 . The angle of bracket 44 , and hence the angle of lid 30 , is adjustable by a rotational adjustment of bolt 54 . For example, to raise the front edge of lid 30 , bolt 54 is engaged further into female threaded coupling 52 .
Wall mount 46 is broadly U-shaped and includes support pins 56 , slot 58 and protrusions 60 . A plurality of wall mounts 46 are attached to rear wall 34 in a spaced manner to accommodate the mounting of a similar number of brackets 44 . The U-shaped cross-section of wall mount 46 accommodates the thickness of the head of bolt 54 . Wall mount 46 has protrusions 60 , which run vertically, to captivate bracket 44 . Wall mounts 46 are vertically positioned on rear wall 34 to establish a base vertical position for brackets 44 .
Slot 58 of wall mount 46 has a circularly shaped portion to accommodate the insertion of the head of bolt 54 at the lower end of slot 58 and slot 58 narrows at the upper end to accommodate passage of the shaft of bolt 54 . The arrangement of slot 58 serves to captivate bolt 54 .
Support pins 56 on wall mount 46 are provided to accommodate bracket 44 and are located to provide vertical positioning to bracket 44 such that the rear edge of lid 30 is substantially at the same height as deck 12 . Support pins 56 on wall mount 46 are positioned to constrain the movement of bracket 44 and to transfer the vertical component of the load from bracket 44 to rear wall 22 .
Now referring to FIG. 5 , another embodiment of bracket 44 of the present invention is shown. In this embodiment, bracket 44 is substantially similar to the previous embodiment, but bracket 44 additionally includes a bolt 72 , a pivoting coupling 74 and a bolt 76 . Pivoting coupling 74 is attached to bracket 44 in a pivotal manner and is threadably engaged with bolt 72 . The head of bolt 72 is positioned in the corner formed by the intersection of bottom 24 and rear wall 22 .
Bolt 76 is threadably engaged with bracket 44 and the head of bolt 76 is constrained in a slot of wall mount 46 . Wall mount 46 is substantially the same as that of the previous embodiment, yet without the need for support pins 56 . Bracket 44 is adjusted by rotating bolt 72 and bolt 76 to properly position bracket 44 .
To install a lid support bracket assembly 34 in a pool cover box, wall mounts 46 are positioned along and attached to rear wall 22 . Bolt 54 is threadably engaged into female threaded coupling 52 of each bracket 44 . The head of bolt 54 is inserted into the generally circular opening of slot 58 in wall mount 46 . Bolt 54 , along with bracket 44 , is then slid upward into a narrowed portion of slot 58 thereby captivating bolt 54 to wall mount 46 . Bracket 44 is raised sufficiently so that it can be rotated downward to engage wall mount 46 and set upon support pins 56 of wall mount 46 .
Once brackets 44 are installed, pool cover box lid 30 is assembled to rear wall 22 of pool cover box 20 and pool cover box lid 30 is lowered onto brackets 44 . If pool cover box lid 30 is not positioned at the desired angle then pool cover box lid 30 is removed and brackets 44 are removed, bolts 54 adjusted and brackets 44 and pool cover box lid 30 are reinstalled as previously discussed.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A lid support bracket assembly for supporting a pool cover box lid includes a wall mount and a bracket angularly adjustably coupled to the wall mount.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to hoists but more particularly relates to mobile hoists for lifting wall and/or ceiling panels used in building construction.
Most buildings are constructed utilizing available forms of cladding for internal walls, which cladding generally comprises flat sheets or panels of various dimensional sizes and weights. Ceilings and internal walls are generally lined with these panels. Where large panels are used, the weight of those sheets makes fixation thereof at least a two and preferably a three man job. The panels are heavy, cumbersome and hard to handle especially where panels are to be placed on the ceiling.
Wallboard panels made from plaster and cardboard are not stiff enough to resist bending and must be carefully handled so that they are kept substantially flat during installation to prevent snapping. For long panels this necessitates adequate support of the panels until they are fixed in position.
In recognition of this problem, special hoists have been constructed for handling panels such as wallboards. One such hoist is the subject of U.S. Pat. No. 3,828,942.
That invention comprises a lifting device for lifting ceiling panels into place flush against the ceiling beams for installation. The device has a supporting structure for supporting the panel and telescopic sleeves for raising and lowering the panels. The device also has a cable and pulley connecting structure for telescoping the sleeves with a drum or spool for winding the cable and a brake mechanism for the drum. The supporting structure may also be pivoted at an angle and carry thereon panels for installation against the upright wall framework.
More particularly, that invention comprises a lifting device for lifting and aligning wallboard panels to and with the ceiling and vertical walls for installation of the panels to the interior frame of a building. The device comprises a telescopic shaft or sleeve structure, an upright frame, a drum mounted to the upright frame having a wheel for rotating the drum, a plurality of pulleys mounted to the telescopic structure and frame, a cable extending from the drum and about the pulleys and interconnecting the telescoping shaft structure whereby rotation of the drum in one direction by turning the wheel will telescope the telescopic shaft structure. Spaced apart support beams are mounted to the upper end of the telescopic shaft structure each of which have hooks at one end whereby a panel may be placed upon the support beams retained by the hooks and raised vertically to the ceiling by the telescopic structure. The support structure may be pivoted to a selected angle whereby the panel rests in the hooks. The device can then be moved toward a vertical wall framework to facilitate placement of the panel in position against the vertical wall for installation of the panel.
One disadvantage of this device is that the user is still required to lift the wall and ceiling panels onto the device itself. Once the panel is lifted by hand onto the device, the device is operated in the usual way by hoisting the ceiling or wall panel into position. It is quite difficult for one individual to lift heavy panels onto the hoist. Using the existing hoist it is still generally a two man job.
SUMMARY OF THE INVENTION
The present invention seeks to overcome this problem by providing a panel lifting and transporting assembly which enables a panel to be lifted from a position off the assembly to a support structure on the assembly.
More particularly the present invention provides an assembly including a panel lifting apparatus for attachment to a panel hoist or panel support trolley thereby providing means to enable lifting of a panel to be fixed to the surface of a building onto the hoist.
The attachment comprises:
means for enabling attachment of the apparatus to a supporting hoist or trolley, clamping means for gripping a panel to be lifted;
control means directly or indirectly linked to the clamp to enable movement/lifting of the panel onto the hoist. Preferably, the attachment is detachable from the hoist and also foldable.
In one broad form the present invention comprises;
a panel lifting assembly including an apparatus for use with a panel lifting hoist or trolley for transferring a panel from an off the hoist or trolley location onto the hoist or trolley in preparation for lifting of said panel to the point of fixation;
the apparatus comprising;
means to enable releasable attachment of the apparatus from the hoist or trolley,
clamp means for grippingly engaging a panel to be lifted;
control means for moving the panel to be lifted from an off assembly location to an on assembly location.
Preferably the attachment apparatus is foldable and is used with an adapter with a connecting saddle which receives a wedge plate on the apparatus.
In another form of the invention, the attachment previously described is mounted on its own supporting trolley enabling carriage and transport of panels.
In its broadest form, the present invention comprises:
a panel lifting assembly comprising;
a panel support hoist or trolley having at least a ground engaging carriage and a support structure, a panel lifting apparatus having means to enable detachable attachment of the apparatus to and from the hoist or trolley;
characterized in that the panel lifting apparatus comprises;
a primary support member,
a clamp for gripping engagement with a panel to be lifted,
control means for actuating the clamp via a cable which links the clamp and the control means;
wherein when a panel is to be lifted from a position off the assembly and onto the assembly, the clamp is brought into engagement with the panel and the control means actuated to draw the panel onto the assembly enabling support and carriage thereof.
In another form the present invention comprises;
a panel lifting apparatus for detachable attachment to a panel lifting hoist or trolley the apparatus comprising;
a primary support member,
a clamp for gripping engagement with a panel to be lifted,
control means for actuating the clamp via a cable linking the clamp and the control means;
wherein when a panel is to be lifted from a position off the assembly and onto the hoist or trolley, the clamp is brought into engagement with the panel and the control means actuated to draw the panel onto the hoist or trolley enabling support and carriage thereof.
In another form the present invention comprises:
a panel lifting trolley of the type comprising a ground engaging carriage, a substantially upright mainframe, a panel support platform connected to the mainframe and capable of being tilted characterised in that the panel support platform has thereon a saddle which detachably receives a wedge plate on a panel lifting apparatus which locates on the support platform; further characterised in that the panel lifting apparatus comprises;
a primary support member,
a clamp for gripping engagement with a panel to be lifted,
control means for actuating the clamp via a cable linking the clamp and the control means;
wherein when a panel is to be lifted from a position off the trolley and onto the trolley, the clamp is brought into engagement with the panel and the control means actuated to draw the panel onto the trolley enabling support and carriage thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail and in each of its forms according to preferred but non limiting embodiments and with reference to the accompanying illustrations wherein;
FIG. 1 shows a prior art hoist;
FIG. 2 shows an isometric view of the panel lifting apparatus according to one form of the present invention;
FIG. 3 shows a cross sectional elevational view of the upper part of the apparatus of FIG. 1.
FIG. 4 shows a carriage trolley adapted to receive the apparatus of FIG. 2.
FIG. 5 shows an alternative carriage to that shown in FIG. 4; and
FIG. 6 shows an isometric view of a trolley adapted to receive the apparatus of FIG. 2.
FIG. 7 shows the trolley of FIG. 6 with the panel support platform rotated; and
FIG. 8 shows a front elevational view of the trolley of FIG. 6 with the apparatus of FIG. 2 fitted.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is shown a known prior art panel lifting hoist 1. The hoist 1 comprises an upright mainframe 2 which comprises a telescopic sleeve structure 3 and splayed legs 4. The upright mainframe supports generally H-shaped platform 6 which is used for supporting a panel (usually a wall or ceiling panel) and placing that panel at the location at which it is to be affixed. The H-shaped panel support platform 6 may be elevated by means of telescopic members 7 and 8. Connecting the upright main frame to the H-shaped platform 6 is pivot 9 which allows the platform 6 to be rotated so that the panel carried by the platform can be presented at the correct attitude for fixing. Thus, the platform 6 can be disposed so that panels for fixing to walls can be presented directly to the wall or alternatively platform 6 can be rotated to a substantially horizontal attitude so that it presents a panel facing a ceiling. Platform 6 generally comprises a longitudinal beam 10 and transverse arms 11 and 12. The transverse arms 11 and 12 have at one end of each arm saddles 13 and 14. The H-shaped member also has extension arms 15 and 16 to enable an increase in the length of the support platform for larger panels. With this platform configuration panels of most, if not all, sizes can be supported on the platform.
Upright main frame 2 is also adapted with support frame 2a which supports cable drum 17 and drive wheel 18. When the panel support platform 6 is to be elevated the drive wheel 18 is rotated causing cable 19 to elevate H-shaped panel support platform 6 via telescopic members 7 and 8.
The main disadvantage of the above described prior art panel lifting hoist is that it is necessary for a user to lift a panel from the floor and onto the platform. Wall and ceiling panels are often large and difficult for an individual to manage thus making it inconvenient for one person to constantly be lifting heavy panels onto the hoist.
Referring to FIG. 2 there is shown a panel lifting apparatus 20 which is an improvement on the prior art hoist and may be used on its own or in conjunction with other means of support such as a trolley (see FIGS. 4 and 5) or, alternatively, may be used as an attachment to a modified trolley (See FIG. 6) or to an existing hoist an embodiment of which has been previously described with reference to FIG. 1.
Panel lifting apparatus 20 comprises a support column 21 of indefinite length. This column may be varied in height/length according to particular requirements. Column 21 is adapted with a wedge plate 22 which engages with tapered saddle 24 on adaptor 23. The adaptor 23 is equipped to enable attachment to the typical prior art hoist as shown in FIG. 1 or to the trolley shown in FIG. 6. The attachment typically takes place by affixing the adapter 23 to longitudinal arm 10 of the prior art hoist by means of hinged posts 25 and 26. Adapter 23 is placed over the longitudinal arm 10 on release of the hinged post 25 and 26 and these are then secured by means of bolts and wing nuts 28 and 29 respectively.
In use, the hoist assembly 20 is connected to saddle 24 via wedge plate 22 as shown by the arrows 30. In use, a panel 31 is gripped in recess 32 by jaws 33 and 34 of clamping assembly 35. The clamping assembly 35 is also equipped with a pantograph 36 which operates the jaws under the assistance of spring bias 37.
When a panel is to be lifted by the jaws, the clamping assembly can be brought down to engage with a panel for instance, lying on the floor and it can be connected with very little effort by the operator. Once the jaws are clamped to the panel by exerting tension on cable 41 on turning of wheel 38 the operator can then start to draw the panel up the column 21 by further operating drive wheel 38 via handle 39. The drive wheel 38 is associated with cable drum 40 around which travels cable 41. The cable travels via pulley 42 and pulley 43 and finally terminates at cable anchorage 44. With this arrangement a simple turning of the drive wheel urges clamping assembly 35 up the support column 21 thereby drawing the panel up and along the column 21. When the hoist assembly 20 is attached to the prior art panel lifting hoist 1 the H-shaped frame can be rotated in the usual manner to orient the sheet in the correct attitude for presentation to the surface to which the panel is to be fixed.
Referring to FIG. 3 there is shown a side elevational cross sectional view of a portion of the panel lifting apparatus of FIG. 2. From this view it can be seen that the column has disposed therein a stop 45 which engages with an arresting arm 46 which is in turn attached to jaw 34. The stop has the effect of arresting the movement of the clamping assembly 35 when it has reached its maximum allowable travel.
Referring to FIG. 4 there is shown a trolley 47 having a ground engaging main frame 48 and support column 49. The main frame 48 is supported on castors 50. Support column 49 has a tapered saddle configured similar to the adaptor 23 shown in FIG. 2. The panel lifting apparatus 20 as shown in FIG. 2 can be inserted into the tapered saddle 51. Thus, wedge plate 22 may be inserted into saddle 51 shown in FIG. 4. In this way a panel may be lifted from a floor surface or from an attitude leaning against the wall and may be transported around the room to a different location without an operator having to lift the panel.
FIG. 5 shows an alternative carriage 52 comprising a single support column 53 and castor wheel 54. The support column is adapted with tapered saddle 55 which receives wedge plate 22 of the panel lifting apparatus 20. The assemblies of FIGS. 4 and 5 may be used for transportation of a panel. The weight of the panel when in the clamping assembly 35 as shown in FIG. 2 increases the gripping force against the panel thereby ensuring safety during lifting.
Referring to FIG. 6 there is shown an isometric view of a trolley 60 for use with the panel lifting apparatus 20 shown in FIG. 2.
The trolley comprises a panel support platform 61 which comprises a longitudinal beam 62 and transverse arms 63 and 64. Both the beam 62 has telescopic extension arms 65, 66.
Transverse arms 63 and 64 have knobs 67, 68 which can be turned to allow saddle arms 69 and 70 to also turn to allow a panel of wallboard to be lowered by depressing spring clip 71.
The panel lifting apparatus of FIG. 2 may be connected to the trolley via saddle 72.
The transverse arms 63 and 64 are connected to longitudinal beam 62 via additional saddles 73 and 74.
Likewise the longitudinal beam 62 is connected to supporting legs 75 and 76 via saddles 77 and 78. The saddles 77 and 78 wedge onto hinges 79 and 80.
The hinges enable rotation of the platform 61 in the direction of arrow 81.
FIG. 7 shows the trolley of FIG. 6 rotated in the direction of arrow 81.
FIG. 8 shows a front elevational view of the trolley shown in FIG. 6 this time with the panel lifting apparatus shown in FIG. 2 fitted thereto.
The panel lifting apparatus according to one aspect of the present invention may in addition to its use as an attachment to a prior art hoist assembly be used for lifting sheets over considerable heights for instance from lower floors to upper floors in buildings along outside walls. Alternatively, the jaws may be used with a short piece of cable as a convenient hand tool for carrying panels.
It will be recognized by persons skilled in the art that numerous variations and modifications may be made to the present invention without departing from the overall spirit and scope of the invention as broadly described herein.
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There is provided a panel lifting apparatus for detachable attachment to a panel lifting hoist or trolley. The apparatus comprises a primary support member, a clamp for gripping engagement with a panel to be lifted, a control device for actuating the clamp via a cable linking the clamp and the control device. When a panel is to be lifted from a position off the apparatus and onto the hoist or trolley, the clamp is brought into engagement with the panel and the control device is actuated to draw the panel onto the hoist or trolley enabling the support and carriage of same.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTIONS
1. Technical Field
The present inventions relate to the components and the procedure for installing a trim assembly at a wall and ceiling junction, and, more particularly, relates to a self-adjusting trim assembly designed to hide unsightly gaps at the junction between the top of a stationary wall finish and a ceiling expected to move.
2. Description of the Related Art
As construction techniques improved in recent years, free span concrete ceilings (poured or pre-cast spans devoid of columns and beams for intermediate support) have come into common usage. These free span structures are usually supported by interior walls or beams at the core of the building and by walls or beams at the exterior of the building.
Exterior support structures are frequently subject to temperature variances and forces not present on and around the interior (core) support structures. The dynamics involved with the exterior support structures cause them to expand, contract and move at different rates than the core structures, resulting in an anticipated flex or movement of the ceiling being supported. Therefore, non-supporting walls constructed between support structures have to be able to withstand the expected movement of the ceilings above them without sustaining damage. To prevent damage to non-supporting walls, deflection allowances are designed into those walls which include deflection framing components and a deflection gap between the top of the stationary wall finishes and the ceiling expected to move.
Initial usage of free span ceilings was primarily in commercial buildings where drop ceilings hid the necessary deflection gaps between stationary elements of a non-supporting wall and a flexing ceiling above. Often in commercial spaces, the area above the drop ceiling was used to house the required electrical feeds, plumbing, fire protection piping and the HVAC ducting. Those areas above dropped ceilings often exceeded a foot in height. When this construction method began to be used in residential building, providing a dropped ceiling below the structural ceiling proved to be impractical. Electrical systems, plumbing, fire protection and HVAC were relocated into the walls or soffits and the dropped ceilings were eliminated. Therefore, the structural ceiling became the finished ceiling. This resulted in eliminating the extra height on each floor required above dropped ceilings. In a multistory building, omitting these extra heights and the dropped ceilings added up to become a significant savings. However, when the structural ceiling became the finished ceiling, the unsightly deflection gap at the top of all the non-supporting walls became visible.
It is commonly desirable to provide aesthetically pleasing junctions or intersections between walls and ceilings. When an unsightly deflection gap is visible due to anticipated flexing of the ceiling, making an aesthetically pleasing junction at the deflection gap between the stationary wall finishes and the ceiling requires a necessary treatment or covering for the exposed deflection gap.
In construction where it is not necessary to have a deflection gap, there are numerous methods of treating the junction between a stationary wall and a stationary ceiling, such as taping the joint (applying a paper or mesh tape angle and finishing compounds to the wall and ceiling junction to make an unbroken finish between the ceiling and the wall) or by applying a standard molding like a crown molding, a cove molding, a square stock molding, a beam, etc. to enhance the appearance of the wall and ceiling junction. However, there are few options for treating the junction between a stationary wall finish and a ceiling that is expected to flex as the ceiling's support members expand, contract or move due normal conditions expected to effect the support structures.
The current, common options for treating a deflecting gap between a stationary wall finish and a slightly deflecting ceiling are flat taping the top of the stationary wall finish (applying paper or mesh tape and finishing compound on the wall surface only with the edge of the tape as close to the ceiling as possible without touching the ceiling) and/or caulking the gap between the top of the stationary wall finish and the ceiling.
The chief advantage to flat taping (as illustrated in prior art FIG. 1 ) is that imperfections on the top edge of the wall finish materials and the fire or sound caulking is partially hidden by the tape. However, the flat taping option is labor intensive, has a built in crack at the top and generally results in an even more unsightly junction once the ceiling deflects down on the top of the tape, which crushes and permanently deforms the tape. (Once the ceiling migrates back upward, an unsightly gap is more pronounced.)
The caulking option is also somewhat unsightly because slight defects (uneven cuts, jagged edges, etc.) at the top of the wall finish material are visible, dust and dirt tend to accumulate in the caulk space over time and the caulk tends to distort when the ceiling migrates in an upward or downward direction. To minimize the unsightly appearance at the edges of the wall finish materials, a finishing bead (as illustrated in prior art FIG. 2 ) was often installed at the top of the wall finish material and finished with finishing compound prior to the installation of the caulk. If a finish bead is used to define the top edge of the wall finish material and hide defects, the caulk method is more costly for materials and more labor intensive than flat taping. Being that caulk tends to loose it's elasticity and bonding propensity over time, it eventually tends to allow small cracks and gaps to develop. In many fire resistant and sound deadening wall designs, caulk is a necessary component. Therefore the cost of the materials and labor for the caulk itself was not a factor in determining the best finishing application for the wall and ceiling junction.
Many trims that could hide an unsightly wall/ceiling gap have been designed through the years past. However, known trims were not self-adjusting and do not accommodate flex in the ceilings. Most known existing trim systems attached to the surfaces of the stationary wall and the stationary ceiling. Many known improvements incorporated concealed brackets and fasteners. While the trims for treating the junction between a stationary wall and a stationary ceiling were functional in their designed environment, they all had one thing in common. They were designed to be applied to the surface of a finished wall and a ceiling and they did not accommodate flexing of the ceiling without distortion or system failure.
One example of a trim system used in stationary wall and ceiling applications was taught in U.S. Pat. No. 4,555,885 by Ronald P. Raymond and William C. Andric (1985). This demonstrated an extruded, trim system where the trim has a barbed protrusion that was designed to friction fit in the gap between the wall and ceiling materials with a nearly flat element of the trim extending onto the ceiling and another nearly flat element of the trim extending onto the wall (having a basic right angle shape visible) which covers the gap between the wall finish and the ceiling finish. Wide variations in the joint width, caused by the flex of the ceiling, challenges the reliability of this system. This system also does not leave sufficient room for fire or sound caulks which are required in many fire and sound rated wall assemblies.
Another example of a trim system used in stationary wall and ceiling applications was taught in U.S. Pat. No. 4,461,135 by Dallas A. Anderson and Harlan J. Grayden (1984). This system is a 2 piece system of a plurality of slip-on clips and a trim piece that pushes onto the clips. This system functions in a manner similar to a slip-on J bead (a common edge treatment for drywall and other panel materials). This system attaches to the top of the finish panel for the wall system. This combination of clips and a trim piece is then manually adjusted after installation by sliding the trim into position immediately adjacent to the ceiling. Because this system is not self-adjusting, once the ceiling flexes in it's expected up and down migrations, a pronounced gap is developed. Being that this system is not self-adjusting, the trim would require periodic adjustment after installation.
A different approach to maintaining a pleasing appearance at the wall/ceiling junction was demonstrated in U.S. Pat. No. 6,581,353 by Ronald J. Augustine (2001), whereby the flexing of the ceiling is compensated through suspending the entire wall construction from the ceiling. This option creates a static wall/ceiling junction which can be finished using any existing finish or stationary trim system. The necessary gap that allows for flexing of the ceiling is just above the floor, with the deflection gap hidden by the baseboard. Lateral support for this wall construction system is at the bottom of the wall and is provided by using the sliding component of this invention. Drawbacks to this type of construction are the extremely high material, labor and fastener costs, the relative instability of the partitions at the base and the inability of this design to meet most fire and sound resistance ratings.
Numerous crown molding designs such as those shown in U.S. Pat. Nos. 5,426,901 by Jaroslav Indracek (1995), 5,433,048 by Jean P. Strasser (1995), 4,642,957 by Troy C. Edwards (1987) and 7,451,574 by Micheal Timothey Spek (2008) include many improvements in reducing costs of installation and material costs for use at the junction of a stationary wall and a stationary ceiling. While many of these designs incorporate improvements such as brackets and preformed corners to help hide fasteners and facilitate faster installations, the chief drawback to all these systems is that they were not designed for use at a junction between a stationary wall finish and a flexible ceiling.
SUMMARY OF THE INVENTIONS
This invention is a self-adjusting trim system in all it's present and future embodiments that can be used in any building where the ceilings are expected to flex due to the inherent properties of the construction materials and support structures while the wall finishes abutting the ceilings are expected to remain stationary. To allow for the expected movement of the ceiling an unsightly gap must exist between the top of the stationary wall finishes and the flexing ceiling. Most often, the ceiling system expected to exhibit some amount of flex would be made of poured concrete or pre-cast concrete that spans from an inside (core) support wall to an outside (exterior) support wall. This invention is designed to have no adverse effect on the fire and/or sound ratings of the wall and ceiling systems. A key benefit of this system, in addition to solving the problem of providing an aesthetically pleasing finish to the stationary wall and flexing ceiling junction, is that this system of components and the installation procedure is very economical.
BRIEF DESCRIPTION OF THE DRAWINGS
The present inventions are illustrated by way of example and are not limited by the accompanying figures, in which like references indicate similar elements. Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.
The details of the embodiments will be more readily understood from the following detailed description when read in conjunction with the accompanying drawings wherein:
FIG. 1 illustrates a cutaway end view of the prior art of flat taping, a common way of hiding the necessary gap between the wall finish and the ceiling;
FIG. 2 shows a cutaway end view of the prior art of exposed caulking in the exposed gap, another common option where a finish bead and compound are installed on the top of the wall finish to establish a straight line defining the necessary gap between the wall finish and the ceiling which is then filled with caulk;
FIG. 3 illustrates a side view of the basic components upon which this invention is based;
FIG. 4 is an isometric view of the Retainer Clip component of the basic system which is essential to this invention;
FIG. 5 is an isometric view of a Joint Tab which is an optional component for aligning abutted trim components of the basic system;
FIG. 6 is an isometric view of a basic trim component, hereinafter referred to as the Trim Strip of the basic system which covers gaps between wall surfaces and ceiling surfaces;
FIG. 7 illustrates a cutaway end view of the components of the basic trim system installed in a typical wall construction;
FIG. 8 illustrates a cutaway end view of the components of the basic trim system with the Retainer Clip sized to accommodate the greater distance of the wall finish from the wall framing installed in another type of typical wall construction;
FIG. 9 is an end view of the Retainer Clip component in just one of many optional sizes;
FIG. 10 is a rear view of the Retainer Clip component;
FIG. 11 is a front view of the Retainer Clip component;
FIG. 12 is an end view of an embodiment of the Trim Strip component;
FIG. 13 is a front view of the Trim Strip component;
FIG. 14 is a rear view of the Trim Strip component;
FIG. 15 is an end view of the embodiments for a hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 16 is an end view of an alternate hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 17 is an end view of an alternate hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 18 is an end view of an alternate hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 19 illustrates a view of a corner in a room with the trim system installed and of the conditions behind properly installed trim after initial installation;
FIG. 20 illustrates a view of a corner in a room with the trim system installed and of the conditions behind the properly installed trim during cold weather exterior wall shrinkage when the designed gap between the static wall finish and the flex ceiling is reduced;
FIG. 21 illustrates a view of a corner in a room with the trim system installed and of the conditions behind the properly installed trim during hot weather exterior wall expansion when the designed gap between the static wall finish and the flex ceiling is expanded;
FIG. 22 illustrates a cutaway end view of the components of the basic trim system installed in a typical retrogressive wall construction using an alternate Retainer Clip designed to be installed after wall finishes have been previously installed;
FIG. 23 illustrates the basic components of a trim kit for a typical room; and
FIG. 24 illustrates the construction process of building a wall which incorporates the trim system during construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the common, aesthetic treatment of the necessary gap between the top of the stationary wall finish and the ceiling that is expected to flex due to expansion, contraction and other anticipated movement of the support walls at each end of the ceilings. Note that the paper tape and finishing compound 15 is applied to the top edge of the wall finish 4 with a gap between the tape and compound 15 and the ceiling 3 above. Also shown are the framing components of this typical construction designed to allow for ceiling flex (vertical framing component 5 in a deflection or slip track 6 ), and caulk 7 in the gap between the top of the wall finish 4 and the ceiling 3 . The problem with this construction results during the anticipated upward and downward travel of the ceiling 3 , which crushes the top of the flat tape and compound 15 and then exaggerates the gap at the top of the tape when the ceiling 3 flexes in an upward direction. This treatment of the wall finish and ceiling gap is labor intensive and costly, but doesn't result in a permanent acceptable finish. A plurality of vertical framing components is usually contained within a wall assembly to provide the structure for the wall finishes to be used. In an assembly where the ceiling is expected to flex, the vertical framing components are expected to slide within the vertical legs of the deflection track without interfering with the up and down movement of the ceiling. For this reason, the vertical framing components and attached wall finishes are not attached to the deflection track. A deflection track is a framing component that is U-shaped with a vertical leg on each side that provides lateral stability to the wall framing assembly while concurrently allowing the ceiling to which the horizontal portion is attached to move without crushing the vertical wall framing components of the assembly.
FIG. 2 shows another common aesthetic treatment of the necessary gap between the top of the stationary wall finish and the ceiling that is expected to flex. This treatment shows a finishing bead with taping compound 16 at the top of the wall finish 4 . The necessary expansion gap between the top of the wall finish 4 and the ceiling 3 is then filled with caulk 7 . This caulk filled gap is always noticeable. As the ceiling 3 flexes, the caulk 7 deforms and eventually allows cracks to develop between the caulk and the ceiling 3 . Due to the uneven texture and shape of the caulk 7 , dust and dirt tends to accumulate in the caulk joint. This treatment is also labor intensive and costly without resulting in a permanent, aesthetically pleasing finish.
FIG. 3 is a side view of the primary components (Retainer Clip 1 and Trim Strip 2 ) of this invention (also shown during typical usage in FIGS. 7 and 8 and in special usage in FIG. 22 ). This invention is essentially; a 2-piece combination of components and the method of installation that enables the Trim Strip 2 of this combination to hide the essential gap that exists in a typical wall/ceiling junction where the wall finishes 4 are stationary and the ceiling construction 3 is designed to flex in response to changes in support structure heights. The following were considerations used in designing this invention:
1. Material Considerations.
In finish systems where it is necessary to maintain fire ratings, metal trim components could be preferable to other known materials such as plastic trim components because metal components tend not to contribute to combustion and do not omit the toxic fumes often generated by melting or combustion of other types of materials. Being the trim component of this system is a visible finish element of the wall construction, the trim component needs to be pre-primed or pre-finished, mold resistant, moisture resistant, resistant to distortion caused by building movement and rust and corrosion resistant. While the retainer clips are not visible after complete system installation, they still need to be resistant to distortion caused by building movement and rust and corrosion resistant. Materials and fabrication of system components need to be affordable. The Retainer Clip and the Trim Strip are preferably each formed from one piece of metal or other material to make the manufacture or installation more affordable.
2. Ease of Installation.
The Retainer Clips 1 for this system are small and light-weight, so that they are easily carried by the installer in a carpenter's pouch or nail apron. Installation of the Retainer Clip 1 is by screw attaching with framing screws 9 to deflection track 6 or a deflection angle 12 in a wall assembly while holding the Retainer Clip 1 up to the ceiling 3 . To make installation as fast as possible, spacing of clips need only be placed 2 ″ off the ends of each wall and placed approximately 2 to 4′ on center between the ends (insuring that the framing screws 9 do not engage the vertical framing component 5 portion of the framing so that movement of the deflection track 6 or deflection angle 12 is not inhibited). Exact spacing of Retainer Clips 1 is not required (except at joints of the Trim Strips 2 where the wall length exceeds the standard length of trim components 2 ). Therefore, installation time for installing Retainer Clips 1 is minimized. The system requires the Trim Strip 2 to be snapped into the Retainer Clips 1 after being measured and cut for length. Where Trim Strips 2 intersect each other or where they are required to abut each other in long wall instances, they have square cut ends during manufacture and are able to be abutted without requiring mitering, special connecting pieces or special cuts. In special instances where it is necessary to maintain alignment where slight deviations in the wall surfaces tend to misalign the butt joints of the Trim Strips 2 , a Joint Tab 10 (shown in FIG. 3 ) may be used. The cost to install these components is off-set by the elimination of flat-taping or the taping and finishing of a tape bead at the top of the wall finish as shown in FIGS. 1 and 2 , making this system extremely cost efficient.
3. Compatibility with Other Wall and Ceiling Components.
This system does not hinder in any way, the installation or performance of the framing or finishes in constructing the wall. In new construction, it does, however require the installation of the Retainer Clips 1 between the wall framing and the installation of the wall finishes. The Trim Strip 2 is installed after the wall finishes are installed. In instances where the walls were finished previously and where it is desired to provide this self-adjusting trim system at a later date, Retainer Clip 18 may be substituted for the basic system Retainer Clip 1 so that the existing wall finishes do not need to be disturbed in order to install this system. The Trim Strip 2 is then installed in the normal manner. Where fire caulk is a necessary component of a fire rated wall system, this molding system allows for the complete, economical installation of the caulk. This system allows for the complete, economical installation of wall framing, wall finishes and caulk, where specified, without slowing any operation or without hindering the operation of any system.
FIG. 4 is an isometric view of Retainer Clip 1 which shows the vertical back portion of the clip 1 a , the horizontal, projecting tongue 1 b and the location of the interlocking hook is portion 1 c . The horizontal tongue portion 1 b of the Retainer Clip 1 acts as a spring. The horizontal tongue portion 1 b of the Retainer Clip 1 is resilient enough to the degree that the interlocking hook 2 c of the horizontal top portion 2 a of the L-shaped Trim Strip can fit between the ceiling 3 and the horizontal projecting tongue 1 b of the Retainer Clip 1 during installation until the interlocking hook 2 c snaps into place and locks into interlocking hook 1 c of the Retainer Clip 1 . The resiliency of the Retainer Clip 1 causes a vertical force against the Trim Strip 2 towards the ceiling 3 thereafter. In certain embodiments made from some metals, Retainer Clips 1 may be made resilient to act like a spring when heat treated after bending. Some materials such as brass or plastics may not require heat treating to provide optimal resiliency due to inherent physical properties. (See FIGS. 15 through 18 for hook embodiments.) The vertical back portion of the retainer clip could range from ¼″ to 3″ wide and up to 4″ high. The horizontal projecting tongue portion of the Retainer Clip could range from ¼″ to 3″ wide and from ½″ to 3″ deep.
FIG. 5 is an isometric view of a Joint Tab 10 that is an optional connector used to align two abutting Trim Strip 2 pieces. This connecting tab is inserted into the end at the upturned portion of each Trim Strip 2 at the joint where each butts to align the components.
FIG. 6 is an isometric view of a primary Trim Strip 2 , showing the horizontal, top portion 2 a , the vertical face portion 2 b and the hook portion 2 c . The Trim Strip 2 is an elongated member formed of a resilient material with an L-shape in the cross section. The face portion 2 b is the only exposed portion of the trim system when properly installed. The top portion 2 a has the interlocking hook 2 c at the end which locks into the Retainer Clip 1 at the interlocking hook portion 1 c . The Trim Strip 2 is resilient enough to the degree that combined with the location of the interlocking hooks on the Retainer Clip 1 and the Trim Strip 2 , the resiliency of the Trim Strip 2 causes a horizontal force to press the lower end of the face portion 2 b of the Trim Strip 2 against the wall finish 4 . In certain embodiments made from some metals, Trim Strips 2 may be made resilient to act like a spring when heat treated after bending. Some materials may not require heat treating to provide optimal resiliency due to inherent physical properties. The face portion 2 b has a small portion that is turned toward the wall finish 4 and up to form a stand-off that rides on the wall finish 4 without damaging the finish of the wall after installation. The face portion 2 b could range from ½″ to 2″ high with the horizontal top portion just long enough to engage and interlock with the Retainer Clip 1 . The length of the Trim Strip 2 is expected to range from 10 to 12′ in standard lengths.
FIG. 7 shows a typical wall framing assembly of a deflection track 6 attached to the ceiling or deck construction 3 with a concrete pin or screw 8 and a vertical framing component 5 . The vertical framing component is usually a wood or metal stud and extends from the floor to within ½″ of the ceiling. Also shown are a wall finish 4 , caulk 7 and in the embodiments containing the Retainer Clip 1 and Trim Strip 2 . Also shown is the optional Joint Tab 10 . Wall finishes can be drywall, plaster, stone, brick, paneling, stucco, acoustical panels or any other synthetic material. While most assemblies use wood or metal framing studs, other materials could be used to serve as the vertical framing component such as concrete block, clay tile, poured concrete, etc.
An installation procedure is as follows: As shown, after the wall framing is installed, attach the Retainer Clip 1 is anchored to the deflection track. A preferred example of how to anchor the Retainer Clip 1 to the deflection track 6 is with a framing screw 9 . After the wall finish 4 is attached to the vertical framing component 5 of the framing assembly (but not to the deflection track 6 or Retainer Clip 1 ) and the caulk is installed, if required for sound or fire ratings, install the Trim Strip 2 component of the invention by forcing the horizontal portion of the Trim Strip 2 between the top of the Retainer Clip 1 and the ceiling construction 3 until it snaps into the Retainer Clip 1 hook. Once installed, the Trim Strip 2 is held tightly to the ceiling by the shape of and the tension exerted by the Retainer Clip 1 . The relative position of the hooks on the Retainer Clip 1 and the Trim Strip 2 is engineered to provide a slight amount of lateral force on the face of the Trim Strip 2 which in conjunction with the resilient properties of the Trim Strip 2 , holds it tight to the face of the wall finish 4 . This illustration shows a finish on one side of the wall framing only. However, finishes and the trim system would commonly be used on one or both sides of the framing in normal construction.
FIG. 8 shows another typical wall construction of a wall structure or framing system 11 (concrete block illustrated in this example, but it could be wood framing, metal framing, poured concrete or any other common construction system), a deflection angle 12 attached to the ceiling construction 3 by pin or screw 8 , wall furring 14 (resilient furring channel for this example) attached to the wall structure or wall framing, a wall finish 4 attached to the wall furring 14 with screw 13 , caulking backer rod 21 (used to minimize the amount of caulk required), caulk 7 and the embodiments with the Retainer Clip 1 and the Trim Strip 2 . This example of the usage of this invention shows that the Retainer Clip 1 needs to be available with various tongue sizes to accommodate the variety of expected wall finish systems. Being that Retainer Clips 1 are much more inexpensive to manufacture in a variety of sizes than a variety of Trim Strips 2 , the variety of Retainer Clips 1 option is currently preferred. This illustration shows a finish on one side of the wall framing only. However, finishes and the trim system would commonly be used on one or both sides of the framing in normal construction. A deflection angle serves the same function as a deflection track (previously described herein) but is usually used on one side only. Sometimes a deflection angle could be used on both sides of a wall structure where a deflection track is impractical. One or both of the deflection angle or the deflection track can be referred to by the generic term deflection component. Wall furring is used in some wall assemblies to improve the sound reduction coefficient of the entire assembly by adding an air space between the wall framing and the wall finishes. Wall furring is also used in some assemblies to provide backing for easier attachment of the wall finishes.
FIGS. 9 , 10 and 11 are end, rear and front views of the Retainer Clip 1 . While the vertical portion of the Retainer Clip 1 a is expected to remain approximately the same size through all embodiments, the tongue portion 1 b will be sized to accommodate various widths of wall finish treatments. Normal wall finish thicknesses in the United States are expected to range from ½″ to 1¾″. International finish thicknesses are expected to have a similar range. Special sized tongue portions 1 b should be made available on a special order basis.
FIGS. 12 , 13 and 14 are end, rear and front views of the primary Trim Strip 2 . The vertical and horizontal dimensions for the Trim Strip 2 are expected to be a standard size in the embodiments. The horizontal portion has a hook 2 c at the engagement side with the Retainer Clip 1 . The vertical side of the Trim Strip 2 is the portion that is faced into the room after installation and is the portion that covers the gap behind.
FIGS. 15 through 18 show possible options for the hook on both the Retainer Clip 1 and the Trim Strip 2 . As shown, FIG. 15 is the preferred hook option.
FIG. 19 illustrates a typical cross-section view of a portion of a multi-story concrete building having concrete walls and ceilings or decks. The blow-up shows an expanded corner of a wall when looking from the room side with the Stationary Wall and Flexible Ceiling Trim System installed. The blow-up shows a cut-away of the Trim Strip 2 (Retainer Clip 1 not shown) to show the top of the wall finish 4 and the resulting, engineered gap filled with caulk 7 . A typical deflection of a ceiling is expected to flex as much as about 0.375 inches or up to about 0.4% of the room height depending on temperature variations and support structure material properties. Further into the corner, another cut-away shows the framing (deflection track 6 and vertical framing component 5 ) behind the wall finish 4 and the caulk 7 . Also shown is the flexible ceiling 3 and the building exterior wall 20 support structure (which is subject to wide temperature variations causing the support structure to shrink and expand as the outside temperature varies).
FIG. 20 illustrates a typical cross-section view of a portion of a multi-story concrete building having concrete walls and ceilings or decks during cold weather. The blow-up shows a corner of a wall when looking from the room side with the Stationary Wall and Flexible Ceiling Trim System installed. The cut-away on this drawing shows the effect on the engineered gap between the top of the stationary wall finish 4 and the flexing ceiling 3 . Note that the caulk 7 in the gap is collapsed when the outside wall support structure 20 shrinks due to extremely cold temperatures. Also note that during this extreme temperature event, the Trim Strip 2 remains in tight contact with the ceiling and completely hides the gap distortion behind.
FIG. 21 illustrates a typical cross-section view of a portion of a multi-story concrete building having concrete walls and ceilings or decks during extremely hot weather. The blow-up shows a corner of a wall when looking from the room side with the Stationary Wall and Flexible Ceiling Trim System installed. The cut-away on this drawing shows the effect on the engineered gap between the top of the stationary wall finish 4 and the flexing ceiling 3 . Note that the caulk 7 in the gap is somewhat recovered (after being crushed during cold weather) when the outside wall support structure 20 expands due to extremely hot outside temperatures. However, an exaggeration 19 of the gap tends to develop between the top of the caulk 7 and the ceiling 3 as the total gap continues to grow due to the expanding of the exterior wall support structure 20 . Also note that during this extreme temperature event, the Trim Strip 2 remains in tight contact with the ceiling and completely hides the gap distortion behind.
FIG. 22 illustrates a cutaway end view of the components of the basic trim system installed in a typical retrogressive wall construction using an alternate Retainer Clip designed to be installed after wall finishes have been previously installed. This figure shows a typical wall construction of framing components containing a deflection track 6 attached to the ceiling or deck construction 3 with a concrete pin or screw 8 and vertical framing component 5 . Also shown are a wall finish 4 , caulk 7 and the embodiments substituting Retro-fit Retainer Clips 18 (for the standard Retainer Clip 1 ) and Trim Strip 2 . Installation procedure is as follows: In spaces where the Retro-fit Retainer Clips are to be installed, existing caulk needs to be removed. The Retro-fit Retainer Clip 18 can then be installed between the top of the deflection track 6 and the ceiling 3 using a conventional framing screw 9 to hold it in place. After the Retro-fit Retainer Clips 18 are installed, the caulk needs to be reinstalled where removed. Trim Strip 2 components of the invention are then installed by forcing the horizontal portion of the Trim Strip 2 between the top of the Retro-fit Retainer Clip 18 and the ceiling construction 3 until it snaps into the Retro-fit Retainer Clip 18 hook. Once installed, the Trim Strip 2 is held tightly to the ceiling by the shape of and the tension exerted by the Retro-fit Retainer Clip 18 . The relative position of the hooks on the Retro-fit Retainer Clips 18 and the Trim Strip 2 is engineered to provide a slight amount of lateral force on the face of the Trim Strip 2 which in conjunction with the resilient properties of the Trim Strip 2 , holds it tight to the surface of the wall finish 4 . The trim system would commonly be used on one or both sides of the framing in normal construction.
FIG. 23 illustrates the basic components of a self-adjusting trim kit for a typical room. This kit could have twenty five pieces of the Retainer Clips 1 , five pieces of the Trim Strip 2 and two pieces of Joint Tab 10 . Typically, several Retainer Clips would be supplied for each Trim Strip. When selecting the correct kit for the intended room, the end user would need to select the kit sized for the wall finish to be installed. For example: If the wall finish to be used is ⅝″ thick, the Retainer Clips 1 would need to be sized for the ⅝″ wall finish and the end user would need to select the kit containing the ⅝″ sized Retainer Clips. If the wall finish to be used is 1¼″ thick, the end user would have to select a kit containing the 1¼″ sized Retainer Clips. Every self-adjusting trim kit would contain the standard Trim Strip 2 and the standard Joint Tabs 10 .
FIG. 24 illustrates the steps during construction of a typical wall with the trim system installation incorporated into the final construction of the wall. In most cases, the same installation company would install the framing, wall finishes and the trim system. However, separate operations are usually performed by separate installation crews within the company.
In step 101 the wall partition framing is installed between the floor (not shown) and the ceiling 3 . The framing components include the vertical framing components 5 and the deflection track 6 . Note that the vertical framing components 5 are not attached to the deflection track 6 . Deflection track is attached to the flexing ceiling with fasteners 8 such as pins or screws. Installation of the trim system commences after step 101 .
In step 102 the first step in installing the trim system involves determining the thickness of the intended wall finish 4 . In step 103 following the determination of the wall finish thickness, the appropriate Retainer Clip 1 is selected to accommodate the intended wall finish thickness. A Retainer Clip 1 is chosen having a horizontal tongue sized according to the intended thickness of the wall finish. In step 104 , a plurality of Retainer Clips 1 are installed along the length of each side of a wall to receive a wall finish by attaching to the deflection track adjacent to the ceiling 3 with screws, nails, adhesive, rivets, etc. 9 . In step 105 the trim system installer must then wait until the wall finish system is installed and finished by others. If caulking 7 is needed, it is also installed by others prior to the installation of the Trim Strip 2 portion of the trim system. In step 106 the trim system installer measures the length of the Trim Strips to be installed and cuts the Trim Strips to the appropriate lengths. In step 107 the trim system installer then pushes the horizontal leg of the Trim Strips 2 between the top of the Retainer Clips 1 and the ceiling 3 until the trim strips lock into the Retainer Clips 1 .
During the life of the building, in step 108 , the Trim Strip will hide the gap between the top of the wall finishes and the ceiling during all the anticipated movement of the ceiling relative to the position of the wall finish through and including normal temperature and humidity variations and even including minor earthquakes or other unexpected minor building movements.
Any letter designations such as (a) or (b) etc. used to label steps of any of the method claims herein are step headers applied for reading convenience and are not to be used in interpreting an order or process sequence of claimed method steps. Any method claims that recite a particular order or process sequence will do so using the words of their text, not the letter designations.
Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements.
Any trademarks listed herein are the property of their respective owners, and reference herein to such trademarks is generally intended to indicate the source of a particular product or service.
Although the inventions have been described and illustrated in the above description and drawings, it is understood that this description is by example only, and that numerous changes and modifications can be made by those skilled in the art without departing from the true spirit and scope of the inventions. Although the examples in the drawings depict only example constructions and embodiments, alternate embodiments are available given the teachings of the present patent disclosure.
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A self-adjusting trim assembly used at the junction of a wall and ceiling where the wall finishes are to remain stationary while the ceiling is expected to flex due to loads on ceiling structure and normal variations in the height of the supporting structures due to temperature, moisture, creep or other factors effecting the height of the support structures. This trim assembly has two interlocking components comprised of a retainer clip having a vertical back portion ( 1 a ), a horizontal projecting tongue ( 1 b ) and the interlocking hook portion ( 1 c ) and also of a trim strip having a horizontal top portion ( 2 a ), a vertical face portion ( 2 b ) and an interlocking hook portion ( 2 c ) with the vertical face portion of the trim strip designed to cover the gap between stationary wall finishes and a flexing ceiling while trim strip remains flush with the ceiling structure, thus leaving no unsightly gap.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. 119 based upon German Patent Application No. 103 31 080.0, filed Jul. 9, 2003. The entire disclosure of the aforesaid application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention refers to a vehicle door latch with a locking mechanism, at least one operating lever for the locking mechanism and a motor drive for opening the locking mechanism. As usual, the locking mechanism mainly consists of a catch and a pawl.
[0003] Such vehicle door latches are adequately known and are used where such a latch is to be opened electrically. As such a motor drive generally contains an electric motor. The described electric opening is, for instance but not exclusively, initiated by a so-called “keyless entry” or “keyless go” operation. In this case, an upstream wireless authorization check is carried out on an operator seeking to gain access, which after a positive check actuates the motor drive for opening the locking mechanism, so that immediately afterwards, a vehicle door can be opened and/or released. This may also be motor-driven or manual process.
[0004] At the same time, it is also possible to operate an internal door handle or external door handle, with this action being detectable by a switch assigned to the respective handle. Depending on the functional position of the vehicle door latch (e.g. unlocked, locked or double locked), the obtained switching signal is converted into a respective execution signal for the motor drive.
[0005] Generally, the motor drive in question only arranges the opening of the respective locking mechanism. This means that, the mechanism must first be moved to the unlocked state if it is not already in this state. Generally, the motor drive can also be used for first unlocking the vehicle door latch and then opening the locking mechanism.
[0006] Prior art has already disclosed successful attempts of developing a vehicle door latch in such a way that its opening is guaranteed in any event. The generic WO 03/018939 A1 suggests, for instance that the motor drive acts indirectly on the operating lever or actuating lever via an intermediate energy-saving device.
[0007] A solution according to also a generic EP 1 091 061 A2 contains an already more complex mechanical system. In this system, the drive disc of the motor drive contains a driving pin, arranged with a stop on a blocking lever, arranged separately from the pawl of the locking mechanism. This blocking lever is moved along by the pawl, during its displacement, into a position releasing the catch, its blocking position. This is mechanically more complex and more expensive.
[0008] A similar system is shown in the generic door latch of EP 1 085 148 A2. In this case, too, a blocking lever is provided in addition to the opening lever with both being arranged to rotate around a common axis. —The invention aims to provide a solution for this problem.
SUMMARY OF THE INVENTION
[0009] The invention aims to solve the technical problem of providing a functional, simple and cost-effective solution for a generic vehicle door latch for motorized opening.
[0010] In order to solve this technical problem, a generic vehicle door latch according to the invention is characterized in that the motor drive directly actuates the locking mechanism and, in particular, the pawl via solely the operating lever. The motor drive may be a reversing drive and preferably contains a drive disk with front-sided cams and a rear-sided element limiting the rotation angle.
[0011] In contrast to the prior art of the two European patents EP 1 091 061 A2 and EP 1 085 148 A2 the invention expressly does not require additional levers, springs, etc. Instead it has been found to suffice for a reliable operation, if the motor drive only operates the operating lever, which in turn actuates the locking mechanism and in this case preferably the pawl. As the suggested solution uses a minimum of required components, manufacturing costs can be kept particularly low, without any danger of malfunctioning.
[0012] Generally, the element limiting the angle of rotation co-operates with a stationary stop. This stationary stop may be fixed to the frame box, latch housing, etc. Together with the element limiting the angle of rotation, the stop ensures that the rotation movements of the motor drives and thus of the drive disk, are limited in the actuation and reverse direction. The stop actually provides two stop surfaces, on one hand, for the element limiting the angle of rotation moving in the actuating direction and, on the other hand, for the element limiting the angle of rotation, moving in the reverse direction.
[0013] In most cases, the operating lever contains two arms with an operating and an actuating arm. In most cases, the operating arm is acted upon by the drive, whilst the actuating arm acts on the locking mechanism and, in this case in particular, the pawl. In addition, the operating lever may also contain a third arm, the opening arm, on which a mechanical opening device can act upon. This third arm of the operating lever thus ensures that if, for instance, the motor drive has failed, the locking mechanism can still be mechanically opened. A closing cylinder with a cam could, for instance, act upon this third arm.
[0014] From a procedural point of view, the motor drive generally acts upon the drive disk in actuation direction for opening the locking mechanism until the element limiting the angle of rotation, lies against the stop in an opening position. As already described, the stop contains two stop surfaces, an actuating and a reversing surface. In the opening position, the element limiting the angle of rotation, lies against the actuating surface of the stop.
[0015] The opening position is then maintained, until the locking mechanism has been reliably opened. It is, for instance, possible to detect this locking mechanism opening using a sensor on e.g. the catch—a catch switch or similar. Once the fully opened catch actuates the respective catch switch, the control unit detects that the locking mechanism is open and that the opening position can be released (again). Whilst the motor drive acts upon the drive disk and/or the operating lever in its actuating direction for opening the locking mechanism and also in the opening position, the operating lever generally ensures that the pawl is lifted off the catch so that the catch can be opened with the aid of a spring. Only once the locking mechanism has been reliably opened, does the control unit send out the reversing command to the motor drive.
[0016] After opening the locking mechanism, the motor drive acts upon the operating lever in its reverse direction until the pawl, previously held by the operating lever, is released. As the catch is open in this situation, the released pawl lies against the catch and can, during the subsequent (manual) closing operation of the vehicle door easily engage with the catch, if the latter is moved into the locking position by a locking bolt during this process.
[0017] The opening position of the operating lever, described above and thus also the drive disk, can be set and maintained without requiring considerable force from the motor drive. This is due to the fact that the operating lever contains a spring against which the motor drive has to act when opening the locking mechanism. According to the invention, this counterforce generated by the spring, is applied radially in direction onto a rotational axis of the drive disc and, preferably, through the cam.
[0018] Because of this design, the motor drive could, strictly speaking, even be switched off in the opening position and its self-locking forces would suffice, as the counterforce of the spring only acts radially in direction of the axis of rotation of the drive disk onto the cam and no lateral forces are applied. As there are no lateral forces, the cam is neither turned in one nor the other direction by the spring on the operating lever in the opening position. Rotations in actuating direction are blocked anyway, as the element limiting the angle of rotation lies against the actuating surface of the stop.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIGS. 1 to 4 show the vehicle door latch of the invention in various functional positions, from the front and rear and, in which
[0020] FIG. 5 shows a schematic functional flow diagram over time.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Below, the invention is explained in more detail with reference to a drawing showing only one embodiment, in which:
[0022] FIGS. 1 to 4 show the vehicle door latch of the invention in various functional positions, from the front and rear and, in which
[0023] FIG. 5 shows a schematic functional flow diagram over time.
[0024] The figures show a vehicle door latch containing, as usual, a locking mechanism 1 , 2 comprising a catch 1 and pawl 2 . The figures also show an operating lever 3 for the locking mechanism 1 , 2 and a motor drive 4 , 5 , 6 , 7 for opening the locking mechanism 1 , 2 . The motor drive 4 , 5 , 6 , 7 actually comprises an electric motor 6 , a drive disk 5 , a cam or actuating cam 4 arranged on the drive disk 5 and an element limiting the angle of rotation 7 . The electric motor 6 is able to move the drive disk 5 in clockwise and counterclockwise direction and thus operates—like the entire motor drive 4 , 5 , 6 , 7 —reversibly. This is indicated by the double arrow in FIG. 1 .
[0025] It is apparent that the motor drive 4 , 5 , 6 , 7 directly acts upon the locking mechanism 1 , 2 via solely the operating lever 3 . For this purpose, the operating lever 3 contains a total of three arms, an operating arm 3 a , an actuating arm 3 b and an opening arm 3 c . The opening arm 3 c ensures that the locking mechanism 1 , 2 can also be opened if the motor drive 4 , 5 , 6 , 7 has failed, e.g. mechanically via a closing cylinder or a similar not expressly shown opening device. This is, however, not mandatory and opening arm 3 c is simply an option for the invention.
[0026] Significant for the motorized opening as part of the invention is, however, the operating arm 3 a , acted upon by drive 4 , 5 , 6 , 7 or, more accurately, by cam 4 . Also the actuation arm 3 b , acting upon the locking mechanism 1 , 2 or, more accurately, pawl 2 .
[0027] The rear views show that the drive disk S contains the element limiting the angle of rotation 7 on its back. This element limiting the angle of rotation 7 co-operates with a stationary stop 8 that can be fixed to latch housing 13 . The stationary stop 8 contains two stop surfaces 8 a , 8 b , an actuating surface 8 b and a reversing surface 8 a.
[0028] Also, two further functional elements are provided, in form of a spring F—only indicated—acting upon the operating lever 3 in the direction shown in FIG. 1 . This means that the operating lever 3 is acted upon by spring F in clockwise direction around its axis in the respective front view. In addition, there are individual sensors 9 , 10 , 11 , to signal, on one hand, the position of catch 1 and, on the other hand, the position of the drive disk 5 and of the motor drive 4 , 5 , 6 , 7 to a control unit 12 . Depending on the functional position of the vehicle door latch, the control unit 12 passes on respective commands to the electric motor 6 for its actuation.
[0029] The system functions as follows. Starting from a position as shown in FIG. 1 with a closed locking mechanism 1 , 2 , i.e. with pawl 2 engaged in the primary position of catch 1 , the motor drive 4 , 5 , 6 , 7 is acted upon in such a way for opening the locking mechanism 1 , 2 that the drive disk 5 in the front view of FIG. 1 carries out the indicated clockwise movement around its axis 5 ′. This corresponds to a counterclockwise movement in the rear view in the right part of FIG. 1 .
[0030] After a certain displacement travel, a sensor surface 11 reaches the sensor or switch 10 , so that it transmits a first signal to the control unit 12 , as indicated by the rising edge in the bottom part of FIG. 5 . Cam 4 then makes contact with the operating arm 3 a of the operating lever 3 .
[0031] The motor drive 4 , 5 , 6 , 7 acts upon the operating lever 3 in its activation direction for opening the locking mechanisms 1 , 2 (clockwise movement of drive disk 5 in front view in FIG. 1 ) until the element limiting the angle of rotation 7 lies against the stop 8 or, more accurately, against its actuating surface 8 b . This status becomes clear in the transition from FIG. 1 to FIG. 2 and on to FIG. 3 . Before, however, this so-called opening position acc. to FIG. 3 has been reached, the sensor surface 11 has ensured that the sensor or the switch 10 has received a switch-off impulse according to a second signal. At the same time, the falling edge of the first square-wave pulse in the bottom diagram of FIG. 5 has been reached.
[0032] The opening position acc. to FIG. 3 now corresponds in such a way that the pawl 2 has been fully lifted off the catch 1 , allowing the catch 1 to turn to its open position with the aid of a spring. The opening position acc. to FIG. 3 is maintained until the catch 1 has reliably reached its opening position. This consequently also applies for the entire locking mechanism 1 , 2 . This status is detected by the sensor or the micro switch 9 , which is a catch switch.
[0033] Due to the reliable opening of the locking mechanism 1 , 2 the control unit 12 now ensures that the motor drive 4 , 5 , 6 , 7 is acted upon in reverse direction. When comparing FIGS. 3 and 4 , the reverse direction corresponds so that the cam 4 and the drive disk 5 on which it is arranged, carry out a counterclockwise movement when seen from the front view. As a result, the cam 4 moves away from the operating arm 3 a of the operating lever 3 . The motor drive 4 , 5 , 6 , 7 is acted upon in reversing direction until the pawl 2 , previously held by the operating lever 3 , is released.
[0034] At the start of the reversing process, the sensor or the switch 10 register a switch-on process again, caused by the sensor surface 11 , gliding past it. This process corresponds with the rising edge of the second square-wave pulse in the bottom diagram of FIG. 5 . Upon release of the pawl 2 , the element limiting the angle of rotation 7 reaches the reversing surface 8 a of the stop 8 , as shown in FIG. 4 . Prior to this, the sensor area 11 generated a switch-off pulse at switch 10 , corresponding with the falling edge of the second square-wave pulse.
[0035] It is apparent that, during the described process, the operating lever 3 carries out the movement shown in the top diagram of FIG. 5 , with individual selected points and positions being specified. It is also significant that in the opening position in FIG. 3 , the counterforce generated by spring F on the operating lever 3 , runs radially in the direction of axis 5 ′ of the drive disk 5 . This is indicated by an arrow in the respective FIG. 3 . The counterforce also runs through cam 4 . In this way, the opening position as shown in FIG. 3 can be reached with a minimum of force, as there are no lateral forces that could turn the drive disk 5 in one or another direction.
[0036] As already described, the top part of FIG. 5 shows the movement of the operating lever 3 , whilst the bottom part shows the signals on the sensor 10 . Individually exposed time points, labeled 1 to 7, are explained below.
[0037] From the start to time point 1 , the electric motor 6 starts or accelerates until there is contact between the cam 4 and the operating lever 3 at time point 1 . This is followed by an operating stroke up to time point 2 , when catch 1 has mainly been released. The operating lever 3 is moved on—by a certain safety angle—until position 3 has been reached. The operating lever 3 is held in this position.
[0038] At time point 4 , sensor 10 first of all detects the falling edge with the passing sensor surface 11 , and the micro switch or catch switch 9 have registered that the catch 1 is open. The electric motor 6 now continues to run until the drive disk 5 with its element limiting the angle of rotation 7 rests against the actuating surface 8 b of stop 8 . This occurs at time point 5 .
[0039] The blocking position of the electric motors 6 can be evaluated and serves as a signal for operating the electric motor 6 in reverse. This occurs starting at time point 5 to time point 6 , with the electric motor 6 accelerating in reverse direction in this time period. Once the end of the sensor surface 11 has passed the sensor or switch 10 and thus the second rising edge has been registered by sensor 10 , the release of the pawl 2 commences at time point 6 . This release of the pawl 2 continues up to time point 7 . Once the falling edge has been registered by the sensor 10 , the electric motor 6 continues to run unchanged until the element limiting the angle of rotation 7 reaches the reversing surface 8 a of the stop 8 in position 8 . In this case, too, the blocking process can be evaluated in order to reverse the direction of movement of the electric motor 6 (again).
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The object of the present invention is a vehicle door latch, whose basic version contains a locking mechanism ( 1, 2 ) with at least one operating lever ( 3 ) for the locking mechanism ( 1, 2 ) and a motor drive ( 4, 5, 6, 7 ) for opening the locking mechanism ( 1, 2 ). According to the invention, the motor drive ( 4, 5, 6, 7 ) directly acts upon the locking mechanism ( 1, 2 ) solely via the operating lever ( 3 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention is directed to a window operator, and more particularly toward an operator for controlling the position of an awning window.
2. Background Art
Window operators are commonly used to move a window sash relative to a window frame between open and closed positions. Window operators known in the art include a base attachable to the window frame and one or more primary arms pivotally mounted about an axis or axes to the base and attachable to the window sash, which itself is pivotally mounted to the window frame. The window operator also includes a suitable drive system for pivoting the primary arm or arms about the axis or axes, and thereby moving the sash relative to the frame between the open and closed positions.
In some window operators known in the art, the primary arm is directly connected to the drive system and the window sash. See, for example, U.S. Pat. Nos. 4,617,758; 4,241,541; 4,143,556; 4,068,408; 3,461,609; 3,044,311; 3,032,330; and 2,674,452; and Canadian Patent Nos. 889,194 and 595,250. Typically, in these window operators, one end of the primary arm is connected to a gear which meshes with the gear or gears of the drive system to pivot the primary arm in response to an input from the drive system. The other end of the primary arm may then be connected the window through a connector which slides along a track attached to the window sash. See, for example, U.S. Pat. Nos. 4,068,408 and 3,044,311. Alternatively, the other end of the primary arm may be fixedly but pivotally attached to the window sash. See, for example, U.S. Pat. No. 4,617,758.
In other window operators known in the art, the primary arm is directly connected to the drive system, but indirectly connected to the window sash through a linkage system. See, for example, U.S. Pat. Nos. 5,272,837; 4,823,508; 4,266,371; 4,253,276; 4,241,541; 3,523,389; 3,422,575; 3,098,647; 2,824,735; and 2,185,321 and Canadian Patent No. 889,194. Typically, in these window operators, one end of the primary arm driveably engages the drive system, and the other end is connected to one or more secondary arms. Typically, a single secondary arm is attached to the primary arm, the secondary arm being fixedly but pivotally attached to the window sash. See, for example, U.S. Pat. No. 5,272,837.
While capable of moving the window sash relative to the window frame significant distances, the window operators discussed above may be bulky and difficult to install. In particular, to have the sash positioned the desired distance from the frame in the open position, the primary arms and secondary arms have generally been required to be so large that they extend a considerable distance laterally from the base with the sash in the closed position. Such lateral extension of the arms from the base can make the window operator difficult to install. The lateral extension of the arms also limits the size of windows with which such operators may be used. For example, narrow windows might require use of operators which will not provide as great an opening distance as might otherwise be desired
Furthermore, in those window operators in which the arm is slidably attached to the window sash, the arm, the connector, and the connector clip (such as is shown in U.S. Pat. No. 3,461,609, for example) can be noisy and prone to corrosion.
The present invention is directed toward overcoming one or more of the problems discussed above.
BRIEF SUMMARY OF THE INVENTION
According to an aspect of the present invention, an operator for controlling the movement of a window sash pivotable relative to a frame about a first edge between open and closed positions includes a first arm having a first end slidably attachable to a second edge of a window sash opposite a first edge of the window sash about which the window sash is pivotable relative to a frame. A second arm has a first end slidably attachable to a second edge of a window sash opposite a first edge of the window sash about which the window sash is pivotable relative to a frame, and is pivotally secured to the first arm. A base is attached to a frame and a mechanism is attached to the base and to second ends of the first and second arms for pivoting the first arm relative to the second arm such that the first ends and second ends of the first and second arms are disposed together with a window sash in an open position and the first ends and second ends are spaced apart with a window sash in a closed position.
According to a further aspect of the present invention, an operator for controlling the movement of a window sash pivotable relative to a frame about a first edge between open and closed positions includes a first arm pivotable about a first axis and a second arm pivotally mounted to the first arm about a second axis. A third arm is also pivotally attached to the first arm, and is translatably attachable to a second edge of a window sash opposite a first edge about which the window sash pivots relative to a frame. A fourth arm is pivotally attached to the second arm and the third arm, and is also translatably attachable to a second edge of a window sash opposite a first edge about which the window sash pivots relative to a frame. A mechanism drives the second arm about the second axis and the first arm about the first axis to move a window sash between open and closed positions.
According to an additional aspect of the present invention, an operator for controlling the movement of a window sash pivotable relative to a frame about a first edge between open and closed positions includes a sun gear pivotable about an axis. A drive gear driveably engages the sun gear. A first arm pivots about the axis, and a second arm is pivotally attached to the first arm and driveably engages the sun gear. A third arm is pivotally attached to the first arm and slidably attachable to a second edge of a window sash opposite a first edge about which the window sash pivots relative to a frame. A fourth arm is pivotally attached to the second arm and the third arm and slidably attachable to a second edge of a window sash opposite a first edge about which the window sash pivots relative to a frame.
According to a still further aspect of the present invention, a connector assembly for slidably attaching an arm of a window operator to a window sash includes a metal track attachable to a window sash, a plastic shoe is translatable along the track, and a plastic post pivotally attached to the shoe about an axis substantially parallel to the track. The post is disposable through an opening in an arm of a window operator such that an end of the post protrudes from the opening, and a mechanism is disposable about the end of the post for securing an arm of a window operator to the connector.
According to a further aspect of the present invention, an operator for controlling the movement of a window sash relative to a frame, the window sash being pivotable relative to an axis, includes a drive mechanism securable to a window frame, the mechanism controllably moving a first drive arm having an opening at one end thereof. The operator further includes a metal track attachable to a window sash, a plastic shoe translatable along the track, and a plastic post pivotally attached to the shoe about an axis substantially parallel to the track. The post is disposable through the arm opening with an end of the post protruding from the opening. A mechanism is disposable about the end of the post for securing the operator first drive arm to the post
It is an object of the present invention to provide a window operator which may be used in existing installations.
It is another object of the invention to provide a window operator which is inexpensive to manufacture and install.
It is still another object of the invention to provide a window operator which will operate reliably over a long useful life.
It is yet another object of the invention to provide a window operator which is highly resistant to corrosion in all environments.
Another object of the present invention is to provide a window operator which may be readily used with a wide variety of installations, including a wide range of sizes of windows.
Still another object of the present invention is to provide a window operator which may be used to minimize inventory costs, handling costs, and design and installation errors.
Yet another object of the present invention is to provide a window operator having only a minimal visual intrusion on the window aesthetics.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a broken partial view of an embodiment of a window operator according to the present invention installed to a window frame and attached to an awning window sash for moving the sash between open and closed positions relative to the frame, the window sash being in the closed position;
FIG. 2 is a perspective view of the window operator of FIG. 1 supporting an awning window sash in the open position;
FIG. 3 is a perspective view of the window operator of FIG. 1 in an extended, open position;
FIG. 4 is a perspective view of the window operator of FIG. 1 in a retracted, closed position;
FIG. 5 is a perspective view of the window operator of FIG. 1 in an intermediate position between the extended and retracted positions;
FIG. 6 is a perspective view of an embodiment of a connector for attaching an arm of a window operator to a window sash;
FIG. 7 is a perspective exploded view of the connector shown in FIG. 6;
FIG. 8 is a perspective view of another embodiment of a window operator according to the present invention in an intermediate position between an extended, open position and a retracted, closed position;
FIG. 9 is a perspective view of another embodiment of a connector for attaching an arm of a window operator to a window sash, the connector including a slider having a shoe and a post unit pivotally connected to the shoe;
FIG. 10 is a cross-sectional view of the slider shown in FIG. 9;
FIG. 11 is a perspective view of the shoe included in the slider shown in FIG. 10; and
FIG. 12 is a perspective view of the post unit included in the slider shown in FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
In an embodiment of the present invention, a scissors-type window operator 20 according to the present invention is installed in an awning-type window 22 including a sash 24 and a frame 26. The sash 24 is pivotally connected to the frame 26 about an upper edge 28 of the sash 24 and an upper edge 30 of the frame 26. Specifically, the sash 24 pivots about hinges 32, 34 which are connected to the sash 24 and the frame 26 at the upper edges 28, 30. Alternatively, as is well known, suitable hinges could be secured to opposite sides of the sash 24 and frame 26. With all such hinges, opening of the sash 24 generally involves pivoting of the sash 24 about one sash edge relative to the frame 26.
It should be understood that although the preferred form of the present invention is as used with an awning-type window, aspects of the present invention could also advantageously be used with other window types including, for example, casement windows and skylights.
The window operator 20 has a base 36 which is secured to a sill 38 of the frame 26. The base 36 has a slot 40 with a rectangular cross-section formed along an underside surface 42 of the base 36. A ridge 44 of rectangular cross-section extends from the sill 38, and mates with the slot 40 of the base 36. The ridge 44 and the slot 40 cooperate to prevent water and air from infiltrating along the interface between the base 36 and the sill 38, as is taught by commonly owned Anderson et al. in U.S. patent application Ser. No. 08/575,143, filed Dec. 19, 1995, the disclosure of which is hereby incorporated by reference.
A linkage system 46 attaches the window operator 20, and in particular the base 36, to a lower edge 48 of the window sash 24 opposite the upper edge 28. The linkage system 46 includes a first primary arm 50, a second primary arm 52, a first secondary arm 54 and a second secondary arm 56. The first primary arm 50 is pivotally secured to the base 36, while the second primary arm 52 and the first secondary arm 54 are pivotally connected to the first primary arm 50. The second secondary arm 56 is pivotally connected to the second primary arm 52 and the first secondary arm 54. The first and second secondary arms 54, 56 are then slidably attached to the lower edge 48 of the window sash 24 as explained in greater detail below.
A drive system 58 is also attached to the base 36. The drive system 58, such as a planetary gear train as shown, causes the first and second primary arms 50, 52 to move in response to the rotation of the worm shaft 60 attached to the worm 62. The worm shaft 60 is shown in FIG. 1 as extending from the cover 64 which limits access to the drive system 58. The cover 64 also prevents dirt and water from contaminating the drive system 58.
To move the window sash 24 from the closed position (FIG. 1) to the open position (FIG. 2), the drive system 58 causes the ends 66, 68 of the primary arms 50, 52 to move spatially closer together. The movement of end 66 spatially toward end 68 causes the ends 70, 72 of the secondary arms 54, 56 to move closer together. As the secondary arms 54, 56 rotate about the pivot 74, the second ends 76, 78 of the secondary arms 54, 56 also move closer together.
The arms 50, 52, 54, 56 are bent at the ends 66, 68, 70, 72 such that the ends 66, 68, 70, 72 slope upward at an approximately equal angle to the horizontal. The slope of the ends 66, 68, 70, 72 allows the arms to follow the upward movement of the sash 24 as typically occurs, for example, with awning windows, in addition to the outward movement as ends 66, 68 and 70, 72 move closer together.
To close the sash 24, the steps of the general method described above for moving the sash 24 from the closed position to the open position are reversed, and the drive system 58 is used to move the ends 66, 68, 70, 72, 76 and 78 further apart. Particularly, as the ends 76 and 78, which are slidably attached to the lower edge 48 of the sash 24, move further apart, the ends 76, 78 draw the sash 24 downward and inward, rotating the sash 24 about the hinges 32, 34. To minimize the vertical dimension of the window operator 20 in the closed position as shown in FIG. 1, the arms 50, 52, 54, 56 are also bent to maintain a sufficient clearance between the arms 50, 52, 54 and 56.
Turning now to FIG. 3, the drive system 58 includes a planetary gear system with a sun gear 80. The sun gear 80 is pivotally attached about an axis 82 to the base 36, and is driveably engaged by the worm 62. The first primary arm 50 is also pivotally attached to the base 36 about the axis 82.
The drive system 58 also includes a planetary gear 84 secured to the end 86 of the second primary arm 52. As shown, the planetary gear 84 is formed integrally with the end 86 of the second primary arm 52. The second primary arm 52 is pivotally attached to the first primary arm 50 at an axis 88, about which the planetary gear 84 rotates.
The remainder of the linkage system 46 is connected to the primary arms 50, 52 which cooperate with the drive system 58 as follows. The first secondary arm 54 is pivotally attached to end 66 of the first primary arm 50 at an axis 90. The second secondary arm 56 is pivotally attached to end 68 of the second primary arm 52 at an axis 92. The first and second secondary arms 54, 56 are pivotally attached to each other at the pivot 74.
The linkage system 46, and in particular ends 76, 78 of secondary arms 54, 56, is slidably connected to the sash 24 through the use of a connector including sliders 94, 96. Sliders 94, 96 are disposed in a C-shaped track 98 which is secured to the lower edge 48 of the sash 24.
Specifically, as best shown in FIGS. 6 and 7, the end 76 of the arm 54, for example, has a opening 100 formed therethrough. The slider 94 includes a shoe 102 which is slidable along the track 98 and maintained in the track 98 by the overhanging lips 104 formed integrally with the track 98. The slider 94 also includes a post 106 which is pivotally mounted to the shoe 102 by pin 108 which is disposed in a passage 110 in the post 106 and passages 112, 114 in the shoe 102.
The post 106 is disposed through the opening 100 in the end 76 of the arm 54. With the post 106 disposed through the opening 100, the internal surface of the opening 100 at least partially abuts a shoulder 115 formed at the proximal end of the post 106. The internal surface of the opening 100 and the shoulder 115 cooperate to limit undesirable relative lateral movement between the arm 54 and the post 106.
The post 106 is maintained in the opening 100 of the arm 54 through the use of a clip 116. The clip 116 is slidably mounted to the arm 54 through the cooperation of the arm 54 and tabs 118 inwardly depending from the downwardly extending arms 120 of the clip 116. The clip 116 preferably includes a thumb engageable portion 121 allowing for easy manual sliding of the clip 116 when desired as described below. The clip 116 also has arms 122 which extend axially outwardly from the clip 116, defining therebetween a recess 124.
To maintain the post 106 in the opening 100, the clip 116 is moved along the arm 54 until edges 126 of the arms 122 contact the post 106. Further application of force to the clip 116 axially in the direction of the post 106 causes the post 106 to force the arms 122 radially outwardly with respect to the axis 128 of the post 106. The arms 122 are disposed radially outward until the post 106 aligns with the recess 124 defined between the arms 122. With the post 106 aligned with the recess 124, the arms 122 elastically return to their original positions.
The post 106 is maintained within the recess 124 through the interaction of the arms 122 and a radially outwardly extending cap or head 130 at the axially outwardmost extending end 132 of the post 106. In particular, the cap 130 is larger than the clip recess 124 to prevent the post 106 from slipping axially out of engagement with the arms 122. In a preferred embodiment, the post 106 (including the cap 130) is only slightly smaller in diameter than the diameter of the arm opening 100 with a reduced diameter neck portion secured to the cap 130, where the clip arms 122 are disposed about the neck portion.
To limit corrosion to the ends 76, 78 of the arms 54, 56, it is advantageous to limit the amount of metal-to-metal contact between the clips a 116, the sliders 94, 96 and the track 98. Therefore, for example with reference to FIGS. 6 and 7, while the track 98, pin 108 and the arm 54 are made of a metallic material, the shoe 102, post 106, and clip 116 are made of a plastic material. With such a configuration, there is no metal to metal contact between components at this area and therefore corrosion is minimized.
In another embodiment of the present invention, a window operator 134 is shown in FIG. 8 in an intermediate position between an extended position and a retracted position. The window operator 134 includes a linkage system 136 and a drive system 138, similar in some respects to the linkage system 46 and drive system 58 previously discussed.
In particular, the linkage system 136 includes a first primary arm 140, a second primary arm 142, a first secondary arm 144, and a second secondary arm 146. The first primary arm 140 is connected to the first secondary arm 144 at a pivot 148, and the second primary arm 142 is connected to the second secondary arm 146 at a pivot 150. The first and second primary arms 140, 142 are connected at a pivot 152, while the first and second secondary arms 144, 146 are connected at a pivot 154. The first and second secondary arms 144, 146 are also slidably connected to a track 156 as explained in greater detail below. The track 156 may be attached, for example, to the lower edge of a window sash (not shown) in the manner described above with respect to the window operator 20.
The drive system 138, such as a planetary gear train as shown, causes the first and second primary arms 140, 142 to move in response to the rotation of a worm shaft 158 attached to a worm 160. For example, to move the window operator 134 from the intermediate position shown in FIG. 8 to an extended position, similar to that shown in FIG. 3, the drive system 138 causes ends 162, 164 of the primary arms 140, 142 to move spatially closer together. The movement of end 162 spatially toward end 164 causes ends 166, 168 of the secondary arms 144, 146 to move closer together. As the secondary arms 144, 146 rotate about the pivot 154, the second ends 170, 172 of the secondary arms 144, 146 also move closer together.
The arms 140, 142, 144, 146 are bent at the ends 162, 164, 166, 168 such that the ends 162, 164, 166, 168 slope upwardly at an approximately equal angle to the horizontal. The slope of the ends 162, 164, 166, 168 allows the arms 140, 142, 144, 146 to follow the upward movement of the track 156 as typically occurs, for example, when the track 156 is attached to a sash of an awning-type window, in addition to the outward movement as ends 162, 164 and 166, 168 move closer together.
To move from the intermediate position shown in FIG. 8 and a retracted position, such as is shown in FIG. 4, the steps of the general method described above for moving from the intermediate position to the extended position are reversed, and the drive system 138 is used to move the ends 162, 164, 166, 168, 170 and 172 further apart. Particularly, as the ends 170 and 172, which are slidably attached to the track 156, move further apart, the ends 170, 172 draw the track 156 downward and inward. To minimize the vertical dimension of the window operator 134 in the closed position, the arms 140, 142, 144, 146 are also bent to maintain a sufficient clearance between the arms 140, 142, 144, 146.
The drive system 138 includes a planetary gear system with a sun gear 174. The sun gear 174 is pivotally attached about an axis 176, and is driveably engaged by the worm 160. The first primary arm 140 is also pivotally attached about the axis 176.
The drive system 138 also includes a planetary gear 178 secured to the end 180 of the second primary arm 142. As shown, the planetary gear 178 is formed integrally with the end 180 of the second primary arm 142. As mentioned previously, the second primary arm 142 is pivotally attached to the first primary arm 140 at the axis 152, about which the planetary gear 178 rotates.
The drive system 138 may be enclosed between a base and cover (not shown) to limit access to the drive system 138 and to prevent the contamination of the drive system 138 by water and dirt, for example.
As mentioned previously, the ends 170, 172 of secondary arms 144, 146 are slidably connected to the track 156. The slidable connection to the track 156 is made through the use of connectors 182, 184 including sliders 186, 188.
FIGS. 9-12 show the connector 184 and, in particular, the slider 188 in greater detail for purposes of illustration.
The slider 188 includes a shoe 190 being slidable along the track 156. The shoe 190 is maintained in the track 156 by overhanging lips 192 and an end tab 194 formed integrally with the track 156.
The slider 188 also includes a downwardly depending post unit 196 (shown in greater detail in FIGS. 10 and 12) which is pivotally mounted to the shoe 190 by a pin 198. The pin 198 is disposed in a passage 200 (FIGS. 10 and 12) in the post unit 196 and passages 202, 204 in the shoe 190 (FIG. 11).
Because the pin 198 is further away from the track 156 than the pin 108 used in the slider 94 described above, the post unit 196 moves closer to the lower edge of the track 156 as the linkage system 136 moves to the extended position, allowing for the slider 188 to be used with sashes which have an outwardly extending lip or surface disposed at the upper edge of the track 156.
The post unit 196 includes a base 206 and a stepped cylindrical extension 208. The cylindrical extension, or post, 208 has a first stepped region, or shoulder, 210 formed adjacent to the base 206. The post 208 tapers to an intermediate neck region 212, terminating in an enlarged cap 214 at the axially outwardmost extending end 216 of the post 208.
The post 208 is maintained in an opening (not shown) of the arm 144 through the use of a clip 218. To that end, the arm 144, the post 208 and the clip 218 cooperate in the same fashion as is described above with respect to arm 54, post 106 and clip 116 in FIGS. 6 and 7, and the clip 218 is substantially similar in structure to the clip 1 16 shown in FIGS. 6 and 7. The clip 218, however, unlike the clip 116, is positioned underneath the arm 144 because the post 208 depends downwardly through the opening in the arm 144.
The post unit 196, and in particular the post 208, is preferably disposed with the axially outwardmost extending end 216 of the post 208 directed outwardly from the slider 188, and hence the track 156 in which the slider 188 is disposed. This orientation of the post 208 assists the operator during installation by disposing the end 216 of the post 208 in a more accessible position.
To maintain the end 216 outwardly oriented from the track 156 in which the slider 188 is disposed, a cantilevered spring arm 220 preferably formed integrally with the shoe 190 contacts the post unit 196. In particular, the spring arm 220 contacts a surface 222 on the base 216 of the post unit 196.
Use of the spring arm 220 may provide some desirable resistance during the attachment of the arm 144 to the slider 188 to maintain the orientation of the post 208. Once the arm 144 has been attached to the post 208, the spring arm 220 preferably provides an insignificant amount of resistance to the pivoting of the post unit 196 relative to the shoe 190.
To limit corrosion to the ends 170, 172 of the arms 144, 146, it is advantageous to limit the amount of metal-to-metal contact between the clips 218, the sliders 186, 188 and the track 156. Therefore, for example, while the track 156, the pin 198, and the arm 144 are made of a metallic material, the shoe 190, post unit 196, and clip 218 are made of a plastic material. With such a configuration, there is no metal to metal contact between components at this area and therefore corrosion is minimized.
It should be recognized that the connector such as shown in FIGS. 9-12, as well as the connector shown in FIGS. 6 and 7, as discussed above could be advantageously used with a wide variety of window operators and window types where a sliding connection to the sash is required.
It should also now be recognized that operators made according to the present invention can be easily and inexpensively manufactured and installed, will operate reliably over a long useful life, and further may be readily used in existing installations.
Further, such window operators may be readily used with a wide variety of installations, as the geometry of the operator linkage is such that a given distance of window opening can be provided by an operator which has a very small lateral dimension when closed. This thus not only allows for narrow windows to have large open distances, but also allows for a single size operator to accommodate a wider variety of window sizes, thereby reducing inventory costs and further reducing handling costs and design and installation errors. This further allows the operator structure to be very compact so as to minimize any visual intrusion which the operator might otherwise have on the window aesthetics.
Still other aspects, objects and advantages of the present invention can be obtained from a study of the specification, the drawings and the appended claims.
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An operator for controlling the movement of a window sash generally pivotable relative to a frame about a first edge between open and closed positions includes a first arm having a first end slidably attachable to a second edge of the window sash opposite the sash first edge. A second arm has a first end also slidably attachable to the sash second edge, and is further pivotally secured to the first arm. A base is attached to a frame and includes a drive attached to the other ends of the first and second arms for pivoting the first arm relative to the second arm whereby the first ends and second ends of first and second arms are disposed together with a window sash in an open position and the first ends and second ends are spaced apart with a window sash in a closed position. A connector for slidably attaching an operator arm to a window sash includes a metal track attachable to a window sash, a plastic shoe translatable along the track, and a plastic post pivotally secured to the shoe by a metal rod substantially parallel to the track. The post is disposable through an opening in the operator arm so that an end of the post protrudes from the opening. A plastic clip is disposed about the end of the post for securing the post in the operator arm opening.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates to a molded brick, in particular made from concrete, for laying ground coverings, the molded brick having an upper side which is delimited in the transition to upright side faces by a side edge which frames the upper side. Furthermore, the invention relates to a ground covering comprising molded bricks of this type.
[0003] 2. Prior Art
[0004] Molded bricks for ground coverings are known from practice in different designs. For example, there are molded bricks with rectilinearly extending side edges, or molded bricks which are reminiscent of natural stones with regard to the design and have irregularly shaped side edges and side faces.
[0005] Proceeding from this, the invention is based on the object of developing molded bricks of the type mentioned in the introduction, in particular with regard to a harmonious course of the side edge.
BRIEF SUMMARY OF THE INVENTION
[0006] In order to achieve this object, a molded brick which is designed according to the invention is a molded brick, in particular made from concrete, for laying ground coverings, the molded brick having an upper side which is delimited in the transition to upright side faces by a side edge which frames the upper side, characterized in that the course of the side edge is of curved configuration at least in regions and corresponds to a mathematical function. According to this, there is provision for the course of the side edge to be of curved configuration at least in regions and to correspond to a mathematical function.
[0007] It has been shown that the use of a mathematical function for fixing the course of the side edge leads overall to an improved appearance of the molded brick in comparison with conventional methods.
[0008] There is provision in one preferred development of the invention for the profile of the side edge to correspond at least in regions to the function ƒ(x)=a*ln(x)+b. The use of a function on the basis of the logarithm surprisingly results in a particularly harmonious appearance.
[0009] A further special feature can consist in that the course of curved regions of the side edge is different, in particular in the case of the use of the above function by using different values for the variables a and b for different regions. In other words, it is proposed not to select the same function for all regions of the side edge, but on the other hand also not to use completely different functions, but rather only to use parameters for always adapting basically the same function.
[0010] According to one preferred development of the invention, the course of the side edge is not stipulated continuously by the mathematical function, but rather the regions of the side edge which are curved according to the mathematical function are connected to circular extending regions. This leads to an appealing exterior of the molded brick.
[0011] A preferably independent achievement of the object can consist in the course of the side edge having concavely and convexly curved regions. In this way, special optical effects can be achieved when laying molded bricks of this type to form a ground covering, such as the impression that the molded bricks appear to have an arched upper side, although the upper side is actually substantially flat.
[0012] There is preferably provision in this context for the side edge to have a bulge in the region of a longitudinal side of the molded brick, such that two concavely curved regions of the side edge enclose a convexly curved region of the side edge.
[0013] It is particularly advantageous if the upright side faces are not of curved configuration, but rather extend substantially in a continuous plane and in an upright manner until shortly before the region of the upper side, the transition between the planar side faces and the curved side edges being compensated for by transition faces, in particular in the region of a circumferential bevel. In this way, the molded bricks can namely be laid particularly easily. In addition, it is simply possible in this way to integrally form spacers on the side faces which are otherwise planar.
[0014] Furthermore, protection is claimed for a ground covering comprising the molded bricks according to the invention.
[0015] A further special feature consists in the adaptation of the molded bricks for carrying horizontal loads.
[0016] Further details result from the subclaims and otherwise from the description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the following text, one preferred exemplary embodiment of the invention will be explained using the drawing, in which:
[0018] FIG. 1 shows a first molded brick according to the invention in a plan view,
[0019] FIG. 2 shows the molded brick according to FIG. 1 in a view from below,
[0020] FIG. 3 shows the molded brick according to FIG. 1 in a view of a short side face,
[0021] FIG. 4 shows the molded brick according to FIG. 1 in a view of a long side face,
[0022] FIG. 5 to FIG. 8 show isometric representations of the molded brick according to FIG. 1 ,
[0023] FIG. 9 shows a diagrammatic plan view of the molded brick according to FIG. 1 with a representation of the construction of the side edges,
[0024] FIG. 10 to FIG. 17 show a second molded brick according to the invention in an analogous representation to FIG. 1 to FIG. 8 ,
[0025] FIG. 18 to FIG. 21 show a ground covering comprising molded bricks according to FIGS. 1 to 17 in a plan view and in a three-dimensional representation,
[0026] FIG. 22 shows a further molded brick according to the invention in a plan view,
[0027] FIG. 23 to FIG. 27 show the molded brick according to FIG. 22 in further views and isometric representations,
[0028] FIG. 28 to FIG. 33 show a further molded brick according to the invention in an analogous representation to FIGS. 22 to 27 ,
[0029] FIG. 34 to FIG. 39 show a further molded brick according to the invention in an analogous representation to FIGS. 22 to 27 , and
[0030] FIG. 40 to FIG. 43 show a ground covering comprising molded bricks according to FIGS. 22 to 33 in a plan view and three-dimensional representations.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] First of all, the exemplary embodiment according to FIGS. 1 to 21 will be described. After this, the exemplary embodiment according to FIGS. 22 to 43 will be described, only the differences from the first exemplary embodiment being concentrated on there. Here, consistent designations are used for identical parts.
[0032] The first exemplary embodiment is concerned with the production of a ground covering 10 from two different types of molded bricks 11 , 12 which, combined with one another, are laid to form the ground covering 10 . A first type of molded brick 11 is shown in figs FIGS. 1 to 9 , and the second type of molded brick 12 results from FIGS. 10 to 17 .
[0033] The molded bricks 11 , 12 in each case have a planar upper side 13 , a corresponding lower side 14 and four upright side faces, namely longer longitudinal side faces 15 , 16 and shorter transverse side faces 17 , 18 . While the transverse side faces 17 , 18 have a continuous rectilinear course, the longitudinal side faces 15 , 16 are of angled away or kinked configuration, with the result that the molded bricks 11 , 12 have an elongate hexagonal design in outline, the longitudinal side faces 15 , 16 being angled away in the region of the longitudinal center.
[0034] A further feature is spacers 19 which are arranged on the side faces 15 , 16 , 17 , 18 and, starting from the lower side 14 , extend until shortly before the upper side 13 of the molded bricks 11 , 12 . The spacers are integrally formed on the side faces 15 , 16 , 17 , 18 in pairs as elongate web-like structures with a beveled upper side. Depending on the intended use, the spacers 19 can also be dispensed with, or the spacers 19 can have a different design and/or arrangement.
[0035] One special feature of the molded bricks 11 , 12 lies in the design of side edges 20 which extend circumferentially in the region of the upper side 13 of the molded bricks 11 , 12 . In the present case, the side edge 20 of the upper side 13 is understood as being the transition from the upper side 13 to the upright side faces 15 , 16 , 17 , 18 . In the present case, the special feature consists in the circumferential side edge 20 being of curved configuration in outline. To this end, reference is made to FIG. 9 . The individual sections of the side edge 20 are shown diagrammatically there, with in each case regions of different curvature. Furthermore, it can be seen that the molded brick 11 has an axis of symmetry 21 which extends transversely through the two longitudinal side faces 15 , 16 , namely in the longitudinal center of the latter.
[0036] The following regions result with reference to FIG. 9 :
1. A region 22 extends along the left-hand half of the longitudinal side face 15 as far as via the corner into the region of the transverse side face 18 . 2. A region 22 ′ results from mirroring the region 22 at the axis of symmetry 21 . 3. A region 23 lies between the two regions 22 and 22 ′. 4. A region 24 adjoins the region 22 in the region of the transverse side faces 18 . 5. A region 24 ′ lies, mirrored via the axis of symmetry 21 , on the opposite transverse side face 17 . 6. A region 25 adjoins the region 24 and extends in the region of the corner between the transverse side face 18 and the longitudinal side face 16 . 7. A region 25 ′ results once again by mirroring of the region 25 at the axis of symmetry 21 . 8. In a similar manner to the region 22 along the longitudinal side face 15 , a region 26 extends along the longitudinal side face 16 , however. 9. A region 26 ′ corresponds to the region 26 mirrored at the axis of symmetry 21 . 10. A region 27 is situated between the two regions 26 and 26 ′ in the region of the axis of symmetry.
[0047] The course of the side edge 20 in the regions 22 , 23 , 24 , 25 , 26 , 27 results as follows:
[0000] 1. Regions 22 and 22 ′: ƒ(x)=3*ln(x)−19.5
2. Region 23 : constant radius r=56
3. Region 24 : constant radius r=1.322
4. Regions 25 and 25 ′: ƒ(x)=ln(x)−137.5
5. Regions 26 and 26 ′: ƒ(x)=3*ln(x)−19.5
6. Region 27 : constant radius r=28.3
[0048] The special feature of the molded brick 11 consists in the course of the side edge 20 therefore corresponding in the regions 22 , 22 ′, 25 , 25 ′ and 26 , 26 ′ to a mathematical function, namely on the basis of the logarithm. The regions which are curved in this way are connected to one another by constantly curved regions 23 , 24 , 24 ′ and 27 .
[0049] In this way, the result is a particularly harmonic course of the side edge 20 . It goes without saying that the formula for the logarithmically curved regions can be varied according to the example:
[0000] ƒ( x )= a *ln( x )+ b
[0050] Different values can be used for the variables a and b. Furthermore, the regions can be displaced by transformation.
[0051] A further special feature consists in the regions 26 and 26 ′ of the side edge 20 being concavely arched, namely in relation to the center point of the upper side 13 , whereas the remaining regions 22 , 22 ′, 23 , 24 , 24 ′, 25 , 25 ′ and 27 are of convexly arched configuration.
[0052] The molded brick 12 according to FIGS. 10 to 17 differs from the molded brick 11 merely in that the regions 24 and 24 ′ are of concavely arched configuration in the region of the transverse side faces 17 , 18 , and not of convexly arched configuration as in the first exemplary embodiment.
[0053] A common feature of both molded bricks 11 , 12 is that the upright side faces 15 , 16 , 17 , 18 are not of arched configuration, but rather are of rectilinear configuration. This results in a different course of the upright side faces in comparison with the side edge 20 . This difference is compensated for by what are known as transition faces 28 .
[0054] It can be seen from FIGS. 18 to 21 that the molded bricks 11 and 12 are laid together to form a common ground covering 10 . Here, the molded bricks 11 , 12 are laid in rows 29 , the molded bricks 11 , 12 being laid alternately within a row 29 .
[0055] In addition, the rows 29 are arranged offset with respect to one another by half a brick length, in what is known as the half brick lattice. This manner of laying results in the following special features: the molded bricks 11 , 12 lie so close to one another that, in the region of the transverse side faces 17 , 18 , a molded brick 11 with a convexly arched transverse side face 17 lies next to a molded brick 12 with a concavely arched transverse side face 18 . A convex bulge 34 , formed by the region 27 , on the side edge 20 comes to lie between two transverse side faces 17 , 18 of molded bricks 11 , 12 of an adjacent row 29 . The course of the joints between the molded bricks 11 , 12 accordingly follows the course of the side edges 20 .
[0056] The ground covering 10 has an interesting optical effect as a result of this type of laying. The impression is namely produced that the molded bricks 11 , 12 have an arched upper side 13 , which is actually not the case. The representation according to FIG. 20 shows this optical effect clearly.
[0057] A further advantage results from the longitudinal side faces 15 , 16 of angled away configuration. Within the ground covering 10 , the two “halves” of the longitudinal side faces 15 , 16 bear against correspondingly angled away regions of longitudinal side faces 15 , 16 of adjacent molded bricks 11 , 12 . In this way, horizontal forces which act transversely with respect to the rows 29 are transmitted uniformly from a molded brick 11 , 12 to two adjacent molded bricks 11 , 12 of an adjacent row 29 , without the otherwise usual tilting of the molded bricks 11 , 12 and the associated edge pressures occurring.
[0058] FIGS. 22 to 43 show a second exemplary embodiment of the invention. In said figures, a ground covering 30 is produced from three different molded bricks 31 , 32 , 33 . Molded brick 30 is shown in FIGS. 22 to 27 . Molded brick 32 results from FIGS. 33 to 38 , and molded brick 33 results from FIGS. 28 to 32 .
[0059] The molded brick 31 shown in FIGS. 22 to 27 corresponds substantially to the molded brick 12 shown in FIGS. 10 to 17 , but with shorter longitudinal side faces 15 , 16 . By way of example, a version is also shown without spacers on the upright side faces 15 , 16 , 17 , 18 .
[0060] The molded brick 32 shown in FIGS. 34 to 39 corresponds substantially to the molded brick 11 shown in FIGS. 1 to 9 , but the angled away portion of the longitudinal side face 16 is not situated in the longitudinal center of the molded brick 32 , but rather offset laterally with respect thereto. The molded brick 33 shown in FIGS. 28 to 32 is configured in accordance with the molded brick 32 , but with a mirrored position of the angled away portion.
[0061] Within the laid ground covering 30 , in each case two different types of molded bricks 31 , 32 or 31 , 33 are laid within a row 29 , to be precise alternately as in the first exemplary embodiment. This therefore results in a corresponding laying pattern as in the first exemplary embodiment, but with a different optical impression.
[0062] It goes without saying that the ground coverings can also be configured with a greater number of different molded brick types.
LIST OF DESIGNATIONS
[0000]
10 Ground covering
11 Molded brick
12 Molded brick
13 Upper side
14 Lower side
15 Longitudinal side face
16 Longitudinal side face
17 Transverse side face
18 Transverse side face
19 Spacer
20 Side edge
21 Axis of symmetry
22 Region
22 ′ Region
23 Region
24 Region
24 ′ Region
25 Region
25 ′ Region
26 Region
26 ′ Region
27 Region
28 Transition face
29 Row
30 Ground covering
31 Molded brick
32 Molded brick
33 Molded brick
34 Bulge
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A molded brick, in particular made from concrete, for laying ground coverings ( 10, 30 ), the molded brick ( 11, 12, 31, 32, 33 ) having an upper side ( 13 ) which is delimited in the transition to upright side faces ( 15, 16, 17, 18 ) by a side edge ( 20 ) which frames the upper side ( 13 ). The course of the side edge ( 20 ) of the molded brick is of curved configuration at least in regions and to correspond to a mathematical function, the course of the side edge ( 20 ) preferably corresponding at least in regions to the function ƒ(x)=a*ln(x)+b.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] This invention generally relates to fencing systems. More particularly, the invention relates to mounting brackets useful for installing horizontal rails to vertical posts. Specifically, the invention relates to a bracket for mounting a rail to a post in confined spaces and to a cover plate that snaps around the bracket once the rail has been retained within the bracket.
[0003] 2. Background Information
[0004] It has become more common in recent years to use either vinyl or plastic products for constructing fences for yards or deck railings. While vinyl fencing is aesthetically pleasing and easy to maintain, the material poses somewhat of a problem for the contractor who must connect the various components together. It is especially problematic to connect horizontal vinyl rails to vertically extending posts in confined spaces.
[0005] There is therefore a need in the art for an improved bracket assembly for attaching horizontal rails to vertical posts.
SUMMARY OF THE INVENTION
[0006] The mounting bracket assembly of the present invention comprises a bracket that is secured to a vertical fence post and a cover plate that is snap-fitted over the bracket after the rail has been retained within the bracket. The bracket is preferably substantially U-shaped and is mounted in such a way that it is open at a top end. The rail is dropped into the U-shaped bracket and fasteners are used to secure the rail within the bracket. The cover plate is snap fitted over the bracket after the rail has been retained therein so as to conceal the fasteners. The cover plate provides an aesthetically pleasing finish to the connection between the post and rail.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
[0008] FIG. 1 is a front elevational view of a deck railing incorporating the mounting bracket assembly of the present invention;
[0009] FIG. 2 is a partial perspective view of a rail secured to a post using a first embodiment of a mounting bracket assembly in accordance with the present invention;
[0010] FIG. 3 is an exploded perspective view of the rail and post shown in FIG. 2 ;
[0011] FIG. 4 is a rear view of the cover plate being snap-fitted over the bracket;
[0012] FIG. 5 is a rear view of the bracket and cover plate through line 5 - 5 of FIG. 2 ;
[0013] FIG. 6 is a partial cross-sectional bottom view of the cover plate and bracket;
[0014] FIG. 7 is an enlargement of the highlighted area of the cover plate and bracket from FIG. 5 ;
[0015] FIG. 8 is a side view through line 8 - 8 of FIG. 5 ;
[0016] FIG. 9 is a top view through line 9 - 9 of FIG. 5 ;
[0017] FIG. 10 is a cross-sectional front view of a post with two rails connected thereto by way of bracket assemblies in accordance with the present invention;
[0018] FIG. 11 is a perspective view of a second embodiment of bracket assembly in accordance with the present invention;
[0019] FIG. 12 is a rear view of the bracket assembly shown in FIG. 11 ; and
[0020] FIG. 13 is a perspective view of the bracket of the bracket assembly of FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIGS. 1&2 , there is shown a section of a deck railing 10 including a post 12 , mounted to deck planking 14 , and having a plurality of rails 16 secured thereto. A plurality of balusters 18 extend between the upper and lower rails 16 . Rails 16 are secured to post 12 by way of mounting bracket assemblies in accordance with the present invention and generally indicated at 20 .
[0022] Referring to FIGS. 3-9 , there is shown a rail 16 connected to a post 12 by way of the mounting bracket assembly 20 in accordance with the present invention. Bracket assembly 20 comprises a bracket 22 and a cover plate 24 .
[0023] In accordance with a specific feature of the present invention, bracket 22 has a back wall 26 , a peripheral outer wall 28 extending outwardly away from the back wall 26 and having an opening 30 formed therein. Opening 30 preferably extends entirely across one end of bracket 22 . Peripheral outer wall 28 is substantially U-shaped with the opening 30 therein extending from side section 28 a across to side section 28 b ( FIG. 3 ). Back wall 26 of bracket 22 is also substantially U-shaped. Back wall 26 and peripheral outer wall 28 of bracket 22 substantially define a U-shaped receptacle 27 into which rail 16 may be received. Bracket 22 is complementary shaped and sized to receive an end of rail 16 therein. The distance between side sections 28 a and 28 b is therefore substantially equal to the width “A” of rail 16 ; and the distance between end section 28 c and edge 29 is substantially equal to the height “B” of rail 16 . It should, however, be understood that the bracket could alternatively be sized and shaped to receive rail 16 therein when it is turned through 90 degrees. In that instance, the distance between side sections 28 a and 28 c would have to be substantially equal to the height “B” of rail 16 and the distance between end section 28 c and edge 29 would have to be substantially equal to the width “A” of rail 16 . No matter which way rail 16 is to be oriented, an end of rail 16 is received within receptacle 27 in bracket 22 . So, as is shown in FIG. 3 , rail may be dropped or slid vertically into receptacle 27 through opening 30 (i.e., in the direction of arrow “C”) or, if space provides, may be slid horizontally into receptacle 27 in the direction of arrow “D”. Bracket 22 has a longitudinal axis “E-E” that runs substantially parallel to post 12 and a horizontal axis “F-F” that runs perpendicular to post 12 .
[0024] Back wall 26 of bracket 22 defines a plurality of first apertures 32 therein. A plurality of first fasteners 34 are received through first apertures 32 to secure bracket 22 to a side wall 36 of post 12 . Peripheral outer wall 28 defines a plurality of second apertures 38 therein. Second apertures 38 are provided to receive second fasteners 40 therethrough in order to secure rail 16 in shear within bracket 22 . Side sections 28 a , 28 b of peripheral outer wall 28 preferably are also each provided with a flange 42 which extends from an outer edge 44 of bracket 22 through to a short distance inwardly from back wall 26 thereof. Flanges 42 preferably taper forwardly from back wall 26 through to outer edge 44 ( FIG. 3 ). Outer edge 44 of peripheral outer wall 28 is preferably beveled and the beveling may include a front end 42 a of flanges 42 . End section 28 c ( FIG. 4 ) of peripheral outer wall 28 may also be provided with a pair of spaced apart ridges 46 thereon and a pair of notches 48 are provided at a top end of back wall 26 . The purpose of ridges 46 and notches 48 will be described hereinafter.
[0025] Cover plate 24 is complementary shaped to surround bracket 22 and, more specifically, to encompass peripheral outer wall 28 thereof, including spanning the opening 30 between side sections 28 a and 28 b . Consequently, because bracket 22 is substantially U-shaped, cover plate 24 is substantially rectangular in shape. Cover plate 24 comprises a perimeter wall 50 that has a top end 50 a , a bottom end 50 b and sides 50 c and 50 d which together define an interior cavity 52 into which bracket 22 is received. The exterior surface of perimeter wall 50 may be provided with a decorative profile so as to give railing 10 a more decorative appearance. A slot 54 extends from a front edge 56 of cover plate 24 through to a back edge 58 thereof. The cover plate 24 is manufactured in such a way that it can flex and sides 50 c and 50 d can be pulled apart from each other as shown in FIG. 4 . Tabs 60 are provided on each of sides 50 c , 50 d proximate back edge 58 thereof. As may be seen from FIG. 5 , tabs 60 are positioned so that when cover plate 24 is snap-fitted over bracket 22 , tabs 60 slide behind flanges 42 . Tabs 60 will then be positioned between flanges 42 and side wall 36 of post 12 . Cover plate 24 also has a lip portion 62 extending inwardly a short distance perimeter wall 50 . Outer edge 44 of bracket 22 abuts lip portion 62 when cover plate 24 is snap-fitted around bracket 22 . A pair of tapered tabs 64 are also provided on bottom end 50 c alongside slot 54 , with the widest part of tabs 64 being positioned proximate back edge 58 of cover plate 24 . Tabs 64 are positioned to interlock with ridges 46 on bracket 22 . Second tabs 66 are disposed on the interior surface of top end 50 a of being positioned proximate back edge 58 of cover plate 24 . Each second tab 66 further includes a downwardly extending projection 68 disposed proximate back edge 58 .
[0026] Bracket assembly 20 is used to connect rail 16 to post 12 in the following manner. The installer selects the position on side wall 36 of post 12 where he wishes to install bracket 22 . Back wall 26 is placed in abutting contact with side wall 36 , preferably with opening 30 being position at the top of bracket 22 . Fasteners 34 , which are preferably stainless steel screws, are used to secure bracket 22 to post 12 .
[0027] Rail 16 is then dropped into receptacle 27 defined by bracket 22 peripheral outer wall 28 . The end 70 ( FIG. 10 ) of rail 16 preferably is pushed into abutting contact with rear wall 26 of bracket 22 . Second fasteners 40 , which are preferably stainless steel screws, are then used to secure rail 16 within bracket 22 .
[0028] Cover plate 24 is then positioned around bracket 22 . In order to do this, side sections 50 c and 50 d of cover plate 24 are pulled apart ( FIG. 4 ) and then cover plate 24 is moved downwardly over bracket 22 . As the inner surface of the top end 50 a of cover plate 24 engages edge 29 of bracket 22 , projections 68 on cover plate 24 slide into notches 48 on bracket 22 . The installer releases side sections 50 c , 50 d , which then snap inwardly toward each other and around bracket 22 . When this occurs, tabs 60 slide behind flanges 42 . The installer then engages side sections 50 c and 50 d of cover plate 24 proximate bottom end 50 b and gently pushes side sections 50 c , 50 d inwardly toward each other. This causes tabs 64 to slide over ridges 46 , thereby locking cover plate 24 in place. It should be noted that when in this position, cover plate 24 cannot slide outwardly away from post 12 and along rail 16 . This is because projections 68 are engaged in notches 48 and tabs 60 are disposed behind flanges 42 . Furthermore, side sections 50 c and 50 d cannot easily be moved outwardly away from each other because the tabs 64 are interlocked with ridges 46 . Back edge 58 of cover plate 24 lies in abutting contact with side wall 36 of post 12 , and lip 62 is in abutting contact with front edge 56 of bracket 22 . All fasteners, 34 and 40 are hidden from view by cover plate 24 and the connection between rail 16 and post 12 is aesthetically pleasing. As may be seen from FIG. 10 , a second bracket 22 and its associated cover plate 24 may be secured to one of the other side walls of post 12 .
[0029] When cover plate 24 is positioned around bracket 22 , cover plate 24 lies substantially at right angles to the horizontal axis “F-F” of bracket 22 and substantially axially aligned with longitudinal axis “E-E” of bracket 22 .
[0030] In order to unlock tabs 64 from ridges 46 a thin object, such as the end of a flathead screwdriver can be inserted between a bottom wall of rail 16 and the inner surface of lip 62 and a small downward force is applied. Once tab 64 is disengaged from bracket 22 , then side sections 50 c and 50 d are moved arcuately outwardly away from each other so that tabs 60 slide outwardly from behind flanges 42 . Cover plate 24 is then slid slightly upwardly so that projections 68 slide out of slots notches 48 . Cover plate 24 is then completely disengaged from bracket 22 , each one of bottom sections 50 b needs to be individually lifted over substantially prevents this arcuate motion from occurring without a reasonable amount of force being applied thereto.
[0031] Referring to FIGS. 11-13 , there is shown a second embodiment of bracket assembly in accordance with the present invention and generally indicated at 120 . Bracket assembly 120 is adapted to be used in association with a rail 116 . Rail 116 is substantially T-shaped in cross-section and is adapted to be received within a bracket 122 mounted on a post 112 . Bracket 122 includes a substantially T-shaped back wall 126 and a substantially U-shaped peripheral outer wall 128 which terminates in a flange 172 at the base of the crossbar 174 of the “T” shape on the back wall 126 . All other components of bracket assembly 120 are substantially the same as those of bracket assembly 20 . Bracket 122 is secured to post 112 by fasteners 134 . Rail 116 gets dropped into the opening 130 between side sections 128 a and 128 b . The underside 176 a of the flanges 176 on rail 116 abuts flange 172 on bracket 122 . Fasteners (not shown) are then screwed into the side walls 116 a of rail 116 . Cover plate 124 is then snap fitted around bracket 122 by pulling the side sections 150 c and 150 d apart from each other and moving cover plate 124 downwardly until the interior surface of top end 150 a engages upper edge 129 of bracket 122 . Cover plate 124 interlocks and is secured to bracket 122 in the same manner as cover plate 24 and bracket 22 .
[0032] It will be understood that while the figures illustrate bracket 22 secured to side wall 36 of post 12 with the opening 30 at the top so that rail 16 may be slid vertically into bracket 22 in the direction of arrow C, bracket 22 may be placed in any other desired orientation, e.g. with opening 30 effectively facing the front or back of the railing, or at an angle to the vertical, or even downwardly. The latter orientation is the least favored only for the reason that the end section 28 c of bracket 22 assists in carrying the load of rail 16 and if opening 30 is disposed facing the deck planking 14 , then the load of rail 16 is effectively carried by the fasteners 40 , instead of a combination of the fasteners 40 and end section 28 c.
[0033] Furthermore, while a generally rectangular shaped rail and bracket assembly; and a generally T-shaped rail and bracket assembly have been illustrated and described herein, it will be understood that the complementary bracket and rail assembly can be of any desired shape and configuration without departing from the spirit of the present invention.
[0034] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
[0035] Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.
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A bracket assembly for securing a rail to a post. The bracket assembly includes a bracket that is secured to the post and a spring-biased cover plate. The cover plate includes a perimeter wall that includes a slot which extends from its front edge through to its back edge. A portion of the perimeter wall terminates adjacent either side of the slot. These portions of the perimeter are movable relative to each other. The bracket includes a back wall with a peripheral outer wall extending upwardly and outwardly away therefrom. The peripheral wall defines a rail receiving receptacle into which an end of a rail is placed. The rail is preferably secured in position by a plurality of fasteners inserted through the rail and into the housing. Once the end of the rail is retained in the bracket, the terminal portions of the perimeter wall are arcuately separated from each other and the cover plate is snap-fitted over the peripheral outer wall of the bracket.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
RELATED APPLICATION
[0001] This patent arises from a divisional of U.S. application Ser. No. 13/532,379, which was filed on Jun. 25, 2012 and is hereby incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] This patent generally relates to insulated doors and more specifically to doors that comprise a flexible panel such as an insulated curtain.
BACKGROUND
[0003] Cold storage rooms are refrigerated areas in a building that are commonly used for storing perishable foods. Cold storage rooms are typically large enough for forklifts and other material handling equipment to enter. Access to the room is often through a power actuated insulated door that separates the room from the rest of the building. To minimize thermal losses when someone enters or leaves the room, the door preferably opens and closes as quickly as possible.
[0004] Vertically operating roll-up doors and similar doors with flexible curtains are perhaps some of the fastest operating doors available. When such a door opens, its curtain usually bends upon traveling from its closed position in front of the doorway to its open position on an overhead storage track or take-up roller.
[0005] Such bending is not a problem if the curtain is relatively thin. However, an insulated curtain may not bend as well due to the required thickness of the insulation. When a take-up roller or curved track bends a thick curtain, relative translation may occur between opposite faces of the curtain. Designing a thick, insulated curtain that can accommodate such translation can be challenging.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a front view showing an example door in a closed position.
[0007] FIG. 2 is a front view similar to FIG. 1 but showing the example door partially open.
[0008] FIG. 3 is a front view similar to FIGS. 1 and 2 but showing the example door in an open position.
[0009] FIG. 4 is a cross-sectional view taken along line 4 - 4 of FIG. 3 .
[0010] FIG. 5 is a front view of the example door panel of FIGS. 1-3 with a lower-left section of the panel's outer sheet cutaway.
[0011] FIG. 6 is a cross-sectional view taken along line 6 - 6 of FIG. 5 .
[0012] FIG. 7 is a cross-sectional view similar to FIG. 6 but with the insulation omitted to more clearly show one of the example baffles.
[0013] FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 5 .
[0014] FIG. 9 is a cross-sectional view similar to FIG. 8 but showing the example door panel being assembled.
[0015] FIG. 10 is a cross-sectional view similar to FIG. 8 but showing another example assembly and with one pad removed.
[0016] FIG. 11 is a cross-sectional view similar to FIG. 10 but showing another example assembly.
DETAILED DESCRIPTION
[0017] Certain examples are shown in the above-identified figures and described in detail below. In describing these examples, like or identical reference numbers are used to identify the same or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic for clarity and/or conciseness. Additionally, several examples have been described throughout this specification. Any features from any example may be included with, a replacement for, or otherwise combined with other features from other examples.
[0018] FIGS. 1-4 illustrate an example of a vertically operating door 10 that includes a flexible, insulated door panel 12 . Door 10 is shown closed in FIG. 1 , partially open in FIG. 2 , and fully open in FIGS. 3 and 4 . In the illustrated example, as door 10 opens and closes relative to a doorway 14 , door panel 12 bends over a mandrel 16 . Mandrel 16 , in some examples, is a fixed bar or a roller extending across the width of doorway 14 . Although door panel 12 is shown having a certain double-bend, stored configuration, other stored configurations, such as coiled, wound on a roll tube, single-bend horizontal, serpentine, vertically planar, etc., are all well within the scope of this disclosure.
[0019] Although door 10 is useful in unlimited applications, door 10 is particularly suited for providing access to refrigerated cold storage rooms or for separating rooms or areas that are at different temperatures, such as, for example, the interior and exterior of a building at a truck loading dock. In such temperature differential installations, one side of door panel 12 is often colder than the other side, which can subject door panel 12 to an adverse water vapor pressure gradient. While FIGS. 1-9 disclose general features of example door panel 12 , FIGS. 10 and 11 disclose more detailed features specifically intended to address the problems associated with the water vapor pressure gradient.
[0020] To operate door 10 , in some examples, a powered drive sprocket 18 ( FIG. 4 ) engages a cogged strip 20 at each lateral edge of door panel 12 to move door panel 12 between a lower guide track 22 , where door panel 12 is blocking doorway 14 , and an upper track 24 where door panel 12 is clear of the doorway 14 . It should be noted, however, that door panel 12 can be applied to various other types of doors that operate with different drive or storage configurations.
[0021] In some examples, door panel 12 includes a plurality of pliable baffles 26 ( FIGS. 5, 8 and 9 ) that restrict the redistribution of air contained between a first sheet 28 and a second sheet 30 of door panel 12 . Sheets 28 and 30 are joined and generally sealed along their outer perimeter to create one large overall air chamber 32 between sheets 28 and 30 . Baffles 26 divide chamber 32 into a plurality of more manageable smaller chambers 34 . For illustrative clarity, baffles 26 and chambers 32 and 34 are shown in FIG. 5 to extend slightly less than a full width 40 of door panel 12 , however, baffles 26 and chambers 32 and 34 preferably extend the full width of door panel 12 . As door 10 opens and creates a horizontal crease in sheets 28 and 30 (e.g., where door panel 12 bends over mandrel 16 ), baffles 26 help prevent air trapped within chamber 32 from over inflating the lower end of door panel 12 . Thus, baffles 26 prevent the area between mandrel 16 and a lower leading edge 36 of door panel 12 from bulging excessively as door 10 opens.
[0022] In some examples, baffles 26 are sufficiently flexible to accommodate some relative translation between sheets 28 and 30 as door panel 12 bends over mandrel 16 . The flexibility of baffles 26 may also enable door panel 12 to restorably break away if something were to accidentally collide with the door 10 . Additionally or alternatively, some examples of baffles 26 are sufficiently flexible to conformingly mate with the lateral edges or vertical seams 33 of sheets 28 and 30 so that there is minimal leakage or air exchange between chambers 34 . Further, in some examples, baffles 26 are sufficiently stiff to maintain a desired spacing between sheets 28 and 30 , particularly in examples where insulation is not used for maintaining such spacing. Further yet, in some examples, baffles 26 have a thermal resistance (i.e., R-value) that is equal to or greater than that of sheets 28 and 30 .
[0023] Although the actual construction of door panel 12 may vary, the illustrated examples have sheets 28 and 30 being made of any suitable polymeric or natural fabric material that is preferably pliable and can be joined along their outer perimeter by adhesion, tape, melting/fusing/welding, sewing, hook-and-loop fastener, snaps, rivets, zipper, etc. The term, “polymeric,” as used in this patent to describe a material means that the material includes at least some plastic or polymer base, substrate or coating. The term, “pliable” as used in this patent to describe a sheet of material means the sheet is sufficiently flexible to be folded over onto itself and subsequently unfolded without appreciable permanent damage. For toughness, wear resistance, heat seal weldability and flexibility, some examples of sheets 28 and 30 comprises polyurethane sheet material between about 1 and 2 mm thick (thickness 52 ). In some examples, substantially the entire outer perimeter, including seams 33 and the upper and lower edges of door panel 12 , is sealed to prevent appreciable amounts of air from flowing in and out of chamber 32 Inhibiting moist air from repeatedly entering chamber 32 can prevent mold-promoting water vapor from condensing inside chamber 32 on a panel sheet that is facing, for example, a cold storage room.
[0024] Baffles 26 can be made of a material similar to or different than that of sheets 28 and 30 . The flexibility of sheets 28 and 30 enables door panel 12 to bend over mandrel 16 , while the flexibility of baffles 26 enables limited relative translation between sheets 28 and 30 as door 10 opens and closes. As door 10 opens or closes and door panel 12 travels and bends across mandrel 16 , this action urges relative vertical translation between sheets 28 and 30 . In some examples, thermally insulating pads 38 (e.g., resiliently compressible foam pads, polyester batting, etc.) are installed within chambers 34 . The term, “thermally insulating,” as used in this patent to describe pads 38 within door panel 12 means that the pads provide the greatest contribution of the door panel's overall thermal resistance or R-value.
[0025] For the illustrated examples, baffles 26 are horizontally elongate, which enable the baffles 26 to not only restrict vertical airflow within door panel 12 but also to accommodate relative vertical translation between sheets 28 and 30 . In other examples, door panel 12 is provided with vertically elongate baffles or a combination of vertical and horizontal baffles.
[0026] To effectively restrict airflow within door panel 12 , horizontally elongate baffles 26 preferably extend along at least most of the full width 40 of door panel 12 . To facilitate manufacturing, however, baffles 26 can be made slightly shorter than the panel's full width 40 to make it easier to join the lateral vertical edges of sheets 28 and 30 together. Baffles 26 being a little shorter than full width 40 of door panel 12 places the plurality of air chambers 34 in fluid communication with each other. Thus, as door 10 opens and door panel 12 travels across mandrel 16 , some air within door panel 12 will be temporarily redistributed to at least one of the lower chambers (e.g., air chamber 34 ′) of the plurality of chambers 34 , thereby slightly increasing the air pressure within chamber 34 ′ temporarily, but not really detrimentally.
[0027] Although the general assembly of door panel 12 can be accomplished by various means, FIG. 9 illustrates one example manufacturing method. One horizontal edge of each baffle 26 is melted or ultrasonically welded to first sheet 28 , thereby creating a plurality of fused joints 42 between sheet 28 and each of baffles 26 . Fusing baffles 26 to at least one of sheets 28 and 30 is schematically depicted by the block at reference number 44 of FIG. 9 . Alternate methods of attaching baffles 26 in place include, but are not limited to, bonding, taping, sewing, fastening via hook-and-loop fastener, riveting, etc.
[0028] An outer perimeter of sheet 28 is fused, sewn or otherwise connected to sheet 30 as schematically depicted by the block at reference number 46 of FIG. 9 . The plurality of baffles 26 are installed between sheets 28 and 30 , as schematically depicted by arrow 48 and insulation pad 38 is installed within chambers 34 , as schematically depicted by arrows 50 . The example method represented by the block at reference number 44 and arrows 48 and 50 may be done generally together in a progressive sequence from one end of door panel 12 to another or in any other suitable order. FIG. 9 , for example, shows door panel 12 being assembled progressively from the bottom up.
[0029] Sheets 28 and 30 , when made of polyurethane, have significant resistance to water vapor transmission therethrough. Nonetheless, some water vapor might still permeate the warmer of sheets 28 and 30 and migrate through pads 38 toward the colder sheet 28 or 30 . If sheet 30 , for example, is warmer than sheet 28 , water vapor might permeate door panel 12 through sheet 30 and condense and perhaps freeze on the inner surface of sheet 28 . An accumulation of trapped liquid water or ice within chamber 34 may inhibit normal operating characteristics of the door panel 12 .
[0030] To address this potential problem, thermally insulating pads 38 , as shown in the example of FIG. 10 , is substantially encircled and/or surrounded and preferably encased by a sheet 54 (third sheet) that has a lower water vapor transmission rate than that of polyurethane. In some examples, sheet 54 starts as a tube in which pad 38 is inserted. After pad insertion, the axial ends of the sheet's tubular form are, in some examples, heat sealed to totally encase pad 38 within sheet 54 , somewhat analogous to a bed pillow in a pillow case. Examples of sheet 54 include, but are not limited to, polyester, polyethylene and aluminum foil. In some examples, sheet 54 is between about 0.1 and 0.2 mm thick (thickness 56 ) with an R-value that is less than that of sheets 28 and 30 . Sheet 54 being much thinner than sheets 28 and 30 maximizes the insulating pad's thickness and thus the pad's R-value for a given door panel thickness. Having sheet 54 be relatively thin is a viable option because sheet 54 is protected by the tough outer sheets 28 and 30 . While the above example describes the sheet 54 surrounding the pad 38 , in other examples, the sheet or sheets 54 may be positioned adjacent one or more surfaces and/or faces of the pad 38 . For example, the sheet 54 may be positioned adjacent a face of the pad 38 between pad 38 and the sheet 30 (e.g., the sheet to be adjacent a warmer side of the building) while not being adjacent the other faces of the pad 38 . In other examples, the sheets 54 may be positioned adjacent opposing surfaces of the pad 38 , one of which being positioned between the sheet 30 and the pad 38 and the other of which being positioned between the sheet 28 and the pad 38 .
[0031] In addition or alternatively, in some examples, baffles 26 lean downward toward the warmer sheet, e.g., toward sheet 30 . In the illustrated example, the baffles 26 are at a non-perpendicular angle relative to a longitudinal axis of the panel 12 such that ends of the baffles 26 are longitudinally displaced along the longitudinal axis of the panel 12 . This allows baffles 26 to drain any accumulated liquid water within chamber 34 down through optional condensate drain holes 58 in sheet 30 . Baffle 26 being inclined also allows adjacent pads 38 to overlap at the pads' upper and lower edges, thereby ensuring vertically overlapping insulation at baffles 26 . A baffle 26 ′ is an alternate example configuration of baffle 26 .
[0032] In addition or alternatively, as shown in FIG. 11 , a sheet 60 (another example third sheet) having a lower water vapor transmission rate than that of polyurethane is installed between pad 38 and sheet 30 to block water vapor on the exterior side of sheet 30 from penetrating chamber 34 . Examples of sheet 60 include, but are not limited to, polyester, polyethylene and aluminum foil. In some examples, sheet 60 is about 0.5 mm thick (thickness 62 ) with an R-value that is less than that of sheets 28 and 30 . The lower R-value of sheet 60 , in some examples, is due to sheet 60 being thinner than sheets 28 and 30 .
[0033] To help hold multiple sheets 60 in place, in some examples, a continuous or segmented sheet 64 (fourth sheet) is thermally or otherwise joined to sheet 30 and/or baffles 26 to create a plurality of pockets 66 in which sheets 60 are inserted. To facilitate effective thermal bonding of sheet 64 with sheet 30 and/or baffle 26 , in some examples, baffles 26 and sheets 28 , 30 , and 64 each comprise polyurethane.
[0034] An example flexible door panel movable between an open position and a closed position relative to a doorway includes a first pliable sheet made of a first polymeric material. The first sheet has a first water vapor transmission rate. The example flexible door panel also includes a second pliable sheet made of a second polymeric material. The second sheet is generally parallel to the first sheet when the door is in the closed position. The second sheet has a second water vapor transmission rate. The example flexible door panel also includes a thermally insulating pad between the first sheet and the second sheet. The thermally insulating pad is resiliently compressible. The example flexible door panel also includes a third sheet between the first sheet and the thermally insulating pad. The third sheet has a third water vapor transmission rate. The third water vapor transmission rate is lower than the first water vapor transmission rate, and the third water vapor transmission rate is lower than the second water vapor transmission rate.
[0035] In some examples, the first sheet has a first R-value, the second sheet has a second R-value, and the third sheet has a third R-value. The first R-value is greater than the third R-value, and the second R-value is greater than the third R-value. In some examples, the first sheet has a first thickness, the second sheet has a second thickness, the third sheet has a third thickness. The first thickness is greater than the third thickness, and the second thickness is greater than the third thickness. In some examples, at least one of the first sheet or the second sheet includes polyurethane. In some examples, at least one of the first sheet or the second sheet defines a condensate drain hole.
[0036] In some examples, the example flexible door panel also includes a plurality of baffles connecting the first sheet to the second sheet to define a plurality of chambers between the first sheet and the second sheet. The plurality of baffles is connected to the first sheet and the second sheet at a plurality of fused joints. In some examples, the example flexible door panel also includes a plurality of thermally insulating pads disposed within the plurality of chambers. The plurality of thermally insulating pads includes the thermally insulating pad. In some examples, the third sheet encircles the thermally insulating pad. In some examples, the example flexible door panel also includes a fourth pliable sheet made of a fourth polymeric material. The fourth sheet has a fourth water vapor transmission rate that is greater than the third water vapor transmission rate of the third sheet. The fourth sheet is joined to at least one of the first sheet or the plurality of baffles to define a pocket between the fourth sheet and the first sheet. The third sheet is disposed within the pocket. The fourth sheet is interposed between the third sheet and the thermally insulating pad. In some examples, the first sheet is to be colder than the second sheet when the door is installed in the doorway of a cold storage room.
[0037] In some examples, a flexible door panel movable between an open position and a closed position relative to a doorway includes a first pliable sheet made of a first polymeric material and a second pliable sheet made of a second polymeric material. The second sheet is generally parallel to the first sheet when the door is in the closed position. The flexible door panel also includes a plurality of baffles connecting the first sheet to the second sheet to define a plurality of chambers between the first sheet and the second sheet. The plurality of baffles is connected to the first sheet and the second sheet. The flexible door panel also includes a plurality of thermally insulating pads disposed within the plurality of chambers. A thermally insulating pad of the plurality of thermally insulating pads is between the first sheet and the second sheet. The thermally insulating pad is resiliently compressible. The flexible door panel also includes a third sheet encircling the thermally insulating pad.
[0038] In some examples, the first sheet has a first R-value, the second sheet has a second R-value, the third sheet has a third R-value. The first R-value is greater than the third R-value, and the second R-value is greater than the third R-value. In some examples, the first sheet has a first thickness, the second sheet has a second thickness, the third sheet has a third thickness. The first thickness is greater than the third thickness, and the second thickness is greater than the third thickness. In some examples, at least one of the first sheet or the second sheet includes polyurethane. In some examples, at least one of the first sheet or the second sheet defines a condensate drain hole. In some examples, the third sheet has a third water vapor transmission rate. The third water vapor transmission rate is lower than the first water vapor transmission rate, and the third water vapor transmission rate is lower than the second water vapor transmission rate.
[0039] An example flexible door panel movable between an open position and a closed position relative to a doorway includes a first pliable sheet made of a first polymeric material. The first sheet has a first water vapor transmission rate. The flexible door panel also includes a second pliable sheet made of a second polymeric material. The second sheet is generally parallel to the first sheet when the door is in the closed position. The second sheet has a second water vapor transmission rate. The flexible door panel also includes a plurality of baffles connecting the first sheet to the second sheet to define a plurality of chambers between the first sheet and the second sheet. The plurality of baffles is connected to the first sheet and the second sheet. The flexible door panel also includes a plurality of thermally insulating pads disposed within the plurality of chambers. A thermally insulating pad of the plurality of thermally insulating pads is between the first sheet and the second sheet. The thermally insulating pad is resiliently compressible. The flexible door panel also includes a third sheet between the first sheet and the thermally insulating pad. The third sheet has a third water vapor transmission rate. The flexible door panel also includes a fourth pliable sheet made of a fourth polymeric material. The fourth sheet is joined to at least one of the first sheet or at least one of the plurality of baffles to define a pocket between the fourth sheet and the first sheet. The third sheet is disposed within the pocket. The fourth sheet is interposed between the third sheet and the thermally insulating pad. The third water vapor transmission rate is lower than the first water vapor transmission rate, and the third water vapor transmission rate is lower than the second water vapor transmission rate.
[0040] In some examples, the first sheet has a first R-value, the second sheet has a second R-value, the third sheet has a third R-value, the first R-value is greater than the third R-value, and the second R-value is greater than the third R-value. In some examples, the first sheet has a first thickness, the second sheet has a second thickness, the third sheet has a third thickness. The first thickness is greater than the third thickness, and the second thickness is greater than the third thickness. In some examples, at least one of the first sheet or the second sheet includes polyurethane. In some examples, at least one of the first sheet or the second sheet defines a condensate drain hole. In some examples, the first sheet is to be colder than the second sheet when the door is installed in the doorway of a cold storage room.
[0041] An example door includes a first sheet coupled to a second sheet to define a chamber therebetween. The door also includes a thermally insulating pad within the chamber and a third sheet adjacent the thermally insulating pad to substantially prevent water vapor from permeating the thermally insulating pad. The third sheet is positioned between the thermally insulating pad and at least one of first sheet or the second sheet. In some examples, the third sheet substantially surrounds the thermally insulating pad. The door may also include a baffle and a drain hole. The baffle is coupled to the first and second sheets at a non-perpendicular angle relative to a longitudinal axis of the door when the door is in a closed position. The drain hole is defined by one of the first sheet or the second sheet adjacent the baffle to enable liquid to flow within the chamber along at least one of the baffle, the first sheet, or the second sheet through the drain hole.
[0042] Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of the coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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Example insulated pliable door panels or curtains include various internal vapor barriers. The vapor barriers have a relatively high water vapor transmission rate that inhibits water vapor from permeating through the door panel. With such vapor barriers, outer sheets of the door panel can be made of polyurethane or other tough materials that might have an inadequate water vapor transmission rate. In some examples, the vapor barrier encircles or encloses a thermally insulating pad. In some examples, the door panel includes a sleeve or pocket that holds the vapor barrier in place. Some examples include means for draining water that might condense within the door panel.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
RELATED U.S. APPLICATION
This application claims the benefit of U.S. Provisional Application No. 61/556898 filed Nov. 8, 2011.
FIELD OF THE INVENTION
This invention relates to a mobile support device for supporting and moving concrete spreading hoses.
BACKGROUND
In the construction industry it is common for concrete to be used and conveyed to the job site via hoses. Concrete is typically either delivered by transit mix trucks or mixed on site. The problem is that these sources of mixed concrete are typically at some distance from the actual site where the concrete is needed. Typically, uncured concrete is pumped from a mixing truck to the area to be filled utilizing a pumping device which feeds a flexible hose. Mixed but uncured concrete has a slurry-like consistency, and is difficult to deliver by hose. A common solution to this problem is to use a large diameter hose, which may range from about three inches in diameter to about ten inches in diameter, with about five inches being typical. When filled with uncured concrete, this hose may weigh up to 30 pounds per foot. With tens of feet of hose being a typical installation, devices which support and move the hose are advantageous. In order to facilitate distribution of the uncured concrete, it is desirable to position the hose off the ground, and provide a structure to support the hose so that it is easily movable, even though carrying substantial weight.
Devices have been developed which attempt to perform these functions. U.S. Pat. No. 5,219,175 (Woelfel) and U.S. Pat. No. 6,209,893 (Ferris) disclose support devices for concrete hoses. Both of these devices use a single, short support to hold the hose resulting in the hose only being supported for less than one foot of its length. In addition, these supports both arrange the supports so that the weight of the supported hose is centered below the tops of the wheels, thereby making the devices more stable. The present designs, however, are still inherently unstable, allowing the supports to rock in relation to the hose, and allowing the hose to contact the ground. Further, surges and collapses in the flexible hose can result in tipping of the hose supports in relation to the hose, which can sometimes impede the pumping process. Another shortcoming in the prior art is the relatively short portion of the support which underlies the hose. This abbreviated dimension allows the hose to flex excessively unless many separate support assemblies are employed. These design features mean that multiple supports may be needed to support a significant length of concrete spreading hose. Likewise, the low center of gravity means that these supports have very low ground clearance and therefore must be lifted over obstacles. In addition, the placement of the lifting handles is such that operators must place their feet on either side of the wheels in order to lift the device, placing the operator's feet in danger of being rolled over by the wheels.
It is desirable then, that a mobile support device for supporting and moving concrete spreading hoses be available which overcomes these limitations. In particular, it is desirable to provide a concrete pumping flexible hose support which resists tipping as it is moved from one distribution location to the next, which discourages buckling or collapsing, which provides readily accessible handles for repositioning, and which elevates the hose above the work site, while at the same time providing improved support along the longitudinal axis of the hose.
SUMMARY OF THE INVENTION
Aspects of the present invention provide for a mobile support device for supporting and moving concrete spreading hoses. Disclosed herein is a mobile support system for supporting a concrete spreading hose, comprising two or more supports spaced apart so as to support a length of concrete spreading hose; at least four large-diameter casters; a frame arranged to rotatably fixture the casters and to position the supports above the casters; and a hand hold arranged around the perimeter of the mobile support system above the wheels and below the supports. It is an object of the invention to provide an improved wheeled support for flexible concrete carrying hoses which provides stability for the flexible hose in all three dimensions, while still allowing a high degree of mobility. It is a further object of the invention to provide such a support which prevents or inhibits collapses of the hose during the concrete pumping and distribution process. It is a further object of the invention to provide such a support which offers increased clearance between the flexible hose and the work surface over which it is suspended, and to provide convenient hand holds for positioning the support and improved safety for the operator in positioning the support.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of an embodiment of this invention;
FIG. 2 is a side view of an embodiment of this invention;
FIG. 3 is a front view of an embodiment of this invention; and
FIG. 4 is a top view of an embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Aspects of the present invention provide for a mobile support device for supporting and moving concrete spreading hoses. FIGS. 1-4 show a mobile support assembly 10 for supporting a concrete spreading hose 12 . The assembly is preferably constructed as a metal framework having sufficient strength to support the anticipated loads, while the hose 12 as above described is generally flexible. It will be appreciated that the preset invention will also function effectively when used with rigid or semi-rigid pipes or similar conduits. The mobile support assembly 10 comprises two or more holders 14 spaced apart on a support beam 15 so as to support a length of concrete spreading hose 12 . The holders 14 are preferably in the configuration of a semi-cylindrical section, open at the upper end and affixed by fasteners or weldment to a support beam 15 . Elongated support beam 15 is of rigid solid or tubular construction and may be of circular or polygonal cross-section. The support beam 15 is affixed to hand hold 28 , which in turn is affixed to frame 18 at tubular sockets 32 . The frame 18 , hand hold 28 and sockets 32 form a box-like structure which imparts rigidity to the assembly 10 . The ends 30 of support beam 15 extend outward from opposing sides of the rigid frame 18 to facilitate manipulation of the assembly 10 as will be further described herein.
The assembly 10 further comprises at least four large-diameter casters 16 , where large diameter is defined as 16 inches in diameter or greater. Large casters 16 are preferable in the typical work environment, where small, commonly occurring debris, such as gravel, nails, and the like may interfere with the operation of smaller wheels. The casters 16 may be provided with either solid or pneumatic tires 20 , which pivot on caster mounts 22 in the conventional fashion. The invention incorporates a frame 18 arranged to position legs 24 and casters 16 and to position the support beam 15 above the casters 16 . The frame 18 is preferably constructed of solid bar stock or hollow metal tubing, and is in the form of a rectangular structure to which is attached a plurality of legs 24 constructed of like material. The legs 24 extend downwardly and outwardly of said frame 18 , and at their distal ends are provided with the caster mounts 26 above described. A hand hold 28 is arranged above the frame 18 of the mobile support assembly 10 , above the wheels 16 and below the supports 14 , so that operators can lift or move the mobile support assembly 10 without placing their feet in danger from the casters 16 . Although the mobile support assembly 10 , by virtue of having the hose supports 14 well above the casters 16 , has a high center of gravity, the four casters 16 are located at the corners of the mobile support assembly 10 so as to provide adequate stability during use. In addition, the location of the elongated support beams 15 extending beyond the perimeter of the mobile support assembly 10 helps to keep the operator away from the hose 12 during use and permits operators to have additional safe and effective hand holds. To provide rigidity to the frame 18 and legs 24 , diagonal brace 38 is provided which extend from one corner 34 of the support frame 18 to a diagonally opposed corner 34 of said frame, and an additional brace 38 extends from one corner 34 of hand hold 28 to a diagonally opposed corner 34 of said hand hold. Preferably said braces 38 are constructed of solid bar stock, or hollow tubing.
Legs 24 are preferably constructed in pairs and each pair is interconnected by lateral brace 37 . Frame 18 is provided with tubular sockets 32 attached to the frame 18 and held hold at corners 34 . The upper end 36 of leg 24 are sized to removably fit within sockets 32 , where legs 24 may be secured with fasteners (not shown). Likewise, legs 24 may fit into sockets 32 utilizing only a slide fit, whereby the weight of frame 18 and hand hold 28 serves to hold the sockets 32 in engagement with the upper ends 36 of legs 24 . In this fashion, the assembly may be disassembled for compact storage.
With reference to FIG. 4 , it will be appreciated that support beam 15 extends laterally across hand hold 28 , and extends distance “A” beyond the track “B” of the support assembly. This facilitates manipulation of the entire assembly by the operator, reducing risk that the casters 16 will interfere with the operator's person during re-positioning of the hose 12 .
Embodiments of this invention use four supports 14 to support about ten feet of hose 12 and clear obstructions less than two feet high and two feet wide, permitting the hose 12 to be supported and moved forward, backward or side to side. Each assembly has a supporting beam 15 that typically supports 10 to 16 feet of hose. The normal gap between the support assemblies is between four and six feet. Therefore a set of four mobile support assemblies 10 can support over 80 feet of hose and keep it clear of the work surface. A typical pumping hose weighs over 30 pounds per foot when filled, giving the operators over 2400 pounds of concrete to transport.
Concrete pouring generally proceeds from areas distant from the concrete source to the source. As the pour proceeds, a way to handle the decrease in distance from the source is to remove sections of hose, a time-consuming and messy task. Aspects of this invention permit the mobile support assemblies carrying the hose sections to be moved in opposite directions thereby folding the hose back on itself, thereby shortening the effective hose length and reducing the need to remove sections of hose. In addition, the placement of the last section of hose on the mobile support system permits the operator to distribute the concrete directly from the hose on the mobile support system thereby reducing the burden on the operator to lift and move the end of the hose while distributing concrete.
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A mobile support system for supporting a concrete pouring hose supports ten to sixteen feet of hose while providing sufficient ground clearance to avoid common obstacles. The mobile support system features large castors and conveniently placed hand holds to permit the mobile support system to be moved safely and easily. The system provides for socketed leg attachment, thereby allowing for ease of disassembly and storage.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a sheet, especially for use in the building sector, with a planar sheet body.
2. Description of Related Art
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.
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).
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
Therefore, the object of this invention is to avoid the disadvantages of the prior art.
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.
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.
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.
Otherwise, this invention relates fundamentally to sheeting of any type as well as film products, where the sheet body is made of plastic.
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.
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.
The effect in accordance with the invention can be achieved by the following different principles:
1. Use of Adhesive-containing Microcapsules in the Sheet.
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:
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.
b) The microcapsules contain a binary adhesive. The reaction partners react with one another only after release.
c) The contents of the microcapsules react with the material (for example, steel) of the fastener (for example, nails) and form a sealing mass.
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.
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.
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:
a) The solvent evaporates, the sealing mass becomes hard.
b) A dispersion is present, the liquid evaporating. Then, the viscosity of the sealing mass rises.
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.
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.
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.
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.
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:
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.
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.
c) A layer of a viscoelastic gel is used as the sealing layer.
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.
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.
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).
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.
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.
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.
Even if an intermediate layer of a viscoelastic gel is not an ideal elastomer, it is still subsumed under the term “elastic layer”.
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.
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.
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.
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
MDA=F r ×D
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.
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.
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.
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.
The chemical basis of the microencapsulated adhesives (core materials) is, for example, acrylates, polyesters, epoxy resins or polyurethanes.
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.
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.
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.
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.
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.
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.
The adhesive which is released from the damaged capsules after the curing process establishes a water-impermeable bond to the perforation medium.
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.
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%.
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.
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 .
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).
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.
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.
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.
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).
It is expressly pointed out that all of the aforementioned range data comprise all individual values and all intermediate values within the indicated range limits, even if they are not given in particular. All unnamed individual values and intermediate ranges are regarded as encompassed by the invention.
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
FIG. 1 is a schematic depiction of a first embodiment of a sheet in accordance with the invention,
FIG. 2 is a schematic depiction of a second embodiment of a sheet in accordance with the invention,
FIG. 3 is a schematic depiction of a microcapsule,
FIG. 4 is a schematic depiction of a third embodiment of a sheet in accordance with the invention,
FIG. 5 is a schematic depiction of a fourth embodiment of a sheet in accordance with the invention,
FIG. 6 is a schematic depiction of a fifth embodiment of a sheet in accordance with the invention,
FIG. 7 is a schematic depiction of a sixth embodiment of a sheet in accordance with the invention,
FIG. 8 is a schematic depiction of the sheet from FIG. 1 in the perforated state,
FIG. 9 is a schematic depiction of the sheet from FIG. 1 with a counter lath in place in the perforated state,
FIG. 10 is a schematic depiction of the sheet from FIG. 6 in the perforated state,
FIG. 11 is a schematic depiction of a seventh embodiment of a sheet in accordance with the invention without fasteners,
FIG. 12 is a schematic depiction of the sheet from FIG. 11 with fasteners,
FIG. 13 is a schematic depiction of an eighth embodiment of a sheet in accordance with the invention,
FIG. 14 is a top view of the sheet from FIG. 13 , with the uppermost layer removed,
FIG. 15 is a schematic cross sectional view of another embodiment of a sheet in accordance with the invention and
FIG. 16 is a perspective partial view of another embodiment of a sheet in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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 .
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.
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.
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 .
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 .
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 .
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.
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 .
Otherwise, sheets are also possible in which the structure of the film composite is different.
Thus, the following exemplary embodiments of sheets and their respective production which are also possible.
Film Composite 1
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
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
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
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
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.
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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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention is directed to a shock-absorbing unit for vehicle barriers and, more particularly, to a shock-absorbing unit for cushioning the impact of a vehicle that hits a safety barrier or a guard rail.
Vehicle barriers such as highway guard rails are designed to stop or to return a misdirected vehicle into a direction approximately parallel to the guard rail with a deceleration acceptable to the occupants of the vehicle. Their primary function is to increase the length of time of the entire event of stopping or redirecting the vehicle, to increase the distance through which the impact energy is alleviated, and to reduce correspondingly the forces of deceleration on the passengers of the car.
Highway guard rails are adapted to intercept an impacting vehicle at a low angle of incidence and are placed in generally parallel alignment with the direction of traffic flow along shoulders of a roadway, along median strips of a divided highway and elsewhere wherever movement off the highway would be hazardous to the vehicle and its passengers. Thus, the guard rail should not only be a mechanical guide but should also function as a shock absorber that dissipates the kinetic energy of the vehicle tending to leave the road and causing immobilization along the guard rail without violently rebounding the vehicle onto the traveled lanes. However, a problem has existed in designing highway guard rails in such a manner that they have both the strength to retain the vehicle and the ability to absorb the force of impact. For example, a conventional highway guard rail structure in common usage comprises lengths of a heavy corrugated or profiled sheet metal strip spanning a plurality of inflexible posts, usually of wood or concrete, arranged in spaced apart relationship along the side of a road, the lengths of sheet metal strip overlapping at their ends. Such a guard rail possesses high elasticity so that vehicles colliding with the rail are often rebounded into the path of moving traffic. Guard rail structures of lower resiliency featuring hollow or foam-reinforced sheet metal profiles and flexible posts are known but suffer the disadvantage of high cost.
Vehicle barriers such as safety barriers are designed to receive the impacting vehicle at a high angle of incidence and are located at the gore noses of highway exit ramps, at the ends of parallel bridges or highway rails, or in front of pilings of overhead crossing bridges, massive posts, signs, buildings or other unyielding obstacles with which an out of control vehicle might collide. Conventional safety barriers have been formed from crushable metals and plastics, but they are permanently deformed by an impacting vehicle and must be replaced after each incident as they are incapable of self restoration to usefulness. Safety barriers featuring metal springs as the means of absorbing the impact elastically store too much of the energy and consequently tend to rebound the vehicle after the impact.
The present invention provides a reusable vehicle barrier having sufficient elasticity to absorb the force of impact while, at the same time, it is not so elastic as to rebound the vehicle into the path of moving traffic.
SUMMARY OF THE INVENTION
The present invention is directed to a shock-absorbing unit for vehicle barriers comprising, in combination, a post provided with upper and lower generally coparallel passages therethrough for the reception of individual push rods, the inboard ends of said push rods supporting a rail, an oriented elastomer member connecting the outboard end of said push rods, and said post, and means for pretensioning the elastomer member a predetermined amount thereby affording an energy absorber responsive to displacement of the push rods under impact. Means for supporting the oriented elastomeric member is fixed to the outboard ends of said push rods. Preferably, the elastomeric member is in the form of a belt encircling said support means and said post between said passages. Conveniently, the oriented elastomeric member is pretensioned by employing at least one spacer located between the post and the belt support means. Generally, means for supporting the elastomeric member is a plate or rod spanning the push rods. The oriented elastomer preferably is a copolyetherester.
DESCRIPTION OF THE DRAWING
The above features and advantages of the present invention become more readily apparent from the following description, reference being made to the accompanying drawing in which:
FIG. 1 is a plan view of the device of the invention in the form of a highway guard rail;
FIG. 2 is a side elevation of the device; and
FIG. 3 is a perspective view of the device in the form of a safety barrier shown in the position reached at full impact.
DETAILED DESCRIPTION OF THE INVENTION
While it is recognized that the shock-absorbing unit of this invention for vehicle barriers such as safety barriers and guard rails can be used in different environments, for example, parking lots, alongside buildings, in docks, etc., it is particularly applicable to use along highways, and it will be hereinafter described primarily in relation to that principal field of application.
Referring to FIG. 1 and FIG. 2 of the drawing depicting a highway guard rail, post 1 is provided with generally coparallel passages 7 normally aligned with respect to the border of the highway for passage of push rods 3. Post 1 can be of any shape, e.g., rectangular or square, and it is generally made of wood or cement. The push rods are usually made of metal, e.g., steel. Rail 2 is mounted on the inboard end of push rods 3 by any suitable means, e.g., bolted or riveted. The rail can be the usual steel rail used on most guard rails or various modifications thereof, such as rubber or foam plastic reinforced guard rails. An oriented elastomeric belt 6, preferably a copolyetherester elastomer, is wrapped around post 1 between coaligned passages 7 and support means plate 4 for holding belt 6. The belt is pretensioned to a predetermined amount and this can be accomplished by any convenient means, for example, inserting a spacer 5 that functions as a pretensioner lock. Conveniently, the spacer can be a "U" shaped wedge located between post 1 and plate 4, the depth of the spacer determining the degree of pretensioning of belt 6. If desired, a skid support can be mounted anywhere along lower push rod 3 to better hold the rail in proper position upon impact by a vehicle.
FIG. 3 illustrates a safety barrier for vehicles that is a modification of the highway guard rail shown in FIGS. 1 and 2 and is designed to receive the impacting vehicle at a high angle of incidence. Again support post 1' is provided with generally coparallel passages 7' for passage of push rods 3'. Rail 2' is mounted on the inboard end of said push rods. The elastomeric member 6' encircles post 1' between coaligned passages 7' and support means bar 4', spanning both push rods. The primary difference between the illustrations is that in FIG. 3 spacer 5' comprises a clamp fixed to push rods 3' to prevent its movement along said rods and to maintain a fixed minimum space between bar support means 4' and post 1' necessary to pretension belt 6' a predetermined amount. Thus, belt 6' can be pretensioned a predetermined amount by appropriate placement of the spacer clamp on rod 3'. When the device is in position ready for operation spacer 5' rests against post 1', thus maintaining tension on oriented elastomer belt 6'.
The elastomeric member of the device, represented in the drawings as belt 6, is an oriented elastomer and preferably an oriented copolyetherester elastomer. A copolyetherester elastomer used to form the belt consists essentially of multiplicity of recurring long-chain and short-chain ester units joined head-to-tail through ester linkages, said long-chain ester units being represented by the structure: ##STR1## and said short-chain ester units being represented by the structure: ##STR2## wherein:
G is a divalent radical remaining after removal of terminal hydroxyl groups from poly(alkylene oxide) glycols having a molecular weight between about 400-6000, e.g., poly(tetramethylene oxide) glycol;
R is a divalent radical remaining after removal of carboxyl groups from a dicarboxylic acid having a molecular weight less than about 300, e.g., phthalic, terephthalic or isophthalic acids; and
D is a divalent radical remaining after removal of hydroxyl groups from a low molecular weight diol having a molecular weight less than about 250; said short-chain ester units constitute about 15-95% by weight of the copolyetherester and said long-chain ester units constitute the balance.
The copolyetheresters can be made conveniently by a conventional ester interchange reaction. A preferred procedure involves heating the dicarboxylic acid, e.g., dimethyl ester of terephthalic acid, phthalic or isophthalic acid, with a long-chain glycol, e.g., poly(tetramethylene oxide) glycol having a molecular weight of about 600-2000 and a molar excess of diol, e.g., 1,4-butanediol, in the presence of a catalyst at about 150°-260° C and a pressure of 0.5 to 5 atmospheres, preferably ambient pressure, while distilling off methanol formed by the ester interchange. Thus, preferably, in the above formula G is the group remaining after removal of hydroxyl groups from poly(tetramethylene oxide) glycol having a molecular weight of about 600-2000; R is the group remaining after removal of carboxyl groups from phthalic, terephthalic or isophthalic acids or mixtures thereof, and D is the group remaining after removal of hydroxyl groups from 1,4-butanediol. At least about 1.1 mole of diol should be present for each mole of acid, preferably at least about 1.25 mole of diol for each mole of acid. The long-chain glycol should be present in the amount of about 0.0025 to 0.85 mole per mole of dicarboxylic acid, preferably 0.01 to 0.6 mole per mole of acid.
Preferred copolyesters are those prepared from dimethyl terephthalate, 1,4-butanediol, and poly(tetramethylene oxide) glycol having a molecular weight of about 600-2000 or poly(ethylene oxide) glycol having a molecular weight of about 600-1500. Optionally, up to about 30 mole percent and preferably 5-20 mole percent of the dimethyl terephthalate in these polymers can be replaced by dimethyl phthalate or dimethyl isophthalate. Other preferred copolyesters are those prepared from dimethyl terephthalate, 1,4-butanediol, and poly(propylene oxide) glycol having a molecular weight of about 600-1600. Up to 30 mole percent and preferably 10-25 mole percent of the dimethyl terephthalate can be replaced with dimethyl isophthalate or butanediol can be replaced with neopentyl glycol until up to about 30% and preferably 10-25% of the short-chain ester units are derived from neopentyl glycol in these poly(propylene oxide) glycol polymers.
The copolyetherester compositions comprising belt 6 may also contain up to about 5 weight percent of an antioxidant, e.g., between about 0.2 and 5 weight percent, preferably between about 0.5 and 3 weight percent. The most preferred antioxidants are diaryl amines such as 4,4'-bis(α,α-dimethylbenzyl) diphenylamine.
The most preferred copolyetherester compositions comprising belt 6 may also contain up to about 5 weight percent of an antioxidant, e.g., between about 0.2 and 5 weight percent, preferably between about 0.5 and 3 weight percent. The most preferred antioxidants are diaryl amines such as 4,4'-bis(α,α-dimethylbenzyl) diphenylamine.
Belts of the oriented copolyetherester can be formed in a number of ways. For example, a billet can be molded from the polymer in a conventional manner and the billet oriented by stretching, heat setting, and cooling. The copolyetherester belt is oriented by stretching the copolyetherester by conventional means at least 300% of its original length and preferably at least 400% at a temperature below its melting point by at least 20° F. It is maintained at that length and brought to or maintained at a heat setting temperature between 150° and 20° F below its melting point. It is then cooled to a temperature below the heat setting temperature by at least 100° F.
The copolyetheresters used to make the elastomeric member are further described in Witsiepe, U.S. Pat. No. 3,766,146, and the oriented copolyetheresters are also described in Brown and McCormack, Ser. No. 542,257, filed Jan. 20, 1975, the disclosures of which are incorporated herein by reference.
The oriented copolyetherester is, preferably, in the form of a belt encircling post 1 and plate 4 and most preferably is a lapped belt having multiple windings. A lapped belt can be fabricated conveniently by making multiple windings of a tape or belt of oriented elastomer around said post and support means, e.g., plate or bar, as the case may be, and securing the belt from unwinding by suitable means, e.g., heat or solvent welding the free ends to the adjacent strip of belt, or clamps or other fasteners. The number of windings of the belt will depend upon the weight of the belt needed for a particular energy absorbing capacity as described below.
To prepare the shock-absorbing mechanism shown in FIGS. 1 and 2 for operation, belt 6 is prestressed by inserting spacer 5, for example, a "U"-shaped metal wedge, between post 1 and plate 4. Thus, the displacement of plate 4 stretches belt 6 and places it under tensile stress, as shown in FIG. 1. The belt is of such length that such displacement causes the desired degree of prestressing and provides high initial impact force for greater energy absorption. Impact upon rail 2 causes push rods 3 to move in a direction toward their outboard end relative to post 1. The distance between the support means for the belt and the post that is maintained by spacer 5 determines the degree of tensioning and stretching of belt 6 whereby the energy of impact is absorbed and the movement of rail 2 is cushioned. As can be seen from FIG. 3, the safety barrier device illustrated therein operates in the same manner. Spacer 5 is a clamp that is so positioned on push rods 3' that the elastomeric belt 6' in the operating condition is pretensioned. Some of the energy absorbed is reversibly stored in the belt and is used to return the shock-absorbing device to its original position and the remainder of the energy is dissipated. Thus, after the impact is so dissipated, push rods 3 and rail 2 return to their original positions as a consequence of the elastic nature of belt 6 with spacer 5 again resting against post 1 and plate 4 and the shock-absorbing unit is ready to function again, when needed, in the manner described above.
Dimensions of belt 6 of oriented elastomer and the depth of spacer 5 will depend upon the amount of energy required to be absorbed by the shock absorbing mechanism and the desired rate of absorption. Factors which increase the energy absorbing capacity are: (1) enlarging the cross-sectional area of the belt, (2) increasing the potential displacement of the rail by lengthening the push rods and the belt, and hence, increasing the ultimate stretch and stress level of the extended belt, and (3) increasing the degree of prestressing of the belt by increasing the depth of spacer 5. Selecting a higher modulus elastomer for fabrication of belt 6 is another factor that can be used to increase energy absorbing capacity of the shock-absorbing unit. For highway guard rails and dock guards the above specifications will vary because of varying energy absorption requirements and varying limitations on maximum force and maximum deflection. A typical belt for a guard rail, as represented in FIGS. 1 and 2, when made of the preferred oriented copolyetherester elastomer, as referred to above, has a cross-sectional area of about 2.6 sq. cm. and a circumference of about 102 cm, weighs about 0.67 kg., and the depth of spacer 5 will be sufficient to permit the belt to be prestrained by stretching to about 10% of its original length. This belt when struck by a vehicle at an angle of incidence of about 10° and stretched to a maximum strain of 40% will exert a maximum total restoring force of 2380 pounds. A safety barrier because of its exposure to impacts of high angle incidence must have a greater energy absorbing capacity than a guard rail and consequently will have a larger belt. The stopping distance for the impacting vehicle and the maximum force developed will be directly and inversely proportional, respectively, to the original length and cross-sectional area of the belt. Typically, a belt capable of absorbing the full energy of a 3000 pound vehicle in impact at an angle of 90° at an initial speed of 50 miles per hour weighs 11.3 kg. (25 lbs.), has a cross-sectional area of 4.3 sq. cm. and a circumference of 2030 cm., is installed with a 10% prestrain, and stretched in impact to 40% strain. The vehicle is stopped within about 10 feet after impact with a maximum total force of about 40,000 pounds and a maximum deceleration of about 13.2 G.
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A shock-absorbing unit comprising a post with upper and lower generally coparallel passages therethrough, e.g., bores, for the reception of individual push rods, the inboard ends of the push rods supporting a rail, an oriented elastomer, e.g., a copolyetherester, connecting the outboard end of the push rods and the post, and means for pretensioning the elastomer, e.g., a wedge, a predetermined amount.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
RELATED PENDING APPLICATION
This application is a continuation-in-part of copending U.S. application, Ser. No. 679,491 filed Apr. 22, 1976, now U.S. Pat. No. 4,040,211. This application is also a continuation-in-part of application Ser. No. 626,332 filed Oct. 28, 1975, now abandoned.
BACKGROUND OF THE INVENTION
This invention is in the field of construction tiles and more particularly in the field of roofing tiles, sometimes of metal or of a synthetic material such as a plastic.
For many years roofing material has been commonly corrugated galvanized iron, or consisted of tiles made of fired clay. More recently, cement tiles have been utilized. These types of tiles however are extremely heavy and expensive to manufacture and ship. Certain of these tiles are in overlapping configuration as to their portions, particularly the cement tiles, making them difficult to mold and economically prohibitive to fabricate.
The prior art also does not provide construction tiles of metal that are self-interlocking without the use of external clips or fasteners.
SUMMARRY OF THE INVENTION
It is therefore an object of this invention to provide a lightweight tile, which has the appearance of a conventional clay or concrete tile, made of various types of metals, resins or plastics, and to provide an interlock means as part of each tile for joining other similar tiles to each other.
Another object is to provide a simulated spanish mission tile but made of lightweight metal.
Still another object is to make such tiles inexpensive so that outer and inner walls or roof may be lined therewith to fireproof same.
Therefore, in accordance with this invention, a metal tile is provided made of a one piece or integrated construction comprising a first portion having a convex upper surface and a second portion adjacent to and integral with the first portion having a concave upper surface. The tile at the upper end having ends of these portions that are coterminous while the lower or opposite ends of such portions are not coterminous. The tile is open faced in cavity-like appearance in its understructure, and the two portions thereof are not in overlapping configuration. Such tiles may also be made of a synthetic resin or plastic which is not flammable as well as of sheet metal, copper or aluminum. If made of aluminum the tile can be anodized in different colors. If made of copper the tile is permitted to form an oxide coating of copper to render a roof of such tiles beautiful in appearance and expensive looking. Such tile is also provided with a curled corner of the second portion for interlocking similar tiles.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in perspective the convex surface of a first portion of the tile and the concave surface of a second portion of the tile integral with the first portion and in non-overlapping configuration with each other. This figure illustrates a clip in perspective for securing the tile to a roof structure, which clip is an integral part of the second portion. Also shown is the interlock curled portion for joining other tiles to each other.
FIG. 2 shows the same tile in perspective view as in FIG. 1 except that such tile is flipped about so as to view the underside thereof, thereby showing the concave surface of the first portion and the convex surface of the second portion in cavity-like structure. The clip shown in FIG. 1 is omitted from this figure.
FIG. 3 shows a cylinder in perspective view cut by imaginary planes lengthwise parallel to its central axis so as to result in arc-shaped structures describing the general shapes of the portions of the tile.
FIG. 4 shows partly in cross-section and partly in elevation the use of an independent clip holding ends of several tiles when such tiles are assembled in a roof structure.
FIG. 5 is a perspective view similar to FIG. 1 showing details of particulate matter embedded in a binding coating on the outer tile surface.
DETAILED DESCRIPTION
Referring to FIGS. 1, 2, 3 and 5, a tile according to the principles embodied in this invention comprises the combination of portion 100 integral with the non-overlapping portion 200.
Portion 100 has exposed to view, during use of the tile, its convex surface at 101. Likewise portion 200 has exposed to view, in such normal usage, its concave surface 201.
The undersurfaces of both portions 100 and 200 are generally not exposed to view when the tile is in actual usage, and these undersurfaces are open faced forming the appearance of cavities. Undersurface 102 of portion 100 is therefore concave with flanges and ribs integral therewith, whereas undersurface 202 of portion 200 is convex and likewise with flanges and ribs as integral portions thereof.
The structure of portions 100 and 200 may be readily described as to their general form in terms of arc-shaped sections of a cylinder C. Portion 100, without the consideration of flanges and ribs, could be obtained when an imaginary plane at P-P slices a section of cylinder C. Portion 200, also without consideration of flanges and ribs, could be obtained when an imaginary plane at Q-Q slices another section of cylinder C. Planes P-P and Q-Q would be parallel to each other and to central axis A of cylinder C, which central axis would be coaxial with the walls of cylinder C.
Portions 100 and 200 are disposed with respect to each other along directions parallel to axis A wherein convex surface 101 faces in the same direction as concave surface 201.
Portion 200 is in non-overlapping configuration with any part of portion 100 as illustrated by the fact that a step or flange at 105 is integral with portion 100 and joins an edge of portion 200.
Portions 100 and 200 have edges at 110 and 210 respectively, which edges are generally parallel to axis A.
Portion 100 has ends at 115 and 120, and portion 200 has corresponding ends at 215 and 220, which ends are generally orthogonal to the edges and to axis A.
Insofar as material that the tile is structured, it may be metallic such as sheet metal that is galvanized, aluminum which may be anodized, or may be made of fireproof or fire resistant synthetic resin or plastic. Surfaces 101 and 201 may be coated chemically or painted as at 197 and 297 respectively in desirable color and may have material such as sand, stone, brick, reddish colored particles or bituminous particles as at 198 and 298 respectively bound within the coating material of varying and preselected sizes and colors. A reddish color may also be used as the coating and binder material thereby simulating the appearance of a spanish type solid tile made of clay or adobe. If the tile is of anodized material such as aluminum a variety of different and interesting permanent colors may be obtained. This tile may also be made of copper which when permitted to oxidize will develop a brilliant green copper oxide coating and render the structure upon which the tiles are installed very expensive looking and beautiful in appearance.
Portion 100 is generally longer than portion 200, one end of portion 100 being longer than a corresponding end of portion 200. Portion 100 has a flange at 125 extending radially inward away from surface 101 toward axis A. Portion 200 has a flange 225 at end 220 extending radially outward away from surface 201 and axis A. Hence the additional length of portion 100 forms a shoulder with portion 200 at ends 120 and 220, represented by flanges 125 and 225 respectively. Such shoulder facilitates assembly of a plurality of these tiles into a structure such as a roof.
Flange 130 integral with portion 100 is provided at end 115 extending radially outward from surface 101 away from axis A.
Flange 110 is terminated in a flange-hook configuration as at 135 directed inwardly toward surface 102 and toward axis A. It should be noted that flange 110 does not extend the entire length of portion 100 but terminates prior to reaching end 120.
Flange 225 at end 220 extends radially outward away from surface 202 and axis A and does not extend to the edges of portion 200, thus leaving scalloped cut-outs thereat, at 226 and 227, that limits the width of flange 225 and inhibits flange 225 from cooperating with flanges 105 and 235.
Flange 230 is integral with and is provided at end 215, which flange extends radially inward toward axis A.
Flange 235 is integral with portion 200 and is provided at edge 210. This flange is oriented generally at an obtuse angle with respect to surface 201 at edge 210. Flange 235 is tapered so that its highest point at 236 close to end 220 is higher than its lowest point at 237 near edge 215 for ease of sliding this flange beneath fingers of a clip to be hereinbelow discussed. Flange 235 makes a slight ear-like depression 238 in cooperation with flange 230 at the junction of edge 210 and end 215.
Ear-like depression 238 is the location at which first finger 281 of a tile fastening clip 280 is formed as an integral part of portion 200. Finger 281 is scored at 286 so that this finger and thusly the clip may be broken off thereat when not in use. Clip 280 has finger 282 provided for holding down the high point at 236 of flange 235 of a like tile installed on surface 201 above the instant tile, as well as flange-hook 135 of flange 110 at 112. Finger 283 is provided for holding down still another tile placed on surface 201 adjacent to the instant tile. Clip portion 284 is provided with a hole at 285 for securing this and other tiles held by the clip to a generally wooden surface beneath the tiles forming part of the roof structure as illustrated in FIG. 4 below.
End 115 of portion 100 is generally coterminous with end 215 of portion 200, which ends may be represented by flanges 130 and 230 respectively.
At least one rib as at 150 is provided as an integral part of portion 100, which rib is generally parallel to ends 115 and 120 for strengthening portion 100 particularly when made of metal of about 0.050 inches thick or less. Sheet metal lends itself to easy and economical fabrication by die stamping same into the shape desired.
At least one rib as at 250 is provided as an integral part of portion 200, which rib is generally parallel to ends 215 and 220, though more like ribs may be utilized for strengthening portion 200.
At least one rib as at 225 is provided as an integral part of portion 200, which rib is generally parallel to edge 210, though more like ribs may be provided if needed for strengthening portion 200. Rib 255 extends along most of edge 210 adjacent to flange 235. Rib 255 is raised progressively from surface 201 at 256 to a raised location at 257. Raised location 257 and flange 235 form a recess at 260 into which an adjacent hook portion of a like tile, such as hook portion 135, can be seated.
At least one rib as at 265 integral with portion 200 may be oriented at an angle with respect to ends 215 or 220 providing reinforcement of portion 220.
Portion 100 is provided with a depression as at 155 for providing securing capability of the tile by driving a nail therethrough into a wood member of a roof structure running the length of portion 100 and the roof. Such nail would be hidden when another like tile is placed on top of a part of portion 100 wherein end 120 of such other tile covers the nail and also covers a part of the instant tile.
With reference also to FIG. 4, clip 290 may be provided as an alternate to clip 280, which clip 290 is not attached to portion 200 permanently. Clip 290 only requires two fingers, namely fingers 291 and 292. Finger 291 holds down flange 235 at 237 and also hook member 135 of an adjacent tile at 111. Finger 292 holds down flange 235 at 236 of another like tile mounted vertically and overlapping the instant tile and also holds down hook 135 at 112 of such another like overlapping tile. A hole is provided in part of clip 293 into which nail 294 is generally used to be driven into undersurface of wood at 295 of a typical roof structure.
It should be noted that not only do the various flanges act as strengthening means, but they also act as weather checks to inhibit rain or water flow or moisture from the underside of a matrix of similar tiles affixed to a roof or other part of a structure. Additionally, it should be noted that the various ribs also strengthen the tiles, even when such tiles are made of thin material.
Of special significance is the formation by inexpensive fabrication a two-portion tile which two portions do not overlap, wherein the underface of the tile exhibits a cavity in each of the two portions to enable the achievement of the invention objectives of a light weight inexpensive tile that simulates the expensive spanish roof tile or expensive and beautiful roofing structure made from such tiles particularly when the material used is copper.
With special reference to FIGS. 1, 2 and 3, it may be seen that curl member 236' at 236 formed from a portion of flange 235 is an integral part of portion 200.
Curl 236' is formed at a slight angle, between 10 and 30 degrees approximately with respect to surface 201 and away from axis A. This curled member enables adjacent tiles and tiles below the tile illustrated to be held by the curl member thereby substituting for the integral clip 230 and the separate clip 290 as discussed above, making such clips unnecessary.
An advantage to be gained by using the curled member is not only to eliminate the clips but reduce labor in nailing down such clips. The only hardware needed would be a nail such as 294 to hold down the tile at a point diagonally opposite curl 236' by using hole at 156 to fasten the tile to the wooden under structure as at 295.
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A tile, generally used for roofing purposes, made of metal or synthetic material, has two portions, one portion has a convex upper surface and another portion has a concave upper surface. These portions are integral with each other and do not overlap one another. The underfaces of these portions exhibit cavities thereat. The length of one of the portions is greater than the length of the other portion. When laid upon a roof area the ends of the tiles will be made to overlap a predetermined length of the tile to give the appearance of a roof formed with conventional spanish mission tiles. Adjacent or contiguous tiles are interlocked by means of a curled corner of the other portion of the tile.
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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 use of foam to speed a startup portion of a Steam Assisted Gravity Drainage (SAGD) process in parallel horizontal wells. Specifically, the invention relates to the use of foam to increase a pressure gradient between horizontal injector and producer wells, after an initial localized steam breakthrough.
BACKGROUND OF THE INVENTION
World energy supplies are quite substantially impacted by the world's heavy oil resources. Indeed, heavy oil comprises 2,100 billion barrels of the world's total oil reserves. Processes for the economic recovery of these viscous reserves are clearly important.
Asphaltic, tar and heavy oil are typically in deposits near the surface with overburden depths that span a few feet to a few thousand feet. In Canada vast deposits of this oil are found in Athabasca, Cold Lake, Celtic, Lloydminster and McMurray reservoirs. In California heavy oil is found in the South Belridge, Midway Sunset, Kern River and other reservoirs.
In the large Athabasca and Cold Lake bitumen deposits oil is essentially immobile--unable to flow under normal natural drive primary recovery mechanisms. Furthermore, oil saturations in these formations are typically large. This limits the injectivity of a fluid (heated or cold) into the formation. Furthermore, many of these deposits are too deep below the surface to effectively and economically mine.
In-situ techniques for recovering viscous oil and bitumens have been the subject of much previous investigation and can be split into 3 categories: 1) cyclic processes involving injecting and producing a viscosity reducing agent; 2) continuous steaming processes which involve injecting a heated fluid at one well and displacing oil to another set of wells; and 3) a relatively new Steam Assisted Gravity Drainage process (SAGD) by R. M. Butler (U.S. Pat. No. 4,344,485).
Cyclic steam or solvent stimulation in these two reservoirs is severely hampered by the lack of any significant steam injectivity into the respective formations. Hence, in the case of vertical wells a formation fracture is required to obtain any significant injectivity into the formation. Some success with this technique has been obtained in the Cold Lake reservoir at locations not having any significant underlying water aquifer. However, if a water aquifer exists beneath the vertical well located in the oil bearing formation, fracturing during steam injection results in early and large water influx during the production phase. This substantially lowers the economic performance of wells. In addition, cyclic steaming techniques reduce the economic viability of the process. Clearly, steam stimulation techniques in Cold Lake and Athabasca deposits are severely limited.
Vertical well continuous steaming processes are not technically or economically feasible in very viscous bitumen reservoirs. Oil mobility is simply far too small to be produced from a cold production well as is done in California type of reservoirs. Steam injection from one well and production from a remote production well are not possible unless a formation fracture is again formed. Formation fractures between wells are very difficult to control and there are operational problems associated with fracturing in a controlled manner so as to intersect an entire pattern of wells. Hence, classical steam flooding, even in the presence of initial fluid injectively when artificially induced by a fracture, has significant limitations.
Steam Assisted Gravity Drainage (U.S. Pat. No. 4,344,485; Butler, 1982) describes a parallel set of horizontal wells spaced relatively close together. In this process both wells are pre-heated by conduction. As fluid between the wells warms, a pressure difference is applied between the upper and lower wells to drive the fluid from between the wells. A SAGD startup process has been described in detail (Edmunds, N. R. and Gittins, S. D.; CIM Paper No. 91-65). When steam breaks through at some point between the horizontal wells, the pressure difference disappears and large amounts of steam are produced from the lower well. At this point in the startup, temperature control at the wellhead begins and produced steam volumes are throttled, placing the rest of the startup process in a gravity dominated regime.
Steam begins to rise upwardly and spreads laterally along the length of the well. The process is completely governed by gravity due to the imposition of steam trap control. For long wells a complete formation of a steam chamber along the length of the wellbore may take several months--thereby reducing the effectiveness of the long wellbore.
Complicating this problem is a substantial impossibility of drilling two perfectly parallel horizontal wells--either from a tunnel or from the surface. It is more probable that the two wells will have some wavy characteristics (sinuosity). Hence, steam breakthrough is more likely to occur at the point of closest spacing of the two wells. A picture of the initial breakthrough looks like two very long horizontal wells (say 500 meters) with only 1 or 2 meters having steam communication. The steam chamber can now grow only slowly along the length of the well.
Therefore, what is needed is a method of forcing the steam/liquid communication zone between wells to grow laterally, during the startup phase, at a rate substantially faster than that obtained by pure gravity drainage.
SUMMARY OF THE INVENTION
This invention is directed to a method to reduce startup time in a Steam Assisted Gravity Drainage (SAGD) process where parallel horizontal wells are used to remove hydrocarbonaceous fluids from a formation or reservoir. In the practice of this invention, steam is circulated within upper and lower horizontal wells while maintaining a substantial pressure gradient between said wells. By maintaining this pressure gradient, hot fluids are forced from the upper well into the lower well. Steam is continuously circulated until it breaks through from the upper to said lower well which causes a steam breach zone to come into existence.
A surfactant is added to liquid entering the upper well along with steam in an amount sufficient to generate foam and fill the steam breach zone. The foam filled steam breach zone causes an increase in the pressure gradient, between the two wells. An increase in the pressure gradient causes a complete steam chamber to be formed, along the wells which causes substantial increased displacement of hydrocarbonaceous fluids between said wells. Increased displacement of hydrocarbonaceous fluids allows the near well areas to be heated substantially more quickly than before possible, thereby reducing startup time during a SAGD process.
It is therefore a primary object of this invention to substantially reduce the time of startup in the creation of a steam chamber during a Steam Assisted Gravity Drainage process.
Another object of this invention is to combine the use of foam with dual horizontal wells to improve steam process performance by reducing startup time.
It is also an object of this invention to augment a gravity drainage process during startup by increasing the pressure gradient between well pairs after steam first breaches an area between the wellbores.
These and other objects of this invention will become apparent to those skilled in the art when reading this specification and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional, axial, schematic view of a dual horizontal well pair where vertical sinuousity has been depicted as would exist in a pair of wells drilled in a formation.
FIG. 2 is a schematical representation which demonstrates steam breakthrough at the point of closest approach between two superimposed horizontal wells.
FIG. 3 demonstrates schematically foam formation in a steam breached zone between two superimposed horizontal wells.
FIG. 4 is a schematic representation that demonstrates a lateral growth of a steam/liquid/foam region between superimposed horizontal wells.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to provide additional clarity to the invention, the current method of startup is described in order to contrast the old startup method with the new startup method. Current startup procedures detailed herein may be found in the recent publication "Effective Steam Assisted Gravity Drainage to Long Horizontal Well Pairs" by N. R. Edmunds and S. D. Gittins on page 65-2 of the CIM proceedings for 1991. The startup section from that paper is quoted below.
"SAGD with parallel wells depends on the existence of fluid communication between the injector and producer. In the McMurray field, the initial bitumen viscosity and saturation are so high that communication must be developed artificially before SAGD can proceed. The Phase A startup procedure. . . used a combination of conduction heating followed by a mild steamflood, implemented by circulating steam in both wells with a pressure differential (at the wellhead) of about 350 kPa.
Thermal conduction can be used to heat the sand in the vicinity of the wellbore, regardless of fluid transmissibility, by circulating hot fluid in the well. For an isolated single well, heating is very slow at radii greater than a meter or so, but simulations showed that when a second hot well is nearby, conduction is surprisingly effective in the space between the wells for separations of several meters; useful temperatures can be generated in a few months. This delay is more than compensated for by predictability: the thermal properties of oil sand are well known and fairly homogeneous, so that conduction heating is virtually guaranteed if simple conditions are met.
Once the bitumen is marginally mobile, at around 50-100 degrees C., hot water can displace enough of it to finger through and initiate rapid convective heating. Under a small pressure differential, the ensuing steamflood takes only a few days to reach the producer, while at the same time the new steam chamber begins growing up and out due to SAGD.
The discussion now returns to the three dimensional, long well pair. . . . It is easy to see how an initial startup can be created,. . ., by applying a pressure differential. After the first breakthrough, however, it is not possible to maintain a significant pressure difference without driving huge volumes of steam directly from injector to producer (Emphasis added). It will be shown. . . that no pressure differential is in fact required: startup can occur by gravity alone at any cross section of the well pair where the liners are kept hot, they are within a certain distance of each other, and there is reasonable permeability between them.
At this point it is useful to review how wellbore conditions are controlled, and what happens after the initial breakthrough, in a real well pair of significant length. As reported. . ., the proper injection rate is that which maintains the desired steam chamber pressure by replacing any steam that is condensed at the expanding front. This is accomplished at an [Underground Test Facility] UTF with an industrial pressure controller at the wellhead.
The Phase A production control scheme essentially controlled temperature, rather than pressure or rate. The temperature set point was chosen based on the flowing pressure, so that fluids were produced to maintain the wellhead temperature a specified value below the boiling point of water. Correct drawdown was automatically maintained, since no steam could be produced but neither could production accumulate and cool at the bottom of the chamber. This scheme is called steam trap control, because it mimics the function of standard industrial thermodynamic steam trap.
The most important point. . . is that, if the permeability is good, gravity alone is sufficient to allow startup; in other words a SAGD process can be operated at an injector annulus pressure that is identical to the producer annulus pressure. The startup could be characterized as heating the bitumen and then letting it fall through the sand into the producer.
As an example of how fast this can be, the superficial velocity of bitumen falling through a column of porous media having equal pressures at top and bottom can be calculated from Darcy's Law. In consistent units, ##EQU1## where k o is the effective permeability to bitumen and u o is the bitumen viscosity. For Athabasca bitumen at about 200° C., and 5 Darcy's effective permeability, the resulting superficial velocity will be . . . about 40 cm/day."
From the discussion presented in Edmunds and Gittins and detailed above, it is clear that: startup is controlled by conduction and then, after steam communication, gravity.
Conduction begins the process by interwell heating until steam circulated in the upper well breaks through at the lower wellbore. After breakthrough at the lower well steam is throttled back and gravity drainage continues to power the startup.
In the practice of the present invention, startup begins by making use of interwell conduction heating precisely as used in the old startup method as is shown in FIG. 1. Both wells are steam circulated to provide conduction heating in the interwell region. A fixed, nonzero pressure gradient held between the upper and lower wellbore slowly convects hot water and steam from the upper well to the lower well. When sufficiently warmed, first water and then steam breaks through at a small, localized area between the wellbores.
As steam breakthrough occurs, the pressure gradient between the wellbores vanishes for reservoirs having reasonable permeability. As noted in the discussion above, further clearance of oil between the wellbores occurs by gravity drainage alone.
At the time of breakthrough, 1-2% solution of a high temperature, commercial surfactant (SD-1020, a non-ionic surfactant by Chevron for example) is added to liquid injected in the upper well. In addition, one mole percent (1 mol. %) of nitrogen is added to the injection steam. The foam should not be pre-formed so as to minimize axial pressure gradients within the wellbore. Steam, rather than being choked back in the production well, continues to be produced. As surfactant solution flows past the point of communication some of it flows into the porous medium. Vapor and liquid surfactant solution are known to generate in-situ foam within a porous medium. Thus, the breach between the two parallel horizontal wellbores is partially plugged temporarily.
Foam formation within the steam breached zone between wells permits a pressure gradient to be maintained after steam breakthrough between wells--in contrast to the current method where the pressure gradient vanishes as steam breaks through. This is the key to a faster startup. As more steam is formed between the wells, more foam forms continuously permitting a pressure gradient to exist between the upper and lower wellbores.
Once the entire length of the horizontal well pair has experienced steam communication, surfactant injection is stopped. The total volume of surfactant between well pairs will be small and easily removed by produced fluids.
After surfactant injection is stopped, steam trap control is begun thereby choking off steam at the production wellbore and initiating typical SAGD chamber rise.
As is shown in FIG. 1, upper horizontal well 12 and lower horizontal well 20 are drilled into formation or reservoir 10. Wells 12 and 20 contain slots or perforations 14. An interwell region 18 is positioned between wells 12 and 20. Steam is circulated into wells 12 and 20 via tubing 16. Steam exiting tubing 16 is directed into reservoir 10 via slots 14 in wells 1 and 20. Steam is continuously circulated in wells 12 and 20 while maintaining a significant pressure gradient between both wells. Wellbore or well arrangements which permit continuous circulation are discussed by Butler in U.S. Pat. No. 4,344,485 which issued on Aug. 17, 1982. This patent is incorporated by reference herein. As the interwell region or zone 18 between wells 12 and 20 warms, hot fluid is forced from upper well 12 to lower well 20 by the pressure gradient.
When enough heating has taken place, water channels through from upper well 12. Steam channels through post water break through. FIG. 2 provides a schematic representation of steam filled breached zone 22. At the time of steam breakthrough, the pressure differential vanishes. Gravity takes over as the dominant mechanism of draining the oil between wells.
At this point, surfactant and 1.0 mole % nitrogen are added to a liquid stream with enough concentration (1-2%) to generate a relatively strong foam 24 in steam breached zone 22 in interwell region 18. The production or lower well 20 is not put on steam trap control although the total amount of steam produced may be regulated. A pressure gradient now exists as a result of the flow resistance caused by foam 24 between wellbores 12 and 20 as shown in FIG. 3. This added pressure gradient aids gravity in displacing the oil from between wellbores 12 and 20.
As an example consider the former numerical example (1) with an additional component from the pressure. Here the equation for the flow velocity is: ##EQU2## where ΔP is the pressure differential between wellbores and L is the interwell wellbore spacing. Numerically, the flow velocities, as a function of increased pressure for an interwell spacing of 7 meters, are shown in Table 1.
TABLE 1______________________________________Influence of Small Interwell Pressure Gradient onInterwell Displacement Velocity k.sub.o Δ/μ.sub.o L k.sub.o P.sub.o g/μ.sub.o = U.sub.o q U.sub.o + (cm/ΔP (psia) (cm/day) (cm/day) day U.sub.o + /U.sub.o g______________________________________0.00 0.000 39.4 39.4 1.000.01 0.046 39.4 39.5 1.000.10 0.427 39.4 39.9 1.011.00 4.410 39.4 43.8 1.1110.0 44.20 39.4 83.6 2.1250.0 220.8 39.4 260.0 6.60______________________________________
As can be seen from the above table, even relatively small pressure gradient increases can substantially increase the displacement velocity. Increased displacement velocities are directly related to reduced startup time. The faster the steam zone communicates in the lateral direction along the two wellbores, the faster a full SAGD process can start producing oil.
FIG. 4 depicts the lateral steam foam in interwell region 18 between the wellbores 12 and 20 prior to chamber rise. Increased rates of propagation in interwell region 18 result in a faster startup time for the whole SAGD process thereby reducing the steam oil ratio and increasing process performance. Although wellbore 12 and 20 are shown in an above and below relationship, those skilled in the art will readily recognize that other wellbore arrangements will work similarly e.g., side by side.
Obviously, many other variations and modifications of this invention as previously set forth may be made without departing from the spirit and scope of this invention as those skilled in the art readily understand. Such variations and modifications are considered part of this invention and within the purview and scope of the appended claims.
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A method for reducing the time during which steam moves in a lateral direction between two parallel superimposed horizontal wells when utilizing a Steam Assisted Gravity Drainage (SAGD) process. Foam is added while injecting steam into an upper horizontal well once steam breakthrough occurs in an interwell region. Foam enters the interwell region thereby causing an increased pressure gradient. This increased pressure gradient adds to the gravity force thereby providing a greater interstitial oil velocity which increases oil drainage between wells during startup.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a method and device for controlling and eliminating the deposition and build up of paraffin, salts and other scale sediments on the inside of downhole oil string lines and surface or subsurface oil flow transmission lines used for the transportation of crude oil. More particularly the invention relates to the utilization of a novel coupling device having a liner or a section of the conduit composed of a non magnetic and substantially non electrically conductive material surrounded by at least one magnet held in place by a restraining device and surrounded by a magnetic shield.
The oil tools of the invention may be employed in oil flow transmission lines or incorporated as a coupling in downhole oil strings. The utilization of the combination of a magnet and non magnetic and substantially non electrically conducted conduit disposed between sections of downhole oil string and oil flow transmission lines prevents paraffin and shale materials from depositing on the inside of the downhole oil string and surface flow lines without requiring expensive chemicals or extensive down time normally involved in the clogging or oil transmission lines. Paraffin clogging is particularly a problem in paraffin producing oil territories which is believed to result from a combination of magnetic and electrostatic forces resulting from friction in the flowing of oil in the oil conduit that contributes to the collecting of paraffin, salt and scale deposits on the inside of oil transmission lines.
2. Description of the Prior Art
Paraffin and paraffin clogging from deposits in crude oil has long been recognized as a problem in both pumping crude oil from the ground through the downhole oil string and in the transmission of crude oil through oil pipelines. A variety of mechanical, chemical, electrical heating and magnetic systems have been proposed in the prior art for removing paraffin or reducing the affinity of paraffin to deposit or combine with salt, shale, and result in paraffin clogging of crude oil conduits which as known by those skilled in the oil industry results in significant down time and problems in removing the plugging or clogging of downhole oil strings and above ground flow lines.
The prior art chemical systems for removing paraffin plugging of crude oil transmission lines are costly not only in terms of the amount of chemicals required to treat downhole oil strings and flow lines but also in terms of time in interruption of pumping and problems in the subsequent removal or the chemical solvents and the potential environmental impact of such chemicals. Typical chemical treatments for each oil well range from $150.00 to $600.00 per month per well and irrespective of the foregoing problems have been the procedures currently employed in the field due to cost effectiveness considerations.
As a result an effective mechanical system for removing or preventing paraffin clogging has been sought not only because of environmental considerations but also in view of cost effectiveness in terms of efficiency and the number of mechanical units that are required to maintain a given length of pipe. Unfortunately many of the prior art mechanical systems have not been effective in removing or preventing paraffin clogging or have required an unpractical number of units be placed in the oil transmission line for example every five to seventy five feet which make such systems unfeasible in view of cost and the number of units required and in view of space limitations in downhole oil strings which generally have outside diameters of 3 to 4 inches (7.6 to 10.2 cm) and may be as long as 25,000 feet. Other prior art electromechanical systems which involve heating are expensive to operate and maintain which has resulted in the predominant use of chemicals and hot oils and solvents.
Typically some of the prior art declogging systems employ hot oil, hot water or chemical solvents that are pumped through or back down the downhole oil string to force paraffin clogs back through the downhole oil string casing or through above ground flow lines to remove clogs and accumulations of paraffin, salt and paraffin scale deposits on the inside of the crude oil line from which the crude oil flows. These prior art systems result in substantial down time and costs in terms of heating a sufficient amount of water or oil necessary to melt and dissolve paraffin clogged lines as a result of their length and surrounding environmental conditions of the downhole oil line or the surface or buried oil flow transmission lines. Representative of prior art providing for a paraffin controlled coupling with the introduction of hot oil or other solvent for the removal of paraffin from clogged lines is U.S. Pat. No. 3,085,629. Consequently in recent years chemicals have been preferred in view of their effectiveness and cost ratio in terms of down time.
Chemical or solvent systems while effective and widely utilized in the industry are nevertheless costly and present environmental problems in the removal and disposal of the chemical solvents or agents. As a result a number of other mechanical, electrical and magnetic systems have been proposed for the removal or reduction of the amount of paraffin deposits resulting from the transmission of crude oil. The most pertinent prior art system known pertaining to preventing the buildup of paraffin by attempting to control electrostatic forces by the insulation of the pump and tubing from the well casing and the ground attributes paraffin accumulates in oil wells as a result of the actions of electric currents resulting from friction between the moving parts of the well pumping machinery. In U.S. Pat. No. 2,368,777 the friction problem is solved by insulating ground with non conductive washers at such points and in such a manner as to prevent the flow of electric current between the parts and the earth. As such various insulation sleeves and washers are provided between the pumping apparatus and the downhole oil string to reduce the effects of friction and the electrostatic forces which are believed to charge particles in the flow line and cause them to deposit on the inside of the crude oil conduit.
U.S. Pat. No. 2,368,777 does not utilize a special coupling in the oil flow line to dissipate and prevent the building up of the electrostatic forces resulting from the flow of crude oil in flow lines or prevent the deposition of paraffin inside above ground flow lines. U.S. Pat. No. 2,368,777 furthermore does not utilize magnets or the combination of materials of different conductivity and magnetivity in accordance with the present invention for the purpose of not only dissipating frictional forces along the section of the pipe but also to magnetically charge the particles of the constituents of crude oil flowing inside the pipe so as to prevent the subsequent deposition of paraffin, salts and paraffin scale deposits further along the downhole oil string or thereafter in the above ground pipeline or flow line.
U.S. Pat. No. 3,222,878 represents the closest prior art uncovered which pertains to the use of magnetic forces for the purposes of controlling the build up of paraffin deposits in above ground flow lines. U.S. Pat. No. 3,222,878 is not applicable to downhole oil lines in view of the size and arrangement of magnets. This patent appears relevant at first glance but is not particularly relevant to the present invention since U.S. Pat. No. 3,222,878 does not electrically isolate sections of pipe either along the downhole oil string or in surface or subsurface oil transmission flow lines and does not disclose a practical system in terms of practicability or in terms of economic feasibility.
U.S. Pat. No. 3,222,878 does not pertain to a downhole device for oil string lines but pertains only to a device for above ground oil flow lines to prevent the deposition of paraffin and diamagnetic deposits including scale since the arrangement of magnets having a radius of 4 5/16th of an inch could not be utilized downhole since it would not fit down inside an oil string casing which typically are 2 or 21/2 inches (5.1 to 6.4 cm) in diameter. The above ground magnetic system of U.S. Pat. No. 3,222,878 furthermore does not electrostatically isolate sections of pipe and requires magnets disposed along the length of the pipe from about 10 to perhaps 150 times the length of the magnetic field. The length of the magnetic field described in U.S. Pat. No. 3,222,878 is produced from a magnet of about 5 15/16th of an inch (15.08 cm) in length which therefore would require repeating the installation of the arrangement of magnets every 5 to about 75 feet ( 1.5 to 22.9 meters) along the length of the pipe. Therefore even if such a mechanical system could be employed downhole it would be far in excess of the $150 to $600 a month per well and as a result of these and other problems such systems as U.S. Pat. No. 3,222,878 have generally resulted in the industry not accepting magnets and magnetic systems for the control of paraffin.
As a result there is a need for an effective, efficient and inexpensive system for preventing the deposition of paraffin and build up of paraffin, salt and shale combinations on the inside of oil string production lines and above and below ground flow lines that does not interfere with the oil production capabilities of existing wells. The reduction of crude oil production in high paraffin content wells is further compounded by the build up of paraffin in flow lines which require extensive and costly maintenance and have also raised environmental concerns over the elimination of solvents and other materials after dissolving paraffin from the oil lines.
The method of the invention and oil tools constructed in accordance therewith employ a combination of magnetic forces together with the isolation of sections of the crude oil conduits to break up the electrical conductivity and the propagation and build up of electrostatic charged in crude oil conduits by introducing a non magnetic and non electrically conductive liner surrounded by magnets along with a magnetic augmenting shield to magnetically charge crude oil constituents in oil conduits to provide an economically effective oil tools and method to prevent and remove paraffin and paraffin salt, shale combination on the inside of oil transmission pipes. The combination of the non magnetic substantially non electrically conductive liner of the novel oil tools and couplings together with magnets are believed to both disrupt the propagation of electrostatic forces that are believed to assist in the deposition of paraffin and paraffin combination deposits on the pipe wall while at the same time magnetically charging the particles to prevent their deposition on the downhole oil string or above ground flow line for distances of 1,200 feet (366 meters) or more utilizing magnets of about 13/4 inch in length ( 3.5 cm).
The novel oil tools constructed in accordance with the invention that employ a combination of magnetic and non magnetic materials together breaking up the propagation of electrostatic charges unlike the prior art provides for the disposition of magnets along the path of flow of about 6,000 times the dimension of the magnetic field. The method of the present invention therefore allows the disposition of magnets at 1,200 or more feet intervals as opposed to 75 feet intervals of the prior art and allows the device of the present invention to be utilized both in above ground in oil flow lines and below ground in downhole oil strings at an economically and environmentally attractive alternative to the utilization of chemicals, solvent or systems for heating oil, water, solvents or combinations thereof to remove and prevent clogging of crude oil conduits.
SUMMARY OF THE INVENTION
The disadvantages and limitations of prior art methods and devices for removing or preventing paraffin clogging in downhole oil string lines and surface or buried terrain flow lines are obviated by the utilization of the present method and oil tools for preventing the accumulation of paraffin, salts and scale deposits on the inside of oil conduits. The problem of friction in oil flow lines leading to static charges and paraffin build up and clogging of downhole oil string lines compounded by temperature differentials resulting from temperature variation in the earth strata as the oil is pumped up the oil string line is eliminated by the introduction of a coupling having a non magnetic or non conductive material forming an inner conduit surrounded by magnets interposed at various locations along the downhole oil string line and/or the above ground flow lines.
The method of the invention contemplates the strategic placement of a non magnetic and preferably non conductive section of pipe between conventional magnetic and conductive lines or pipe in combination with magnetic forces disposed around the non magnetic and non conductive material. The non magnetic and non conductive liner or section of conduit surrounded by a magnetic force in the preferred embodiment includes a magnetic shield or magnetic covering material which may interrupt the flow of electrostatic forces and act as a static drain to remove the effects of frictional static forces built up in the process of oil flowing in the oil conduit lines. It is believed the combination of non magnetic and non conductive section plus the utilization of magnets as a static drain for the disruption of electrostatic build up and the transmission of electrostatic charges that are believed to result in the eventual coagulation and disposition of paraffin, salt and scale that ultimately plugs up downhole oil string lines and terrain or subterranean oil flow lines.
The magnets together with the difference in the magnetivity and electrostatic conductivity of the liner of the coupling and the interruption in the static conductivity of the conduit may function as a static drain or means for the interruption and dissipation of the flow and build up of electrostatic forces that ultimately contributes to the plugging crude oil conduits. It is believed this interruption of the electrostatic could be provided with other types of static drains in combination with the non magnetic or non conductive section of the pipe to construct oil tools in accordance with the method of the invention.
In the preferred embodiment of the invention a combination of non magnetic and relatively poor conductive sections of pipe are interdisposed between the normally electromagnetic and conductive pipe sections of oil conduits in existing oil string lines and terrain flow lines to provide a break in the propagation and accumulation of electrostatic charges that are generated as a result of the flow of crude oil and oil products in oil conduits such as downhole oil string lines and above ground and buried flow lines. It is further believed the method and oil tools constructed in accordance with the invention may be effective in coacting the magnetic forces of the earth in combination with the non conductive sections of pipe to both remove and eliminate electrostatic forces generated and built up in the flowing of oil in oil conduits while at the same time magnetically charging particles in the flow line to prevent their aggregation, coagulation and bonding to charged sections of oil conduit pipes.
Paraffin control oil tools in accordance with the present method for controlling, preventing or dissolving the build up of paraffin, salt and scale deposits which block up and plug flow lines and downhole oil string lines result from the joining of sections of non magnetic and disparate non conductive lengths of pipe between conductive sections of pipe which further include one or more magnets disposed axially around the inside liner or section of a non magnetic and non conductive pipe that in the preferred embodiment may be surrounded by a magnetic augmenting shield or conduit pipe composed of a magnetic and conductive material. The combination of non magnetic and non conductive section of pipe in combination with the magnets and conductive shielding or surrounding conduit serve to not only dissipate electrostatic forces along the length of the conduit but also to magnetically charge the constituents of crude oil which prevent or control the coagulation and cohesion of paraffin, salt and scale deposits on the inside of crude oil conduit pipes.
The magnets are believed to charge crude oil constituent particles flowing through the crude oil conduits to augment the disruption of electrostatic forces which in combination to the magnetic susceptibility of particles passing through the flow lines prevent their subsequent coagulation and interferes with their attractive forces that results in the plugging of the flow lines and downhole oil string lines. It is believed the combination of the dissipation of the electrostatic forces and the charging of crude oil constituents results in the excellent and economical advantages provided by oil tools constructed in accordance with the invention to prevent paraffin clogging of downhole oil string lines and above ground and subterranean flow lines.
Devices constructed in accordance with the preferred embodiment of the invention for use in downhole oil string lines are couplings constructed of a coupling material having a suitable hang weight and preferably a hang weight of over 70,000 pounds such as J-55 and preferably in the range of 100,000 to over 200,000 pounds such as utilized in C-75, L-80, N-80, C-90 and P-105 which are industry standards for downhole oil string pipe and coupling material of the American Petroleum Institute from which downhole oil tools of the invention can be constructed. The novel oil tools can be constructed from these oil tool couplings by increasing the diameter of these couplings from about 1/4 to 1/2 inch to accept one or more magnets in a suitable magnet restraining device of a non magnetic material which surrounds a section of inside liner composed of a non magnetic and non conductive material. The standard couplings are generally about 9 inches long (22.9 cm) for pipe having about a 21/4 inch inside diameter (5.7 cm) or 93/4 inches long (23.8 cm) for pipe having an inside diameter of about 25/8 inch inside diameter (6.67 cm) although other lengths and other inside diameters may be utilized depending upon the inside liner of non magnetic and non conductive material may be either sealed with locking rings or the liner may be deformed into restraining grooves formed in the coupling to position the non magnetic, non conductive inside liner in the outside conductive pipe forming the body and conductive covering of the coupling.
The magnet cavity and magnets surrounding the inside liner are insulated from the crude oil flowing through the oil tool by the utilization of O-ring seals of rubber or other non conductive material to seal. The combination of magnets and inner liner are believed to operate by disrupting the resonance frequency in constituents of the crude oil flowing through the magnetic field which prevent them from attaching to the conduit or by polarizing the constituents, preventing seed material from coagulating or by removing and dissipating electrostatic forces. Oil tools constructed in accordance with the invention prevent the coagulation of paraffin and the accretion of paraffin on the inside walls of ordinary downhole oil string lines. The magnets cooperate with the non magnetic and electrically non conductive inside liner by assisting in the induction of electrical forces in constituents of the flowing crude oil such as paraffin and salt to assist in the elimination of the potential for clogging in the downhole oil string line. In the preferred embodiment of oil tools designed for use in the downhole oil string pipes at least two magnets and preferably six rectangular magnets having two layers, the top layer being for example the north pole and the bottom layer being the south pole with the magnets being axially displaced and their poles reversed around the circumference of the non magnetic and non electrically conductive inner liner to assist in the induction of magnetic forces in crude oil constituents flowing through the inside liner while assisting in the elimination of electrostatic forces propagated along the length of the downhole oil string.
Oil tools constructed for above ground or subterranean flow lines for the transportation of crude oil or oil products from the well head to a collection or refining facility employ the same principles as downhole oil tools except the oil flow line oil tools do not have to be made to withstand the hang weight requirements of couplings designed for downhole oil line use. In the preferred embodiment of flow line couplings in accordance with the invention a non magnetic conduit or tubing is either in place or is spliced into an existing magnetic or a static electrically conductive flow line. In either embodiment the non magnetic conduit is surrounded by one or more magnets backed with an electrically conductive or magnetic backing material to disrupt the propagation of electrostatic forces along the flow line and to increase the effectiveness of the magnetic inductive forces on crude oil constituent particles flowing through the above ground or subterranean flow line.
Oil tools for oil transmission flow lines constructed in accordance with the preferred embodiment are provided in the form of a sleeve of roughly 2 halves disposed around a non magnetic section of pipe in which preferably 8 or more rectangular magnets are maintained in each half of the sleeve having a steel backing of a magnetic and conductive material surrounded by an environmentally protective coating such as stainless steel that forms the housing for the 2 halves which may be joined together with bolts or other means for fastening the sleeve with respect to the above ground flow line or conduit. Preferably the magnets are rectangular magnets having two magnetic layers a top layer and a bottom layer disposed along the length of the magnets which magnets are arranged in the halves so that the north and south poles of the magnets are in axial non alignment to the direction of flow of crude oil and oil products in the flow line.
The combination of non magnetic inner liner or conduit in combination with the magnets and backing plate of a magnetic and conductive material are believed to focus and concentrate the lines of magnetic force on the crude oil constituents flowing through the section of non magnetic conduit which by interrupting the resonance frequency of the constituents of crude oil, polarization, disruption of the attractive forces in seed crystal materials or by the disruption of the electrostatic charges in flow lines prevent and disrupt the coagulation and subsequent clogging of the flow lines with paraffin, salt and scale combinations which ultimately plug existing flow lines.
The oil tool couplings or sleeves constructed in accordance with the invention can be placed at long distances along the length of the pipe and are effective in preventing and eliminating paraffin, salts and other scale producing elements in crude oil from clogging flow lines. The effectiveness of the combination of materials and magnets and their action on the flow of crude oil and oil products in the flow line to charge the particles allows the couplings to be placed every 1,000 feet (304.8 meters) or more to allow the system of the present invention to effectively compete with the least expensive chemical and solvent systems for declogging and preventing the clogging of crude oil flow lines and downhole oil strings.
The oil tools constructed in accordance with the invention are easily manufactured, require little or no maintenance and virtually have an unlimited life since the magnets utilized generally lose only about 5% of their efficiency in 100 years and therefore the novel tools once in place effectively reduce and prevent or unplug the flow lines or in downhole oil string for the life of the oil conduit. Oil tools constructed in accordance with the invention are furthermore economically constructed such that the general cost of the unit pays for itself in less than a year in cost of chemicals plus the novel oil tools do not impede the flow of crude oil, result in down time, pollute the environment, or require the removal of the chemicals from the crude oil in subsequent refining processes.
The magnetic non conductive and non magnetic combination not only prevents the formation of paraffin and clogging build ups within the pipeline but also efficiently and economically removes clogging in pipelines and oil flow lines used for the transportation of oil. The novel couplings of the invention may be utilized in both above ground or in subterranean flow lines as well as in downhole applications to reduce and prevent clogging of the oil flow lines.
The features of the invention reduce and eliminate the amount of oil pipe maintenance and flow line maintenance required for pipelines transmitting crude oil at a price and cost effectiveness better than the utilization of chemicals which can otherwise result to damage to the environment. Moreover as a consequence of the design and construction of novel oil tools of the invention they can be economically and conveniently manufactured and placed in downhole oil string lines and terrain and subterranean flow lines to reduce the problems of plugging and clogging of crude oil transportation lines while reducing the possibility of damage to the environment resulting from oil line breaks or the spilling of chemical solvents.
DESCRIPTION OF THE DRAWINGS
Other advantages of the invention will become apparent to those skilled in the art from the following detailed description of the invention in conjunction with the accompanying drawings in which:
FIG. 1 is an elevational view partly in section of an oil well pumping unit and downhole oil string including novel couplings constructed in accordance with the invention;
FIG. 2 is an exploded side elevational view partly in section of a novel downhole oil string coupling constructed in accordance with the invention;
FIG. 3 is a cross sectional view of the downhole oil string coupling of FIG. 2 illustrating the arrangement of the components in a preferred embodiment;
FIG. 4 is a side elevational view illustrating the arrangement of the north and south poles of magnets utilized in oil tools constructed in accordance with a preferred embodiment;
FIG. 5 is an enlarged sectional view of the section of the reference circle of FIG. 3 illustrating a means for securing the non magnetic liner in the novel downhole oil string coupling;
FIG. 6 is a side elevational view of a flow line oil tool constructed in accordance with the invention and attached to a non magnetic section of a flow line;
FIG. 7 is an enlarged side elevational view taken along the line 6--6 of the novel flow line oil tool of FIG. 6;
FIG. 8 is a side elevational view of an alternative embodiment of a flow line oil tool including a section of non magnetic conduit constructed in accordance with the invention;
FIG. 9 is an enlarged side elevational view taken along the line 8--8 of the novel flow line oil tool of FIG. 8;
FIG. 10 is a schematic view of magnetic flow line forces directed to crude oil constituents flowing in oil lines when a magnetic backing is not utilized;
FIG. 11 is a schematic view of magnetic flow line forces directed to crude oil constituents flowing in oil lines when a magnetic backing is utilized;
FIG. 12 is a schematic view of magnetic flow line forces directed to crude oil constituents flowing in oil lines where opposing magnets and steel backing is utilized;
FIG. 13 is a schematic view of a preferred arrangement of magnets around a magnetically non conductive oil conduit; and
FIG. 14 is a schematic diagram illustrating an application of the oil tool of FIG. 6 to a crude oil flow line for controlling clogging.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is applicable to all systems involving the transmission of crude oil from below the ground to its transportation to the refiner through terrain or subterranean flow lines to a storage facility. The invention employs slight variations in the oil tool depending upon whether the oil tool is utilized downhole in oil string or above ground in oil flow lines. Oil tools utilized in the downhole environment require considerations involving hang weight and adaptability of the outside diameter of the oil tool to the size and dimension requirements of the downhole oil string casing. Downhole oil string casing or lines are oil transmission lines or oil conduits designed for removing crude oil from its below ground environment to the above ground flow lines for ultimate transportation to storage containers or to the refinery.
Referring now to FIG. 1 a well known oil well extending below ground together with a typical pumping unit is illustrated having a standard above ground derrick 2 partly shown having a support means 4 bearing a walking beam 6 having a horsehead 8 for activating a sucker rod 10 in the downhole oil string casing 12 through a wire line 14. Wire line 14 is connected to sucker rod 10 through a standard polished rod clamp 16 and carrier bar 18 through polished rod 20 to the polished rod liner 22 to the stuffing box 24. A pumping tee 26 connects the stuffing box 24 with a pup joint 28 to the tubing head 30 which connects the downhole oil string casing 12 from its position above ground to its position below the surface of the earth.
The casing head 32 caps the surface casing 34 which provides a separation between the surrounding ground 36 and the downhole oil string casing 12. The downhole casing 12 predominantly employs downhole oil string pipes having an internal diameter of about 2 inches (5.08 cm) or 21/2 inch (6.35 cm) that are threaded together through couplings. These sections of oil string pipe which form the downhole oil string casing have male threads at both ends and are connected utilizing standard couplings 38 for joining the sections of oil string casing 12 together. The oil tool 40 of the present invention are substituted for couplings 38 at various positions along the length of the oil string with the distances between the oil tool 40 depending upon the paraffin content of the crude oil. The oil tool 40 can be formed from a standard coupling composed of material of a suitable hang weight so that the outside surface 42 appears the same as the standard couplings 38 used in the oil string casing 12.
The standard coupling 38 for 2 inch (5.08 cm) inside diameter pipe is about 9 inches long (22.9 cm) and has an external diameter of about 33/4 inches (9.53 cm) while the standard oil tool coupling 38 used for 21/2 inch downhole tubing is about 93/8 inches long (23.83 cm) and has an external diameter of 37/8 inches (9.86 cm). The standard coupling like the novel downhole oil tool constructed in the preferred embodiment includes internal threads at both ends for receiving the sections of oil string pipe which form the downhole oil string casing 12.
The oil tool 40 of the invention can be constructed from the standard coupling 38 and as a result has the same dimensions as coupling 38 and for all purposes substitute for the standard couplings 38 heretofore utilized to connect downhole oil string pipes. The novel oil tool 40 can therefore be connected to the oil string casing pipe at various locations in the downhole oil string to serve the dual function of performing as an ordinary coupling for joining sections of downhole oil pipe while at the same time serving to prevent paraffin and salt laden crude oil from scaling and clogging the inside of the pipe as it is drawn up through the oil string casing 12. The crude oil is pumped to the surface by the action of walking beam 6 and subsurface pump 44 (FIG. 1) through the perforated pup joint 46. The downhole drill string further includes a standard tubing and mud anchor 48 connected to a bull plug 50.
Crude oil containing paraffin, salts and other scaling and clogging materials is pumped to the surface through the perforated pup joint 28 through subsurface pump 44 through the oil string casing 12 by sucker rod 10 which itself is connected to the subsurface pump 44 through sections of the sucker rod connected with sucker rod couplings 52. The pumping action of the sucker rod coupled with the flow of crude oil through the oil string casing 12 is believed to generate electrostatic forces which depending upon the rates of flow and the paraffin and salt content of the crude oil results in the deposition of scale, deposits and paraffin clogging of the downhole oil string casing which is detected at the surface by drops in the pressure gauge 54 at the surface.
The clogging of the oil string casing 12 is fostered by not only the salt constituents of the crude oil but also by the paraffin content of the crude oil together with temperature gradient existing between layers of the earth from the oil downhole to the surface. The clogging of the downhole oil string casing has heretofore required the shut down and maintenance of the oil well by the introduction of hot oil or solvent being pumped down the oil string casing for a sufficient time and in a sufficient quantity to dissolve the paraffin clog in the downhole oil string casing. This maintenance is costly in terms of down time, chemicals and energy required to unclog an oil string which can be prevented by utilizing the novel oil tool 40 of the present invention at various locations in the oil string casing which may be employed together with the standard coupling 38 for joining sections of the oil string together.
The novel downhole oil tool 40 in the preferred embodiment serves the dual function of performing the function as an ordinary coupling for joining sections of oil string pipe together which form the downhole oil string casing while functioning as an oil tool for preventing and dissolving aggregations of the constituents of crude oil that would otherwise clog the oil string casing 12. The novel downhole tool 40 is believed to operate by magnetically inducing charges in salt and paraffin constituents in the crude oil and to disrupt the electrostatic forces resulting from the flow of crude oil in the downhole oil string casing. Referring now to FIGS. 1 and 2 the novel downhole oil tool 40 includes an outside surface 42 includes a pair of threaded ends 60 and 62 for connecting threaded ends of sections of oil string pipe 61 which form the oil string casing 12. The novel oil tool 40 has an outside surface 42 of a diameter which is preferably the same outside diameter as the standard coupling 38.
The oil tool 40 may also be of the same length, shorter or longer than the standard coupling 38 used to join the sections of oil string pipe together to form the oil string casing 12. The novel oil tool 40 may also be of the same material as the standard oil string coupling 38 except that oil tools constructed from couplings with low hang weights of for example under 70,000 pounds are not particularly advantageous at positions in the oil string casing at or near the surface for example at position 66 (FIG. 1) since the weight of the entire oil string casing 12 in deep wells could be greater than the hang weight tolerance limits of the material. It will be recognized that a low hang weight however could be employed for a coupling for an oil tool 40 at position 64 (FIG. 1) in the drill string might be utilized at or near the bottom of the oil string casing in view of the reduced amount of hang weight at position 64.
In the preferred embodiment of the invention oil tools are formed from materials having a hang weight of 100,000 pounds or greater such as L80 and N80 or P105 as described in the Specification on Performance Properties of Casing, Tubing and Drill Pipe of the American Petroleum Institute Standards. These standards will be revised in the future as new materials are available having hang weights in excess of 200,000 pounds are available and as new materials become available having greater weights. The invention contemplates the use of these materials since the material of the present oil tool employs the same materials as the couplings for these pipes for utilization in oil string pipe for deeper oil wells. Materials having the hang weight of J55 which is about 72,000 pounds can be utilized although recent materials having a hang weight of over 200,000 pounds are preferred in view of the fact that the inside diameter of the novel oil tool 40 is reduced to form an annular cavity 68 of increased diameter (FIG. 2) to provide a cavity for a plurality of magnets 70.
The annular cavity or recess 68 reduces the wall thickness from 1/4 to 1/2 an inch (0.64 to 1.27 cm) to make room for the magnets 70 and a magnet restraining and positioning ring 72 which is of a non magnetic material which separates each magnet 70 from the internal wall 74 of the annular cavity 68. The magnets 70 are maintained at a distance from the internal wall 74 of the magnetic metal of the oil tool 40 by the positioning ring 41 which is of a non magnetic material and preferably of aluminum. The decrease in strength resulting from the formation of the annular cavity 68 is offset in part by utilizing materials with greater hang weights such as L80 and N80 which have hang weights of 104,300 pounds and 135,400 pounds respectively and materials such as P105 which have a hang weight of 177,700 pounds.
The decrease in hang weight strength is further partially offset by the insertion and anchoring of an inside liner 76 composed of a non magnetic material and preferably a non magnetic alloy of stainless steel. Stainless steel by itself does not have sufficient hang weight to justify its use in substitution for the material forming the body of the oil tool 40. Non magnetic alloys of stainless steel are also relatively poor conductors of static charges which are believed to assist in the scaling and plugging of oil string casing with paraffin. The inside liner 76 can also be constructed of other non magnetic materials such as plastic or elastomeric materials where the material of the oil tool 40 is selected from a material of a suitable hang weight strength or has a wall of increased thickness to provide a suitable hang weight strength to support the weight resulting from the length of downhole oil string casing 12.
The inside liner 76 is preferably locked in the inside of the oil tool 40 by providing a locking annular recess 78 and 80 at the ends of the oil tool 40 between the threaded portions 60 and 62. The inside liner of a non magnetic material such as stainless steel, copper or other non magnetic metals and alloys may then be compressed at ends 82 and 84 to deform, roll or turn the ends 82 and 84 into the annular recess 78 and 80 by crimping, compressing or increasing the inside diameter of ends 82 and 84 as illustrated in FIG. 5.
A pair of O-ring seals 86 and 88 are provided between annular cavity 68 and locking annular recess 78 and annular cavity 68 and locking annular recess 80 respectively to seal the magnets 70 from the flow of crude oil from inside the oil tool through liner 76 to prevent the introduction of crude oil into cavity 68 to disrupt the propagation of electrostatic forces along the downhole oil string casing 12 and assist in the magnetic induction of paraffin and other materials flowing inside and through oil tool 40. It is believed that the difference in the conductivity of the materials together with the action of magnets 70 are responsible for preventing the clogging of the downhole portions of oil string casing of oil tool 40.
The magnets 70 in annular cavity 68 are preferably magnets having a residual flux density of greater than 2,000 gauss. Magnets utilized in annular cavity 68 are also flat rectangular magnets or curved magnets of minimal height in view of the dimensions of downhole oil string which has an internal diameter of 2 inches or 21/2 inches (5.1 to 6.4 cm) depending upon the size and type of pipe used in the downhole oil string. The preferred magnets in accordance with the invention are about 11/2 inches long (3.8 cm) by 5/16th of an inch (0.79 cm) by 5/16th of an inch (0.79 cm) and have residual flux densities of over 10,000 gauss. Each of the magnets 70 in the preferred embodiment are flat rectangular magnets with their north pole 71 and south pole 73 aligned in a layer arrangement with the north pole and south pole layered along the 11/2 inch length of the magnet 70 as illustrated diagrammatically in FIG. 3 and 4. The magnets 70 are also spaced laterally adjacent to one another with their north pole 71 and south pole 73 facing one another across the path of crude oil flowing through the novel oil tool 40.
The magnetic forces generated by magnets 70 are divided into major forces 152 which are directed across the flow as depicted in FIG. 13 and minor forces 77 (FIGS. 2 and 3) which propagate from the layered magnets 70 through the ends of the oil tool 40 out through the conductive pipe 61 connected to the novel oil tools of the invention. It is believed the minor magnetic forces which extend out along the length of the magnetic pipe together with the non magnetic inner liner and conduit assist in the disruption of the propagation of static charges and the further magnetic action on the constituents of crude oil flowing through the combination of fields provided by oil tools constructed in accordance with the invention.
The magnets 70 may be made of any material of suitable flux density with neodymium magnets being preferred such as neodymium alloy magnets being preferred such as neodymium type 37T and neodymium iron combinations such as neodymium, iron and boron alloy magnets known as NDFe 35 having a residual flux density of 12,200 gauss. These magnets are utilized in combination with the non metallic inside liner work together to charge salts, paraffin and other magnetic materials flowing through the crude oil conduit to prevent their coagulation and scaling of the inside of the downhole oil string line while at the same time interfering with frictional and the propagation of electrical static forces which are believed to contribute to the scaling and clogging of crude oil transmission lines.
The novel oil tool of the invention may be utilized in the downhole oil string at every 1,000 (304.8 meters) or 1,500 feet (457.2 meters) or more to prevent the clogging of the oil string depending upon the paraffin and salt consistency of the pumped crude oil. The tool once in place of the ordinary coupling requires no maintenance since the magnets are effective in charging particles flowing through the inside liner 76 of the oil tool and lose only 5% of their effectiveness in 100 years. The neodymium, iron, and boron content of magnets utilized in accordance with the invention coupled with the preferred liner of a non magnetic stainless steel is also maintenance free while assuring the constant production of crude oil by preventing the down time, maintenance, chemicals and other problems associated with clogged downhole oil lines.
The stainless steel alloys utilized for the inside liner 76 are preferably a non magnetic alloy of stainless steel or other non magnetic material to not interfere with the magnetic forces generated by the magnets upon salts, paraffin and other constituents of crude oil flowing through the inside liner 76. The magnets 70 are also increased in their effectiveness by the utilization of a magnetic shield provided around the magnets or the spacing of the magnets 70 away from the magnetic body of the oil tool 40 together with the non magnetic positioning ring 72 which may be aluminum or elastomeric material to dampen the transmission of vibrational forces in oil string casing 12 in oil tool 40.
As heretofore discussed the magnets 70 are maintained away from contact with the walls of the annular cavity 68 to direct their magnetic forces upon the crude oil flowing through the inside liner 76 and in the preferred embodiment the magnets 70 are arranged in radial non alignment. As indicated in FIGS. 3 and 4 magnets 70 have their north pole 71 oriented for example in the direction of flow of crude oil whereas the laterally adjacent magnet 70 has its south pole oriented in the direction of the flow of crude oil. It is believed the preferred arrangement of the laterally adjacent magnets having a layer of north and south poles facing one another across the path of flow of crude oil through the inner liner 76 assists in the induction of magnetic forces in particles flowing through the liner and disrupts the propagation of electrostatic forces along the outside of the outside surface 42 of the oil string casing 12 that are believed to promote the scaling and clogging of oil flow lines.
The plugging and scaling of oil string casing 12 occurs not only downhole in oil string casing 12 but also above ground from the pumping tee 26 through the terrain or subterranean oil flow transmission lines 100. The above ground oil transmission lines 100 from the well head to the storage tank or refinery also become plugged and clogged with paraffin due to the same electrostatic frictional forces and temperature variation in the environment as were encountered in the downhole oil string. These flow lines from the well head to the refinery or storage area may be either terrain or subterranean oil conduits but generally are oil lines which horizontally follow the surface of the earth to the storage facility or refinery.
These flow lines like the downhole oil string lines become clogged and require maintenance to unplug the line by utilizing either hot oil, hot solvents or chemicals which are potentially environmentally dangerous when oil flow lines are broken or when the solvents are subsequently removed and discarded from the crude oil in the refining process. It has been found the problems of plugging and clogging of oil flow lines like the plugging and clogging of downhole oil strings can be solved by the utilization of oil tools constructed in accordance with the invention. These oil tools employ the same principals of magnetism and disruption of the electrostatic forces resulting from the frictional forces of the oil flowing through the oil flow line to remove and prevent the scaling and paraffin clogging of the oil flow lines.
Referring now to FIGS. 6 and 7 an oil flow tool 102 is illustrated having an environmental coating or covering 104 which may be composed of a non magnetic and fairly non conductive alloy of stainless steel. Environmental coating 104 could also be constructed of other non magnetic materials such as plastic, elastomeric materials or other non magnetic metal alloys for environmentally protecting the components of the novel oil tool 102.
Oil tool 102 is constructed in the form of a sleeve that is about 31/2 inches (8.9 cm) to about 4 inches (10.2 cm) long designed to fit around a section of non magnetic plastic pipe 106 non magnetic stainless steel or other non magnetic section of conduit in existing oil flow transmission lines or added between sections of magnetic pipe. Alternatively oil tool 102 may be a unitary sleeve (FIGS. 8 and 9) having an internal conduit 108 having threaded ends 107 and 109 for connection or splicing between two sections of magnetic oil flow lines.
In the preferred embodiment the flow line oil tool is constructed in two halves 110 and 112 with each of the halves containing the same components which halves 110 and 112 can be separated or pivoted apart by a hinge to allow the two halves to be fixed around an existing non magnetic section of flow line pipe. The environmental covering 104 can terminate in fastening tabs 114 and 116 for connecting each of the two halves together through bolts 118 having suitable locking means 120. The halves 110 and 112 may further be positioned with respect to one another through the utilization of shims or washers 122 to assist in the fitting and securement of the oil tool 104 around existing section of non magnetic pipe.
The flow line oil tool 102 includes a pair of highly magnetic steel shields 124 along with a plurality of magnets 70 are disposed in contact with each of the magnetic shields 124. The magnets 70 are restrained and positioned with respect to each of the magnetic shields 124 by a pair of non magnetic holding means 126. The concave side of the magnetic shields includes the plurality of magnets 70 having a layer of north pole and south pole as illustrated and discussed with respect to FIG. 4. The plurality of magnets 70 may be the same neodymium, iron, boron allow magnets or other magnets having a suitable flux density as discussed with respect to the downhole coupling and may be instead of 11/2 inches (3.81 cm) long or 3 inches (7.62 cm) long and positioned with their north and south poles laterally positioned with respect to each other in each of the halves 110 and 112 by magnetic holding means 126.
The embodiment of the flow line oil tool as illustrated in FIGS. 8 and 9 include many of the same components except the oil tool in FIGS. 8 and 9 include a section of the non magnetic conduit for connection to a magnetic oil flow line. The flow line oil tool includes an outer covering 105 of a non magnetic metal alloy or a non magnetic plastic or elastomeric material. Otherwise the oil tool of FIGS. 8 and 9 includes a pair of magnetic shields 124, magnets 70 arranged as in FIG. 7 and a pair of non magnetic holding means 126.
This arrangement of magnets, magnetic shields and non magnetic conduit for the transportation of crude oil operates to induce magnetic charges in the crude oil petroleum constituents to prevent their scaling and clogging the oil line in the manner as heretofore described. The combination of the shield plus magnets non magnetic outer covering and section of non magnetic pipe are also believed to serve as a means for disrupting the electrostatic charges resulting from the flow of crude oil in the oil flow pipe line and discharge the static forces that would otherwise build up along the length of the pipe and result in the attractive forces between the walls of the pipe and ionic particles in the crude oil to result in the paraffin clogging of the oil flow line.
The principals of the operation of the downhole oil tool and the flow line oil tool are the same in effecting the magnetic and electrostatic forces in the constituents of the crude oil. These forces are best dispelled with a plurality of magnets disposed axially along the length of a section of non magnetic conduit. The number of magnets utilized depend upon the diameter of the oil flow lines and preferably are 2 to 6 pairs of magnets for conduits of up to 3 inches in diameter and 4 to 12 or more pairs of magnets for pipes of larger diameter.
The magnetic forces believed responsible for preventing the scaling and build up of constituents of crude oil flowing through crude oil conduits are illustrated in FIGS. 10 to 13. In FIG. 10 lines of force 140 are illustrated as exerting a force of a given magnitude represented by line 139 at a distance represented by arrow 141 from magnet 70 in FIG. 10. The application of a magnetic backing 142 to magnet 70 exerts the same magnitude of force at line 145 at a much greater distance as represented by line 144 demonstrating the increase on the power of the magnets by the addition of a magnetic shield 124.
Referring to FIG. 12 the arrangement of magnets 70 laterally disposed with respect to one another is schematically illustrated. The lines of force 140 between magnets 70 with a pair of magnetic shields is illustrated in relation to the flow path of crude oil as represented by line 150. The non magnetic inner liner does not impede the magnetic forces directed across the path of flow of the constituents of the crude oil. As illustrated in FIG. 13 the utilization of a plurality of magnets 70 around a non magnetic inner liner 76 or a section of non magnetic conduit 100 direct the lines of force 152 substantially across the path of crude oil flowing in the conduit to the magnet disposed on the opposite side of the pipe. It will be understood that while even pairs of magnets have been described it is possible to employ odd numbers of magnets to obtain the advantages of the invention. It will be further understood the steel backing addition to the magnets 70 further concentrate the force of the magnets 70 and 92 upon the crude oil flowing through the oil conduit. It is believed that the force of the magnetic field assists in the polarization of the constituents in crude oil along with the resonance effect which both prevents and dislodges paraffin build up in pipe lines.
The effectiveness of the present system for removing and preventing paraffin clogging of oil conduits is demonstrated in FIG. 14 which is a schematic diagram cf oil flow line having paraffin build up problems from oil wells producing crude oil in Wyoming. The paraffin build up inside the flow lines prior to the introduction of the oil tools of the present invention resulted in high flow line pressures requiring the injection of paraffin chemicals solvents at three locations at a rate of 2 quarts per day at each site. These chemical treatments had been previously required to prevent paraffin clogging and maintain pump pressure in the normal range. The normal pressure in the flow lines varied from between 35 pounds to 65 pounds before the use of the paraffin control oil tools of the invention.
Prior to the application of oil flow oil tools constructed in accordance with FIG. 7 of the invention to the oil flow line illustrated diagrammatically in FIG. 14 all chemical paraffin solvent injection was discontinued during the period of the test. The novel downhole oil tool were not utilized but only the above ground oil flow line oil tools were employed so that paraffin build up in the oil string was not controlled for purposes of the test. The seven oil wells 6-18, 7-18, 8-18, 9-18, 10-18. 8-19 and 9-19 are illustrated as circles on the diagrammatic oil flow line along with the distances between various sections of pipe illustrated in feet along the sides of the oil flow lines. The flow line oil tool units were disposed in eight locations 160, 162, 164, 166, 168, 170, 172 and 174 with some of the units 160, 162, and 174 located near the surface of the oil well. The pump pressures were monitored in the flow lines to determine whether paraffin was building up in the flow lines after the use of chemical solvents ceased. The results of the test are reported below in Table I.
TABLE I______________________________________DATE 5-11-89 ALL CHEMICAL INJECTION STOPPED.PRESSURES ON DATEWELL 05/11/89 05/12/89 06/12/89______________________________________6-18 65 lbs. 110 lbs. 45 lbs.7-18 55 lbs. 50 lbs. 45 lbs.8-18 45 lbs. 35 lbs. 35 lbs.9-18 65 lbs. 120 lbs. 45 lbs.10-18 35 lbs. 40 lbs. 35 lbs.8-19 40 lbs. 40 lbs. 35 lbs.9-19 35 lbs. 32 lbs. 30 lbs.______________________________________
As previously indicated, the control of paraffin downhole was not controlled utilizing downhole oil tools constructed in accordance with FIGS. 2 and 3. The paraffin coagulation and aggregation noted at wells 6-18 and 9-18 on 05/12/89 may have partially resulted from paraffin coagulation starting in the downhole oil string casing as it was being pumped from the ground to the surface since paraffin coagulation was not controlled until the paraffin reached the surface. It is believed these increases but then the subsequent decrease in pump pressures to normal on well 6-18 and well 9-18 were the result of paraffin formations being brought to the surface and subsequently breaking loose and being dissolved or dislodged from the walls of the flow line which resulted in an increase in pressure the first day after the installation of the paraffin units. Thereafter the pressures dropped and remained within the pump pressure normal tolerance limits for the 30 day test period as indicated in Table I.
It is believed paraffin coagulation was arrested by the introduction of the flow line oil tool units as a result of the action of the magnets upon the constituents of crude oil bearing salts and paraffin elements together with the use of materials differing from the material of the conduit flow line and more particularly materials that are non magnetic and/or less electrically conductive than the flow line or downhole oil conduit so that propagation of electrostatic charges along the oil conduit are broken to prevent the subsequent build up of sufficient forces to result in scaling and paraffin blockage of the oil conduit. It is believed the electrostatic forces can be interrupted in various procedures alone or together with the utilization of magnets and dissimilar materials to prevent the propagation of electrostatic forces resulting from the flow of crude oil in a crude oil conduit.
The novel oil tools of the present invention provide significant advantages over prior art methods and tools for removing paraffin and unclogging oil conduits such as the use of chemicals, hot oils and solvent treatments which require the shut down and maintenance of the oil conduit. These procedures not only interfere with the normal operation of the equipment but also interfere with the production capabilities and transportation capabilities of the oil line. In addition the utilization of oil tools constructed in accordance with the invention for preventing the clogging of oil conduits provides a low cost, low maintenance and an environmentally attractive alternative to solvents which have to be removed, which are expensive and which present environmental problems of disposal when they escape to the environment as a result of breakage of the oil pipe line. The method of the invention further allows a great degree of adaptability depending upon the paraffin content of the oil and the disposition of the oil tool along the downhole oil string as well as in the terrain and subterranean flow line to increase the production of oil by decreasing the down time resulting from the clogging of oil conduits.
The novel oil tools of the invention may be readily modified by providing virtually an unlimited application to various types of pipe fittings such as curved or T shaped joints, valves and other components utilized in pipelines where paraffin build up and scaling present problems. It is therefore understood that the present invention can be applied to T shaped joints, valves and other pipeline components together with the utilization of various means for removing electrical charges or interfering with electrical charges that might otherwise result in the concentration and build up of salts, paraffin and other components of crude oil in oil conduits which result in clogging.
It will also be appreciated by those skilled in the art that the invention may be implemented in a variety of ways to prevent paraffin build up or settling from crude oil once the magnetically induced effect on the particles have been dissipated such as when the crude oil is placed in storage facilities or containers. In such applications the method of the present invention contemplates the movement of crude oil by circulation pumping through novel oil tools constructed in accordance with the invention to maintain the components of crude oil in suspension until the crude oil has been refined.
Those skilled in the art will further recognize the invention has a wide range of applicability to various oil flow circulation systems to prevent the coagulation, settling and deposition of paraffin, scale and other constituents of crude oil prior to refining without the use of chemical treatments, solvents, back washing or hot oil or water treatments which are time consuming and many times interrupt the normal production or flow of oil. It will be further understood the invention may be implemented in a variety of ways to suit the particular applications of the novel oil tools of the invention to downhole applications and above ground flow lines to, suit the particular requirements of the oil conduit either above ground or below ground so as to provide the advantages inherent in the combination of magnets and non magnetic material to interrupt the static forces propagating electrostatic charges while magnetically inducing and influencing the particles and constituents of crude oil flowing through an oil pipeline. Consequently it is intended that these and other modifications and applications of the invention to a variety of systems may be made within the spirit and scope of the invention as defined in the following claims.
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An oil tool and method for controlling the accumulation of paraffin and deposits in downhole oil string and oil transmission flow lines is provided by employing at various locations in the downhole oil string or in the oil transmission flow lines a coupling device with an inside liner of a non magnetic material surrounded by a magnet and shield of a magnetic material. The preferred application employs at least two magnets having their north pole and south pole aligned in opposite directions held in place in relation to a magnetic outer shield or casing by a non magnetic restraining ring. The non magnetic inside liner or non magnetic section of flow line in combination with the magnetic shield or casing increases the magnetic field which in combination with the electrostatic differential in the materials in the coupling and oil line prevents and controls paraffin and other substances having the potential for clogging and blocking downhole oil strings and oil transmission flow lines used for the transmission of crude oil. The novel coupling may be either employed as a threaded coupling or as a covering to cover the non magnetic tubing spliced into existing flow lines at strategic locations to prevent the clogging of crude oil transmission lines. The method and oil tool prevent the clogging of downhole oil string casing and above ground flow lines by utilizing magnetic and dissipation of electrostatic forces to increase oil production while eliminating paraffin and scale build up in downhole well pipe and flow lines.
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BACKGROUND OF THE INVENTION
The Invention concerns a method of operating an electrochromic element which consists of at least the following layers:
a first electrode layer;
first layer, in which ions can be reversibly inserted;
a transparent ion-conducting layer;
a second layer, in which ions can be reversibly inserted; and
a second electrode layer,
where the first and/or the second layer, in which ions can be reversibly inserted, is an electrochromic layer and the other of these layers acts as counter-electrode to the electrochromic layer, and where a voltage is applied to the electrode layers which induces a colour-change process, which voltage possesses values in a redox-stability range of the electrochromic layer system and the current flows through electrochromic element is measured continuously.
1. Field of the Invention
The term colour-change process denotes either forced colouring, that is to say a reduction in transmittance or reflectance of the electrochromic element, in particular in the visible region of the spectrum, or decolouring or bleaching, that is to say increasing the transmittance or reflectance. It can also however consist primarily of a change in the colour location of the transmitted or reflected radiation. Voltage values in a redox-stability range of the electrochromic layer system denotes voltages where the electrochromic layer system consisting of the electrochromic layer, the ion-conductive layer and the layer acting as counter-electrode experiences no or at all events very slight irreversible changes.
The electrochromic element incorporates at least one electrochromic layer, whose colour can be reversibly changed. This is combined as counter-electrode either with another electrochromic layer or with a transparent ion storage layer, which does not change its transparency significantly as a result of the insertion of ions. For the sake of simplicity, the two layers in which ions can be inserted are both designated below as electrochromic layers.
The layers of the electrochromic element mentioned above can also if necessary follow one another with further layers being interposed, such as for example protective layers, insulating layers, optically effective auxiliary layers, reference electrode layers, or the like. At least one of the electrode layers is a transparent layer. If the electrochromic element is to be used as a transparent window element with variable transmittance, the second electrode layer will also be transparent. If, on the other hand, the electrochromic element is to be used as a mirror with variable reflectance, one of the two electrode layers will preferably take the form of an opaque reflection layer of a suitable metal, such as aluminium or silver. It is also possible however to operate with two transparent electrode layers and to provide an additional metal reflection layer. For the sake of simplicity, only electrochromic elements with variable transmittance will be discussed, without however the Invention being restricted to this.
It is possible, by means of the voltage applied via the electrode layers to the electrochromic element, to alter its transmittance. This change generally takes place more quickly, the higher is the voltage applied. Of course, if the electrochromic element is not operated in optimum fashion, if therefore, in particular, the voltage applied is too high, it can be permanently damaged. It is then possible for the transmittance of the electrochromic element to cease being variable, or that the difference between minimum and maximum transmittance will no longer be as great as in undamaged state, under otherwise identical ambient conditions. It is also to be feared that the electrochromic element will no longer colour homogeneously, possibly irreversibly coloured or no longer colourable areas will be formed.
Above all, if a polymer electrolyte is used as ion-conductive layer, there is also a risk of the electrochromic layer delaminating, that is to say that the ion-conductive layer will become detached from the electrochromic layers in some areas.
According to the application of the electrochromic element, it will be exposed to a greater or lesser degree to wide temperature fluctuations. Thus, for example, in the case of an electrochromic element which is used in motor vehicles as window glass, roof glazing panel, or the like, it can be expected that it will operate satisfactorily at temperatures in the range of −20° C. to +80° C. Similar temperatures are to be expected in the case of applications in the outer skin of buildings, for example in the field of building curtain walls. It is known that a temperature increase will lead to reduction of the specific resistance of the system components. In particular, the resistance of the ion-conductive layer can decrease drastically with a temperature increase. If suitable measures are not taken, this can easily lead to the fact that, at high temperatures, the redox stability range of the electrochromic layer system will be exceeded and irreversible changes will occur.
2. Description of the Prior Art
From EP 0 475 847 B1, according to which the Preamble of the Patent Claim is formulated, a process for operating an electrochromic element is known, where the voltage applied to the electrochromic element is temperature-dependent. The temperature is measured directly with a thermometer, or indirectly, by a voltage pulse being generated prior to each colour-change process, by means of which with simultaneous current measurement, the resistance of the ion-conductive layer is determined, and from this the temperature of the electrochromic element is determined. According to the temperature determined, a voltage is applied to the electrochromic element for a predetermined time. When the desired transmittance is reached, the voltage is disconnected.
EP 0 718 667 A1 has as its subject a process for operating an electrochromic element which can be influenced by the user, which process can be adapted via an interface to electrochromic elements of different designs, to the ambient temperature and to the dimensions of the electrochromic element. Here, the voltage with which the electrochromic element is operated is also to be a function of the temperature. A disadvantage of the known process is that, for each individual electrochromic element, matching of the control parameters to the window dimensions must take place.
EP 0 683 419 A1 discloses a method to trigger an electrochromic element in which a current is impressed on this.
SUMMARY OF THE INVENTION
The purpose of the present Invention is to provide a process for operating an electrochromic element which will operate over a wide temperature range, which is largely independent of the area of the electrochromic element, which permits a change in transmittance over a wide range, which permits sufficiently rapid colour change, and with which a long service life of the electrochromic element can be achieved.
This problem is solved by a process in accordance with Patent claim 1 . Advantageous configurations are the subject of the Subclaims.
According to the Invention, provision is made for the current I flowing through the electrochromic element to be measured continuously, for the voltage U applied to the electrochromic element during a starting stage of the colour-change process to be increased or reduced continuously up to maximum to a final value U max predetermined as a function of temperature, where the temperature dependence of the final value U max is determined by the design of the electrochromic element, but is independent of the area to be subjected to colour change, and that the voltage U is controlled during the course of the colour-change process as a function of the current I, where the voltage U does not exceed in magnitude the magnitude of the final value U max . The final value U max can possess a different magnitude for a colouring process than for a bleaching process.
Current measurements will normally take place regularly at always the same, sufficiently short intervals of time, typically several times a second. It is also possible to proceed in such a way that, for example in the starting stage of the colour-change process, measurements are carried out at shorter intervals than in later stages, because in the starting stage, the current and the voltage will normally change at the fastest rate.
For most applications, it will suffice for the temperature dependence of the final value U max of the voltage U is determined by a linear relationship, for example:
U max =A−B·T, (1)
where T is the temperature of the electrochromic element, and A and B are constants determined by the design of the electrochromic element, which are to be established empirically. If the temperature T is in ° C., A will correspond in value to the voltage U which may be applied as maximum to the electrochromic element at 0° C. With the constant B is determined to what extent the final value U max of voltage U is to be modified in the event of temperature changes. A and B may be different for a colouring process and a bleaching process respectively. They are characteristic of a certain design of electrochromic element, but independent of its dimensions. They can be established on the basis of cyclic voltammetric preliminary investigations on the electrochromic layers, for example by means of systematic test series, where electrochromic elements of the same design and dimensions are operated with different values of U max at different temperatures, and the maximum voltages in magnitude determined at which the electrochromic elements do not, over a large number of (minimum approximately 1,000−10,000) colour-change cycles, experience any significant deterioration in their colour-change properties.
An essential feature of the Invention is the regulation of the voltage U applied to the electrochromic element as a function of the current I. The Invention utilizes the surprising principle that evaluation of the continuous measurements of the current I renders superfluous any knowledge of the exact dimensions of the electrochromic element for safe operation of this element. The measured values of the current I can basically be utilized in a different fashion for regulation of the voltage U. Thus, for example, provision can be made for the voltage U to be increased in magnitude initially in the starting stage up to the final value U max and subsequently to maintain it at the value reached until the current I falls below a temperature-dependent first threshold referred to the maximum current I max —as explained in detail below—following which the voltage U is reduced in value continuously or in several steps, until the current I reaches a lower switch-off threshold also referred to the maximum current I max , dependent on temperature. Advantageously, this current-controlled regulation of the voltage U takes place however with the aid of an arithmetic value for the total resistance R ges of the electrochromic element determined from current and voltage measurements.
The total resistance R ges of the electrochromic element can be determined preferably in the starting stage of the colour-change process from the voltage U and the current I. To compensate for any voltage offset (open-circuit voltages), the total resistance R ges is preferably calculated as the first derivative of the voltage U to the current I. This is obtained in first approximation by the formation of the quotient ΔU/ΔI of the magnitudes of voltage difference and current difference at consecutive moments of time t i , t i+1 , ΔU=|U (t i+1 )−U (t i )|, ΔI=|I (t i+1 )−I (t i )|. The accuracy of the calculation can be increased by averaging being carried out from several quotients ΔU/ΔI determined at different points in time. By carrying out the measurements and calculation in the starting stage of the colour-change process, it is possible to a large extent to avoid falsifying the measurement results due to internal voltages occurring during the course of the colour change.
As the total resistance R ges is temperature-dependent, it is basically possible to conclude the temperature T of the electrochromic element from this, if it should be necessary to dispense with separate temperature sensors. Particularly in the case of large-area electrochromic elements, preference should of course be given to direct temperature measurement with the aid of a temperature sensor, on account of the greater degree of accuracy obtained.
Especially long service life of the electrochromic element can be achieved by calculating from the voltage U, the current I and the total resistance R ges , a voltage U eff which is effective electrochemically at the electrochromic layers, and by regulating the voltage U such that U eff does not in magnitude exceed a predetermined value U eff,max , above which irreversible changes can occur at the electrochromic element. Here, the following Approximation Equation is preferably used to determine the voltage U eff effective electrochemically at the electrochromic layers; how it is arrived at is described below:
U eff =U−I·D·R ges (2)
where D is a correcting variable, to be used where necessary to compensate for approximation errors. It will suffice in most cases to use the value of 1 for D. To optimize the voltage regulation with a view to maximum possible service life of the electrochromic element, it may however be advantageous to work with a correcting variable D differing from 1, this being determined in orientation trials. Cases are conceivable, for example, where measurement of the total resistance R ges is only carried out at a relatively late stage of a colour-change process, in which the individual resistances of the electrochromic layer system depend to an especially large extent on the colouration state or in which the electrochromic layers possess an unusually high ohmic resistance.
Rapid, but nevertheless careful colour change is achieved by an especially simple method of control if, after completion of the starting stage, and as long as the voltage U eff electrochemically effective at the electrochromic layers does not yet reach the maximum permissible value U eff,max in magnitude, the voltage U is kept essentially constant at the final value U max , reached at the end of starting stage. Of course, it could even be possible to operate with voltages U which are lower in magnitude than the final value U max . Such a process would however result in longer colour-change times, which is normally undesirable.
A switch-off criterion of the voltage U can, in particular where complete colouring or bleaching is desired, be defined particularly simply according to the Invention with the aid of the maximum current I max which has flowed during the colour-change process. It can thus be determined that the voltage U is switched off when the ratio of instantaneously flowing current I to maximum current I max falls below a specified value which is determined by the design, the type of colour-change process and generally by the temperature T.
If only partial colour change is desired, it is possible for example to monitor the transmittance or the reflectance of the electrochromic element and to switch off the voltage U when the transmittance or reflectance reaches a predetermined value.
Another alternative consists of determining the quantity of electricity which has flowed in the electrochromic element since commencement of the colour-change process and to switch off the voltage U when the quantity of electricity which has flowed reaches a specified value. The quantity of electricity which has flowed can be determined by time integration of the current I.
With the process according to the Invention it is possible, as soon as the design-related parameters A, B, D, U eff,max and the switch-off ratio I/I max have been determined, to carry out self-calibration of the control process, essentially independently of the area of the electrochromic element to be subjected to colour change, which will permit safe operation of the electrochromic element. It lies within the scope of the Invention however, for the purpose of refining and further optimizing the control process to define various size classes for electrochromic elements, within which in each case the same design-dependent parameters are applied, for example in increments of approximately 0.5 to 1 meter, referred to the shortest element dimension.
The process according to the Invention permits, with a simple method of control, rapid, reproducible and uniform colour change of electrochromic elements, where additional switch-off criteria can be applied for partial colour change. In practical form, it is determined decisively by its starting stage, in which self-calibration is carried out, that is to say in which essential control parameters of the process are determined.
BRIEF DESCRIPTION OF THE DRAWINGS
The Invention will be explained in detail with the aid of the enclosed Drawings. These show:
FIG. 1 the diagrammatic construction of an electrochromic element;
FIG. 2 a simplified equivalent circuit diagram of the electrochromic element of FIG. 1;
FIG. 3 a diagrammatic block diagram to illustrate the measurement and control variables for operating an electrochromic element according to the Invention;
FIG. 4 the diagrammatic characteristic curve of current and voltage when the electrochromic element of FIG. 1 is operated in accordance with a preferred embodiment of the process according to the Invention;
FIG. 5 a measurement curve of the current and voltage characteristic during a colouring process which utilizes a preferred process according to the present Invention, carried out on an electrochromic element with the dimensions 70 cm·100 cm; and
FIG. 6 a bleaching process according to the Invention with an electrochromic element in accordance with FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates in diagrammatic form the construction of a specimen electrochromic element. On a glass substrate 10 is located a first transparent electrode layer 12 , on which as first layer, in which ions can be reversibly inserted, is provided an electrochromic layer 14 . A transparent ion-conductive layer 16 , which may take the form of polymer electrolyte, separates the electrochromic layer 14 from the second layer, in which ions can be reversibly inserted, here an ion storage layer 18 which acts as counter-electrode to the electrochromic layer 14 . The ion storage layer 18 can take the form of a layer with transmittance essentially independent of the insertion state. It can however possess more or less pronounced electrochromic properties. Layers 14 , 18 are designated for the sake of simplicity as electrochromic layers 14 , 18 , without the field of use of the process according to the Invention being restricted to electrochromic elements with layers capable of changing their colour.
The layer construction is symmetrically supplemented by a second transparent electrode layer 20 and a glass plate 22 . The electrode layers 12 and 20 are provided with electrical connections 24 , 26 , to which a control voltage U can be applied via supply leads which are not illustrated. The electrochromic layer 14 and the ion storage layer 18 consist of materials which are known and suitable for this purpose, as are described for example in EP 0 475 847 B1, in which cations can be reversibly inserted, in particular protons or Li + ions, where the electrochromic layer 14 assumes differing degrees of colouring according to the insertion state.
The voltage U applied to the electrochromic element must fulfil two conditions during the entire process of colour change:
(I) The magnitude of the voltage U may not exceed the magnitude of a specified final value U max dependent on the temperature T. The temperature dependence of this final value U max is dependent of the design of the electrochromic element and is determined primarily by the material used for the electrochromic layers 14 , 18 and for the ion-conductive layer 16 .
(II) The voltage U eff , which is effective electrochemically at the electrochromic layers 14 , 18 may not exceed a certain value U eff,max . As the potentials prevailing on the electrochromic layers 14 , 18 can only be influenced indirectly and only recorded at considerable expense, the voltage U applied to the electrochromic element is preferably regulated on the basis of the total resistance R ges determined in the starting stage of the colour-change process and by evaluation of the continuous measurements of the current I in such a way that condition (II) is complied with at all times. The maximum permissible magnitude U eff,max of the voltage U eff effective electrochemically at the electrochromic layers 14 , 18 generally depends on different parameters, that is to say for example on the temperature T of the electrochromic element, on its design and on the nature of the colour-change process (colouring or bleaching).
The voltage U eff effective electrochemically at the electrochromic layers 14 , 18 is reduced in magnitude in relation to the voltage U applied externally to the electrochromic element, that is to say by the ohmic losses at the various other components of the electrochromic element including its supply leads. The voltage U eff is in fact not accessible for direct measurement with an electrochromic element producible at an industrially viable cost. It can however be calculated approximately with sufficient degree of accuracy, as described below.
FIG. 2 shows a simplified equivalent circuit diagram of the electrochromic element according to FIG. 1 . Here, R 1 is the ohmic resistance of the electrode layer 12 including connection 24 , as well as any supply leads not illustrated, R 2 the ohmic resistance of electrochromic layer 14 , R 3 the ohmic resistance of the ion-conductive layer 16 , R 4 the ohmic resistance of the ion storage layer 18 and R 5 the ohmic resistance of the electrode layer 20 , including connection 26 as well as any supply leads not illustrated.
The total resistance R ges of the electrochromic element is thus obtained as the total of resistances R 1 to R 5 ,
R ges =R 1 +R 2 +R 3 +R 4 +R 5 .
With the current I flowing through the electrochromic element , one obtains therefrom the applied voltage U=I·R ges , where the voltage components I·R 2 +I·R 4 dropping across the electrochromic layers 14 , 18 correspond to the previously mentioned electrochemically effective voltage U eff . It is therefore true to say that:
U=U eff +I·(R 1 +R 3 +R 5 )
or—resolved according to U eff —:
U eff =U−I·(R 1 +R 3 +R 5 ). (3)
From this Equation (3) it is possible, assuming that in any case in the starting stage of the colour-change process, the resistances R 2 and R 4 are small in relation to R 1 +R 3 +R 5 , with R ges ≈R 1 +R 3 +R 5 to derive the Approximation Equation (2) stated above.
From Equation (3) or Approximation Equation (2) it can be deduced directly that the voltage U eff effective electrochemically at the electrochromic layers 14 , 18 can be regulated by means of voltage U and with the aid of measurement of the current I. The value of U eff calculated in this way can of course only be an approximate value, as the voltage drop I·R, in particular in the case of large-area electrochromic elements is not constant over the entire area of the element, but is greatest at the edges, whilst it assumes a minimum value at its centre. The resistance characteristic of an electrochromic element is described correctly in physical terms by means of complex variables (impedances). The determination of complex impedances however requires comparatively complex instrumentation, which is not justified in terms of cost-effectiveness. It has been found that in practice, for determination of the required operating parameters of the control process, merely taking account of the ohmic part of the impedances of the system components will provide a quite adequate approximate value.
From the two above-mentioned conditions (I) and (II), which are to be maintained during operation of the electrochromic element in a redox-stability range of the electrochromic layer system, in combination with Approximation Equation (2) for each moment in time of the colour-change process, two upper limits are determined for the magnitude of the voltage U to be applied to the electrochromic element, neither of which may be exceeded:
|U|≦|U eff| (4)
|U|≦|U eff,max +I·D·R ges| (5)
The voltage U is regulated by evaluation of the continuous measurements of the current I so that the lower of the upper limits obtained from the Relations (4) and (5) is not exceeded in magnitude.
In order to initiate a colour-change process, a voltage U is applied to the electrical connections 24 and 26 (FIG. 1) of the electrochromic element, this voltage proceeding from a measurable open-circuit voltage U EC with the electrochromic element in zero-current state. The voltage U is now—according to the type of process desired —increased or decreased, increase or decrease taking place continuously, but need not necessarily proceed linearly. Of course, according to the sign of the open-circuit voltage U EC , initially zero crossing of the voltage U can take place, where therefore the magnitude of the voltage U will initially drop, before finally an increase in the voltage magnitude will take place. The increase in the voltage magnitude and thus the starting stage of the colour-change process will be completed at the latest when the lower of the upper limits according to Relations (4) and (5) is reached.
In the case of the process described here, Relation (4) will normally provide the lower upper limit, whilst the upper limit according to Relation (5) will only come into consideration during the further course of the colour-change process. It can however happen that the increase in the magnitude of the voltage U is completed in the starting stage of the colour-change process as a result of reaching the upper limit according to Relation (5), and thus before reaching the final value U max .
During the starting stage of the colour-change process, according to the Invention the total resistance R ges of the electrochromic element is determined as previously defined from the quotient ΔU/ΔI. Here, a mean value is preferably formed from several individual values of the total resistance R ges determined at different moments in time, in order to increase accuracy of measurement.
During the further course of the process according to the Invention, it is preferable as long as the upper limit according to Relation (5) is higher than that from Relation (4), for the voltage U to be maintained at or close to the final value U max . The current I through the electrochromic element generally decreases with time. Thus, the upper limit from Relation (5) decreases as well. This then generally results after a certain period of time in the situation that Relation (5) provides the lower upper limit for the magnitude of the voltage U, so that from then onwards the voltage U is regulated in accordance with Relation (5), that is to say, is generally reduced in magnitude according to the progressive reduction of current I at the end of the colour-change process.
According to the Invention, the current I is also measured continuously after the starting stage in order to ensure observance of Relations (4) and (5) by continuous correction of the voltage U. It is of course permissible to undershoot the upper limits provided, where in respect of magnitude, time duration, frequency of undershoot and the like, there is basically no form of restriction from safety aspects. It should be taken into account at all times that undershoot of the permissible upper limits for the magnitude of the voltage U will extend the times until complete colour change is reached, which is generally undesirable.
FIG. 3 shows a highly simplified block diagram to explain the measured and controlled variables in the process according to the Invention for operating an electrochromic element (ec element). The temperature of the electrochromic element is generally established by means of a suitable temperature sensor (designated T), whose measured values are sampled by the controller monitoring and controlling the colour-change process. The temperature sensor can be arranged in a suitable position outside or inside the electrochromic element. Furthermore, the current flowing through the electrochromic element is measured with a measuring instrument designated I and the measured values are passed to the controller. The controller then carries out the calculations as described above and passes the resultant controlled variable to a voltage source (designated U), which in turn applies the adjusted value to the electrochromic element. According to the type of voltage source, either the controlled variable passed to the voltage source can be used directly as a measure of the voltage applied to the electrochromic element, or the latter can be determined with the aid of a separate measuring instrument, which is not illustrated. The controller, the measuring instruments and the voltage source combine to form a control unit for implementing the process according to the Invention. The controller comprises inter alia means for carrying out the necessary calculations (for example a microprocessor) for input and output of measured and controlled variables, and for storage of the control parameters, as well as of other variables, such as for example of the maximum current which has flowed I max .
The end of the complete colour-change process is reached when the current I flowing through the electrochromic element falls below a predetermined fraction of the maximum current I max which has flowed since the beginning of the colour-change process. The value of this ratio I/I max serving as a termination criterion is determined by the temperature T and the design of the electrochromic element, as well as the nature of the process taking place, that is to say colouring or bleaching. As the current I is measured continuously during the entire colour-change process, it presents no difficulty in determining a maximum value I max and for storing the termination criterion.
The process according to the Invention in its preferred embodiment can normally be divided into three stages, as illustrated in FIG. 4 . The colour-change process commences with the starting stage designated Stage I, in which voltage U and current I are increased or reduced steadily, avoiding voltage or current peaks, until the voltage reached a specified final value U max . This is followed by Stage II, in which the voltage remains at the final value U max . Generally, Stage II takes the longest time of the colour-change process. Stage III, with current I reducing until it reaches a value corresponding to the termination criterion according to the Invention and voltage U reducing in magnitude, follows as soon as the upper limit of Relation (5) drops below U max . In the starting stage, the total resistance R ges , which is important for the moment of inception of Stage III and for the time characteristic of the voltage U to be obtained in this stage, is determined. The smooth, steady increase in the current I and of the magnitude of the voltage U in the starting stage also surprisingly ensures an evening out of the degree of colouration over the surface of the electrochromic element.
EXAMPLE
The Invention will be explained in its use for a completely bleached electrochromic element, where, on application of a positive voltage U, a current with positive polarity flows through the element, which leads to colouring of the element. Proceeding from a coloured state of the electrochromic element, a voltage U of negative polarity induces a current I of negative polarity, which leads to bleaching of the electrochromic element.
A suitable control unit, consisting of controller, voltage generator and measuring instruments in accordance with the schematic in FIG. 3 provides the necessary voltages and currents and continuously measures, preferably at regular intervals, the voltage U, the current I and the temperature T. In practice it has proved useful with colour-change times in the minutes range to measure the current I several times per second.
In the example chosen, the electrochromic element is in its bleached state. Between the connections of the electrochromic element, an open-circuit voltage U EC is measurable with the electrochromic element in zero-current state. Proceeding from this open-circuit voltage, a voltage U is applied to the electrochromic element, so that a current I, which leads to colouring of the element, flows. The voltage U is increased steadily and —apart from an initial stage with increasing slope of the current/voltage curve—preferably essentially in a linear relation to time. The current/voltage characteristic is in any case regulated in each case such that no current or voltage peaks occur. During this stage of increase of the voltage U, the values of the voltage applied to the electrochromic element U (t i ), U (t i+1 ) are determined at various moments in time t i , t i+1 . At the same moments in time, the current flowing through the electrochromic element I (t i ), I (t i+1 ) is measured in each case. From the pairs of variates:
ΔU=|U(t i )−U(t i+1 )|
and
ΔI=|I(t i )−I(t i+1 )|
a resistance value R ges (t i , t i+1 ) is determined. As soon as there is a sufficient number of resistance values to permit averaging, but at the latest on reaching the final value U max , the arithmetic mean is formed from the individual values R ges (t i , t i+1 ), and thus the total resistance R ges is calculated. The current I flowing through the electrochromic element is measured continuously from the beginning of the colouring process; the maximum value I max measured in this time is stored.
As soon as the voltage U reaches the final value U max , the starting stage (Stage I in FIG. 4) is completed. The final value U max is temperature-dependent. A simple relationship of the temperature dependence of the final value U max is obtained from the equation already stated above:
U max =A−B·T (1)
where T is the temperature. The parameters A and B must be determined in advance for each design of an electrochromic element. They are essentially independent of the area of the electrochromic element.
On reaching the final value U max for the voltage, Stage II commences (FIG. 4 ), in which the voltage U remains at or below the final value U max , if quickest possible colouring is desired. The current I is measured continuously by the control unit during Stage II as well. If at any point in time, a higher value for I is measured than was previously stored for I max , the higher value at this point is stored as I max . In addition, checking is carried out continuously based on the measured values for the current I, as to whether the upper limit according to Relation (5) is higher than the final value U max currently set for the voltage U. The value used in this Relation (5) for the maximum permissible voltage U eff effective electrochemically at the electrochromic layers 14 , 18 is not generally a constant, but varies in a similar fashion to U max as a function of temperature T. When it is found from Relation (5) that the upper limit established has dropped in magnitude below the final value U max , Stage II ends.
In the immediately following Stage III, Relation (5) now leads to limitation in magnitude of the voltage U to be applied to the electrochromic element. As the voltage U eff , which is effective electrochemically at the electrochromic layers 14 , 18 , can be influenced by means of the voltage U, the voltage U is regulated in Stage III such that U eff does not exceed the specified value U eff,max . The upper limit for the magnitude of the voltage U which is calculatable from Relation (5) is at all times during Stage III lower than the final value U max valid in Stage II as upper limit. As the current I influencing U eff according to Approximation Equation (2) varies as a function of time, that is to say normally decreases steadily towards the end of the colour-change process, U must constantly be corrected by the control unit. In the process, the voltage U is preferably adjusted to the upper limit steadily decreasing in magnitude according to Relation (5), in order to minimize the colour-change time. During Stage III, current I is also measured continuously for this purpose. In addition, the measured values for current I are used in this stage to establish when complete colouring is reached. This moment is reached according to the Invention when the current I drops below a specified threshold value in relation to the maximum current I max which has flowed. As soon as the control unit establishes that the end of Stage III has been reached, the voltage is switched off and thus the current flow through the electrochromic element terminated. The threshold value for I/I max generally dependent on temperature is determined by the design of the electrochromic element and by the process in progress (colouring, bleaching) and can be established beforehand by means of orientation trials.
The reverse process of bleaching essentially takes place as described previously. Starting from an open-circuit voltage U EC , which normally differs from that at the beginning of the colouring process, the voltage U is steadily reduced in the starting stage, that is to say at its maximum in this case up to a negative final value U max , whose magnitude may differ from that for the colouring process. This is followed by Stage II, in which the voltage remains at the final value U max until the upper limit from Relation (5) becomes lower in magnitude than U max . In the final stage III, the voltage U increases successively, that is to say decreases in magnitude, until on account of reaching the switch-off criterion, which may differ from that for the colouring criterion, switch-off takes place. The bleaching process is completed, the electrochromic element is again in the same state as at the beginning of the example.
FIGS. 5 and 6 show for an electrochromic element with the dimensions 70 cm·100 cm the characteristic curve respectively of a complete colouring and bleaching process at room temperature, where the voltage U and the current I have been plotted in each case as a function of the time t. The electrochromic element (see FIG. 1) incorporated two glass substrates 10 , 22 provided with transparent electrode layers 12 , 20 of ITO (indium tin oxide) with a surface resistance of approximately 10 ohms. On the electrode layer 12 was applied an electrochromic layer 14 of WO 3 , with a thickness of approximately 300 nm, whilst on the electrode layer 20 was also arranged an approximately 300 nm thick ion storage layer 18 of cerium titanium oxide. As ion-conductive layer 16 , a polymer electrolyte according to WO 95/31746 was used, with a thickness of 1 mm. The electrical connections 24 , 26 in the form of metal strips were applied along the longer element sides diagonally opposite one another and joined conductively to the corresponding electrode layers 12 , 20 . The parameters necessary for control according to the Invention of the colouring process and the bleaching process were determined using a series of preliminary tests (cyclic voltammetry, cyclic colour-change at various temperatures over up to 1000 cycles on electrochromic elements of the same design). For U eff,max , cyclic voltammetric trials for both types of colour-change processes provided magnitudes of 2 V (20° C.) or 1 V (80° C.), from which magnitudes for other temperatures can be determined by linear extrapolation. Proceeding therefrom, the magnitudes of U max at 20° C. as being 3.5 V and at 80° C. as being 2 V were determined with the aid of further systematic tests as described above. This provided the magnitudes of the parameters A and B for Equation (1) as A=4 V and B=0.025 V/° C. (temperature T in ° C. ), that is to say U max =4 V−0.025 V/° C. ·T for the colouring process and U max =−4 V+0.025 V/° C. ·T for the bleaching process. From FIGS. 5 and 6 , it can be seen that the voltage U starting in each case from an open-circuit voltage of approximately−0.7 V (colouring) and+0.7 V (bleaching) was steadily increased or respectively reduced, where the starting stage was completed in the case of the colouring process after approximately 16 seconds, and in the case of the bleaching process after approximately 12 seconds by reaching the final value U max of 3.5 V and−3.5 V respectively. The voltage U was subsequently maintained for approximately 75 seconds at this value until the current had reduced to the extent that the upper limit from Relation (5) dropped in magnitude below U max . The correction variable D from Relation (5) had the value of 1. In Stage III, the voltage U was adjusted to the gradually decreasing upper limit according to Relation (5). The current I had reached its maximum value I max =460 mA in each case at the end of the starting stage. Stage III was completed in both cases when I/I max fell below 20%, which in the case of the colouring process was after approximately 95 seconds and in the case of the bleaching process was after about 100 seconds. At a temperature of 80° C., the switch-off ratio I/I max was 50%.
The features of the Invention disclosed in the Specification, in the Drawing and in the Claims can be essential both individually and in any combination for the implementation of the Invention.
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A process is disclosed for driving an electrochromic element which consists of at least the following layers: a first electrode layer; a first layer in which ions can be reversibly intercalated; a transparent ion-conducting layer; a second layer in which ions can be reversibly intercalated; and a second electrode layer. One of the layers in which ions can be reversibly intercalated is an electrochromic layer and the other layer acts as a counter-electrode to the electrochromic layer. A voltage with values in a redox stability range of the electrochromic layer system is applied to the electrode layers and causes a change in color. The process is characterised in that the current (I) which flows through the electrochromic element is continuously measured. During a starting phase of the change in color, the voltage (U) rises or diminishes continuously to a maximum, predetermined, temperature-dependent end value (U max ). The extent to which the end value depends on the temperature varies with the model of the electrochromic element, but not with the surface area of the electrochromic element which changes color. During the change in color, the voltage (U) is controlled depending on the current (I) and does not exceed the end value (U max ).
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BACKGROUND OF THE INVENTION
This invention is directed to an oil boom and method of deploying and retrieving the same for an open sea skimmer barge for the removal of crude oil, refined hydrocarbon product or other floating pollutant slicks for water surfaces, particularly those slicks caused by accidents while handling, transporting, processing, controlling, producing or exploring for hydrocarbons.
For many years, crude oil and refined hydrocarbon product spillages at sea have been a problem. The environment damage and cleanup costs of large spills can reach millions of dollars, which along with damaging publicity present a serious problem for the industries involved. As more crude oil and refined hydrocarbon products are being transported over longer distances by larger tankers, and with the increases in offshore hydrocarbon exploration and production, the problem of dealing with spillages is likely to increase.
Since crude oil and refined hydrocarbon product spillages are likely to continue at an ever increasing rate, a method and apparatus are needed for reliably removing the spillages as rapidly as possible from the surface of the water in open seas or large bays, lakes and rivers.
Slicks in the open sea vary considerably in their characteristics depending upon the type of crude oil or refined hydrocarbon product spilled, the weather, size of the spillage and the condition of the sea. The slick thickness may vary on the surface of the sea and be considered as having a portion extending below the surface of the sea due to the continual degradation of the slick by the elements and natural evaporation of the hydrocarbons.
When compared with the problems of recovering spillages in quiet, calm seas, bays, harbors or rivers, the recovery of spillages in the open sea, particularly under adverse weather conditions, is clearly more difficult. Open sea spillage recovery requires equipment which must be self-contained, capable of maintaining its station over long periods of time and capable of operating in adverse weather conditions, such as in seas of eight feet or more. Frequently in the past, many types of spillage recovery equipment have only been effective in relatively calm conditions and were intended for short term operation.
To date, many types of methods and apparatus have been used in attempts to deal with spillages.
Detergents and other chemical treatments of slicks have been and continue to be utilized, but each has limitations and inherent hazards which can be as undesirable as the slicks themselves.
In the past to confine spillages in specific areas, floating containment booms were often deployed. The floating booms were either an inflatable type or had buoyant materials secured thereto and had permeable or impermeable barriers extending below the surface of the water.
Other types of floating containment booms often employ storage or deployment devices for the handling and storage thereof. Such typical types of containment booms are shown in U.S. Pat. Nos. 3,532,219; 3,563,036; 3,664,504; 3,679,058; 3,922,860; 4,076,624; 4,089,178; and 4,123,911.
Yet other types of floating containment booms are utilized to collect and direct spillages on the surface of the water to a skimming device being towed by the vessel for the removal of the spillage. Such typical types of containment booms and skimming devices are shown in U.S. Pat. Nos. 3,612,280; 3,653,510; 3,710,943; 3,983,034; 4,116,833 and 4,133,765.
Another type of prior spillage removal equipment employing endless belt transports, such as those described in U.S. Pat. Nos. 3,314,540 and 3,314,545, are considered by their design to have a limited capacity to collect floatage of both solid and liquid forms of the spillage. More particularly, some prior constructions depend on the adherence of floatage to the belt transport to recover solid and liquid floating material of the spillage. Others provide structures that push the spillage to recover the same, and still others require pumps to enhance the collection of floatage, such as the belt transport sold by Marco Pollution Control, Seattle, Wash. Yet others tend at least to partially bulldoze the spillage being recovered, which increases the likelihood that some spillage will be pushed to the side and hence not collected.
Another prior skimming type spillage recovery equipment utilizes a submerged forward lip or edge and processes all the inflow, whether floatage to be removed or the liquid spillage being skimmed, which is above the shelf edge. This type of recovery equipment generally takes in the floatage and liquid spillage which is above the shelf edge, and hence leaves floatage and liquid spillage uncollected where there is a considerable depth thereof. This type of arrangement is illustrated in U.S. Pat. Nos. 3,690,464; 3,875,062 and 3,823,828. This skimming equipment illustrated utilizes the forward velocity of the vessel and the pumping or suction action of either the vessel's propulsion means or a separate pumping means to help enhance the flow of spillage over the submerged forward lip. Wave action will affect this type of skimming equipment since heavy seas will cause the excessive inflow of water with the spillage since the control of the depth of the forward lip below the surface of the water is difficult. With the excessive inflow of water with the spillage, it will also become more difficult to subsequently separate the spillage therefrom, thereby requiring other types of separation equipment or much larger on-board holding tanks for the excessive water and spillage.
Yet another prior skimming type spillage recovery equipment utilizes a downwardly inclined member having a horizontal slot or opening at the lower end thereof to force the slick downwardly during the passage of the inclined member thereover and into the slot or opening due to the pressure differential created by the buoyancy of the slick. The pressure differential may be increased to ensure the slick will flow into the slot or opening through the use of pumps to decrease the pressure within the cavity fed by the slot or opening. Typical examples of this type of equipment are described in U.S. Pat. Nos. 3,465,882; 3,615,017; 3,715,034; 3,860,519 and 3,966,615 and published U.K. Patent Application No. GB 2,005,554. In this type of skimming equipment the skimmer may be stationary having a flowing body of water moving thereby, as in U.S. Pat. No. 3,465,882, may be self-propelled through the water utilizing a reduced collection tank pressure, as in U.S. Pat. No. 3,615,017, may be self-propelled utilizing a variable flap to control the slot or opening width and merely utilize a gravity settling technique in the collection tank, as in U.S. Pat. No. 3,715,034, or may be self-propelled utilizing a reduced collection tank pressure and a wave-receiving splash plate on the bow thereof, as in published U.K. Patent Application No. GB 2,005,554. This type of spillage recovery equipment requires relatively high velocities downwardly along the inclined member of the spillage relative to the inclined member, i.e., for example, five to ten knots, for most efficient operation and also has a tendency to sidewardly deflect a portion of the spillage, even with the addition of vertical extensions along the inclined member to prevent the same. As with the submerged forward lip type skimming equipment, this type of equipment suffers performance degradation in heavy seas since it is difficult to control the height of the inclined member with respect to the wave height. Also, since in open sea skimming operations high forward velocities are required to maintain the high velocities of the spillage downwardly along the inclined member with respect to the inclined member, sideward deflection of the slick and splashing of the slick over the bow of the vessel and large bow waves created by pushing and churning of the spillage, even in calm seas let alone heavy seas, are a problem.
Still another type of spillage recovery equipment utilizes a rotating downwardly inclined endless belt to force the slick downwardly during the passage of the belt thereover and into a collection tank due to the pressure differential created by the buoyancy of the slick as it is depressed. Such equipment is illustrated in U.S. Pat. Nos. 3,314,540; 3,804,251; and 3,812,968. While not necessarily requiring high forward velocities for skimming operations, such velocities can be artificially created by increasing the rotational speed of the belts. For open sea skimming operations this type of equipment may require the use of many rotating endless belt assemblies, may have problems operating in heavy seas due to the inability to compensate for wave height variation thereby having waves break over the vessel on which the equipment is installed, and may sidewardly deflect portions of the slick during operations thereby lowering the effective skimming efficiency of the device.
Other types of recovery equipment utilize a combination of slick separation techniques in order to remove as much water from the spillage in order to reduce handling and storage problems on board the equipment. One such device having an initial submerged forward lip to skim the slick, a plurality of rotating drums to further separate the water from the slick and a gravity settling processing tank to further separate the water from the slick is illustrated in U.S. Pat. No. 3,700,107. Another such device having an initial suction type skimming device, a further gravity settling tank for a secondary water and slick separation means and finally a centrifugal type separating means is illustrated in U.S. Pat. No. 3,957,646.
SUMMARY OF THE INVENTION
The open sea skimming barge of the present invention is self-contained, capable of maintaining its station over extended periods of time, capable of operating in adverse weather conditions and utilizes a multiplicity of separation techniques to ensure the most efficient recovery of open sea spillages. The open sea skimming barge of the present invention utilizes a unique containment boom arrangement, spillage suction tunnel having an integral variable flap therein for initial separation of spillage into a collection tank, a secondary recovery means for further separation of the spillage in the collection tank and a tertiary recovery means for the final separation of the spillage for subsequent storage in holding tanks for offloading.
The present invention and the advantages thereof will be better understood when taken in conjunction with the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the open sea skimmer barge of the present invention.
FIG. 2 is a partial cutaway side view of the open sea skimmer barge of the present invention.
FIG. 3 is a partial plan view of the main deck of the open sea skimmer barge of the present invention.
FIG. 4 is a cross-sectional view along line 4--4 of FIG. 3.
FIG. 5 is a cross-sectional view along line 5--5 of FIG. 3.
FIG. 6 is a cross-sectional view along line 6--6 of FIG. 3.
FIG. 7 is a plan view of the main deck of the open sea skimmer barge of the present invention.
FIG. 8 is a partial plan view of the main deck of the open sea skimmer barge showing various lines for oil boom deployment of the present invention.
FIG. 9 is a side view of one end of the oil boom of the present invention.
FIG. 10 is a side view of the partial line attachment for one end of the oil boom of the present invention.
FIG. 11 is a cutaway side view of the deployed oil boom of the present invention and its attachment to the open sea skimmer barge.
FIG. 12 is a schematic diagram of the line attachment for securing one end of the oil boom of the present invention to the open sea skimmer barge.
FIG. 13 is a top view of the deployed oil booms of the present invention and their relationship to the open sea skimmer barge.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the open sea skimmer barge 10 of the present invention is shown in its preferred embodiment.
The open sea skimmer barge 10 comprises a hull 12 having a raked bow 14 and transom stern 16, deckhouse 18, cranes 20, helideck 22, control tower 24, skimmer control tower 26, oil booms 28 and life boats 30.
The main deck 32 of the hull 12 is constructed having no camber or shear and the bottom 34 of the hull 12 is constructed having no deadrise. The hull 12 is further constructed having a bilge radius, having rub rails 36, having a plurality of suitable fenders 38 thereabout, having retractable bow thrusters 40 on each side of the raked bow 14, having a transverse stern thruster 42 (see FIG. 8), having aft ramps 44 for the deployment and retrieval of the oil booms 28, having oil boom storage supports 46 on the port and starboard side thereof for the storage of the oil booms 28 when not in use, and a centerline entry slot 48 (see FIG. 8) at the transom stern 16 for the entry of the spillage into the hull 12.
The hull 12 further contains various compartments and equipment not shown in FIG. 1 which will be described hereafter.
Referring to FIG. 2, the open sea skimmer barge 10 is shown in a partial cutaway view showing one of the aft ramps 44 for the deployment and retrieval of the oil booms 28. The aft ramps 44 extend along a portion of aft portion of the hull 12 on either side thereof. The aft ramps 44 provide a surface along which the oil booms 28 may be transported from their storage position on oil boom storage rails 46 when the booms 28 are being deployed and retrieved.
The aft ramps 44 terminate along the aft portion of the hull 12 having the ends 50 of the ramps 44 being arcuately shaped for the guidance of the booms 28 with respect to the hull 12 when the open sea skimmer barge 10 is not loaded and at an even keel.
When the booms 28 are deployed, to control the relationship of the boom height with respect to the stern 16 to compensate for draft changes of the barge 10, the lines securing the boom 28 to the barge 10 are positioned about a guide roller 52 which is movably retained in track 54. The guide roller 52 may be vertically adjusted with respect to the hull 12 by any suitable means secured thereto, such as a pair of traveling nuts mounted on a powered screw-threaded member secured in slides.
Referring to FIG. 3, a partial planform view of the main deck of the open sea skimmer barge 10 is shown.
As shown, each aft ramp 44 supports a portion of a track 56 which extends throughout approximately the entire length of the barge 10 being supported by oil boom storage supports 46 where not secured to the aft ramp 44.
Referring to FIG. 4, the oil boom 28 is shown being supported by the track 56 which is, in turn, supported by brackets 58 secured to the side walls of an aft ramp 44. As shown, the bottom of the oil boom 28 is provided with sufficient clearance to permit the free movement of the boom 28 along each aft ramp 44 without interfering therewith.
Referring to FIG. 5, the oil boom 28 is again shown being supported by the track 56 which is, in turn, supported by brackets 58 secured to the side walls of an aft ramp 44.
Referring to FIG. 6, the oil boom 28 is shown being supported by the track 56, which is, in turn, supported by brackets 60 secured to an oil boom storage support 46. As shown, the bottom of the oil boom 28 is provided with sufficient clearance to permit the free movement of the boom 28 along the main deck 32 without interfering therewith during deployment and retrieval operations.
Referring to FIGS. 1 through 6, it can be easily seen that each oil boom 28 comprises a plurality of boom floats 500 having transverse supports 502 secured thereto having, in turn, rotatable wheels 504 thereon which are received in the tracks 56, flexible members 506 interconnecting the boom floats 500, impermeable boom apron 508 secured to the bottom of boom floats 500 and flexible members 506 and permeable boom apron 510 secured to the bottom of impermeable boom apron 508 having a suitable line 514 retained within the bottom 512 of the permeable apron 510.
Running through the boom floats 500 is a line 516 suitable for use in towing operations of the open sea skimmer barge 10.
The first boom float 500' has an attachment means 518 secured thereto which is, in turn, secured to line 516, impermeable apron 508, permeable apron 510 and line 514. An attachment ring or other suitable means is included on end 520 of attachment means 518 for a line from a suitable towing means to be secured thereto.
The line 514 contained within the bottom 512 of the permeable apron 510 is utilized to weight the aprons 508 and 510 to maintain them in a submerged state and provide stability to the oil boom 28 during skimming operations.
Referring to FIG. 7, the main deck 32 is shown in planform. As shown the main deck 32 has a plurality of pedestal cranes 20 located thereon to assist in loading and unloading operations of the open sea skimmer barge 10. The winches 62 to assist in line handling operations and a plurality of washing units 64 for cleaning operations, particularly in the deployment and retrieval of the oil booms 28. The stern portion of the main deck 32 further includes the base portion of the skimmer control tower 26, which is utilized for deck observation, communication, skimmer control and storage purposes.
Forward of the stern portion of the main deck 32 are a plurality of observation hatches 66 which allow the observation of the spillage contained within the forward portion of the oil collection tank therebelow.
Located approximately amidship inboard of the cranes 20 thereat are teritary oil separation means 82 which may be of any suitable separation device, such as a gravity, electrostatic or centrifuge type separation device.
Located outboard of the tertiary oil separation means 82 are washing means 64 which assist in the cleaning of the oil booms 28 during retrieval and storing of the booms 28 on storage supports 46 (not shown.)
Forward of the cranes 20 and tertiary oil separators 82 is the main deck portion of the deck house 18. The main deck portion of the deck house 18 includes storage area 84, workshop 86, locker room 88, stairwell 90, storage room 92, laundry 94, pipe chase 96, equipment removal trunk 98, auxiliary generator 100, air handling equipment area 102, refrigerated storage 104, dry storage area 106, supply storage 108, galley 110, supply storage 112, mess 114 and stairwell 116 leading to below decks.
Located outboard of the main deck portion of the main deck 32 near the bow 14 of the open sea skimmer barge 10 are bow thruster hatches 118 which allow access to the retractable bow thrusters 40 located therebelow.
Located on the bow portion of the main deck 32 are oil boom winches 120, anchor winch 122, chemical dispensant storage tanks 124, jet fuel storage tanks 126 and anchor 128.
Located at various positions on the port and starboard sides of the main deck 32 are a plurality of padeyes 130, bitts 132 and cleats (not shown).
Forward of the observation hatches 66 is a deck storage compartment 68 for the storage of equipment or stores therein.
On the forward side of the storage compartment 68 are a plurality of filter belt hatches 70 which allow access to the secondary filter belt separation means 230 (not shown) located in the oil collection tank 144 therebelow.
Forward of the filter belt hatches 70 are a plurality of sump hatches 72 which allow access to the sump 150 for the secondary oil separation means 230 (not shown) located in the oil collection tank 144.
Forward of the sump hatches 70, located on the port and starboard side of the open sea skimmer barge 10, are auxiliary boom winches 74 which assist in the deployment and retrieval of the oil booms 28.
Slightly aft and outboard of the auxiliary boom winches 74 are washing units 64 which are utilized to clean the oil booms 28 when retrieving and storing the booms 28 on storage supports 46 (not shown).
Forward of the auxiliary boom winches 74 are a plurality of pump hatches 76 which allow access to the pumping means therebelow, while forward of the pump hatches 76 and aft of the cranes 20, located amidship of the open sea skimmer barge 10 on the port side of the barge 10, is an escape scuttle 78, and located on the starboard side is an enclosed stairway 80 leading to below decks.
BOOM DEPLOYMENT PROCEDURE
Referring to FIG. 8, a partial plan view of the deck 32 of the open sea skimmer barge 10 is shown.
To deploy the oil boom 28, a line 600 is attached to one end of the oil boom 28. A line "A" from a bow winch 120 (see FIG. 1) is secured to the other end of the oil boom 28 and is let out while the oil boom 28 floats out. When the last boom float 500 of oil boom 28 passes winch 74 on the main deck 32, the play out of line "A" is halted.
At this point, lines "B" and "C" from winch 74 are attached to the end of oil boom 28 and line "A" is detached therefrom and taken in on bow winch 120.
Referring to FIG. 9, the deployment of the end of oil boom 28 is shown where lines "B" and "C" are attached thereto.
As shown, line "A" running to bow winch 120 has been disconnected from ring 602 while lines "B" and "C" have been connected thereto. Ring 602 also has connected thereto lines 604 and 516 respectively extending through the center and bottom of permeable apron 510 and the oil boom 28. Secured to the end of line 516 running through the boom floats 500 is ring 606 to which one end of line 604 is secured.
Also secured to ring 606 at this time is line "D" which runs to winch 62 located on the stern portion of the main deck 32.
It should be noted that line "C" is passed under adjustable roller 54 before securing the line "C" to ring 602 so that when the oil boom 28 is fully deployed, line "B" will pass over the top of the adjustable roller 54 while line "C" will pass under adjustable roller 54 thereby permitting the adjustable roller 54 to control the relationship between the end of oil boom 28 with respect to the stern 16 of the open sea skimmer barge 10. During the deployment of the oil boom 28 having lines "B" and "C" secured thereto as well as line "D" from the open sea skimmer barge 10, line "C" is taken in on winch 74 while line "B" is being played out.
Referring to FIG. 10, while the oil boom 28 is being launched and line "C" is being taken in, line "E" is secured having one end fastened to ring 608, which is at an intermediate position in line "C" at a location on the main deck 32, while the other end is fastened to a pad eye 130 on the main deck 32 of the open sea skimmer barge 10.
The line "E" is attached to a pad eye 130 on the main deck 32 and line "C" is let out from the winch 74 until tension from the boom floats 500 (not shown) is indicated on line "E".
Referring to FIG. 11, the relationship between the end of the oil boom 28 and the roller 54 is shown. When the boom floats 500 are fully extended in the sea, line "D" is taken in by winch 62 on the stern portion of the main deck 32 until the boom float 500 on one end of the oil boom 28 is lightly touching the outboard side of the aft ramp 44. At this time, the height of roller 54 may be adjusted to achieve the proper trim of the end of the oil boom 28 with respect to the open sea skimmer barge 10.
Referring to FIG. 12, the position and attachment of the various lines are shown. As can be easily seen to conveniently releasably attach the various lines to the rings 602 and 608, as well as at any other points, shackles 610 are utilized.
Referring to FIG. 13, the oil booms 28 are shown in their deployed position. When deployed the oil booms 28 have vee lines 612 attached thereto in the portion of the oil booms 28 adjacent the stern 16 of the open sea skimmer barge 10.
The vee line 612 adjacent the stern 16 of the open sea skimmer barge 10 has tag lines 614 running to pad eyes 130 on the stern portion of the main deck 32, as well as line 616 running to winch 62 located on the centerline of the barge 10 on the stern portion of the main deck 32.
As described previously, shackles are utilized at all connections of the various vee lines 612, tag lines 614 and winch line 616 to the oil booms 28 or each other for the ready attachment or release thereof.
Also shown are suitable towing vessels 5, such as tug boats, each having one end of the oil boom 28 secured thereto.
It should be understood that the various vee lines 612, tag lines 614 and winch line 616 are secured to the boom floats 500 at suitable positions and to each other when the oil booms 28 are being deployed and as the various winch lines "A", "B", "C" and "D" and line "E" are being attached to the oil booms 28.
Referring in general to FIGS. 8 through 13, the recovery of the oil booms 28 will be described.
Initially to recover the oil booms 28, tension is taken up on line "C" by actuating winch 74 and line "E" is detached from the pad eye 130 on the main deck 32. Subsequent to the detachment of line "E", line "B" is taken up on winch 74 while line "C" is played out from winch 74 and line "B" is played out by winch 62 on the stern portion of the main deck 32.
When the boom float 500 on one end of the oil boom 28 is adjacent the winch 74, line "D" is detached from ring 606 which is attached to boom float 500 and line "D" is taken up on winch 62. At this time, line "A" is let out by winch 120 and attached to ring 602 and lins "B" and "C" are removed therefrom. Tension is taken in on line "A" by winch 120 to draw the oil booms 28 along track 56 which runs along aft ramps 44 and boom supports 46. For storage, lines "B" and "C" are connected together with shackles and slack is taken up on line "C" by winch 74.
The winch 120 takes in line "A" until the boom float 500 on the end of oil boom 28 is located at the boom support 46 adjacent the winch 120 and the line running to the towing means 5 is detached from the other end of the oil boom 28. In this position the oil booms 28 are stored on boom supports 46 along either the port or starboard side of the open sea skimmer barge 10.
During the recovery of the oil booms 28, the vee lines 612, tag lines 614 and winch line 616 must also be recovered. To recover these lines the cranes 20 on the stern portion of the main deck 32 are utilized.
As the oil booms 28 are recovered and the vee lines 612 are within the reach of the cranes 20, the cranes 20 are extended over the stern 16 of the open sea skimmer barge 10 having grappling hooks on the lines running therefrom to lift the vee lines 612 from the sea. When on the main deck 32, the tag lines 614 and winch line 616 are disconnected from the initial vee line 612 and stored. With each subsequent vee line 612, the procedure is repeated with the lines being stored after removal from the oil booms 28.
It should be understood that during the recovery of the oil booms 28, the cleaners 64 on the main deck 32 are utilized to clean the oil booms 28 and the various lines.
Those skilled in the art may recognize additions, deletions, substitutions and modifications which may be made with respect to the oil booms, their method of deployment and retrieval and the open sea skimmer barge but which lie within the purview of the invention as defined by the appended claims.
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Oil boom for an open sea skimmer barge comprising a hull having a bow, bottom, side walls, stern having a substantially elongate slot extending across a portion thereof and a deck, a spill suction tunnel, a collection tank, secondary oil separation means and tertiary oil separation means.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] The collapsible expansion joint relates generally to pavement, and more specifically, to a joint extending the full depth of a slab and that remains below the top of the slab during lateral compression.
[0002] Since the time of the Romans, owners and contractors have made structures of all kinds with concrete. Concrete has been made into walls that stand upright, slabs that lay flat, and structural members that connect walls and slabs. Because concrete requires a time to set and forms must be constructed, concrete structures are often assembled in sections. Adjacent sections of concrete meet at joints.
[0003] Concrete also endures the elements and the environment, such as temperature and moisture. As with other materials, concrete expands and contracts as the ambient temperature rises and falls. At a joint, two sections of concrete expand towards each other in warmer temperatures and pull away from each other in colder temperatures. In hot temperatures, adjacent concrete sections abut upon a joint and may rise upwards creating a ridge. Such ridges can impede traffic upon slabs or crack walls. In cold temperatures, a joint widens between adjacent concrete sections allowing contaminants to fall within the joint. Then moisture introduced in a joint can damage adjacent concrete sections particularly in cold weather. In colder weather, moisture in a joint freezes and in doing so expands. When expanding, ice can split concrete and degrade a joint. Deicing compounds applied to concrete also infiltrate a joint under the action of moisture and chemically degrade the concrete over time.
[0004] A common location for joints is in slabs, such as roads or driveways adjacent to walls. Roads are constructed by slabs of concrete placed to meet concrete setting criteria and the limits of construction schedules. Day by day, a contractor and its labor force form and place concrete in slabs that accumulate over a project into a road. Adjacent slabs have a joint between them that requires filling. The joints generally extend across the travel lanes of a road and along the centerline. The joints are filled to prevent introduction of moisture and contaminants therein and to permit expansion and contraction of the slabs. Where a driveway meets a wall, a slab encounters upright concrete. The slab and wall expand and contract perpendicular to each other. Often the slab expands into the wall causing the wall to tip and to crack and perhaps weaken structurally. A joint between the driveway and the wall allows the driveway to expand with less risk of cracking an adjacent wall.
DESCRIPTION OF THE PRIOR ART
[0005] Presently, joints in concrete are filled with various materials. Contractors use wooden boards, fiberboard, epoxy, plastic, rubber, tar, asphalt and other resilient but compressible materials. These materials are placed into a gap, or joint, between adjacent concrete sections and the sections compress the materials when they expand. At high temperatures, the expanding sections may exude the compressible material upwards from the joint which vehicles bump over in summer. In extremely high temperatures, ridges form at joints that require chipping, sawing or other removal methods and then replacement. On the other hand, the materials may reopen a gap when the sections contract in colder temperatures. A reopened gap permits the entry of moisture and chemicals that degrade the concrete over time. In colder climates, snow plows scrape over joints and cause damage to them in various degrees.
[0006] In some cases, joints are made by placing a board or other material in setting concrete. The board extends from the top into the slab for less than the full depth of the slab. During temperature fluctuations, the adjacent slabs expand and contract while flexing the concrete below the board. In time, the concrete below the board crumbles and the board sinks to expose the joint to moisture.
[0007] The present invention overcomes the limitations of the prior art explained above. The present invention extends for the full depth of a joint in two adjacent concrete sections and connects to the sections to prevent the invention from rising upward or sinking downward between two sections. That is, the art of the present invention provides a full depth joint that does not erupt upwardly from the joint under the thermal expansion and contraction of concrete slabs.
SUMMARY OF THE INVENTION
[0008] Generally, the present invention provides an elongated joint that connects to adjacent concrete sections, usually slabs, and that remains below the top surface of the slabs during temperature fluctuations of the slabs. The joint has a grooved top surface and an opposite keyed bottom, and two mirror image spaced apart sides. The top, bottom, and sides form a generally rectangular cross section. Within the joint, upright risers, flat braces, and angled knees provide stiffness to the joint yet allow bending to withstand expansion and contraction of adjacent slabs. The joint has a generally symmetrical cross section. Upon the sides and bottom, the joint has keys that connect the joint to adjacent slabs.
[0009] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and that the present contribution to the art may be better appreciated.
[0010] Further, the present invention also includes knees and a riser that stiffen the top for vehicle loads, rounded keys that reduce the requirement for vibration of setting concrete, and a raised key that permits lateral movement of the joint as adjacent slabs compress it.
[0011] Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of the presently preferred, but nonetheless illustrative, embodiment of the present invention when taken in conjunction with the accompanying drawings. Before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0012] It is, therefore, the principal object of this invention to provide a collapsible expansion joint for concrete slabs that extends for the full slab depth and does not rise above the top of the slab.
[0013] Another object of this invention is to provide a collapsible expansion joint that folds downward when compressed from the sides.
[0014] Another object of this invention is to provide a collapsible expansion joint with a mechanical connection to adjacent concrete slabs that prevents the joint from rising upwards.
[0015] Another object of this invention is to provide for a collapsible expansion joint with a bottom that folds upwards into the joint to prevent contacting the subgrade.
[0016] Another object of this invention is to provide for a collapsible expansion joint with a low cost of manufacture so that the consuming contractors may obtain the joint.
[0017] Lastly, it is an object to provide a collapsible expansion joint with a grooved top that folds downwards into the joint and that directs water and debris lengthwise off of the joint.
[0018] These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In referring to the drawings,
[0020] FIG. 1 shows an isometric view of present invention installed between two slabs of pavement in accordance with the principles of the present invention; and,
[0021] FIG. 2 describes an end view of the present invention showing the interior members before compression by adjacent slabs.
[0022] The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The present art overcomes the prior art limitations by having a durable compressible joint secured between two slabs or a slab and a wall for the full depth of a slab with the slab resting upon a subgrade or lower foundation. For ease of description, FIG. 1 shows the preferred embodiment of the collapsible expansion joint 1 emplaced between two slabs C. The joint may be used where two other concrete sections abut following the same principles and description herein provided for abutting slabs C. For sidewalks, driveways abutting garages, some runways, and roads, concrete is used as a durable pavement that resists the elements and turning vehicles, and has a long life span and low maintenance costs. FIG. 1 shows two adjacent slabs as in a road. The slabs C have a depth and an expansion spacing as specified in the construction documents. The expansion spacing is occupied by the joint 1 .
[0024] The joint 1 is generally an elongated hollow member with a cross section that appears somewhat rectangular. The joint can be made to any length by extrusion or other means. The length of the joint matches the length of the expansion spacing between the slabs. The expansion joint of the present invention has sufficient rigidity and stiffness to remain upright. The expansion joint also can serve as formwork for the placement of plastic concrete or other pavement materials, a straight edge for bull floating tools and other pavement finishing tools, and can support tools, personnel, and light equipment for other construction and maintenance activities.
[0025] The description continues upon the cross section of the joint that is used throughout the length of the joint. In cross section, the joint has a top 2 , generally at the elevation of the surface of the adjacent slabs. The top has a centered groove 3 running the length of the joint. The groove 3 denotes the low part of the top and directs the halves 2 a of the top to fold downwards when the joint is compressed by the expanding slabs. Opposite the top, the joint has a bottom 4 . The bottom has a raised center portion 5 that guides the bottom to fold upwards when the slabs expand. In folding upwards, the bottom limits pressing into the subgrade. Connecting the top and the bottom, two spaced apart and symmetric sides 6 abut the faces of the adjacent slabs. The sides are generally the longer portion of the rectangular joint cross section. The sides have a key 7 , here shown as concave, generally centered that permits concrete to enter within the outer shape or limits of the cross section. When that concrete sets, the key prevents removing the joint from between the slabs. Inside of the top, the sides, and the bottom, the joint has a web of internal members that stiffen and support the joint under various loads.
[0026] The cross section of the collapsible expansion joint is shown in more detail with FIG. 2 . The joint has a top 2 , generally horizontal in an installed joint. The top has two halves 2 a that descend and extend towards the center of the top. The halves meet at the groove 3 that runs for the length of the joint. The groove is lower than the corners where the top meets the sides 6 . Opposite the top, the joint has the bottom. The bottom has two outer portions 4 , sloped downwardly and generally parallel to the top that have a raised key 5 centered therebetween. The raised key 5 is centered upon the bottom of the joint and has a concave shape, generally upwardly, as shown in FIG. 2 . In an alternate embodiment, the raised key 5 is a chevron shape, upwardly pointing, with straight members, as shown in FIG. 1 . The raised key allows the bottom to rise upwards when adjacent slabs expand into the joint during high temperatures. Spanning between the top and the bottom, the joint has two symmetric and spaced apart sides 6 . Each side has two outer portions 6 a located proximate to the top and the bottom respectively. The outer portions are generally coplanar and perpendicular to the top. Centered between the outer portions, the side 6 has a key 7 that extends into the joint in a generally concave shape. The key has the same thickness as the outer portions 6 a. Each key 7 allows concrete to set within the sides and prevent the joint from rising above adjacent slabs. Within the perimeter of the joint, internal members span between the top, the sides, and the bottom for a stiff but compressible joint.
[0027] The internal members are generally symmetric though offset designs of the internal members are possible. Here in FIG. 2 , the internal members begin with the first riser 8 . The riser has an narrow elongated shape that extends from the intersection of the raised key 5 with the bottom 4 . The riser extends substantially vertical, generally perpendicular to a half 2 a of the top 2 , and into the height of the key 7 . Above the first riser, a second riser 8 a continues in a narrow elongated shape from the first riser, also substantially vertical, generally perpendicular to a half. The second riser stops at the height of the upper end of the key 7 .
[0028] From the key 7 , a first brace 9 extends radially into the joint and is generally parallel to a half and perpendicular to the first riser. The first brace has a narrow elongated shape having a similar thickness as the first riser 8 . The first brace continues through the intersection of the first riser and the second riser into the center of the joint. Parallel to and spaced above the first brace, a second brace 9 a extends from the upper end of the key 7 where it intersects the outer portion 6 a into the joint generally parallel to the first brace. The second brace also has a similar thickness to the first brace. The second brace ends at a generally perpendicular angle to the second riser 8 a. Inside of where the half 2 a intersects with the upper outer portion 6 a, a first knee brace 10 spans at an angle to the vertical from the outer portion to the half. Here the first knee brace spans from the intersection of the second brace 9 a with the outer portion up and inward to the half 2 . Parallel and inward from the first knee brace, a second knee brace 10 a spans from the intersection of the second riser with the second brace at an angle to the vertical. The second knee brace ends at the centerline of the joint. Where the second knee brace ends, a third riser 9 b extends upwards to the top 2 generally beneath the groove 3 . As the joint is symmetric, each left and right half of the joint has a first riser, second riser, first brace, second brace, first knee brace, and a second knee brace, while having a third riser shared between the left and right halves of the joint. Generally, the internal members each have the same thickness as shown in FIG. 2 .
[0029] During use, the internal members respond to forces applied to the joint while preventing complete collapse of the joint. When a vertical load, such as a wheel load, is applied to the top, the halves fold downwards thus lowering the third riser, second knee brace, and first knee brace. Upon contact with the outer portions 6 a, the first knee braces and second knee braces stiffen the top. Meanwhile, the vertical load continues downward through the second knee braces and into the second riser and into the first riser. The first riser then transmits a portion of the vertical load to the raise key 5 and into the subgrade. When the adjacent slabs expand into the joint, the horizontal loads are applied to the sides. The sides transfer those loads into the outer portions, the first braces 9 , the second braces 9 a, the first knee brace 10 , and a half 2 . Under those loads, the raised key 5 moves upwards into the joint as the bottom sections, as at 4 , move inwards, the first brace folds downward at the centerline of the joint. The second brace 9 a also moves inward which raises the second knee brace and the third riser to stiffen the top. When lower temperatures cause the adjacent slabs to pull away from each other, the joint returns to its normal shape pulled outwards by the key. The joint supports vehicle loads in warm and cold weather using the internal members cooperating with the top, the bottom, and the sides of the present invention.
[0030] From the aforementioned description, a collapsible expansion joint has been described. The joint is uniquely capable of supporting loads while having a hollow construction and remaining in position between adjacent slabs using keys. The collapsible expansion joint and its various components may be manufactured from many materials including but not limited to polymers, EPDM, rugged plastics, textiles, ferrous and non-ferrous metals and their alloys, and composites.
[0031] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Therefore, the claims include such equivalent constructions insofar as they do not depart from the spirit and the scope of the present invention.
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An elongated joint connects adjacent concrete sections, usually slabs, and remains below the top surface of the slabs during temperature fluctuations. The joint has a grooved top surface and an opposite keyed bottom, and two mirror image spaced apart sides. The top, bottom, and sides form a generally rectangular cross section. Within the joint, upright risers, flat braces, and angled knees provide stiffness to the joint yet allow bending to withstand expansion and contraction of adjacent slabs. The joint has a generally symmetrical cross section. Upon the sides and bottom, the joint has keys that connect the joint to adjacent slabs. The joint can also serve as formwork for concrete.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/055,861, filed Aug. 15, 1997.
FIELD OF THE INVENTION
This invention relates to diamond impregnated drill bits. In one aspect, it relates to diamond impregnated drill bits with areas of differing wear resistance on the face of the bit.
BACK GROUND OF THE INVENTION
Diamond impregnated drill bits are used for boring holes in very hard or abrasive rock formations. The cutting face of such bits contains natural or synthetic diamonds distributed within a supporting material to form an abrasive layer. During operation of the drill bit, diamonds within the abrasive layer are gradually exposed as the supporting material is worn away. The continuous exposure of new diamonds by wear of the supporting material on the cutting face is the fundamental functional principle for impregnated drill bits.
The construction of the abrasive layer is of critical importance to the performance of diamond impregnated drill bits. The abrasive layer typically contains diamonds and/or other super-hard materials distributed within a suitable supporting material. The supporting material must have specifically controlled physical and mechanical properties in order to expose diamonds at the proper rate.
Metal-matrix composites are commonly used for the supporting material because the specific properties can be controlled by modifying the processing or components. The metal-matrix usually combines a hard particulate phase with a ductile metallic phase. The hard phase often consists of tungsten carbide and other refractory or ceramic compounds. Copper or other nonferrous alloys are typically used for the metallic binder phase. Common powder metallurgical methods, such as hot-pressing, sintering, and infiltration are used to form the components of the supporting material into a metal-matrix composite. Specific changes in the quantities of the components and the subsequent processing allow control of the hardness, toughness, erosion and abrasion resistance, and other properties of the matrix.
Proper distribution of fluid used to remove the rock cuttings and cool the exposed diamonds is essential for proper function and performance of diamond impregnated bits. The cutting face typically includes an arrangement of recessed fluid paths intended to promote uniform flow from a central plenum to the periphery of the bit. The fluid paths usually divide the abrasive layer into distinct raised ribs with diamonds exposed on the tops of the ribs. The fluid provides cooling for the exposed diamonds and forms a slurry with the rock cuttings. The slurry must travel across the top of the rib before reentering the fluid paths, which contributes to wear of the supporting material.
The manufacturing process for diamond impregnated bits usually involves placing prefabricated abrasive components and other abrasive or filler materials in a suitable mold. The mold is then infiltrated with an appropriate metal alloy, which binds the abrasive and other materials together. Subsequent finishing operations may include attachment of prefabricated abrasive components or appropriate threaded connections. Several alternative methods, including brazing or welding of prefabricated abrasive components may also be used to construct impregnated drill bits.
SUMMARY OF THE INVENTION
The present invention provides in one aspect, an adaptive matrix diamond impregnated drill bit for boring holes in rock formations that may have significant variations in hardness. The cutting faces of these bits contain an arrangement of different abrasive compositions, which allow adaptation to the different rock types. During operation of these bits, selective wear of specified areas improves the performance of the bit by adjusting diamond exposure to suit the rock formation. The use of different abrasive compositions to establish different diamond exposure in specified areas of the bit face is the primary functional principle for adaptive matrix impregnated drill bits.
The abrasive compositions for adaptive matrix bits contain diamond and/or other super-hard materials distributed within a supporting material. The supporting material may include a particulate phase of tungsten carbide and/or other hard compounds, and a metallic binder phase of copper or other primarily non-ferrous alloys. The properties of the resulting metal-matrix composite material depend on both the percentage of each component and the processing that combines the components. The size and type of the diamonds, carbide particles, binder alloy or other components can also be used to effect changes in the abrasive or erosive wear properties of the abrasive composition.
The primary difference between standard and adaptive matrix bits involves the use of two or more abrasive compositions in specific areas of the bit face. Standard bits sometimes use different abrasive compositions in concentric areas of the bit face. Adaptive matrix bits use two or more different abrasive compositions in alternating ribs or in staggered alternating zones of each rib.
The initial shape of the fluid passages and cutting ribs in the face of adaptive matrix bits is similar to standard impregnated bits. The difference in wear properties of the abrasive composition between alternate ribs or along each rib causes additional exposure of the diamonds in selected areas. The additional exposure or matrix relief in the selected areas increases fluid flow across the tops of the ribs, and provides improved cooling of the diamonds and cleaning of the cuttings. The magnitude of the additional relief or exposure is affected by the differences in the abrasive composition and the properties of the rock formation. The arrangement of different abrasive compositions to form specifically relieved areas within the cutting face is the significant improvement of adaptive matrix bits when compared to standard impregnated bits.
The mold used for construction of adaptive matrix bits is similar to the molds used for standard impregnated bits. Prefabricated blocks of abrasive material are placed in the mold at specified positions. The spaces between the blocks are filled with a different abrasive material, which may be in the form of prefabricated blocks or a moldable abrasive slurry. Several different abrasive compositions in the form of blocks or slurries can be arranged at specific locations in the mold using this general method. The specific combination of prefabricated abrasive components and/or moldable abrasive slurry allows precise construction of the detailed arrangement of different abrasive compositions used in adaptive matrix bits.
Additional discrete cutting elements, such as large natural diamonds or shaped synthetic diamonds can also be added to the cutting structure of the adaptive matrix bits. The added cutting elements may be placed directly in the mold, included within the prefabricated blocks, or attached to the bit after casting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial end view of the face of a prior art impregnated bit;
FIG. 2 is a partial sectional side elevational view of the head of a prior art bit;
FIG. 3 is a partial end view of the face of an impregnated bit made in accordance with the present invention;
FIG. 4 is a partial sectional side elevational view of the head of an impregnated bit of the present invention;
FIGS. 5-10 are partial sectional side elevational views of various embodiments of the present invention;
FIGS. 11-16 are partial end views of various embodiments of the present inventions;
FIGS. 17-20 illustrate various wear patterns on ribs made in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate partial views of a prior art impregnated bit, generally indicated by arrow 10. In FIG. 1, approximately one half of the circular face 11 is shown, with the other half being approximately the mirror image of the part that is shown. Similarly in FIG. 2, one half of the prior art bit body 13 is illustrated, with the other half, not shown being the mirror image of the part shown.
The bit body 13 is cylindrical in form, with the upper end thereof (not shown) forming a threaded pin which is adapted to be connected to the lower end of a drill string. The lower end of the bit body 13 forms the end face 11. The end face 11 has a plurality of elevated ribs 15 formed thereon, with channels 17 formed between the ribs 15.
The bit body 13 is preferably made of a steel core 12 having an outer shell 14 comprised of a carbide powder matrix material. The ribs 15, are made of a metal-matrix composite. The ribs 15 also have a quantity of synthetic or natural diamonds (not illustrated) embedded within the metal-matrix material. The metal-matrix combines a hard particulate phase with a ductile metallic phase. In the preferred mode, the hard phase consists of tungsten carbide and other refractory or ceramic compounds. Copper or other non-ferrous alloys are typically used for the metallic binder phase. Common powder metallurgical methods, such as hot pressing, sintering and infiltration are used to form the components of the supporting material into a metal-matrix composite. During drilling, as the bit rotates, the bit face 11 contacts the bottom of the borehole, which initially wears away the matrix material on the ribs 15 to expose the diamond particles. The diamond particles then function to wear away the bore hole formation as the bit rotates. The channels 17 function to allow drilling fluid to pass through a central plenum 19 from the interior of the bit body 13 and run along the channels 17 to cool the ribs 15 and to carry the formation cuttings up the annulus formed between the bit and the bore hole.
FIGS. 3 and 4 illustrate a bit, generally indicated by arrow 20, made in accordance with the present invention. The shape of the bit body 21, end face 23, ribs 25 and channels 27 are similar to the construction of the prior art bit shown in FIGS. 1 and 2. The difference in construction is that the ribs 25 include preformed portions 31 and slurry portions 32 made of a different composition than the other. Both compositions, making up ribs 25, include natural diamond or synthetic diamond particles embedded therein.
The composition slurry portion 32 preferably includes a particulate phase of tungsten carbide and/or other hard compounds, and a metallic binder phase of copper or other primarily non-ferrous alloys. The preformed portions 31 are made from the same basic constituents except that the percentages of each component is varied and the processing parameters are changed to form a support material having different properties, including wear properties. The size and type of the diamonds, carbide particles, and binder alloy can also be varied to effect changes in the abrasive or erosive wear properties of the abrasive composition. The information, given below, gives a matrix of the constituents that can be varied with size ranges.
The typical components and volume fractions of those components used in the abrasive composition are listed below:
Diagram 1: Materials
Diamond;
Natural or Synthetic Origin,
Sizes from 1 to 1000 stones per carat,
Fraction from 0.12 to 0.50 of total volume.
Hard Phase;
Tungsten carbide, chrome carbide (or other refractory compounds),
Sizes from 1 to 500 micron (typically a distribution of sizes),
Fraction from 0.0 to 75.0 of total volume.
Ductile Phase;
Tungsten, cobalt, iron or other metals,
Sizes from 0.5 to 500 micron,
Fraction from 0.0 to 0.50 of total volume.
Binder Phase;
Copper, Zinc, Tin, Manganese, Nickel, (and other metals),
Size 0.5 micron to 0.5 inch (used for sintering or infiltration),
Fraction from 0.12 to 0.88 of total volume.
The compositions are adjusted by the following criteria:
Increased fraction of the hard phases causes increased erosion resistance,
Increased hardness of the binder phase causes increased abrasion resistance,
Increased fraction of the ductile, and binder phases reduces wear resistance,
Increased diamond size for softer rock formations.
______________________________________Diagram 2: Example Compositions Ductile Diamond Hard Phase Phase Binder______________________________________For Soft Formations;Composition 1 20%, 4 spc WC, 30% 0% 50%Composition 2 25%, 20 spc WC, 50% 0% 25%For Medium Formations;Composition 1 25%, 20 spc WC, 30% W, 5% 40%Composition 2 30%, 80 spc WC, 45% 0% 25%For Hard Formations;Composition 1 25%, 80 spc WC, 30% W, 10% 35%Composition 2 33%, 300 spc WC, 42% Co, 5% 20%______________________________________
The abrasive compositions above can be produced by sintering or infiltration. In each of the examples above, Composition 1 will have lower erosion and abrasion resistance than Composition 2. During operation of the adaptive matrix drill bit, the metal matrix will wear more rapidly in the areas containing Composition 1. The increased fluid flow through those areas will improve cooling and cleaning of the cutting structure. Composition 1 includes larger diamonds, which remain effective with the increased exposure in those areas.
The primary advantage to selective use of sintering and infiltration is in the effective separation of abrasive compositions. Prefabricated blocks of abrasive material can be used to form distinctly separated areas of different compositions. The blocks can be placed adjacent to each other, or the areas between can be filled with a different type of block or with different abrasive slurries. The use of relatively few different sizes and shapes of blocks can effectively used to construct the geometry of the cutting face also reduces inventory of components for the adaptive matrix bits.
In this embodiment, the difference in composition allows the portions 31 to wear at a different rate than the slurry portions 32.
In manufacturing the bit face 23 in accordance with the present invention, the portions 31 are preformed and placed in a mold while the composition of the bit body 21 is formed from a thick slurry that is packed into the mold.
FIG. 5 illustrates an embodiment in which the entire rib 25 is formed form preformed portions 31, all of which have the same composition. As before, the rest of the bit body 21 is made form a matrix material.
FIG. 6 illustrates an embodiment in which the entire rib 35 is formed from preformed blocks of two different blocks numbered 41 and 42 and interspersed as shown.
FIG. 7 illustrates an embodiment in which the rib 45 is formed from preformed blocks of two compositions 46 and 47 and a single slurry 48. As mentioned previously, the blocks 46 and 47 are inserted into the mold which forms the ribs, and the slurry 48, which is in the form of paste is packed into the areas of the rib not taken up with the preforms.
FIG. 8 illustrates an embodiment in which the rib 50 is formed by two preformed blocks 51 and 52 of two different compositions and slurry portions 53 of the same compositions interspersed therebetween.
FIG. 9 illustrates and embodiment in which each rib 55 is formed from blocks 57 of the same composition with slurry portions 56 and 58 of two different composition interspersed therethrough as shown.
FIG. 10 illustrates an embodiment in which the rib 60 is formed from two sets of blocks 61 and 62 of different compositions located between slurries 63 and 64 of different compositions.
FIG. 11 illustrates an embodiment in which the face 70 of the bit includes ribs having different compositions which cover the entire surface of a respective rib. Ribs are shown as 71, 72 and 73 having three compositions which can either be formed from preformed blocks or slurries.
FIG. 12 illustrates an embodiment in which certain ribs 74 and 75 are formed with abrasives of different compositions covering various areas of each rib. Again, each rib can be made from different preform blocks inserted into the rib volumes formed in the die or different slurries that are packed into those volumes.
FIG. 13 illustrates a bit face 80 in which each of the ribs 81 and 82 are formed with preformed blocks 83 and 84 surrounded by a slurry 85 and 86 which differ in composition of blocks and slurries of the other rib.
FIG. 14 illustrates a bit face 87 in which each of the ribs 88 and 89 are formed with preformed blocks 90 of the same compositions and slurries 91 and 92 of different compositions for the ribs 88 and 89.
FIG. 15 illustrates a bit face 93 in which each rib is formed with a slurry 94 of similar composition, and preformed blocks 95 and 96 of different composition.
FIG. 16 illustrates a bit face 97 in which some of the ribs are formed with a slurry 98 of similar composition and preformed blocks 99, each of which is formed from two smaller preforms of different compositions.
FIGS. 17-20 illustrate some wear patterns that are possible with the present invention. FIG. 17 illustrates a plurality of ribs 100 as manufactured. Each rib 100 is formed with a taper having preformed blocks 101 surrounded by a slurry 102. The ribs are illustrated to show that the preforms are staggered with respect to preforms on the other ribs.
FIG. 18 illustrates the ribs 100 during use. In operation, the preforms 101 are softer in composition than the slurry 102 and as a result wear away faster to form channels to allow fluid to more easily pass over. Some of the channels 106 pass completely through the rib to enable the fluid to cool the rib and carry away the cuttings. Some of the channels 107 pass partially through the rib to create a pressure gradient.
In FIG. 19 the hardness of the preforms 101 and slurry 102 is reversed to show the cavities formed by the faster wearing slurry portions 102.
Finally in FIG. 20, still another wear pattern is illustrated in which half of the preforms 103 are of different compositions than the other half of the preforms 104. In addition the preforms 103 are, in turn softer than the slurry 105 while the preforms 104 are harder. As a result, deeper peaks and valleys are formed to create channels for the fluid flow.
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. It's, therefore, to be understood that within the scope of the appended claims, this invention may be practiced otherwise as specifically described.
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The present invention provides a diamond impregnated bit with an adaptive matrix in the ribs. The ribs have at least two different areas of metal-matrix composite impregnated with diamonds with different wear resistance such that during boring of formation, the areas will wear at different rates and provide fluid flow spaces across the surface of the ribs.
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[0001] This application is a continuation of and claims priority from PCT/AU2006/001948 published in English on Jul. 12, 2007 as WO 2007/076571 and from AU 2005907342 filed Dec. 30, 2005, the entire contents of each are incorporated herein by reference.
[0002] This invention relates to a method and apparatus for in-pit waste dumping.
[0003] Many mathematical models exist for open pit mining to schedule mining of material at particular parts of the pit whilst taking into account various constraints. These mathematical models enable extraction schedules to be developed which optimise the net present value of mine over the operating life of the mine.
[0004] Typically, a pit is divided into a number of “blocks” which are typically rectangular prisms of material, or aggregates of blocks, and mining takes place according to a predetermined schedule to maximise the net present value of the mine. This involves removing material from the mine and sending material to waste, to stockpile or to processing.
[0005] Typically a number of pits may be mined in a particular region concurrently and waste is usually dumped at a convenient location. However, often there is limited space available for the dumping of waste and also the dumping of waste may be environmentally undesirable. Waste disposal therefore needs to be considered to optimise net present value.
SUMMARY
[0006] The object of the invention is to provide a method of open pit mining which optimises net present value by including waste dumping, as well as an apparatus and program for performing the method.
[0007] The invention may be said to reside in a method of open pit mining with waste dumping, comprising: extracting material from the open pit and determining whether the material is sent to any one or more of stockpiling, waste and processing; defining a road network interconnected a plurality of zones; determining waste movement along the network from its origin being the zone in which the waste was produced to a destination being the zone in which the waste is to be dumped, to provide a joint extraction and waste movement strategy which optimises the net value of a joint extraction and waste movement schedule; and each zone containing a plurality of blocks, material extracted from one of the blocks in a zone being sent to a predetermined entry point on the road network, moving the material across the network and depositing the waste material at least one external waste dump, and some of the waste material being moved on the road network to terminate at one of the zones within the pit, and allocating the material moved to one of the zones within the pit proportionally to an in pit waste dump defined by a refill aggregate that overlaps with that zone, the refill aggregate being a space formed after extraction of material from that aggregate and therefore cleared of original material and after any refill aggregate which sits below that aggregate has been completely refilled.
[0008] Thus, a concurrent material and waste dump schedule is developed which can take into account environmental constraints on where waste can be dumped and in view of those constraints, produce an extraction and waste dump schedule which optimises net present value of the mine.
[0009] Most preferably the zone in which the waste is dumped is an in-pit zone.
[0010] By moving the waste along the network to a zone within the pit, the waste can be moved from one available space to another available space within the pit based on mining considerations and, in particular, which parts of the pit are to be next mined.
[0011] The invention may also be said to reside in a method of open pit mining with waste dumping, comprising: extracting material from an open pit and determining some proportion of the extracted material to go to waste; defining a road network having a plurality of nodes, at least some of the nodes defining entry points to a plurality of waste dumps, and wherein the waste dumps are selected from the group of at least one in pit waste dump and at least one external waste dump; and moving the material to go to waste along the network of roadways from a location in the pit to an entry node relating to one of the waste dumps and depositing the material to go to waste at the waste dump, to provide a joint extraction and waste movement strategy which optimises the net value of a joint extraction and waste movement schedule.
[0012] Preferably the step of extracting material comprises extracting material based on a block model extraction schedule, and wherein the waste dump comprises an in pit waste dump defined by a space in the pit which is determined from one or more blocks of the block model which have already been subject to extraction.
[0013] In one embodiment the space comprises a block aggregation determined by aggregating a plurality of blocks in the block model.
[0014] Preferably the shape of the spaces is chosen to ensure that the spaces may be independently scheduled for refilling with waste, subject to precedent rules, without violating maximum waste repose slope constraints.
[0015] Preferably the pit is divided into a plurality of zones, each zone containing a plurality of blocks and potential refill spaces which form in pit waste dumps.
[0016] In one embodiment the method comprises moving waste from a zone in the pit, along the road network, to an external waste dump, and eventually from that external waste dump to an in pit waste dump.
[0017] Preferably a cost of extraction of material and its movement to waste is determined from the zone from which the waste is removed in the pit, the path the waste is moved on the road network via the nodes and to the waste dump in which the waste is dumped.
[0018] Preferably the pit is divided into a plurality of zones, each zone containing a plurality of blocks, material extracted from one of the blocks in a zone being sent to a predetermined entry point on the road network, moving the material across the network and depositing the waste material at at least one external waste dump, and some of the waste material being moved on the road network to terminate at one of the zones within the pit, and allocating the material moved to one of the zones within the pit proportionally to an in pit waste dump defined by a refill aggregate that overlaps with that zone, the refill aggregate being a space formed after extraction of material from that aggregate and therefore cleared of original material and after any refill aggregate which sits below that aggregate has been completely refilled.
[0019] The invention may also be said to reside in an apparatus for scheduling open pit mining with waste dumping, wherein material is extracted from an open pit and a determination is made that some proportion of the extracted material is to go to waste, a road network is provided having a plurality of nodes, at least some of the nodes defining entry points to a plurality of waste dumps, and wherein the waste dumps are selected from the group of at least one in pit waste dump and at least one external waste dump, and material to go to waste is moved along the network of roadways from a location in the pit to an entry node relating to one of the waste dumps and depositing the material to go to waste at the waste dump, the apparatus comprising: a processor for dividing the pit into a plurality of zones, and for allocating the material to be moved to one of the zones within the pit proportionally to an in pit waste dump defined by a refill aggregate that overlaps with that zone, the refill aggregate being a space formed after extraction of material from that aggregate and therefore cleared of original material and after any refill aggregate which sits below that aggregate has been completely refilled, to thereby provide a joint extraction and waste movement strategy which optimises the net value of a joint extraction and waste movement schedule.
[0020] The invention may also be said to reside in a computer program for scheduling open pit mining with waste dumping, wherein material is extracted from an open pit and some proportion of the extracted material is to go to waste, comprising: code for defining a road network having a plurality of nodes, at least some of the nodes defining entry points to a plurality of waste dumps, and wherein the waste dumps are selected from the group of at least one in pit waste dump and at least one external waste dump, so material to go to waste is moved along the network of roadways from a location in the pit to an entry node relating to one of the waste dumps and depositing the material to go to waste at the waste dump; code for dividing the pit into a plurality of zones, each zone containing a plurality of blocks so material extracted from one of the blocks in a zone is sent to a predetermined entry point on the road network and moved across the network and deposited at at least one external waste dump, and some is sent on the road network to terminate at one of the zones within the pit; and code for allocating the material moved to one of the zones within the pit proportionally to an in pit waste dump defined by a refill aggregate that overlaps with that zone, the refill aggregate being a space formed after extraction of material from that aggregate and therefore cleared of original material and after any refill aggregate which sits below that aggregate has been completely refilled, to thereby provide a joint extraction and waste movement strategy which optimises the net value of a joint extraction and waste movement schedule.
[0021] Preferably the program further comprises code for scheduling extraction of material based on a block model extraction schedule, and code for determining an in pit waste dump defined by a space in the pit which is determined from one or more blocks of the block model which have already been subject to extraction.
[0022] Preferably the program further comprises code for determining a cost of extraction of material and its movement to waste, from the zone from which the waste is removed in the pit, the path the waste is moved on the road network via the nodes and to the waste dump in which the waste is dumped.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Preferred embodiments of the invention will be described, by way of example, with reference to the accompanying drawings, in which:
[0024] FIG. 1 is a plan view of an open pit and road network according to one embodiment of the invention;
[0025] FIG. 2 is a side elevation of one of the pits shown in FIG. 1 ;
[0026] FIG. 3 is a side elevation of the other of the pits shown in FIG. 1 ;
[0027] FIGS. 4 , 5 , 6 and 7 are the same as FIG. 2 but showing in detail the aggregates which are being extracted to mine material at point P in the mine; and
[0028] FIGS. 8 , 9 , 10 , 11 , 12 , 13 , 14 and 15 are diagrams the same as FIG. 2 showing the refilling of aggregates to provide in-pit waste dumping.
DETAILED DESCRIPTION
[0029] Strategic mine planning optimisation is concerned with deciding when to schedule the extraction of blocks (or aggregate) of ore in an ore body over the life-of-operation whilst respecting all geotechnical slope restrictions and mining and processing capacity constraints. Typically an extraction schedule is determined which divides the pit of the mine (i.e. the region from which material is to be extracted) into a block model comprising typically between 10,000 and 20,000 blocks or aggregates. Typically a determination of the optimal ultimate pit limits for the blended ore operation taken over all block models that have been input by a user is determined. These limits are used to constrain the collection of blocks to be considered in constructing the detailed annual schedule for extraction of material. The various block models are partitioned into aggregates so that the user has a measure of control as to how many such aggregates there will be. Precedence structure among these aggregates is inherited from the precedence relationships that hold for their constituent blocks, and the resulting precedence rules are imposed upon the aggregates.
[0000] These aggregates can be sub-partitioned into smaller aggregates generally referred to as bins. A decision to extract an aggregate forces the extraction of every bin within the aggregate, but the processor is still free to make separate processing decisions for each of the constituent bins. The user defines the bins in such a way as to maximise the flexibility in processing material within the aggregates.
[0030] Taking an example from an iron ore operation, a typical bin would be the collection of hard cap material in an aggregate that has iron grade between 57% and 60% and silica grade less than 1.5%. There will typically be between 10 and 20 bins in each aggregate.
[0031] These aggregates and bins are scheduled over the life of mine in such a way as to maximise net present value whilst obeying mining capacity, processing capacity, market capacity and slope constraints.
[0032] The principle of the preferred embodiment of the invention for open pit mining with in-pit waste dumping is that the same way that rock is tracked as it is removed from the ground, we can also track the rock that is replaced in the ground. In particular, every block in a block model occupies a position in space, so in the same manner as there are 0,1 variables of the form y(j,t)=1 if and only if block j has been mined at or before period t, there are 0,1 variables w(j,t) with w(j,t)=1 if and only if the location occupied by block j has been refilled with waste at or before period t. Precedence constraints are provided among the w(j,t) to encode the slope constraints for the dumped waste, i.e. that the location of block j cannot be refilled in period t unless various other locations are also full at period t (either because they have been refilled themselves with waste at or before period t, or because they have never been extracted in the first instance).
[0033] Preferably the location at which waste is generated is tracked from each location j with variables of the form u(j,k,t) denoting the tonnes of waste from location j that are dumped into location k during period t. The origin of the waste to be dumped in k is relevant as it determines the transportation cost. By dividing each pit into a network of interconnected zones, the number of variables is reduced, thereby making the problem of tracking waste manageable.
[0034] Thus, it is only necessary to introduce variables u(p,q,t) for zones p and q that are adjacent to one another, as well as costs associated with the movement of material between them, and a processor will then determine the best route from origin to destination via these elementary moves from zone to adjacent zone.
[0035] Preferably each pit zone will satisfy mass-balance constraints that ensure that the amount of waste produced in the extraction clumps that intersect the zone, plus the amount of waste transported into the zone from outside is equal to the amount of waste dumped in the zone plus the amount of waste transported out of the zone. A processor will decide how to allocate the volume of waste assigned to be dumped in the zone to the various refill clumps that intersect the zone. So long as one ensures that there are no non-positive cost cycles in the network, every optimal solution to this network flow sub-problem will be decomposable into path flows from locations in which waste is produced to locations in which waste is dumped.
[0036] Zones need not necessarily be subsets of pits. A zone can be a location along a road (in which case no waste is produced or dumped there), or an external waste dump. In this way the processor can properly cost movements along the mine's road network and to and from the external waste dumps as well.
[0037] One of the principal difficulties with the above approach is that enforcing precedence constraints on the refill spaces requires a binary variable for each “refill clump” and each period. This essentially doubles the number of integer variables with which the optimizer needs to concern itself.
[0038] To reduce the number of integer variables, it is preferred that the problem be solved in the following two phases.
[0039] In the first phase, precedences among the refill clumps will only be modelled approximately via continuous variables. The constraint will state that no refill clump can be more full than are its predecessors. The important observation is that while these “precedence constraints” do not fully capture the reality of the precedence relationship within the model (as a refill clump cannot start at all until its predecessors have been completely filled), they do in fact guarantee that a valid precedence relationship exists. That is, although the variables that represent the proportion of a refill clump filled at a particular time t may not describe any feasible reality, nevertheless a “feasible” solution to this relaxed model implies that there exists some genuinely feasible dumping schedule (for the unrelaxed model) that is compatible with the extraction schedule returned by the solution to the relaxed model. The reason for this, in broad terms, is that while it may not be possible to half fill a space that sits above a space that is only half full, we could nevertheless imagine that the material dumped into the air in this higher space simply falls into the lower space.
[0040] Given a solution to the “phase 1” problem, a “phase 2” problem can be solved in which extraction is forced to follow (or follow approximately) the schedule determined in phase 1 (thereby simplifying the problem and allowing us to implement the unrelaxed version of the precedence constraints) and the processor finds the best genuinely feasible solution to the waste dumping scheduling problem that is consistent with the extraction schedule.
[0041] With reference to FIG. 1 which shows a plan view of two pits 10 and 12 interconnected by a road network 14 with a plurality of nodes 16 defined along the road network 14 . It should be understood that the pits 10 and 12 may be a large distance apart and the network 14 extremely long. The road network 14 has a plurality of waste dumps labelled waste dump 1 to waste dump 5 , with each waste dump having an entrance node 16 a associated with it.
[0042] FIGS. 2 and 3 show elevation views of the pits 10 and 12 respectively.
[0043] Each pit 10 and 12 , as is shown in FIGS. 2 and 3 , is divided into waste zone boundaries shown by the dashed lines 18 (only some labelled with the reference numeral 18 ) in FIGS. 2 and 3 . The pit also has a plurality of raw material aggregate boundaries which define the blocks or aggregate of blocks, as represented by the fine black lines 20 (only some with the reference numeral 20 ) in FIGS. 2 and 3 . The pit is also divided into a plurality of refill aggregate spaces which are defined by boundaries drawn in thick black lines 21 (only some labelled) in FIGS. 2 and 3 . Material to be extracted from the pits is extracted in accordance with the block scheduling models previously described, and some of the material will go to processing, some to stockpiling for possible further processing and some will go to waste. In some operations, stockpiling may not be used and the material either goes to processing or to waste.
[0044] Initially, in the early years of the life of mine, the waste will go to the external waste dumps 1 to 5 because space has not been cleared in the pits 10 and 12 for in pit waste dumping. However, as more material is extracted from the mine, the refill boundaries 21 will define open spaces into which waste material can be dumped.
[0045] Typically the cost associated with moving waste material from its extraction point in the mine to one of the external waste dumps and then to an end pit waste dump, or directly to an end pit waste dump, is determined by the path the waste will follow in order to be moved from its place of extraction to the external waste dump or the in pit waste dump. This path is defined by the node 16 and therefore, by virtue of the number of nodes 16 which are crossed, a cost of waste movement can be determined. Each of the nodes 16 on the road network 14 are defined by a node number, a road number and a location number on that road. The same node number can be associated with multiple roads (this would indicate an intersection of two roads at that point). The locations along any one road are numbered consecutively from one. Costs per unit distance forward (i.e. to the next location number on the same road) and backwards are defined for each of the roads within the network, and the external waste dumps are each assigned a location on the network (as identified by the entry nodes 16 a ).
[0046] For each block in the block model, the user can assign up to three potential entry points 24 , 26 , 28 shown in FIG. 1 for waste produced in that block to enter the road network 14 , along with the associated cost per cubic metre of waste to gain access to the road network 14 . The entries from the pits 10 and 12 on to network 14 are shown as a single line for ease of illustration. It can be assumed conversely that these entry points also serve as departure points from which waste material on the road network may be dumped back into the space occupied by that block, and associated costs in dollars per cubic metre are also assigned.
[0047] However, to facilitate tractability, the movement of waste is not tracked at a block level. Instead, to facilitate tractability, the movement of waste is tracked at a zone level as defined by the zone boundaries 18 shown in FIGS. 1 to 3 . The zones defined by the boundaries 18 are chosen so that two blocks can only belong to a single zone if they both link to the same road or roads on the network 14 . For each road to which the block in a zone link, all blocks within the zone are considered to link to the average of the road locations of the constituent blocks, and at the average of the associated costs. In other words, for each block in a single zone, the same cost is associated with movement of waste onto the road network 14 .
[0048] Therefore, the preferred embodiment of the present invention provides three distinct types of aggregation, namely: aggregation of blocks into extraction aggregations and bins; aggregation of the space occupied by blocks into refill aggregation spaces; and aggregation of the space occupied by blocks into waste zones.
[0049] These aggregations can be defined independently and thus, a zone may overlap several extraction aggregations, as well as several refill aggregations.
[0050] The optimised extraction and waste dumping schedule may seek to extract material identified at point P in FIG. 2 . To do this, aggregates are initially extracted, as shown in FIG. 4 and cross-hatched. Additional aggregates shown in FIG. 5 and cross-hatched are then extracted to extract the material at point P. Alternatively, the schedule may merely specify that the sum of the two sets of aggregates shown in FIG. 4 and FIG. 5 are extracted in one operation rather than in two operations mentioned above.
[0051] Slope constraints would prevent extracting the aggregates shown in FIGS. 6 and 7 as an initial step because they would result in slopes which are likely to cause a landslide or cave-in.
[0052] As is best shown in FIGS. 2 and 3 , refill aggregates 30 , 35 , 40 and 50 are spaces that may potentially be filled with waste material. The refill aggregates 30 , 35 , 40 and 50 are constructed from the input block models by aggregating the space occupied by blocks in the block model (possibly including air blocks) into disjoint spaces. The specific shape of these refill aggregates 30 , 35 , 40 and 50 is chosen in such a way as to ensure that the refill aggregates may be independently scheduled for refilling, subject to precedence rules, without violating maximum waste repose slope constraints. These constraints can be set by the user and merely comprise maximum slope angles for the waste when dumped into the spaces.
[0053] For example, if the space occupied by some constituent block in refill aggregate 30 must be refilled before the space occupied by some constituent block in refill aggregate 40 , then according to the preferred embodiment of the invention, it will always be the case that there is no constituent block in refill aggregate 40 that must be refilled before the space occupied by any constituent block in refill aggregate 30 . It is therefore sufficient to enforce a precedence rule that refill aggregate 30 must be completely filled before any dumping may take place into refill aggregate 40 , as the shape of aggregate 30 is such that aggregate 30 can indeed be filled before any dumping is initiated into aggregate 40 . The refill aggregate 35 is not considered available for dumping until all extraction aggregates that overlap the aggregate 35 by a predetermined radius have been cleared of their original material, and until all of its precedent refill aggregates (such as the aggregates 30 , 40 and 50 ) have been completely refilled.
[0054] FIGS. 8 to 15 show the refill spaces being refilled in sequence with the space 29 being refilled first ( FIG. 8 ), then the space 30 being refilled ( FIG. 9 ), then the space 40 being refilled ( FIG. 10 ), followed by the space 51 being refilled ( FIG. 11 ), then the space 50 ( FIG. 12 ), followed by the space 35 ( FIG. 13 ), and then the space 52 ( FIG. 14 ), and then the space 53 ( FIG. 15 ). It should be emphasised that this is merely exemplary and the dumping of waste in the refill aggregates could follow a different schedule, depending on the available spaces whilst maintaining the slope constraints in order to provide optimum net present value of the mine in terms of both the extraction of material from the mine and the dumping of waste.
[0055] A refill aggregate 61 may extend above original ground level of the pit as shown in FIG. 3 .
[0056] In another embodiment of the invention, an additional constraint relates to the filling of blocks which are located below the water table of the pit. In this embodiment, the entire refill aggregate containing a block that sits under the water table needs to be refilled and, to do this, those refill aggregates are split at the water table so that no extra refilling will be required to take place. To satisfy this constraint, material can be reclaimed from an external waste dump in the final year of the mine life and moved through the road network 14 back into the pits.
[0057] Since modifications within the spirit and scope of the invention may readily be effected by persons skilled within the art, it is to be understood that this invention is not limited to the particular embodiment described by way of example hereinabove.
[0058] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise”, or variations such as “comprises” or “comprising”, is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
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A method, apparatus and computer program for pit mining with waste dumping is disclosed, in which material is extracted from an open pit and some of that material is sent to waste. The method optimises a joint extraction and waste refill schedule.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to vending machines, and particularly to a vending machine with a locking assembly.
[0003] 2. Description of Related Art
[0004] In many direct type vending machines, each vending machine includes a chassis and a number of goods channel modules secured to the chassis. Generally, each goods channel module is secured to the frame by screws, which is inconvenient and time-consuming when in assembly or disassembly of the goods channel modules to the frame. Therefore, there is room for improvement in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Many aspects of the embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0006] FIG. 1 is an exploded, isometric view of one embodiment of a part of a vending machine.
[0007] FIG. 2 is an assembled, isometric view of the vending machine of FIG. 1 , with a sliding member in a first position.
[0008] FIG. 3 is another assembled, isometric view of the vending machine of FIG. 1 , with the sliding member in a second position.
[0009] FIG. 4 is an assembled, isometric view of one embodiment of a vending machine, with the sliding member in the first position.
DETAILED DESCRIPTION
[0010] The disclosure is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean “at least one.”
[0011] FIG. 1 shows one embodiment of a part of a vending machine. The vending machine includes a plurality of goods channel modules 100 (only one of the goods channel modules 100 is shown), an installation member 200 , and a locking assembly 300 .
[0012] The goods channel module 100 includes a channel case 10 and a sliding assembly 20 secured to the channel case 10 . The channel case 10 defines a goods channel (not shown) therein for securing goods. The sliding assembly 20 includes a frame 21 and two sliding rails 23 secured to two sides of the frame 21 . The frame 21 includes a bottom plate 211 and two side plates 213 extending perpendicularly from the bottom plate 211 . The bottom plate 211 is secured to the channel case 10 and defines an insertion slot 2113 . Each sliding rail 23 is mounted outside of one of the two side plates 213 . Two posts 2131 extend from one of the two side plates 213 . The two posts 2131 and the sliding rail 23 are located on two opposite sides of the side plates 213 . The two posts 2131 can be integrated with the side plate 213 . The two posts 2131 can also be screws, which are inserted through the side plate and secure the sliding rail 23 to the side plate 213 , so that there is no need to set extra two posts 2131 from the side plate 213 . In one embodiment, the insertion slot 2113 is substantially rectangular.
[0013] The installation member 200 is secured to a chassis (not shown) and includes a top wall 201 and two sidewalls 203 . In one embodiment, each sidewall 203 is substantially perpendicular to the top wall 201 . A limiting plate 205 extends from a side edge of the top wall 201 . Each sidewall 203 defines a slideway 207 for the sliding rail 23 to slide along. In one embodiment, the limiting plate 205 is substantially perpendicular to the top wall 201 and the sidewalls 203 , and the top wall 201 is substantially perpendicular to the sidewalls 203 .
[0014] The locking assembly 300 includes a mounting member 30 , a sliding member 50 , and a resilient member 60 .
[0015] The mounting member 30 includes a mounting plate 31 and a receiving portion 33 protruding from a center of the mounting plate 31 . The mounting plate 31 defines a receiving slot 313 , from which the receiving portion 33 protrudes. The receiving portion 33 defines an opening 331 . In one embodiment, each of the receiving slot 313 and the receiving portion 33 is substantially “U” shaped.
[0016] The sliding member 50 includes a sliding piece 51 , a connecting piece 52 , and an operation piece 53 . The sliding piece 51 and the operation piece 53 extend perpendicularly from opposite edges of the connecting piece 52 . The sliding piece 51 is substantially parallel to the operation piece 53 and defines a mounting hole 511 . A rolled portion 55 extends from a top edge of the operation piece 53 towards the sliding piece 51 , in order to avoid scuffing.
[0017] The resilient member 60 is used for resiliently securing the sliding member 50 to the goods channel module 100 . In one embodiment, the resilient member 60 is an extension spring.
[0018] Also referring to FIGS. 2-4 , in assembly, the sliding piece 51 is inserted through the insertion slot 2113 . The mounting member 30 is moved to be adjacent to the sliding member 50 , allowing the operation piece 53 and the rolled portion 55 to extend out of the opening 331 . The mounting plate 31 is secured to a side of the channel case 10 by screws or other methods. The sliding piece 51 is received in the receiving slot 313 . A first end of the resilient member 60 is secured to the mounting hole 511 , and a second end of the resilient member 60 is secured to the post 2131 . Thus, the locking assembly 300 is secured to the goods channel module 100 . In this position, the connecting piece 52 abuts a top edge of the opening 331 , the resilient member 60 is in an initial position, and the sliding member 50 is in a first position.
[0019] The sliding assembly 20 is moved to be adjacent to the installation member 200 , to align the sliding rail 23 with the slideway 207 . The goods channel module 100 is slid into the installation member 200 along a first direction, until the sliding piece 51 abuts an outer surface of the limiting plate 205 . In this position, the goods channel module 100 is blocked by the limiting plate 205 . The operation piece 53 is pulled to slide the sliding member 50 downwards, until the connecting piece 52 abuts a bottom edge of the opening 331 . In this position, the resilient member 60 is elastically deformed, the sliding piece 51 is slid over the limiting plate 205 into a second position. The goods channel module 100 is further slid into the installation member 200 along the first direction, until the sliding rail 23 is completely received in the slideway 207 . In this position, the sliding member 50 is released, the resilient member 60 rebounds to slide the sliding piece 51 upwards, until the sliding piece 51 abuts an inner surface of the limiting plate 205 , preventing the goods channel module 100 from moving along a second direction opposite to the first direction. Thus, the goods channel module 100 is secured to the installation member 200 , and the sliding member 50 is in the first position.
[0020] When moving the goods channel module 100 , the operation piece 53 is pulled to slide the sliding member 50 into the second position, the sliding piece 51 is slid over the limiting plate 205 , and then the goods channel module 100 is removable from the installation member 200 .
[0021] It is to be understood, however, that even though numerous characteristics and advantages have been set forth in the foregoing description of embodiments, together with details of the structures and functions of the embodiments, the disclosure is illustrative only and changes may be made in detail, especially in the matters of shape, size, and the arrangement of parts within the principles of the disclosure, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A dispensing device for a vending machine includes an installation member, a goods channel module, and a locking assembly. The goods channel module is slidably secured to the installation member. The locking assembly is secured to the goods channel module and includes a sliding member. The sliding member is slidable into the installation member to lock the installation member to the goods channel module. The sliding member is further slidable out of the installation member, allowing the installation member to be removed from the goods channel module.
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PRIORITY
This application claims priority of the non provisional patent application No. 61/898,805 filed on Nov. 1, 2013, the contents of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates storm protection covers of windows and doors and a method to attach protective covers. More specifically the invention relates to a bracket for attaching protective covers.
BACKGROUND OF THE INVENTION
Hurricanes and tropical storms generate high winds that can typically cause tremendous damage to buildings. Usually glass windows and doors are destroyed first by the wind and windborne debris. Once the glass is broken the inside of the building will be exposed to the destroying storm elements also.
There are various methods and devices to protect windows from the wind. One often used method is to nail plywood panels over the building openings. Usually plywood is attached over the opening and nailed or screwed on the frame of the opening. This method has various flaws. A major flaw is that if the frame is wooden the nails and screws leave ugly holes on the frames. Often times in modern business buildings the frames are not wood but of metal or other hard material. In such case the plywood panel has to be attached to this hard material, which is slow and there may not be enough time to cover hundreds and hundreds of metal framed business building windows. Also screws and nails leave ugly holes into the metal frames.
Yet another flaw in the method of attaching plywood covers by nailing or srewing onto window or door frames is the fact that when the window frame is not rectangular or when the opening locates in a vault or a curved depression the plywood may need to be shaped before it can be attached to the frame.
There are various methods that have been introduced to make installation of storm panels and shutters faster.
For example US Patent Application Publication US2007/0101667 discloses a storm panel bracket system that secures a storm panel inset within the frame of building openings. The bracket system includes one or more storm brackets and one or more resilient bumpers. The storm bracket includes an adjusting screw and adjustment nut. Turning the adjustment nut moves the nut along the adjusting screw. The movement of the nut moves a movable member of the storm bracket. The movable member holds a protecting storm panel and forces the panel against the frame of the window, providing a clamping action that holds the storm panel in place. The resilient bumpers are placed between the storm panel and the frame to provide a cushion for the frame and to enhance friction between the frame and the storm panel. The flaw in this approach is that the plywood has to be sized exactly to fit into the frame, otherwise the plywood panel cannot be attached to the bracket. Therefore, this method requires measurement of the frame sizes and custom work on the plywood panels to make them fitting.
U.S. Pat. No. 7,337,582 provides another similar type of protection system. Several anchor clips are attached to the window frame and the storm panel is supported by these clips. Again the flaw is that the plywood panel has to be cut to fit inside the frame. Moreover, the structure of the clips is such that most probably a large number of clips are needed to attach the panel properly.
U.S. Pat. No. 5,335,452 discloses a system were a horizontal bar is attached in front of a pair of window panels with anchor members that are attached to the window frame. In this system the window panels do not obviously need to be cut to same size as the frame. However, the flaw in this system is that the bar may not provide enough support to hold the panels on place during a storm. Further support could be provided by nailing or screwing the panels on place and in such case installing the bar would be just an extra step and slower the work.
U.S. Pat. No. 7,997,036 provides a corrugated hurricane panel attachment and a strengthening strap system. The flaw in this system is that the panel is not plywood but specially made corrugated polycarbonate storm shutter, which naturally increases the costs of the system. Also the shutter has to be measured to fit into the frame.
U.S. Pat. No. 8,074,408 discloses another system for corrugated polycarbonate plastic hurricane shutter panel. The corrugated polycarbonate plastic shutter panel is attached from its upper end and lower end within a U-shaped pocket of a aluminum bar which is attached on the window frames. The flaw in this system is the cost of the aluminum bars and the plastic shutter. Moreover, the shutters need necessarily be of such size that it fits within the frame.
U.S. Pat. No. 6,341,455 discloses a system where a high strength fabric covering the window is supported by brackets, a rod and a bar and stretched over the window to protect it from the winds.
Accordingly, there is a need for an easy, affordable and effective system to protect building openings, such as windows during storms and hurricanes. There is a need for a system that does not require specifically shaped panels or panels of any other material than simple plywood. There is also a need for a system where attaching hurricane or storm panels would not require multitude of nail or screw holes in the window frames.
This disclosure provides solution to the flaw of the prior art. Embodiments of this invention are illustrated in the accompanying drawings and will be described in more details below.
SUMMARY OF THE INVENTION
The invention of the present disclosure is distinguished over the prior art in general and particularly the instant disclosure solves the above flaws of the prior art.
The invention according to this disclosure provides a hurricane bracket comprising: a substantially rectangular back plate having four sides and at least one aperture; two side plates having two vertical sides and two horizontal sides and at least one aperture; and a substantially rectangular end plate having two vertical sides and two horizontal sides; wherein one horizontal side of each side plate is connected substantially perpendicularly to opposite sides of the back plate, thereby forming a substantially U-formed groove; and each vertical side of the end plate being connected substantially perpendicularly to one vertical side of each side plate, and one horizontal side of the end plate being connected substantially perpendicularly to one side of the back plate, whereby the end plate closes the U-formed groove from one end.
It is an object of this invention to provide a hurricane bracket comprising: a rectangular back plate having two long sides and two short sides and two linearly positioned apertures; two rectangular side plates having two vertical sides and two horizontal sides and two linearly positioned apertures, wherein one vertical side is longer than other, and the horizontal sides have same length as the long sides of the back plate; and a rectangular or trapezoid shaped end plate having two vertical sides having same length as the longer vertical side of the side plates and two horizontal sides at least one of which having same length as the short side of the back plate; wherein one horizontal side of each side plate is connected in 90 degrees' angle to each opposite long sides of the back plate, and each vertical side of the end plate is connected in 90 degrees angle to the longer vertical sides of the side plates, and one horizontal side of the end plate with same length as the short side of the back plate is connected in 90 degrees' angle to one short side of the back plate.
Another object of this invention is to provide a kit for protection of building openings, said kit having four storm brackets disclosed in this application, nails or screws suitable for attaching the brackets through the apertures onto a frame of the opening, optionally two wooden bars suitable to be inserted from one end to one bracket and from another end to another bracket, and a plywood panel capable of being attached with nails or screws on the bars resting on the brackets.
Still another object of this invention is to provide a method to protect a building opening, said method comprising: a) providing at least two storm brackets disclosed in this application, at least one bar and a plywood big enough to cover the building opening; b) Attaching the at least two brackets on opposite sides of frame of the building opening; c) Inserting one end of the bar to one bracket and another end to the other bracket; d) Securing the bar ends to the brackets by screws or nails; and e) attaching the plywood on the bar with nails or screws in a manner that it covers the opening.
It is an object of this invention to provide brackets suitable to hold preferably wooden bars of standard measures to provide support for plywood panels to be nailed on the bars to cover building openings during a storm.
An advantage of this invention is that attaching storm panels becomes easy and fast.
Another advantage of this invention is that the plywood panels do not need to be shaped or trimmed even if the building opening had curved frames or locate in a vault or a curved depression.
Yet another advantage of this invention is that the plywood panels, and the bars for attachment can be used again.
Still another advantage is that the screws or nails may be left on the window frames permanently and when needed the brackets can be inserted quickly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the bracket of this invention.
FIG. 2A shows a perspective view of four brackets provided as a kit.
FIG. 2B shows a front view of four brackets provided as a kit.
FIG. 2C shows a side plate.
FIGS. 3A . and 3 B show the bracket manufactured as a flat sheet that can be bent to form the bracket shown in FIG. 1 .
FIG. 4 . shows a window and window frame where a bracket has been attached close to an upper corner of the frame.
FIG. 5 . shows a window and window frame where a bracket has been attached close to a lower corner of the frame.
FIG. 6 . shows a window and a window frame and two wooden bars attached from their ends to rest in the brackets attached on opposite sides of the window frame.
FIG. 7 shows plywood panel being attached on the bars resting on the brackets attached on opposite sides of the window frame.
FIG. 8 shows plywood panels covering a window.
FIG. 9 shows a broken door where brackets have been attached on the door frame and wooden bars are resting in the brackets.
FIG. 10 shows a plywood panel attached to cover a door.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described with reference to FIGS. 1-10 and identical elements in the various figures are identified with the same reference numerals.
FIG. 1 shows a perspective view of the bracket of this invention. The figure shows the bracket 100 . The bracket has a back plate 120 , two side plates 140 , and an end plate 160 . The end plate 160 has two vertical sides 162 and two horizontal sides 164 . The back plate 120 has two long sides 126 and two short sides 128 . The back plate has two apertures 122 , and the side plates have two apertures 142 each. The side plates 140 have two vertical sides 146 , 146 a and two horizontal sides 148 . The side plates 140 have also triangularly broadened end portions 144 .
FIGS. 2A and B show the bracket provided as a kit of four brackets in group.
FIGS. 3A and B show an embodiment where the bracket is made of one flat sheet that can be bent to the bracket. The sheet comprises the rectangular back plate 120 , on both sides of the back plate there are the side plates 140 which have the triangularly broadened end portion 144 at one end, and the end plate 160 . The side plates 140 and the back plate 120 are shown to have two linearly positioned apertures 122 , 142 each. The bracket can be formed by bending the side plates and the end plate upward so that the vertical sides 146 a of the side plate and the vertical sides 162 of the end plate meet each other in about straight angle.
FIG. 4 shows a window 200 and a window frame 220 . The figure shows a bracket 100 attached close to an upper corner of the window frame. The bracket 100 is attached to the window frame with screws 300 through the apertures 142 . The end plate 160 is positioned downward.
FIG. 5 shows a window 200 and a window frame 220 . The figure shows a bracket 100 attached close to a lower corner of the window frame. The bracket 100 is attached to the window frame with screws 300 through the apertures 142 . The end plate 160 is positioned downward.
FIG. 6 shows a window 200 , a window frame 220 , four brackets 100 attached close to each corner of the window frames. The figure shows two bars 400 , each having two ends and each end resting on one bracket 100 attached onto opposite sides of the window frame.
FIG. 7 shows a window 200 , two horizontal bars 400 and a plywood panel 500 being attached on the bars by screwing.
FIG. 8 shows a window covered with plywood panels 500 attached to a door.
FIG. 9 shows a door with broken glass 700 . The figure shows four brackets 100 attached to the door frame and bars 400 having two ends resting in one in one bracket 100 attached on the opposite sides of the door frame, and thereby the bars are horizontally over the broken glass.
FIG. 10 shows a plywood panel 500 attached on the bars and covering the broken glass door shown in FIG. 9 .
The present invention is now further described by way of example only with reference to accompanying drawings.
Referring now to FIG. 1 , according to one preferred embodiment there is provided a bracket 100 . The bracket has a substantially rectangular back plate 120 . According to a preferred embodiment the back plate 120 is elongated having two long sides 126 and two short sides 128 . Two substantially rectangular side plates 140 have two horizontal sides 148 and two vertical sides 146 and 146 a . In a preferred embodiment the horizontal sides are longer than the vertical sides. Each of the side plates 140 is connected along one horizontal side 148 to the long sides 126 of the back plate 120 and the connection forms preferably an angle of about 90 degrees. According to a preferred embodiment one of the vertical ends 146 a of each side plate 140 is longer than the other vertical end 146 of the same plate. The horizontal side 148 that is not connected to the back plate has a slightly V-shaped bend 149 close to the longer vertical side 146 a . Thereby the side plate 140 has a broadened triangularly formed end portion 144 at one end. A substantially rectangular end plate 160 has two vertical ends 162 and two horizontal ends 164 . The end plate 160 is connected from its one horizontal side 164 to the short end site 128 of back plate 120 . Each of the vertical sides 162 of the end plate 160 is connected to a longer vertical side 146 a of the side plate 140 . The length of the horizontal side 164 of the end plate 160 connected to the back plate is same as the length of the short side 128 of the back plate 120 . In one embodiment the horizontal side 164 that is connected to the back plate is slightly shorter than the unconnected horizontal side, which makes the end plate to be a slight trapezoid. The connection between the back plate 120 and the end plate 160 is approximately a 90 degrees angle. The length of the vertical side 162 of the end plate 160 is same as the length of the longer vertical side 146 of the side plate 140 . The connection between the end plate 160 and side plates 140 is approximately a 90 degrees angle. Thus the two side plates and the back plate form a substantially U-formed groove and the end plate covers one end of the groove.
According to one preferred embodiment the bottom plate 120 has at last one aperture 122 , preferably two apertures, but any feasible number of apertures can be applied. According to a preferred embodiment the side plates 140 have at least one aperture 144 , preferably two apertures, but any number of apertures can be applied. According to a preferred embodiment two apertures locate linearly along a longitudinal axis of the back plate and along a longitudinal axis of the side plates. According to a preferred embodiment the apertures locate on a line that is in about middle of the width of the back plate and similarly in the side plates.
Referring to FIGS. 2 B and 2 C for the preferred measures of the bracket. According to one preferred embodiment the length of the bottom and the side plates (A in FIG. 2C ) is 4 to 10 inches, more preferably 6 to 9 inches and most preferably about 8 inches. The width of the bottom plate ((D in FIG. 2B ) is preferably 1 to 4 inches, more preferably 1.5 to 3 inches, most preferably 1⅞ inches. The height of the side plates from their narrow end (B in FIG. 2C ) is preferably 0.5 to 4 inches, more preferably 0.75 to 2 inches and most preferably 1 inch. The height of the side plates from their broader end (C in FIG. 2C ) is preferably 1 to 4 inches, more preferably 1.5 to 3 inches and most preferably 1¾ inches. The height of the end plate is preferably same as the height of side plate from its broader end.
According to a preferred embodiment there are two apertures 122 in the back plate 120 and two apertures 142 in each side plate 140 . Preferably the distance between the apertures in the back plate is 2 to 6 inches, more preferably 3 to 5 inches and most preferably 4 inches. The distance between the apertures in each side plate is preferably identical to the distance of the apertures in the back plate.
The bracket according to this invention is so designed that a wood bar with standard measures fits inside the groove that is formed by the back plate 120 , the side plates 140 and the end plate 160 . Most preferably the wood bar is a 2″×8″ bar. Therefore in a most preferred embodiment the width of the back plate is 2 inches and thereby the bracket adapts a 2 by 8 bar. The bracket would also adapt a 2″×2″, 2″×4″, 2″6, 2″×10″ etc. bar. However the distance of the apertures would need to be modified especially in case where the bar would be 2″×2″, 2″×4″ or 2″×6″. The end plate 160 has a height that equals to the height of the triangular broadening 144 of the side plates. Thus the triangular broadenings and the end plate form a pocket for the end of the wood bar to rest in.
The distance of the apertures in the side plates is so designed that the wooden bar can easily be attached through the apertures with nails or screws. Thus in a preferred embodiment the bar to be used is a 2″×8″ bar and in such case the apertures need to locate at about 4″ distance from each other to be properly attached to the bar. If a narrower bar would be used the distance of the apertures would be shorter and preferably the bracket would be shorter too. If a broader bar is used the bracket preferably would be longer and the bracket could have more than two apertures on the side plates and preferably also on the back plate.
In one embodiment the apertures are round holes. In another preferred embodiment the holes are drop down holes as is shown in FIG. 1 .
Now referring to FIGS. 2 A and B, the bracket 100 of this invention may be provided in sets of four. Installation of a storm panel with the brackets would preferably need four brackets, and screws or nails to attach the brackets and screws or nails to attach the bar on the brackets. Therefore, according to this invention the brackets may be provided as a kit comprising four brackets and screws and nails for attachment. The kit may also include two bars for a standards sized window and one or more plywood panels.
Now referring to FIGS. 3A and B, the bracket according to this invention may be made as a flat sheet. The sheet would have the elongated rectangular back plate 120 in the middle. On both long sides of the back plate there are the side plates 140 . The side plates preferably have the broadened triangular portions at their one end 144 . The end plate 160 is elongating from a short end of the back plate. If the side plates have the broadened triangular portions 144 , the end plate will locate at same end of the bracket as the broadened portions. The bracket can be assembled by bending the side plates upward and bending the end plate up in a way that the vertical sides 162 of the end plate 160 and the vertical end 146 a of the side plate 140 meet in about straight angle and that the angle between the back plate 120 and the side plates 140 as well as between back plate 120 and the end plate 160 are substantially a straight angle.
Now referring to FIG. 4 , a bracket 100 are attached close to the upper corner of a window frame 210 . The bracket is are attached through the apertures 142 on one side plate 140 with screws or nails. In some cases the bracket 100 could be attached through the apertures 122 in the back plate 120 As is shown the bracket 100 is so positioned that the end plate 160 is downward.
FIG. 5 shows a bracket 100 attached similarly close to a lower corner of the window frame. In a preferred embodiment there are two brackets on each vertical side of the frame 210 , two locating close to the upper end of the vertical side and two locating close to the lower end of the vertical frame. The brackets 100 are attached to the frame through the holes on the side plates. The brackets on the upper part of the frame are approximately at the same height and the brackets on the lower part of the frame are similarly at about the same height.
Now referring to FIG. 6 , it is shown how a wooden bar 400 is attached to rest on the brackets 100 . There are two bars 400 two ends. There are two brackets 100 attached to the lower end of the vertical sides of the frame and two brackets 100 to the upper end of the vertical sides of the frame. The ends of the bars are inserted into the groove of the bracket 100 . 100 . The ends of the bars are now resting in the pocket formed by the end plates 160 and the side plates 140 of the bracket. The bars are attached to the brackets with screws or nails through the apertures 142 .
Now referring to FIG. 7 , it is shown how plywood panels 500 are attached onto bars 400 horizontally crossing a window and resting on brackets from their ends. In this figure it is shown how the plywood panels 500 do not need any trimming. The window 400 has a frame that has a curved upper part. This invention allows covering the window without trimming the panels to the shape of the curved window.
FIG. 8 shows the panels 500 covering the window. The panels have been nailed or screwed to the bars resting from their ends in the brackets.
Now referring to FIGS. 9 and 10 , according to another embodiment the brackets 100 can be used to provide a protection to a broken glass in doors or in windows. In FIG. 9 there is a broken glass door 700 . Four brackets 100 are attached to the frame of the door. Two brackets on the upper end and two on the lower end of the frame. Two brackets on both side of the frame. A bar 400 is inserted into the brackets and the bar is now resting in the pockets formed by the side plates 140 and the end plates 160 of the bracket. The bars are attached to the brackets with nails through the apertures 142 .
FIG. 10 shows how plywood 500 is attached on the bars to cover the broken door window. According to another preferred embodiment there may be hinges attached to the bracket and when used to cover a broken door the hinges would allow one to open the door even with the plywood attached the bars resting in the brackets.
Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.
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This disclosure provides a device and a method to protect building openings with plywood panels during storm. The device and method is also provided to protect inside of buildings when windows or doors are broken. The bracket of this disclosure is simple and easy to make, and it allows attachment of plywood panels without shaping to cover windows and other building openings of any shape.
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This is a division of application Ser. No. 08/173,679, now U.S. Pat. No. 5,441,121 filed Dec. 22, 1993.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to earth boring drill bits and more particularly to such bits which are assembled from two or more separately manufactured portions, one of which includes an external surface adapted to carry cutting elements and the other portion including a shank having a set of threads on one end thereof for connecting the drill bit to a string of drill pipe.
2. Description Of the Related Art
Earth boring drill bits typically include a bit body upon which cutting elements are carried and a separate shank which is mounted on the bit body during the manufacturing process. The cutting elements may include natural or synthetic diamond cutters which are disposed on the bottom and sides of the bit body. The shank is coaxial with the bit body and includes a set of threads on an upper end thereof for connecting the drill bit to the drill string. One example of such drill bit is illustrated in U.S. Pat. No. 4,499,795 to Radtke for a method of drill bit manufacture.
In another known type of drill bit, an infiltratable powder, e.g., tungsten carbide, is formed in a mold around a steel inner core, referred to as blank to which a threaded shank is typically welded after infiltration, it is necessary to position forms in the mold which produce matrix coated ducts in the bit interior to provide flow paths for the drilling fluid to emerge on the face of the bit. After the core and powder are placed in the mold, it is placed in a resistance furnace, or alternatively an induction heater may be positioned adjacent the exterior of the mold, to heat and thereby infiltrate the powder. This is a time consuming process because the material in the mold presents a considerable mass and because the heat must be conducted from the exterior of the mold to the interior thereof. Cutters may be either integrated into the infiltrated matrix or brazed onto the matrix body after the matrix is infiltrated and the bit is removed from the mold. Complex ports which connect with nozzles on the face of the bit must be designed, built and placed into the mold prior to infiltration.
Prior art matrix bits use substantially solid cylindrical blanks which are heavy and which prevent use of matrix techniques for open bits such as that shown in U.S. Pat. No. 4,883,132 to Tibbitts.
In another prior art bit, U.S. Pat. No. 5,101,692 to Simpson discloses a drill bit manufacturing process in which separate portions are assembled to form a drill bit. One of the portions comprises an integrated bit shank and bit head core, referred to collectively as a bit shank. The other portion comprises a bit head in which the bit core is received. In Simpson, the bit head is investment cast from a steel alloy which is highly resistive to abrasive wear and fluid erosion such as a high content cobalt alloy like stellite. The bit shank is made from an easily machined steel and includes threads on both ends thereof, an upper set for connecting to a drill string and a lower set for threadably engaging corresponding threads formed in the bit head. After the head is cast and the shank machined, the same are threaded together and locked to one another by fusion bonding or by a mechanical lock.
According to the Simpson patent, the advantages of the manufacturing process described and claimed therein include providing a bit head and shank with different properties. The bit head is abrasive to wear and resistant to fluid erosion while the shank is easily machinable and has the capability of withstanding high stress or fatigue levels. Investment casting also provide very accurate surfaces for positioning cutter pockets on the bit head.
U.S. Pat. No. 5,150,636 to Hill discloses a rock drill bit and method of making same in which a head having a working face at one end and a recess at the other end having a cross-section corresponding in shape to the tip of a shank except that the recess is slightly smaller than the shank. In assembling the bit, the shank is cooled in a cryogenic gas to reduce its size and thereafter inserted into the head recess. When the components return to ambient temperature, a shrink fit is established between the head and the shank. As in Simpson, the shank and head are made of different materials with the head being made of material which is both tough and hard, such as hardened steels. Such material cannot be easily heated without damaging the head. If it is heated, it must be cooled very slowly to prevent the steel from becoming brittle.
It would be desirable to provide improved techniques for connecting a drill bit shell having an external surface for mounting cutting elements thereon to a complimentary bit core and shank. It would also be desirable to provide for utilizing matrix techniques for manufacturing a bit shell which is connectable to a complimentary integrated bit core and shank and which obviated the need for matrix coated internal ducts for porting drilling fluid bit crown would also be desirable. It would be advantageous to reduce manufacturing time to the face of the bit. Improved hydraulic supply and reduced erosion on the interior of the for drill bits and to eliminate the need for a conventional blank when manufacturing a matrix bit. An engineered, lightweight, blank which supports a matrix or other bit head and which is more open than prior art blanks would also be advantageous. It would be beneficial to provide for interchangeability of different external shells with a single bit core and shank and to provide a single design for a bit core and shank which is suitable for connection to a range of bit head shells having different external shapes or sizes.
SUMMARY OF THE INVENTION
In one aspect, the present invention comprises a method for making an earth boring drill bit in which an outer shell is formed. The shell has an external surface adapted to carry cutting elements and an internal surface adapted for connection to a bit shank. After the shell is removed frown the mold and while it is still hot, the bit shank is engaged with an internal surface of the shell. As the shell cools, it contracts into tight engagement with the shank. Alternatively, the shell may also be rapidly reheated after removal from the mold due to the relatively low shell mass for eventual mounting to the shank or mounting cutters on the external surface.
In another aspect, the shell includes a bore for receiving the bit shank which is then welded to the shell about the periphery thereof. In still another aspect, an interlocking groove and ridge is disposed between an internal surface of the shell and the bit shank. The groove and ridge are oriented to resist relative rotational motion of the shell and shank during drilling.
In still another aspect, a drill bit and method of manufacturing is provided in which an outer shell is attached to a shank by various means. Preferred methods of manufacturing the shell of the present invention include infiltration and machining. Another possible but not preferred method could be investment casting.
The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment which proceeds with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a drill bit constructed in accordance with the present invention.
FIG. 2A is a quarter sectional view of another bit having an external plenum formed between the shell and the shank constructed in accordance with the present invention.
FIG. 2B is a quarter sectional view of another bit having an internal plenum formed in the shank interior constructed in accordance with the present invention.
FIG. 3 is an enlarged sectional view of a nozzle shown in FIG. 2B.
FIG. 4 is a perspective view of an integrated bit core and shank constructed in accordance with the present invention.
FIG. 5 is a perspective view of another drill bit constructed in accordance with the present invention.
FIG. 6 is an exploded perspective view of still another drill bit constructed in accordance with the present invention.
FIG. 7A is an enlarged partial sectional view of a drill bit during assembly in accordance with the present invention.
FIG. 7B is a view similar to FIG. 7A after the bit is assembled.
FIG. 8 is a somewhat schematic sectional view of the drill bit of FIG. 5.
FIG. 9 is a partial sectional view of another drill bit constructed in accordance with the present invention illustrating an attachment method.
FIG. 10 is partial sectional view similar to FIG. 9 of another drill bit constructed in accordance with the present invention illustrating an attachment method.
FIG. 11 is a partial sectional view of another drill bit constructed in accordance with the present invention.
FIG. 12 is an enlarged schematic sectional view of a threaded connection in the drill bit of FIG. 11 before cooling.
FIG. 13 is a view of the threaded connection similar to FIG. 11 after cooling.
FIG. 14 is a partial sectional view of another drill bit constructed in accordance with the present invention.
FIG. 15 is a partial sectional view of another drill bit constructed in accordance with the present invention.
FIG. 16 is an exploded elevational view of a drill bit constructed in accordance with the present invention during the manufacturing process.
FIG. 17 is a perspective view of a prior art matrix drill bit with a portion of the bit sectioned.
FIG. 18 is a quarter sectional view of the drill bit of FIG. 17.
FIG. 19 is a partially sectional view of a drill bit similar to that shown in FIGS. 17 and 18 being manufactured in a furnace.
FIG. 20 is a partially sectional view of a drill bit similar to that shown in FIGS. 17 and 18 being manufactured with an induction heater.
FIG. 21 is a partially sectional view of a drill bit constructed in accordance with the present invention being manufactured in a furnace.
FIG. 22 is a partially sectional view of a drill bit constructed in accordance with the present invention being manufactured with an induction heater.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, indicated generally at 10 is a drill bit constructed in accordance with the present invention. Included therein is an integrated bit core and shank, referred to herein collectively as a shank 12, and an outer shell 14.
Shank 12 includes a threaded upper portion 16 for connecting drill bit 10 to a drill string (not shown). A bevel 20 separates upper portion 16 from a cylindrical portion 18. Similarly, a bevel 22 separates cylindrical portion 18 from a cylindrical disk 24. It should be appreciated that threaded portion 16, bevel 20, cylindrical portion 18, bevel 22 and cylindrical disk 24 are, in the present embodiment of the invention, integrally formed from a single piece of steel. Other techniques for forming shank 12, such as casting, are also within the scope of the present invention.
A cylindrical bore 26 communicates with a lower surface of cylindrical disk 24, as is viewable in FIG. 1, and extends axially therefrom through the bit with an opening at the upper end of threaded upper portion 16. Thus, fluid pumped down the drill string flows downwardly out of bore 26 as will later be more fully described in connection with a description of the operation of the drill bit.
A plurality of ridges or blades, like blades 28, 29, 30 extend downwardly from the underside of disk 24 and radially outwardly from a central longitudinal axis of the drill bit.
Shell 14 includes an external surface 34 which may have pockets (not shown) formed therein suitable for mounting cutting elements (also not shown) thereon. Shell 14 is manufactured utilizing matrix powder packed into a mold body which is thereafter infiltrated in a manner which is hereinafter described. The shell can also be manufactured by infiltrating around a ductile form, as described hereinafter with reference to FIG. 6, or by machining. Natural or artificial diamond cutters, or surface set diamonds, may be cast in to the shell during infiltration instead of or in addition to cutting elements mounted after infiltration is complete.
The embodiment of FIG. 1 provides a one-piece mandrel, unlike prior art bits as described in hereinafter in connection with FIGS. 17-20. The combination of a blank, around which a prior art infiltrated bit is formed, and a shank, which is welded to the blank for providing a threaded connection to a drill string, is referred to in the art as a mandrel. A one-piece mandrel reduces manufacturing time and expense while providing a mandrel with increased integrity. Also, the internal cavity defined between the mandrel and shell 14 provides for better fluid distribution than in prior art bits which improves fluid cooling of the bit and reduces fluid erosion on the bit crown interior. Such a mandrel provides structural integrity with less weight than prior art mandrels and in a more open configuration.
Throughout this description, similar structure is identified with a corresponding number in the various embodiments of the invention. In FIG. 2A, shank 12 includes a substantially solid core which is received into shell 14. Shell 14 is defined by a shell wall 36 having a substantially constant thickness. The shell is connected to shank 12 via a weld 37 about the circumference of the shank and shell. Braze alloys, adhesives or other suitable techniques may be used to connect the shank and shell together.
To form shell 14, a mold body is provided having a cavity therein which includes features conforming to those on the external surface of shell 14. Nozzles, like nozzle 44, are placed inside the mold body in selected positions. This eliminates the need for interior porting extending from the nozzle to the axial cylindrical bore which communicates with the drill pipe.
A bore 52 is formed in shank 12 and communicates with bore 26. An external plenum, i.e., one which is formed adjacent the interior surface of the shell, is formed between a radially inner surface 38 of shell 14 and shank 12. At least one bore, like bore 52, communicate between the plenum and bore 26. This permits fluid to circulate within and adjacent the shell.
Shell internal surface 38 may include a plurality of grooves, like grooves 42, into which a corresponding blade formed on shank 12 is received when the shank is inscribed into shell 14. These interlocking ridges and grooves accept torsion when the bit is drilling and relieve stress on weld 37.
In FIG. 2B, grooves 40 also receive ridges or blades formed on the shank to accomplish a similar stress relieving function in the bit of FIG. 2B. The bit of FIG. 2B has an internal plenum, i.e., one formed internally of shank 12. In FIG. 2B the internal plenum comprises the lowermost portion of bore 26.
During infiltration of the bit of FIG. 2B, forms are placed to provide cylindrical openings, like opening 46, into which a nozzle 48, is inserted after the matrix is infiltrated and cooled to provide fluid communication between bore 26 and the exterior of the bit. Nozzle 48 is illustrated in FIG. 3. In the present embodiment of the invention nozzle 48 is made from tungsten carbide and extends into a central cavity in the bit as shown. The nozzle therefore protects mandrel 12 from wear caused by the high pressures and flow rates of drilling fluid therethrough. A threaded connection 50 is formed between nozzle 48 and a bore formed in blade 28. Nozzle 48 can be changed by unthreading if replacement is required.
In using a drill bit like that shown in FIGS. 1, 2A or 2B, threaded connection 16 is engaged with the lower end of a drill string which is then lowered into a well bore. During drilling, drilling fluid is pumped down the drill string and into bore 26. The fluid passes through the bores, like bore 52, into plenum 38 and subsequently into nozzle 44 (and other nozzles not visible) and thereafter upwardly in the well bore in the annulus between the drill string and the radially inner surface of the well bore. Similarly, fluid flows from bore 26 into nozzle 48 (and other nozzles) and up the annulus.
Turning now to FIG. 4, indicated generally at 58 is a shank and integrated body core constructed in accordance with the present invention. Shank 58 is substantially identical to shank 12 in all respects except for the geometry of the blades, like blade 28-30 in FIG. 1. Shank 58 includes three blades, 60, 62, 64 which might be configured to be received into a shell having an interior shaped to include grooves for receiving the blades. Such a shell has a construction similar to that described above in connection with shell 14. Shank 58 is welded about the circumference thereof in a manner similar to that of shank 12 in FIG. 2A. The shank and integrated bit core of FIG. 4 is easy to machine and is illustrative, along with the other embodiments of the variety of shapes which can be utilized with the present invention.
Turning now to FIGS. 5 and 8, indicated generally at 66 is another drill bit constructed in accordance with the present invention. Included therein is a threaded upper portion 68 for connecting the drill bit to a drill string. Threaded portion 68 is mounted on an integrated shank and bit core, collectively referred to as a shank 70. Shank 70 is received in a shell 72 which may be infiltrated in similar fashion to shell 14, or through another casting process, or may be machined from steel. Shank 70 is received within shell 72 and welded thereto about the circumference of each via a weld 74 which is viewable in both FIGS. 5 and 8. Shank 70 includes a concave portion or junk slot 76 formed thereon. Shell 72 includes a plurality of cutters, like cutters 78, 80 mounted thereon. The cutters are mounted adjacent an opening in shell 72 defined by opposing edges 82, 84. The opening communicates with an interior cavity. A similar opening (not visible), which also communicates with the cavity, is adjacent a row of cutters including cutters 86, 88. Drill bit 66 is constructed generally in accordance with the design disclosed in U.S. Pat. No. 4,883,132 to Tibbitts, which is incorporated herein by reference, for a drag bit for drilling in plastic formation having maximum chip clearance and hydraulic for direct chip impingement except that the gauge and bottom portions of the drilling surface are formed on shell 72 which in turn is welded to shank 70 as described above. Bit 66 includes a nozzle (not visible) formed on a lower portion of shank 70 within the cavity defined between the shell and shank. The nozzle is aimed at the cutters, like cutters 78, 80 and flushes cuttings therefrom during drilling as described in the '132 patent to Tibbitts.
In FIG. 8, drill bit 66 is shown in a somewhat schematic sectional view. A torque lug 96 extends downwardly from the lower end of a center column 97 which is coaxial with the axis of bit 66. The torque lug extends into a slot formed in shell 72. This arrangement provides torsional stiffening to center column 97 during drilling.
As can be seen, fluid passageways in shank 70 permit drill fluid to circulate down the string and into shell 72 where the fluid is forced from nozzles (not shown in FIG. 8) contained in shank 70 into the cavities, like cavity 85, and to the top of the well in which the bit is drilling. The nozzles, cavities and flow passages for the bit of FIGS. 5 and 8 are illustrated in the above-referenced Tibbitts patent.
Turning now to FIG. 6, indicated generally at 90 is another drill bit constructed in accordance with the present invention which is similar in construction to the embodiments of FIGS. 1-4. Visible in FIG. 6 is a facing material 92 which is packed into the mold body before the interior mold portion is positioned and the remaining matrix powders packed between the mold body and inner mold portion.
Nozzle 44 does not need interior porting to connect it to the fluid in bore 26. As in FIG. 2A, the nozzle communicates directly with fluid inside shell 14. This eliminates the need for integrating complicated nozzle porting into the matrix when the shell is formed. If one of the shank blades, like blade 29, interferes with fluid distribution to nozzle 44, a corresponding notch 93 in blade 29 immediately above nozzle 44 provides fluid circulation between the flutes formed on the shank between the blades to the nozzle inside the shell.
Hydraulic fitting may be used to connect the shank to the shell in lieu of or in addition to welding. With reference to FIG. 7A, an O-ring 93 is disposed between shank 12 and shell 14 about the circumference thereof. Fluid is pumped into shell 14 via bore 26 thus expanding the shell. The expansion is sufficient to permit the shank to be pressed down a tapered portion 95 of the shell into a cylindrical collar portion 97. Once the pressure is released, the shell and shank are locked together.
Turning now to FIG. 9, indicated generally at 98 is another drill bit constructed in accordance with the present invention. Included therein is a shank and integrated bit body, collectively referred to as a shank 100, and a shell 102. In drill bit 98 there is a threaded connection 104 between a radially inner surface of shell 102 and a radially outer surface of the lower portion of shank 100. Shank 100 includes a downwardly directed shoulder 105 which seats against an internal surface of shell 102 when threads 104 are fully engaged. Thereafter, a weld 106 is formed about the circumference of the shank (or portions thereof) and shell in order to secure the two together.
Drill bit 108 comprises another embodiment of the present invention in which similar structure corresponding to that illustrated in FIG. 9 is identified with the same numeral in FIG. 10. The invention contemplates use of either a weld or threads or both together as illustrated in FIGS. 9 and 10.
Another drill bit 110, illustrated in FIGS. 11-13, is similar to the embodiments of FIGS. 9 and 10. Drill bit 1 10 in FIGS. 11-13, as are the bits in FIGS. 14 and 15, is assembled using heat shrink fitting. In this process, shell 102 is heated and shank 100, which is at room temperature, is engaged with matrix shell 102 as shown in FIG. 11 by a buttress connection 109. As shown in FIGS. 12 and 13, connection 109 includes a plurality of upward facing shoulders, like shoulder 111, on one side thereof and a plurality of downward facing shoulders, like shoulder 113 on the other side of the connection. The shoulders form continuous annular surfaces which are parallel with one another as opposed to a single helical surface as in a screw thread. With the matrix shell 102 hot and shank 100 at room temperature, connection 104 is configured as shown in FIG. 12. As the shell cools, it contracts in size thus drawing the shoulders together as shown in the view of FIG. 13. This has the effect of securely locking the shank to the shell. Alternately, shell 102 may be allowed to cool after it is formed. Prior to connecting the shell to the shank, the shell is heated in a known fashion to braze the cutters thereto. Such heating expands the shell which may then be fitted to the shank and thereafter cooled to accomplish the heat shrink fit. The shoulders illustrated in FIGS. 12 and 13 may be inverted, i.e., the shoulders are oriented to resist tension between the bit and drill string to which it is attached. Alternatively, drill bit 110 may be assembled using the previously described hydraulic fitting technique.
In FIG. 14 drill bit 112, also constructed in accordance with the present invention, includes a generally cylindrical opening 116 formed in shell 102 with shank 104 having a generally cylindrical lower portion. The two are sized so that matrix shell 102 can receive the lower end of shank 104, as shown in FIG. 14, while the matrix shell is heated. When the same cools it contracts thus providing a firm interference fit between the shell and the shank. In drill bit 114 in FIG. 15, a tapered opening 118 is provided in shell 102. The taper corresponds generally to a tapered radially outer portion of the lower end of shank 104. Shank 104 can be received in opening 118 as shown in FIG. 15 while matrix shell 102 is heated. As the shell contracts during cooling a strong connection between shell 102 and shank 104 is formed. The bits of FIGS. 14 and 15 can also be assembled using the hydraulic fitting technique described herein or by using a threaded connection.
Indicated generally at 120 in FIG. 16 is an assembly fixture for assembling a shank and a shell constructed in accordance with the present invention. Included therein is a cooling jacket 122 having an input line 124 and a return line 126 through which coolant flows. The coolant circulates within jacket 122 thereby cooling a shank 128 received therein which is constructed in accordance with the present invention. A concentric clamp 130 positions a hot shell 132, also constructed in accordance with the present invention, coaxially with shank 128. With the shank and shell positioned as shown in FIG. 16, the shank is lowered into the shell. Coolant in jacket 122 maintains the shank relatively cool even in the presence of the heat generated by shell 132. This both prevents the shank from expanding and prevents the drill collar connective thread of the shank from becoming heated above the "knee of transformation" which would cause it to become brittle. After the shank is positioned within the shell, the shell is left to cool and thus contract and engage the shank as described in the embodiments of FIGS. 11-15.
In FIGS. 17 and 18, a typical prior art matrix drill bit, indicated generally at 134, is illustrated to provide a comparison between such a bit and the bit of the present invention. Bit 134 includes a central longitudinal axis 138 and a coaxial bore 140. Bore 140 is also coaxial with a generally cylindrical blank 142 which includes an upper portion or shank 144. The shank includes threads 145 at the upper portion thereof for connecting the drill bit to a string of drill pipe (not shown). Blank 142 is comprised of a relatively ductile steel which has a coating of matrix material 146 bonded thereto. Bore 140 is formed in part through the matrix material.
This type of bit can utilize cutters, like cutters 147, 149, integrally secured to the matrix during the infiltration process or cutters which are mounted on the hardened matrix after infiltration.
Turning now to FIG. 19 a conventional furnace 150 includes a chamber 152 having a furnace floor 154. A mold 156 is supported on floor 154. The mold supports a funnel 158 which is engaged with a connection 160 with an upper portion of mold 156. Binder material 162 is received on top of matrix powder 146 which is packed in and around blank 142 as shown. Cutters can be placed in the mold body for integrating the cutters into the bit during the infiltration process. Alternatively, cutters can be brazed to the matrix surface after the bit is removed from the mold.
After the mold and the contents thereof are positioned as shown in FIG. 19, chamber 152 is heated thereby infiltrating matrix powder 146 in a known manner. After the bit is so formed the mold is removed from the furnace and after sufficient cooling the bit is removed from the mold. Thereafter, a steel shank, like shank 144 in FIGS. 17 and 18, having threads formed thereon is welded to blank 142.
Turning now to FIG. 20, an alternative form of infiltrating the matrix powder in mold 156 is illustrated. Included in FIG. 20 is an induction coil heater 164 which heats the mold and the contents thereof thereby infiltrating matrix powder 146. The drill bit of FIGS. 17 and 18 can be manufactured using either of the techniques illustrated in FIGS. 19 and 20.
Turning now to FIG. 21 illustrated therein is a mold constructed in accordance with the present invention. As can be seen, matrix powder 146 is formed into a shell shaped by virtue of a mold shell 166, such being also referred to herein as an upper mold body. The mold shell includes a hollow cavity 168. The surface of mold shell 166 which is adjacent matrix powder 146 defines the inner surface of the outer shell of the bit. The features of this mold shell surface define grooves, like grooves 40, 42 in FIGS. 2A and 2B, in which the blades of shank 12 are received.
In an alternative embodiment of the invention, instead of mold shell 166, a similarly shaped steel shell is positioned in the same position as mold shell 166 and forms a finished part of the shell as described in connection with the embodiment of FIG. 6. The steel portion can be ductile relative to the infiltrated material which forms the exterior portion of the shell. In such case, the grooves, like grooves 40,42, are formed on the inner surface of the ductile steel shell.
Illustrated in FIG. 22 is an alternate method of manufacturing a drill bit in accordance with the present invention. Included therein are induction coil heaters 168, 170, 172. Heater 170 can be received within cavity 168 as shown and heater 172 within spaces on the underside of mold 156. With all heaters operating, the matrix powder is uniformly heated which is desirable in forming the infiltrated matrix shell. Induction heating in accordance with the prior art method illustrated in FIG. 20 must be done very slowly because stresses arise between the heated portions and the unheated portions. The system of FIG. 22 permits much more rapid infiltration of the matrix powder without the stresses which would result in the configuration of FIG. 20. Reduced mass coupled with increased surface area and internal heat exposure provides for greatly reduced heating time and more uniform products.
After the matrix powder is infiltrated responsive to heat provided by, e.g., a box heater, a furnace as in FIG. 21 or induction coils as in FIG. 22, the mold is cooled and the bit removed therefrom in the case where the cutters are not integrated into the matrix body during infiltration, they may be brazed to the shell. Brazing requires heating which can be done via a pair of induction coils similar to the configuration of coils 168, 170, illustrated in FIG. 22 except that the mold is removed. When the shell is sufficiently heated, the cutters are brazed thereto in a known manner. When assembling bits of the type illustrated in FIGS. 11-15, in which the shank is inserted into the shell while the shell is hot, the insertion step can be accomplished immediately after brazing the cutters while the shell is still hot from the induction heating necessary for brazing. Thus, the shell can be rapidly heated as a result both of the substantially smaller mass of the matrix material relative to prior art bits and due to use of a second internal induction coil, like coil 170 in FIG. 22. A separate step for heating the shell in order to expand the same to fit it to the shank as described in connection with the bits of FIGS. 11-15 is not require. The assembly fixture illustrated in FIG. 16 and described above can be used for a matrix shell which is heated with induction heaters to expand the shell for assembly.
Having illustrated and described the principles of our invention in a preferred embodiment thereof, it should be readily apparent to those skilled in the art that the invention can be modified in arrangement and detail without departing from such principles. We claim all modifications coming within the spirit and scope of the accompanying claims.
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A method for making an earth boring drill bit which includes an outer shell having an external surface adapted to carry cutting elements and a unitary shank and bit core which is fitted into the outer shell. The shell and bit core are threadably engaged with one another or are interferingly engaged. The shell and bit core may be welded, secured with brazing alloys or with high temperature adhesives. In one embodiment, a ridge formed on the shank is received in a groove formed on an interior surface of the shell to prevent relative rotational movement of the shank and shell during drilling. In another embodiment, the shell is formed using matrix infiltration techniques. After the shell is formed, it is heated to braze cutters thereto. While still hot from the brazing process, the shell and shank are fitted together. After cooling the shell contracts to form heat shrink connection between the shell and the shank.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. Patent Application Ser. No. 12/844,258 filed Jul. 27, 2010, now U.S. Pat. No. 8,458984, which claims the benefit of and priority to U.S. Provisional Patent Application No. 61/229,154, filed on Jul. 28, 2009. Each one of these applications is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates in general to forming an adjustable foundation, and in particular, to a concrete slab foundation capable of being raised above the ground.
BACKGROUND OF THE INVENTION
[0003] Many structures have been built on foundations or slabs made of concrete poured on top of soil. Constant changes in the weather and moisture levels in the soil frequently cause damage to such a foundation. In many instances, the foundation may buckle or even crack. This phenomenon occurs for a variety of reasons, including uneven changes in the water content of supporting soils, uneven compacting of soils, and uneven loads being placed on soils. Over time, uneven movement in the soils under a foundation can cause a foundation to bend or crack.
[0004] Therefore, it would be desirable to provide a method and apparatus that would allow a foundation to be poured on top of soil and subsequently raised to a desired height to eliminate potential problems caused by soil movement and/or problematic soils.
SUMMARY OF THE INVENTION
[0005] An embodiment of the system for forming a movable slab foundation as comprised by the present invention has a slab foundation. At least one substantially vertical support member has a hollow body with first and second ends. The first end of the substantially vertical support member is in abutting contact with at least one support surface. At least one support sleeve surrounds the at least one support member. The at least one support sleeve is encased within the slab foundation and is capable of movement axially along the axis of the at least one support member. The at least one support sleeve has an opening through which the at least one support member extends. The opening is substantially geometrically complimentary to the at least one support member. The at least one vertical support member is capable of rotation relative to the at least one support sleeve to restrict the movement of the at least one support sleeve downward relative to the at least one vertical support member, thereby maintaining the height of the at least one support sleeve and the slab foundation relative to the at least one support surface.
[0006] An embodiment of the system for forming a movable slab foundation as comprised by the present invention has a slab foundation. At least one substantially vertical support member has a generally elliptical shaped hollow body with first and second ends. The first end of the at least one support member is in abutting contacting with at least one support surface. At least one support sleeve has a hollow body with inner and outer surfaces. The at least one support sleeve surrounds the at least one support member. The inner surface of the at least one support. sleeve has a plurality of tabs extending along and radially inward from the inner surface at select intervals to thereby define a generally elliptical shaped opening. The opening is substantially geometrically complimentary to the at least one support member. The inner surface of the at least one support sleeve also has a plurality of apertures located in and extending therethrough. The outer surface of the at least one support sleeve has at least one reinforcing bar connected to and extending outwardly therefrom. The at least one support member initially extends through the substantially geometrically complimentary opening in the at least one support sleeve. The outer surface of the sleeve body and the at least one reinforcing bar are encased within the slab foundation. The at least one support sleeve and the slab foundation are capable of movement axially along the axis of the at least one support member. The at least one support member is capable of rotation relative to the at least one support sleeve to offset the at least one support member from the opening in the at least one support sleeve to thereby restrict the movement of the at least one support sleeve downward relative to the at least one support member. At least one lifting member is surrounded by the at least one support member. The at least one lifting member has a body first and second ends, the first end being in abutting contact with the at least one support surface.
[0007] An embodiment of the present invention is directed to a method for forming a movable slab foundation. The method comprises placing a plurality of support surfaces below an intended slab foundation area. A plurality of support sleeves are placed in abutting contact with the plurality of support surfaces. The plurality of support sleeves have a geometrically shaped opening extending axially therethrough. A plurality of support members being geometrically complimentary to the openings are inserted into the openings and are placed within the plurality of support sleeves. The plurality of support members are slid down within the plurality of support sleeves and into abutting contact with the plurality of support surfaces. A slab foundation is formed such that it encases the plurality of support sleeves. The plurality of support sleeves are simultaneously lifted to move the slab foundation along the axes of the plurality of support members to a desired height. The plurality of support members are rotated relative to the plurality of support sleeves, thereby restricting the movement of the plurality of support sleeves downward relative to the plurality of support members and maintaining the desired height of the slab foundation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] So that the manner in which the features and benefits of the invention, as well as others which will become apparent, may be understood in more detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is also to be noted, however, that the drawings illustrate only various embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it may include other effective embodiments as well.
[0009] FIG. 1 is a sectional view of a single slab support, illustrating a concrete pier and a support sleeve.
[0010] FIG. 2 is a sectional view of the support sleeve taken along the line 2 - 2 of FIG. 1 .
[0011] FIG. 3 is a sectional view of the single slab support with a support pipe and a lifting rod inserted and a lifting assembly connected.
[0012] FIG. 4 is a sectional view of the support sleeve and the support pipe taken along the line 4 - 4 of FIG. 3 .
[0013] FIG. 5 is a sectional view of the single slab support with the slab raised a distance above a ground surface.
[0014] FIG. 6 is a sectional view of the single slab support with the slab raised to a final height.
[0015] FIG. 7 is a sectional view of the support sleeve and support pipe taken along the line 7 - 7 of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein; rather, this embodiment is 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.
[0017] Referring to FIG. 1 , a foundation slab 11 may be used to support a house or other building or structure. In this embodiment, the slab 11 is of concrete and initially rests on a ground surface 17 and a support surface or pier 13 . The foundation or slab 11 is typically supported by a plurality of support surfaces or piers 13 , but for simplification purposes, the single pier 13 will be discussed. In this embodiment, the pier 13 is of concrete and has a base plate 15 embedded therein, such that at least the top or upper surface of the base plate 15 is exposed. In this embodiment, the base plate 15 is circular in shape, but in alternate embodiments may comprise different shapes, for example, a rectangle. In this embodiment, the base plate 15 has an anchor bolt 16 connected to it that extends a select distance into the concrete pier 13 . In alternate embodiments, other support members may be connected to the base plate 15 .
[0018] In this embodiment, the hole for the pier 13 is dug with a diameter such that the base plate 15 is fully encased within the concrete. One the hole is dug as desired, the pier 13 is formed by pouring concrete into the hole. The base plate 15 is then embedded in the concrete of the pier 13 such that the top or upper surface of the base plate 15 is substantially parallel with the ground surface 17 . As previously discussed, in this embodiment, the anchor bolt 16 is connected to the base plate 15 and extends into the concrete of the pier 13 a distance below base the plate 15 .
[0019] In this embodiment, a cylindrical exterior pipe or support sleeve 19 has an outer diameter less than the diameter of the base plate 15 . The support sleeve 19 and the base plate 15 are sized such that the bottom surface of the support sleeve 19 is in supporting contact with the base plate 15 . The length of the support sleeve 19 may be less than or equal to the desired thickness of the concrete slab 11 . In this embodiment, the length of the support sleeve 19 is equal to the thickness of the concrete slab 11 . An inner surface 21 of the sleeve 19 has a plurality of support tabs 23 connected therein that extend along the inner diameter and radially inward a select distance. The support tabs 23 may be connected to the support sleeve 19 through various means, including, but not limited to welding and fasteners. As seen in FIG. 2 , in this embodiment, two support tabs 23 are positioned opposite from one another and extend around the inner surface 21 of the support sleeve 19 at select intervals.
[0020] Retelling back to FIG. 1 ., reinforcing bars (rebar) 25 are connected to the outer surface of the sleeve 19 . In this embodiment, a first leg 27 of the rebar 25 is connected to and extends outwardly and downwardly at an angle from the sleeve 19 . A second leg 29 of the rebar 25 is substantially perpendicular to the support sleeve 19 and extends between the first leg 27 and the sleeve 19 . The rebar 25 may be welded around the outer peripheries of the sleeve 19 at desired intervals. In an alternate embodiment, various reinforcing members may be connected to and extend outwardly from the outer peripheries of the sleeve 19 in various shapes and configurations.
[0021] A plurality of lift holes or apertures 33 are located in and extend radially outward through the inner surface 21 of the support sleeve 19 . in this embodiment, two lift holes 33 are positioned opposite from one another. The lift holes 33 are designed to accept a lifting device or lifting link.
[0022] The sleeve assembly 19 is positioned atop the base plate 15 . In an alternate embodiment, the lower end of the support sleeve 19 may be lightly tack welded to the base plate 15 . The concrete slab 11 is then poured, thereby embedding the rebar 25 and the sleeve assembly 19 within the slab 11 . The concrete may be kept from bonding, to the concrete pier 13 and the base plate 15 by an optional bond breaker layer (not shown).
[0023] Referring to FIG. 3 , after the cement slab 11 has hardened, a support. member or support pipe 35 having an elliptical shape ( FIG. 4 ) is inserted into the sleeve 19 and lowered until a lower first end portion makes contact with the base plate 15 . The elliptical shape of the support pipe 35 requires that it be properly oriented with respect to the support sleeve 19 to allow the support pipe 35 to pass by the tabs 23 on the inner surface 21 of the sleeve 19 without interference ( FIG. 4 ). The support pipe 35 is positioned such that the lower first end portion of the support pipe 35 rests on the base plate 15 . The support pipe 35 extends upwardly a selected distance from the base plate 15 . The length of supporting pipe 35 can be varied to accommodate various desired slab 11 heights. As shown in FIG. 4 , the support pipe 35 is elliptical in shape and is adapted to receive a lift bar 37 . The desired final height of the slab 11 . is determined by the length of the support pipe 35 .
[0024] Referring back to FIG. 3 , a lifting member or solid lifting rod 37 , with a smaller diameter than the support pipe 35 is inserted into the support pipe 35 and lowered until it makes contact with the base plate 15 . The length of the lifting rod 37 can be calculated such that it may remain within the support pipe 35 once the slab 11 has reached its final desired height. Alternatively, the lifting rod 37 may be removed from the support pipe 35 Once the slab 11 has reached its final desired height. After the lifting rod 37 is in place, a lift support plate 38 is positioned on the top of the support d 43 . The support plate 38 has a plurality of apertures 39 located in and extending therethrough. A lifting device 41 is then mounted on the top of the support plate 38 . In this embodiment, the lifting device 41 is a hydraulic jack mounted on the top of the support plate 38 . A lift plate 43 is then positioned on top of the hydraulic jack 41 . The lift plate 43 has a plurality of apertures 45 located in and extending therethrough. The lift plate 43 is positioned such that the apertures 45 are in alignment with the apertures 39 in the support plate 38 .
[0025] Attachment members or attachment rods 47 are connected to the lift holes 33 in the sleeve 19 in order to lift the slab 11 to its desired height. In this embodiment, the attachment rods 47 contain threads in at least an upper portion thereof. The attachment rods 47 pass through the apertures 39 in the support plate 38 and the apertures 45 in the lift plate 43 . Nuts 48 are threaded onto upper portions of the attachment rods 47 located between the support plate 38 and the lift plate 43 . The nuts 48 may be adjusted once the slab 11 has been lifted to permit removal of the hydraulic jack 41 . Nuts 49 are threaded onto upper portions Of the attachment rods 47 , above the lift plate 43 . The nuts 49 prevent the lift plate 43 from moving upward independently from the attachment rods 47 when the hydraulic jack 41 is activated.
[0026] Referring to FIG. 5 , hydraulic fluid pressure is applied to the jack 41 , causing the jack 41 to push the lift plate 43 and the attachment rods 47 upwards relative to the base plate 15 . The jack 41 moves the lift plate 43 and the attachment rods 47 upwards until the foundation slab 11 has been lifted above the ground 17 . to the desired height. In the event that the hydraulic jack 41 . needs to be removed during the lifting process, the nuts 48 can be tightened against the support plate 38 , thereby allowing the lifting device 41 and the lift plate 43 to be removed if necessary, while maintaining the height of the slab 11 .
[0027] Referring to FIG. 6 , once the slab 11 has reached its desired final height, the tabs 23 on the inner surface 21 of the sleeve 19 will be positioned above the support pipe 35 . In order to secure the slab 11 at the desired height, the support pipe 35 is then rotated such that the support tabs 23 are no longer offset from the elliptical shape of the support pipe 35 ( FIG. 7 ). Once the support tabs 23 are positioned above the support pipe 35 , and the support pipe 35 has been rotated to the proper position, the sleeve 19 , the slab foundation 11 , and the tabs 23 are lowered such that tabs 23 rest upon the support pipe 35 . Once the tabs 23 are securely resting upon the support pipe 35 , the attachment rods 47 , the support plate 38 , the hydraulic jack 41 , the lift plate 43 , and the lifting rod 37 ( FIG. 5 ) are removed.
[0028] Referring to FIG. 6 , the lifting rod 37 ( FIG. 5 ) may be removed if its length is greater than the final height of the slab 11 . Whether the lifting rod 37 is removed or remains within the support pipe 35 , once the slab 11 has reach its desired height, a cap 49 can be inserted into the sleeve 19 . In the event that the height of slab 11 needs to be adjusted, the cap 49 may be removed, the lifting rod 37 reinserted if not already in place, and the support plate 38 , the hydraulic jack 41 , the lift plate 43 , and the attachment rods 47 reconnected. Once the weight of the slab 11 is lifted from the support pipe 35 , the support pipe 35 is rotated such that the tabs 23 on the inner surface 21 of the sleeve 19 will not interfere with the support pipe 35 . The slab 11 is lowered to its original position. The support pipe 35 may be replaced with a supporting pipe with a length to accommodate the new desired height. Once the desired height has been reached, as previously illustrated, the slab 11 may be secured in place by rotating the new support pipe and lowering the weight of the slab 11 and the sleeve 19 onto the new support pipe. As previously discussed, the hydraulic jack 41 , the support plate 38 , the lift plate 43 , the attachment rods 47 , and the lifting rod 37 may then be removed and the cap 49 reinstalled in the sleeve 19 .
[0029] The invention has significant advantages. The invention provides a method and apparatus that allows a foundation to be poured on top of soil and subsequently raised to a desired height to eliminate potential problems caused by soil movement and/or problematic soils.
[0030] In the drawings and specification, there have been disclosed a typical preferred embodiment of the invention, and although specific terms are employed, the terms are used in a descriptive sense only and not for purposes of limitation. The invention has been described in considerable detail with specific reference to these illustrated embodiments. It will be apparent, however, that various modifications and changes can be made within the spirit and scope of the invention as described in the foregoing specification and as set forth in the following claims.
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An embodiment of the system for forming a movable slab foundation as comprised by the present invention has a slab foundation, at least one substantially vertical support member, at least one support surface, and at least one support sleeve. The at least one supports sleeve surrounds the at least one support member and is encased within the slab foundation and is capable of movement axially along the axis of the at least one support member. The at least one vertical support member is capable of rotation relative to the at least one support sleeve to restrict the movement of the at least one support sleeve downward relative to the at least one vertical support member, thereby maintaining the height of the at least One support sleeve and the slab foundation relative to the at least one support surface.
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[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/763,091, filed Jan. 21, 2004, which claims the benefit of provisional Application No. 60/441,797, filed Jan. 21, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to locking astragals and more particularly to locking astragals with self positioning seals.
[0004] 2. Background Art
[0005] Double entrance doorways are used in a large variety of residential homes and commercial buildings. Typically, an active door provides for day to day ingress and egress to and from the residential home or building, and an inactive door remains closed, except in instances when a width greater than or equal to the width of the active door and less than or equal to the width of the double entrance doorway is required, such as, for example, for delivery of furniture and/or equipment that cannot fit through the double entrance doorway. If large objects, such as furniture and/or equipment must pass through the double entrance doorway, both the normally inactive door and the active door of the doorway are opened, to create a wide entrance way, through which the furniture and/or equipment may pass.
[0006] Mating edges of the inactive door and the active door do not typically contact one another directly, but are separated by an astragal, the astragal being attached to the edge of an inactive leaf, the astragal extending the length of the inactive door, cushioning the closing of the active door and associated inactive leaf of the doorway, and sealing gaps between the inactive door and the active door.
[0007] The astragals often have upper and lower bolt-slide assemblies, which lock the astragals and the inactive doors to upper and lower portions of a door frame surrounding the double entrance door way. The upper and lower bolt-slide assemblies have bolts, which slide within upper and lower ends of the astragal, and are pushed outwardly from the inactive door to extend beyond the ends of the astragal, and are received by upper and lower apertures in the upper and lower portions of the door frame, also known as the header and threshold sill, respectively, to lock the inactive door in place.
[0008] Stationary seals are typically used at the lower end of the astragals for sealing and preventing drafts from entering the residential homes and/or commercial buildings through the double entrance doorways at the threshold sill. Since many different types, sizes, and shapes of thresholds are used, the drafts remain an unwanted by product of using the stationary sills. In many instances, the fixed size of the seals, and the materials used, for the stationary seals, are either too thick or too thin to fill the gap between the lower end of the astragal and the threshold sill, and, thus, result in not providing an adequate seal, and/or the seal degrading over time.
[0009] There is thus a need for an astragal having self positioning astragal seal that prevents unwanted drafts, is easy to use and install in a quick, convenient, and efficient manner, is durable and long lasting, maintains its seal against drafts over time, even in situations where repeated opening and closing of the inactive door is necessary, and can be used with a variety of astragals and threshold sills, types, sizes, and shapes of threshold sills, doors, and door frames.
[0010] The self positioning astragal seal should be capable of automatically positioning at least one seal at the lower end of the astragal adjacent the threshold sill, and prevent drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or of automatically positioning at least one seal at the upper end of the astragal adjacent the header, and prevent drafts at the vicinity of the header.
[0011] The self positioning astragal seal should independently position itself abuttingly adjacent the sill and/or the header when the bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame.
[0012] The astragal should also have a lock for locking the bolts into the extended position, and unlocking the bolts at a user's discretion, thus, provide additional security.
[0013] Different astragals have heretofore been known. However, none of the astragals adequately satisfies these aforementioned needs.
[0014] Locking astragals have been disclosed. However, none of these astragals adequately satisfies the aforementioned needs.
[0015] U.S. Pat. No. 6,666,486 (Fleming) discloses a slide bolt unit for releasably locking a door or window or the like, such as a semi-active door in a double door entry set. The slide bolt unit includes an elongated slide bolt carried by a channel-shaped housing adapted for recessed mounting into a side edge of a door or the like. An actuator tab on the slide bolt is exposed through a position control slot formed in the housing for fingertip actuation to displace the slide bolt between an advanced position engaging a keeper on an adjacent header or sill or the like to lock the door in a closed position, and a retracted position to permit door opening. The actuator tab has a slotted profile defining lock shoulders biased by a spring for releasably engaging and locking with the housing at opposite ends of the position control slot, and a narrowed central slide track for alignment with the position control slot upon fingertip depression of the actuator tab to permit sliding displacement of the actuator tab along the position control slot from one end to the other.
[0016] U.S. Pat. No. 6,491,326 (Massey, et al.) discloses a swing adaptable astragal with lockable unitary flush bolt assemblies, which includes an improved astragal assembly for double door entryways having an extruded aluminum frame into which upper and lower flush bolt assemblies are slidably disposed. The flush bolt assemblies include a relatively long metal bolt about which is injection overmolded a series of retainer guides, which ride in the frame. Locking mechanisms are also integrally overmolded onto the bolts. The frame and all components of the astragal assembly are symmetrical and reversible so that the assembly is non-handed; that is, it can be adapted to both a right hand swing and a left-hand swing inactive door. A strike plate mounting system and bottom-sealing block are provided, and the upper end of the assembly includes means for sealing against the stop of a head jamb. Drafts at the upper and lower inside corners of the doors of a double door entryway are thus prevented.
[0017] U.S. Pat. No. 6,457,751 (Hartman) discloses a locking assembly for an astragal, which is attached to the inactive door of a double door unit that is installed in a residence or a building. The astragal is attached to the edge of the inactive door in the space between the inactive door and the active door. A separate locking assembly is attached adjacent the top end of the door and also adjacent the bottom end of the door. A plug having an elongated locking bolt extending from the plug is mounted in the front end of the carriage member. Additional structure is provided for reciprocal travel of the carriage member between a locked position and an unlocked position.
[0018] U.S. Pat. No. 6,453,616 (Wright) discloses an astragal for use with exterior double door installations, such as french doors. When attached to the edge of the generally inactive door, the astragal provides a door stop for the active door, a seal to prevent intrusion of water, and a lock for the inactive door. The invention particularly pertains to extruded metal astragals capable of increasing the resistance of the double door system to high wind conditions. The astragal comprises a longitudinally extending base member that has at least one longitudinally extending channel and a pair of spaced apart outwardly extending legs. At least one bolt is slidably inserted in the channel adjacent to one of the first and second ends of the channel. The astragal is attached to the door by at least one cleat whose spaced apart arms engage the legs of the base member, providing resistance to the astragal rocking in relation to the door edge when the doors are under wind forces.
[0019] U.S. Pat. No. 5,857,291 (Headrick) discloses an astragal with integral sealing lock block, for use with a double door installation, which includes an astragal strip secured along the vertical edge of the inactive door. A lock block is slidably disposed in at least one end of said astragal strip and can be moved between an extended position for securing the door and a retracted position for freeing the door. The lock block has a projecting bolt receivable in a receptacle in the door frame, when the lock block is slid to its extended position. A gasket is secured to the end of the lock block, and the bolt passes through an opening in the gasket. The gasket engages and seals against the door frame when the lock block is in its extended position. Gaskets are also provided on the sides of the lock block for engaging and sealing against the doors of the double door installation. When the doors are closed and secured in place, the lock block and gasket assembly prevents drafts from flowing under the door installation beneath the astragal thereof.
[0020] U.S. Pat. No. 5,590,919 (Germano) discloses a T-astragal and sleeve for use with double swinging doors, such as french doors. The T-astragal includes a cap portion perpendicular to a base portion, wherein both the cap and base can be formed from wood, such as plywood or plastic. The T-astragal is a moulding that extends the full height of the swinging doors. One side of the base portion is fixably coupled to the free end of one of the swinging doors by nails or screws. The free end of the other swinging doors is able to swing up to and against a shoulder portion formed from the cap and base portions. A metal pipe shaped sleeve having an approximate length of one foot is partially positioned along the longitudinal axis of the T-astragal molding. A bolt slides within the sleeve from a rest position to an extended position, where the extended position locks the attached door to a matching slot in the door frame.
[0021] U.S. Pat. Nos. 5,350,207 and 5,328,217 (Sanders) disclose a locking astragal for attachment to an inactive leaf of a double doorway, in which an elongated astragal casing has a channel and bolt-slide assemblies mounted slidably within the channel. Each bolt-slide assembly includes a latching member and bolt. By depressing the latching member, the latching member can slide through the channel to extend and lock the bolts into indentations in the upper and lower surfaces of the door frame. The bolts may also be retracted back into the astragal to open the inactive leaf. Each latching member has an integral spring, which simplifies fabrication and assembly.
[0022] U.S. Pat. No. 4,999,950 (Beske, et al.) discloses an inwardly swinging door assembly, which includes a door member hingedly mounted to a frame. A multi-point lock engages the frame at more than one point. Weather stripping is cooperatively connected to the edged surfaces. A pressure equalization member is cooperatively connected to the frame, for engaging the weather strip connected to the bottom edged surface.
[0023] U.S. Pat. No. 4,644,696 (Bursk) discloses a patio door assembly for removable astragal, in which a double door installation includes an astragal, which is removably mounted in the head jamb and sill portions of a door frame independently of the doors, and which includes a locking mechanism in one door which incorporates a bolt arranged to project through the astragal into the other door to effect firm locking of both doors to each other and to the astragal. The mounting for the astragal in the door frame includes a sill anchor, which is fixed on the sill, and is provided with a vertical projection that fits in complementary relation within the hollow lower end of the stem portion of the astragal. At its upper end, the astragal is releasably secured to the head jamb by a latch assembly and an anchor of generally inverted cup shape, which is set in a complementary recess in the head jamb and functions as a keeper for the flush bolt, which is mounted for vertical sliding movement in the hollow upper end of the astragal stem portion.
[0024] U.S. Pat. No. 4,535,578 (Gerken) discloses a seal-actuating mechanism for a wall panel, which when mounted in a wall panel of the type having channel-shaped opposed frame members can be installed, replaced or repaired without removing the exterior finished surface of the wall panel. The seal-actuating mechanism includes a rotatable shaft mounted between the opposed frame members, and an operator member including pivot lever means is mounted on each end thereof. At least one tension member is disposed in the cavity of each frame member, one end of which is coupled to the pivot lever means, and the other end of which is coupled to the shiftable seal assembly, so that when the shaft is rotated the seal assembly is shifted respectively from an extended unlatched position to its retracted latched position.
[0025] U.S. Pat. No. 4,489,968 (Easley) discloses a selectively operable doorstop for converting a double-acting door to a single-acting door. A selectively removable or retractable doorstop for converting double-acting, double or single doors to a single-acting, single door, for permitting control over traffic into and out of public premises at desired times. The doorstop includes an intercept portion which can be selectively removably or retractably inserted into the path of a double-acting door thereby restricting it to opening in one direction only. Different embodiments of the doorstop are provided respectively for temporary or permanent mounting on or in a doorjamb, or on or in the stile of a temporarily fixed-in-place door, thus giving a selection of options for any specific situation.
[0026] U.S. Pat. No. 4,488,378 (Symon) discloses an entrance for buildings, which comprises first and second doors mounted in a common door frame, each door including a lock stile positioned adjacent a lock stile of the other door when the doors are closed. A panic device is mounted on at least one of the doors for emergency opening thereof, and a retractable latch is extended between the stiles of the doors when closed, for minimizing or eliminating the unauthorized forced separation of the stiles into a position wherein the panic device can be actuated with an implement inserted from outside the entrance to release and open the door. Mechanism is included for interconnecting the latch and the panic device for retraction of the latch, when the panic device is actuated for opening the door, thus, providing both a substantially safe and secure entrance system.
[0027] U.S. Pat. No. 4,429,493 (St. Aubin) discloses an astragal housing seal and lock, for use in a double door assembly having an active door and a relatively inactive door. The astragal has a vertically extending mullion housing, which is attached to the free edge of the relatively inactive door. A vertically extending slide section is mounted on the mullion housing on the sealing side of the free edge of the inactive door. The slide section extends from the free vertical edge of the inactive door, when the active door is in the closed position. The slide section is vertically movable from an unlocked position to a locked position, wherein the slide section is moved vertically downward with respect to the mullion housing to engage the sill/threshold of the door frame, thereby preventing movement of the inactive door.
[0028] U.S. Pat. No. 4,262,450 (Anderson) discloses a sliding door structure, including an outer frame, at least one fixed and one movable door panel, and a screen door, the frame including a head having a single, inwardly extending movable door panel guiding fin and all mitered corners, which corners include integral, offset abutment structure for insuring proper alignment of the corners in assembly, weather stripping at both the top and bottom rail of both the fixed and movable door panels, bottom adjusting structure for the movable door panel, and two-member glazing structure for the door panels, capable of resisting high wind force and permitting glazing of the door panels from the inside. The frame and door panels include substantially universal and reversible members. Resilient bumpers, a weather stop, and prowler lock structure permitting locking of the sliding door structure of the movable door panel in a number of selected positions are also disclosed.
[0029] U.S. Pat. No. 4,225,163 (Hubbard, et al.) discloses a panic device actuator for a door, which includes apparatus for unlatching a door mounted in a door frame and one or more elements movable for retracting one or more door latches normally engaged with the door frame for positively locking the door. The panic actuator includes a relatively large panel having an enlarged outer face responsive to pressure applied at any area thereon for unlocking the door without a key. A mounting system is provided for supporting the panel on the door for controlled movement in a horizontal direction in continuous parallelism with the face of the door in a direction normal to the door face. A linkage is provided for interconnecting the panel and the door latching element(s) for moving the same to unlock the door latches in response to pressure movement of the panel on the door.
[0030] U.S. Pat. No. 4,204,369 (Hubbard) discloses an entrance door system, which includes an automatic astragal along an edge of a door and an operator on the door for controlling one or more latch assemblies normally engaged to latch an edge of the door with a member of a door frame in which the door is mounted. The latch assembly is mounted on the door to normally latch the door with the door frame, when the door is closed, and the latch is releasable to an unlatched condition, so that the door may be opened. The elongated astragal is mounted in parallel along the edge of the door and is guided for parallel movement between a retracted and an extended position. The door operator is effective for moving the astragal between retracted and extended positions, and the astragal is interconnected for moving the latch assembly to release the latching engagement, when the astragal is moved to the retracted position, so that the door may be opened.
[0031] U.S. Pat. No. 4,058,332 (DiFazio) discloses an astragal and flush bolt assembly to be secured to a relatively stationary member, such as a door jamb or to the edge of an inactive door of a pair of double doors or the like. The astragal assembly includes a flat metal body mounted on the edge of the stationary member and a metal stop member secured to the body along one edge thereof. The flat body includes first and second spaced apart legs extending outwardly from the stationary member, with the flat body and legs defining a channel to receive and retain a door latch bolt from the active door. The stop member prevents movement of the door in a first direction, and when the latch bolt is engaged in the channel, the channel and the latch bolt prevent the door from moving in the opposite direction. A pair of flush bolts are slidably mounted in the channel, one adjacent each end thereof, so that when the astragal assembly is utilized with double doors, the flush bolts are moved to engage the header and sill, respectively, to hold the inactive door stationary. The astragal body is secured to the stop member by a thermal barrier or thermal break structure to provide thermal insulation between the inside and the outside of the doors. The stop member also includes a weather strip to form a tight seal against the active door, and when metal doors or metal covered doors are used, the weather strip may include a magnetic member to form a seal against the active door.
[0032] U.S. Pat. No. 4,052,819 (Beischel, et al.) discloses a double door astragal, which comprises a rigid support member securable to the vertical edge portion of a normally inactive door, a rigid cover member securable in a plurality of positions relative to the rigid support member and mounted on the rigid support member with a U-shaped portion having an outer leg extending into the swinging path of the active door, and a flexible sealing member secured to the rigid support member and extending into the opening formed by the U-shaped portion of the cover member so as to contact the outside surface of the active door when the vertical edge portions of the active and inactive doors are in abutting relation, to provide an adjustable seal against weather.
[0033] U.S. Pat. No. 4,009,537 (Hubbard) discloses an automatic astragal assembly for inclusion or attachment to a door edge, comprising an elongated astragal housing mounted on the door and having an outwardly opening longitudinal recess therein, an elongated astragal slidably mounted in the recess, means supporting the astragal in the recess for upward and inward relative movement in the housing in response to lifting of the astragal from lifting means mounted on an inside surface of the door, the lifting means including a lift slide mounted on the housing for reciprocal vertical movement and having an L-shaped slot defined therein with an interconnecting horizontal and vertical section and a dead lock pin engaged in the slot and secured to the astragal for elevating the same upon lifting movement of the slide, the vertical section of the slot and the dead lock pin engaging to prevent elevation of the astragal from pressure exerted against an outer edge of the astragal tending to force the astragal horizontally into the recess.
[0034] U.S. Pat. No. 3,997,201 (DeSchaaf, et al.) discloses a latch structure for releasably locking a door to a cabinet, including switch structure for permitting operation of electrical apparatus associated therewith to be operated only when the door is in the latched closed position. The switch is hidden within the door behind the latch bolt, so as to be operated substantially only by the strike which has a preselected configuration, to effect the latching and switch operating operations. The bolt may be operated manually to release the door from the latched condition. A pivotally mounted operator is also disclosed for effecting the unlatching movement of the bolt.
[0035] U.S. Pat. No. 3,940,886 (Ellingson, Jr). discloses a door locking structure forming a panic exit device, consisting of an elongated housing recessed within the leading edge of a door structure, an operating rod including latch bolts disposed in the housing, an astragal seated within a channel formed in the leading edge of the housing, link members connecting the rod and the astragal, and operating means carried by the housing operating the rod to move the astragal inwardly and outwardly of the channel, a plurality of cam headed lug members carried by the rod, a plurality of studs corresponding to the cam members extending rearwardly of the astragal, whereby latching movement of the rods moves the cam members to engage their corresponding studs to hold the astragal in an outward or extended dead locked position.
[0036] Astragals with seals and other astragals have been disclosed. However, none of these astragals adequately satisfies the aforementioned needs.
[0037] U.S. Pat. No. 5,857,291 (Headrick) discloses an astragal with integral sealing lock block, for use with a double door installation, which includes an astragal strip secured along a vertical edge of an inactive door. A lock block is slidably disposed in at least one end of the astragal strip, and can be moved between an extended position, for securing the inactive door, and a retracted position for freeing the inactive door. The lock block has a projecting bolt receivable in a receptacle in a door frame, when the lock block is slid to its extended position. A gasket is secured to an end of the lock block, and the bolt passes through an opening in the gasket. The gasket engages and seals against the door frame, when the lock block is in its extended position. Gaskets are also provided on the sides of the lock block, for engaging and sealing against the doors of the double door installation. When the doors are closed and secured in place, the lock block and gasket assembly prevents drafts from flowing under the door installation beneath the astragal thereof.
[0038] U.S. Pat. Nos. 5,350,207 and 5,328,217 (Sanders) disclose locking astragals, for attaching to an inactive leaf of a double doorway, and in particular U.S. Pat. No. 5,350,207. Each of the locking astragals has an elongated astragal casing, which has a channel and bolt-slide assemblies mounted slidably within the channel. Each bolt-slide assembly includes a latching member and bolt. By depressing the latching member, the latching member can slide through the channel, to extend and lock the bolts into indentations in upper and lower surfaces of a door frame. The bolts may also be retracted back into the astragal, to open the inactive leaf. Each of the latching members has an integral spring, which simplifies fabrication and assembly.
[0039] U.S. Pat. No. 6,491,326 (Massey, et al) discloses a swing adaptable astragal with lockable unitary flush bolt assemblies, for double door entryways, which includes an extruded aluminum frame into which upper and lower flush bolt assemblies are slidably disposed. The flush bolt assemblies include a long metal bolt about which is injection overmolded a series of retainer guides, which ride in the frame. Locking mechanisms are also integrally overmolded onto the bolts. The frame and all components of the astragal assembly are symmetrical and reversible, so that the assembly is non-handed; that is, it can be adapted to both a right hand swing and a left-hand swing inactive door. A strike plate mounting system and bottom-sealing block are provided, and the upper end of the assembly includes means for sealing against a stop of a head jamb. Drafts at upper and lower inside corners of the doors of a double door entryway may be prevented.
[0040] U.S. Pat. No. 6,125,584 (Sanders) discloses an automatic door bottom for a hinged door, which is pivotable to be positioned over a sill when closed, the door having a hinge side and a width, the door bottom having an inverted channel having an open bottom, a length corresponding to the door width and a hinge end corresponding to the hinge side of the door; a sealing member having a length corresponding to the length of the channel, the sealing member being housed in the channel and being movable vertically downwardly into a sealing position, in which the sealing member contacts the sill when the door is closed; and a displacement mechanism installed in the channel and coupled to the sealing member, for moving the sealing member vertically into the sealing position in response to closing of the door, wherein the displacement mechanism is coupled to the sealing member at a plurality of points along the length of the sealing member, and is operative to move the end of the sealing member at the hinge side of the channel into the sealing position, prior to the remainder of the sealing member, during closing of the door.
[0041] U.S. Pat. No. 6,457,751 (Hartman) discloses a locking assembly for an astragal, which can be attached to an inactive door of a double door unit of a residence or a building. The astragal is attached to an edge of the inactive door in space between the inactive door and active door. A separate locking assembly is attached adjacent a top end of the door and also adjacent a bottom end of the door. A plug having an elongated locking bolt extending therefrom is mounted in a front end of a carriage member. Additional structure is provided for reciprocal travel of the carriage member between a locked position and an unlocked position.
[0042] U.S. Pat. No. 5,335,450 (Procton) discloses an astragal, which has an exterior aluminum extrusion and an interior wooden portion. The exterior extrusion includes a pair of rearwardly extending center walls, which form a channel for receiving the wooden interior portion. Attachments and door hardware can be installed in the wooden interior portion, while the extruded exterior acts as cladding.
[0043] U.S. Pat. No. 5,590,919 (Germano) discloses a T-astragal and sleeve for door, for use with double swinging doors, such as for french doors. The T-astragal includes a cap portion perpendicular to a base portion, wherein both the cap and base can be formed from wood, such as plywood or plastic. The T-astragal is a molding that extends the full height of the swinging doors. One side of the base portion is fixably coupled to the free end of one of the swinging doors by nails or screws. The free end of the other swinging doors is able to swing up to and against a shoulder portion formed from the cap and base portions. A metal pipe shaped sleeve having an approximate length of one foot is partially positioned along the longitudinal axis of the T-astragal molding. A bolt slides within the sleeve from a rest position to an extended position, where the extended position locks the attached door to a matching slot in the door frame.
[0044] U.S. Pat. No. 4,429,493 (St. Aubin) discloses an astragal housing seal and lock, for use in a double door assembly having an active door and a relatively inactive door. The astragal has a vertically extending mullion housing, which is attached to a free edge of the relatively inactive door. A vertically extending slide section is mounted on the mullion housing on a sealing side of the free edge of the inactive door. The slide section extends from the free vertical edge of the inactive door, when the active door is in the closed position. The slide section is vertically movable from an unlocked position to a locked position, wherein the slide section is moved vertically downward, with respect to the mullion housing, to engage the sill/threshold of the door frame, thereby preventing movement of the inactive door.
[0045] U.S. Pat. No. 4,058,332 (DiFazio) discloses an astragal and flush bolt assembly to be secured to a relatively stationary member such as a door jamb or to the edge of an inactive door of a pair of double doors or the like. The astragal assembly includes a flat metal body mounted on the edge of the stationary member and a metal stop member secured to the body along one edge thereof. The flat body includes first and second spaced apart legs extending outwardly from the stationary member, with the flat body and legs defining a channel to receive and retain a door latch bolt from the active door. The stop member prevents movement of the door in a first direction, and when the latch bolt is engaged in the channel, the channel and latch bolt prevent the door from moving in the opposite direction. A pair of flush bolts are slidably mounted in the channel, one adjacent each end thereof, so that when the astragal assembly is utilized with double doors, the flush bolts are moved to engage the header and sill, respectively, to hold the inactive door stationary. The astragal body is secured to the stop member by a thermal barrier or thermal break structure, to provide thermal insulation between the inside and the outside of the doors. The stop member also includes a weather strip to form a seal against the active door, and when metal doors or metal covered doors are used, the weather strip may include a magnetic member to form a seal against the active door.
[0046] U.S. Pat. No. 6,453,616 (Wright) discloses an astragal for use with exterior double door installations, such as french doors. When attached to the edge of a generally inactive door, the astragal provides a door stop for an active door, a seal to prevent intrusion of water, and a lock for the inactive door. The invention particularly pertains to extruded metal astragals, capable of increasing the resistance of the double door system to high wind conditions. The astragal comprises a longitudinally extending base member that has at least one longitudinally extending channel and a pair of spaced apart outwardly extending legs. At least one bolt is slidably inserted in the channel adjacent to one of the first and second ends of the channel. The astragal is attached to the door, by at least one cleat whose spaced apart arms engage the legs of the base member, providing resistance to the astragal rocking in relation to the door edge, when the doors are subject to wind forces.
[0047] U.S. Pat. No. D293,719 (Stepanian) discloses a combined astragal extrusion and seal.
[0048] For the foregoing reasons, there is a need for a self positioning astragal seal that prevents unwanted drafts, is easy to use and install in a quick, convenient, and efficient manner, is durable and long lasting, maintains its seal against drafts over time, even in situations where repeated opening and closing of the inactive door is necessary, and can be used with a variety of astragals and threshold sills, types, sizes, and shapes of threshold sills, doors, and door frames. The self positioning astragal seal should be capable of automatically positioning at least one seal at the lower end of the astragal adjacent the threshold sill, and prevent drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or of automatically positioning at least one seal at the upper end of the astragal adjacent the header, and prevent drafts at the vicinity of the header. The self positioning astragal seal should independently position itself abuttingly adjacent the sill and/or the header when the bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame. The astragal should also have a lock for locking the bolts into the extended position, and unlocking the bolts at a user's discretion, thus, provide additional security.
SUMMARY
[0049] The present invention is directed to a locking astragal with a self positioning astragal seal that automatically positions at least one seal at the lower end of an astragal adjacent the threshold sill of a door frame, and prevent drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or of automatically positions at least one seal at the upper end of the astragal adjacent the header of the door frame, and prevent drafts at the vicinity of the header. The self positioning astragal seal independently positions itself abuttingly adjacent the sill and/or the header when the astragal's bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame. The self positioning astragal seal prevents unwanted drafts, is easy to use and install in a quick, convenient, and efficient manner, is durable and long lasting, maintains its seal against drafts over time, even in situations where repeated opening and closing of the inactive door is necessary, and can be used with a variety of astragals and threshold sills, types, sizes, and shapes of threshold sills, doors, and door frames. The astragal also has a lock for locking the bolts into the extended position, and unlocking the bolts at a user's discretion, thus, provide additional security.
[0050] The locking astragal with self positioning astragal has a bolt having a bolt retracted position and a bolt extended position, spring means and a latching mechanism having a latch; the latching mechanism retracting the bolt into the bolt retracted position and compressing the spring means when the latch is retracted to a latch retracted position; the latching mechanism releasing the bolt and the spring means forcing the bolt into the bolt extended position and the latch into a latch released position when the latch is released, a self positioning astragal seal, comprising: a seal block having a catch and a hole, the bolt slidably disposed through the hole, the catch catching a portion of the bolt and holding the seal block in a seal block retracted position when the bolt is in the bolt retracted position and releasing the seal block when the bolt is in the bolt extended position; spring means forcing the seal block into a seal block extended position when the seal block is released, and an astragal lock, which locks the bolt into the bolt extended position when the astragal lock is locked and unlocks the bolt when the astragal lock is unlocked, which when unlocked allows the bolt to be moved from the bolt extended position to the bolt retracted position and from the bolt retracted position to the bolt extended position. The astragal lock has a lock cylinder, which is rotatably mounted to the astragal, the lock cylinder having an axis substantially perpendicular to the axis of the astragal bolt, and a notch, which has an axis substantially perpendicular to the axis of the lock cylinder, the notch preferably having an arcuate shape and slidably matingly accepting the astragal bolt therethrough when the astragal lock is unlocked and in an unlocked position, the lock cylinder preventing movement of the astragal bolt and locking the astragal bolt in the bolt extended position, when the lock cylinder is rotated into a locked position, which is substantially perpendicular to the unlocked position. The lock cylinder also has a stop, which limits the angular rotation of the lock cylinder to substantially ninety degrees.
[0051] An astragal having features of the present invention comprises: a bolt having a bolt retracted position and a bolt extended position; a lock having a locked position and an unlocked position, the lock locking the bolt into the bolt extended position when the bolt is in the bolt extended position and the lock is in the locked position, the lock unlocking the bolt when the lock is in the unlocked position; a seal block having a catch and a hole, the bolt slidably disposed through the hole, the catch catching a portion of the bolt and holding the seal block in a seal block retracted position when the bolt is in the bolt retracted position and releasing the seal block when the bolt is in the bolt extended position; spring means forcing the seal block into a seal block extended position when the seal block is released.
DRAWINGS
[0052] 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:
[0053] FIG. 1 is a perspective view of a locking astragal with a self positioning astragal seal, constructed in accordance with the present invention, shown locked with a bolt and the self positioning astragal seal extended;
[0054] FIG. 1A is a perspective section view of the locking astragal with the self positioning astragal seal of FIG. 1 ;
[0055] FIG. 1B is a section view of the locking astragal with the self positioning astragal seal of FIG. 1 ;
[0056] FIG. 1C is an exploded section view of the locking astragal with the self positioning astragal seal of FIG. 1 ;
[0057] FIG. 2 is a perspective view of a locking astragal with the self positioning astragal seal, shown unlocked with the bolt and the self positioning astragal seal retracted;
[0058] FIG. 2A is a perspective section view of the locking astragal with the self positioning astragal seal of FIG. 2 ;
[0059] FIG. 2B is a section view of the locking astragal with the self positioning astragal seal of FIG. 2 ;
[0060] FIG. 2C is an exploded section view of the locking astragal with the self positioning astragal seal of FIG. 2 ;
[0061] FIG. 3 is an exploded view of the locking astragal with the self positioning astragal seal and a latching mechanism;
[0062] FIG. 4 is an exploded view of selected components of the locking astragal with the self positioning astragal seal and a portion of the latching mechanism of FIG. 3 ;
[0063] FIG. 5 is an exploded view of the latching mechanism of FIG. 3 ;
[0064] FIG. 6 is a perspective view of entrance doors, comprising an inactive door, shown in a closed position, and an active door;
[0065] FIG. 7 is a perspective view of the inactive door, showing the locking astragal with the self positioning astragal seal installed on the inactive door, shown locked with the bolt and the self positioning astragal seal extended;
[0066] FIG. 8 is a section view of the locking astragal with the self positioning astragal seal, shown locked with the bolt and the self positioning astragal seal extended;
[0067] FIG. 9 is a section view of the locking astragal with the self positioning astragal seal, shown locked with the bolt and the self positioning astragal seal extended;
[0068] FIG. 10 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0069] FIG. 11 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0070] FIG. 12 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0071] FIG. 13 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0072] FIG. 14 is another section view of the locking astragal with the bolt and the self positioning astragal seal, with the self positioning astragal seal extended;
[0073] FIG. 15 is a section view of the latching mechanism of FIG. 3 , along a portion of line 8 - 8 of FIG. 7 , with the bolt and the self positioning astragal seal extended;
[0074] FIG. 16 is a section view of the locking astragal with the self positioning astragal seal, along a portion of line 8 - 8 of FIG. 7 , shown locked with the bolt and the self positioning astragal seal extended;
[0075] FIG. 17 is a section view of the locking astragal with the self positioning astragal seal, shown unlocked with the bolt and the self positioning astragal seal retracted;
[0076] FIG. 18 is another section view of the locking astragal with the self positioning astragal seal, shown unlocked with the bolt and the self positioning astragal seal retracted;
[0077] FIG. 19 is an exploded view of an upper bolt and latching mechanism of the astragal of FIG. 7 ;
[0078] FIG. 20 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door;
[0079] FIG. 21 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door;
[0080] FIG. 22 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door;
[0081] FIG. 23 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door;
[0082] FIG. 24 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door;
[0083] FIG. 25 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door; and
[0084] FIG. 26 is a perspective view of a locking astragal, constructed in accordance with the present invention, shown locked with a bolt extended;
[0085] FIG. 26A is a perspective section view of the locking astragal of FIG. 26 ;
[0086] FIG. 26B is a section view of the locking astragal of FIG. 26 ;
[0087] FIG. 26C is an exploded section view of the locking astragal of FIG. 26 ;
[0088] FIG. 27 is a perspective view of the locking astragal of FIG. 26 , shown unlocked with the bolt retracted;
[0089] FIG. 27A is a perspective section view of the locking astragal of FIG. 27 ;
[0090] FIG. 27B is a section view of the locking astragal of FIG. 27 ;
[0091] FIG. 27C is an exploded section view of the locking astragal of FIG. 27 ;
[0092] FIG. 28 is an exploded view of the locking astragal of FIGS. 26 and 27 and a latching mechanism; and
[0093] FIG. 29 is another exploded view of the locking astragal of FIGS. 26 and 27 and the latching mechanism of FIG. 28 ;
REFERENCE NUMERALS
[0094] These and other features, aspects, and advantages of the present invention will become better understood with regard to the references and associated reference numerals of the following description and accompanying drawings where:
1 locking astragal with self positioning astragal seal 2 lock 10 self positioning astragal seal 12 seal block 14 seal block hole 16 shoulder 18 compression spring 20 end seal 30 astragal 42 inactive door edge 44 inactive door 46 sill 48 door frame 52 elongated guide 54 elongated guide channel 56 lower bolt 58 shoulder 60 astragal bottom 74 seal block bottom 78 seal block base 80 face plate 82 guide block 84 “T” shaped member 86 compression spring guide holder 88 compression spring bottom end 90 base top 92 barrel 94 barrel extension 96 barrel extension arcuate interior 98 extension 100 extension arcuate interior 102 T top portion 104 arcuate interior 105 angled edges 106 shoulder 108 face plate reinforcement 110 face plate stop 112 guide block edge stop 114 guide block reinforcement 116 guide block stop 130 astragal recess 132 astragal extension stop 134 astragal retraction stop 136 astragal opposing side 138 astragal side portion 140 astragal side 142 side channel 144 threaded hole 146 threaded hole 148 set screw 150 angled longitudinal channel edge 152 compression spring top end 154 seal hole 156 face seal 158 face plate exterior side 160 active door edge 162 active door 164 header 166 seal peel off adhesive strip 168 face seal peel off adhesive strip 180 astragal housing 182 longitudinal channel 184 longitudinal retention guide 185 channel base 186 lockset strike 188 deadbolt strike 190 upper bolt 191 upper bolt assembly 192 lockset 194 deadbolt 196 lockset cover plate 198 deadbolt cover plate 199 screws 200 latching member 202 pull block 204 elongated connector 206 compression spring 208 slide plate 210 bolt lower portion 212 bolt mid portion 214 bolt upper portion 216 bolt slot 218 bolt hole 220 end pin 222 elongated connector hole 224 pin 226 pin 228 pull block track 230 pull block retention track 232 pull block retention track 234 pull block channel 236 pull block channel 238 pull block notch 240 pull block base 242 pull block notch 244 pull block bearing notch 246 pull block notch side 248 lever arm receiving hole 250 lever arm 252 trunnion 254 spring tail 256 latching dog 260 slide plate retraction hole 262 slide plate extension hole 264 slide plate notch 266 slide plate end tab 268 slide plate projecting tab 270 slide plate projecting notch 280 elongated guide notched recess 282 elongated guide end 284 pull block arrow marking 286 arcuate side 288 arcuate base 289 oblique angled side portion 290 longitudinally disposed side channel base wall 291 longitudinally disposed side channel side wall 292 lock mounting hole 293 lock cylinder 294 arcuate keyway 295 arcuate tab 296 lock stop 297 unlock stop 298 head 299 slot 300 alternate astragal housing 302 saw tooth recess 304 finned tail 306 foam weather strip 308 cavity 310 alternate astragal housing 312 thermal break 314 slot 320 alternate astragal 322 alternate astragal housing 324 cover 326 outer seal 328 inner seal 330 alternate astragal 332 thermal break 340 alternate astragal 342 cover element 344 saw tooth recess 346 finned tail 348 weather strip seal 349 inner seal 350 alternate astragal 352 thermal break 400 mounting shoulder 402 bearing surface 404 astragal longitudinal wall 406 lock contact area 408 unlock contact area 410 lock cylinder wall 412 bolt top contact portion 414 other bolt top portion 416 bolt portion 500 locking astragal
DESCRIPTION
[0252] The preferred embodiments of the present invention will be described with reference to FIGS. 1-29 of the drawings. Identical elements in the various figures are identified with the same reference numbers.
[0253] FIGS. 1-19 show an embodiment of the present invention, a locking astragal with self positioning astragal seal 1 , which has a lock 2 and a self positioning astragal seal 10 . The self positioning astragal seal 10 comprises a seal block 12 having a substantially centrally disposed hole 14 therethrough, a shoulder 16 , compression springs 18 , and end seal 20 , for use with an astragal 30 .
[0254] The astragal 30 is mounted to edge 42 of inactive door 44 , and the self positioning astragal seal 10 is mounted to the astragal 30 adjacent sill 46 of door frame 48 , as shown in FIGS. 6 and 7 . The astragal 30 has an elongated guide 52 having a substantially centrally disposed longitudinal channel 54 and a bolt 56 having a shoulder 58 , the bolt 56 slidably mounted therein the substantially centrally disposed longitudinal channel 54 .
[0255] The astragal seal shoulder 16 catches the bolt shoulder 58 when the bolt 56 is retracted to a retracted position, as shown in FIGS. 2, 17 , and 18 , and is released from the bolt shoulder 58 when the bolt 56 is extended to an extended position, as shown in FIGS. 1 and 7 - 16 , the compression springs 18 forcing the seal block 12 into an extended position, when the bolt 56 is in the bolt extended position. The seal block 12 is, thus, retracted to a retracted position, the astragal seal shoulder 16 catching and abutting the bolt shoulder 58 , and holding the seal block 12 in a seal block retracted position when the bolt 56 is in the bolt retracted position. The seal block 12 is extended to the seal block extended position, when the astragal seal shoulder 16 is released from the bolt shoulder 58 , the compression springs 18 forcing the seal block 12 into the seal block extended position, when the bolt 56 is in the bolt extended position. The astragal seal shoulder 16 , thus, acts as a catch, which catches the bolt shoulder 58 when the bolt 56 is retracted to the bolt retracted position, and is released from the bolt shoulder 58 when the bolt 56 is extended to the bolt extended position.
[0256] FIGS. 1 , 1 A- 1 C, 7 - 9 , and 16 show the bolt 56 locked into the bolt extended position with the lock 2 locked. FIGS. 2 , 2 A- 2 C, 17 , and 18 show the bolt 56 in the bolt retracted position with the lock 2 unlocked.
[0257] The self positioning astragal seal 10 automatically and independently adjusts itself to fit snugly and fill any gaps between bottom 60 of the astragal 30 and the sill 46 of the door frame 48 , when the bolt 56 is in the bolt extended position, thus, preventing unwanted drafts between bottom 74 of the seal block 12 and the sill 46 of the door frame 48 , the compression springs 18 forcing the seal block 12 opposingly away from the bottom 60 of the astragal 30 and forcing the end seal 20 , which is affixed to the bottom 74 of the seal block 12 , to abut the sill 46 of the door frame 48 .
[0258] The seal block 12 has base 78 , face plate 80 , and guide block 82 , which is adjacent the inactive door edge 42 , when the self positioning astragal seal 10 and the astragal are installed on the inactive door 44 and the seal block 12 is in the retracted position, the face plate 80 and the guide block 82 being substantially perpendicular to the base 78 , and substantially parallel one to the other.
[0259] The seal block 12 has substantially “T” shaped member 84 integral with the guide block 82 and compression spring guide holders 86 , which hold the compression springs 18 in place, the compression springs 18 being mounted about the compression spring holders 86 , with bottom ends 88 of the compression springs 18 abutting top 90 of the base 78 . The seal block 12 has barrel 92 integral with the guide block 82 , the barrel 92 having the substantially centrally disposed hole 14 therethrough to the bottom 74 of the seal block 12 , the bolt 56 slidable therethrough the substantially centrally disposed hole 14 , and the seal block 12 slidable about the bolt 56 . The barrel 92 has extension 94 , which is integral with the barrel 92 , having arcuate interior 96 , which is substantially collinear with the interior of the barrel 92 , and extension 98 having the shoulder 16 and arcuate interior 100 . The substantially “T” shaped member 84 has T top portion 102 , which has arcuate interior 104 , angled edges 105 , and shoulder 106 . The face plate 80 has reinforcements 108 having stops 110 . The guide block 82 has edge stops 112 and reinforcements 114 having stops 116 . The compression spring holders 86 have splines for reinforcement.
[0260] The elongated guide 52 of the astragal 30 has recesses 130 , which have extension stops 132 and retraction stops 134 at opposing ends thereof, and substantially planar opposing side 136 . The elongated guide 52 of the astragal 30 has substantially planar side portions 138 adjacent the recesses 130 , which oppose the substantially planar opposing side 136 , and sides 140 , which are substantially perpendicular to the substantially planar side portions 138 , the recesses 130 , and the substantially planar opposing side 136 . The elongated guide 52 also has opposing longitudinally disposed side channels 142 . The substantially planar side portions 138 and the substantially planar opposing side 136 have threaded holes 144 and 146 , respectively, therethrough, opposing one another, having set screws 148 therein, the set screws 148 extending across the longitudinally disposed side channels 142 . The elongated guide 52 also has angled longitudinal edges 150 atop the substantially centrally disposed longitudinal channel 54 adjacent the recesses 130 and the substantially planar side portions 138 .
[0261] The substantially “T” shaped member 84 and the face plate 80 of the seal block 12 matingly sandwich the recesses 130 and the substantially planar opposing side 136 of the astragal 30 , respectively, therebetween, and retain the seal block 12 slidably mating about the elongated guide 52 between the seal block retracted position and the seal block extended position, and vice versa.
[0262] The compression springs 18 are mounted about the compression spring holders 86 , with the bottom ends 88 of the compression springs 18 abutting the top 90 of the base 78 of the seal block 12 and top 152 of the compression springs 18 abutting the set screws 148 in the longitudinally disposed side channels 142 of the astragal 30 . The compression springs 18 are held in the longitudinally disposed side channels 142 of the astragal 30 under compression, the extension stops 132 of the astragal 30 preventing the compression springs 18 from forcing the substantially “T” shaped member 84 out of the recesses 130 .
[0263] The barrel 92 of the seal block 12 is matingly slidable about the bolt 56 of the astragal 30 , and the bolt 56 is matingly slidable therethrough the substantially centrally disposed hole 14 of the barrel 92 of the seal block 12 . The angled edges 105 of the substantially “T” shaped member 84 matingly abut the angled longitudinal edges 150 of the astragal 30 . The angled edges 105 of the substantially “T” shaped member 84 and the barrel 92 of the guide block 82 guide the seal block 12 collinearly with the angled longitudinal edges 150 of the astragal 30 and the substantially centrally disposed longitudinal channel 54 , the bolt 56 being substantially aligned with the substantially centrally disposed longitudinal channel 54 .
[0264] The extension stops 132 and the retraction stops 134 limit the extent of travel of the substantially “T” shaped member 84 , and, thus, limit the extent of travel of the seal block 12 and the end seal 20 from the seal block extended position to the seal block retracted position, respectively, the compression springs 18 forcing the seal block 12 into the extended position, other than when the seal block 12 is retracted. The seal block 12 is retracted to the retracted position, the astragal seal shoulder 16 catching and abutting the bolt shoulder 58 , and holding the seal block 12 in the seal block retracted position, when the bolt 56 is in the bolt retracted position. The seal block 12 is extended to the seal block extended position, when the astragal seal shoulder 16 is released from the bolt shoulder 58 , the compression springs 18 forcing the seal block 12 into the seal block extended position, when the bolt 56 is in the bolt extended position.
[0265] The end seal 20 has substantially centrally disposed hole 154 therethrough, which is substantially aligned collinearly with the substantially centrally disposed hole 14 of the seal block 12 , which allows the end seal 20 to slide about the bolt 56 , and vice versa. The self positioning astragal seal 10 has face seal 156 , which is affixed to exterior side 158 of the face plate 78 of the seal block 20 and abuts edge 160 of active door 162 , when the active door 162 is closed abuttingly against the inactive door 44 , thus, preventing unwanted drafts between the self positioning astragal seal 10 and the edge 160 of the active door 162 . The astragal 30 also has edge seal 163 .
[0266] The self positioning astragal seal 10 may be used with the astragal 30 adjacent the sill 46 and/or header 164 of the door frame 48 , and may be used with the inactive door 44 and/or the active door 162 . Typical installations, however, have the astragal 30 mounted to the edge 42 of the inactive door 44 , and the self positioning position astragal end seal 20 mounted to the astragal 30 adjacent the sill 46 .
[0267] The self positioning astragal seal 10 may be used with a variety of astragals but is preferably used with the astragal 30 shown in the accompanying figures. Other astragals may be modified to suit the needs of particular applications.
[0268] The end seal 20 and the face seal 156 may have adhesives covered by peel off adhesive strips 166 and 168 , respectively, the end seal 20 and the face seal 156 being fastened to the seal block 12 with the adhesives, upon removal of the adhesive strips 166 and 168 , respectively.
[0269] The astragal 30 has astragal housing 180 having longitudinal channel 182 , which has longitudinal retention guides 184 , the elongated guide 52 inserted into the longitudinal channel 182 and held in the longitudinal channel 182 by the retention guides 184 and the set screws 148 , and channel base 185 , the set screws 148 locking the elongated guide 52 into the astragal housing 180 . The astragal 30 also has lockset strike 186 , deadbolt strike 188 , and upper bolt 190 mounted to the longitudinal channel 182 of the astragal housing 180 , the bolt 56 and the upper bolt 190 being used to lock the astragal 30 , and, thus, the inactive door 44 , which the astragal 30 is affixed to, to the sill 46 and the header 164 , respectively, of the door frame 48 . The upper bolt 190 may be used with the self positioning astragal seal 10 and/or alternatively the upper bolt 190 may use an alternative sealing means. Upper bolt assembly 191 having the upper bolt 190 is installed into the longitudinal channel 182 in substantially the same manner as the elongated guide 52 . The active door 162 has lockset 192 and deadbolt 194 , which are received by lockset strike 186 , deadbolt strike 188 , respectively, on the inactive door 44 , for securing the active door 162 to the inactive door 134 when the active door 162 is closed abuttingly adjacent the inactive door 44 . The astragal housing 180 has lockset cover plate 196 and deadbolt cover plate 198 , which are mounted to the astragal housing 180 , the lockset strike 186 and the deadbolt strike 188 being fastened to the lockset cover plate 196 and the deadbolt cover plate 198 with screws 199 .
[0270] The astragal 30 has latching member 200 , pull block 202 , elongated connector 204 , compression spring 206 about the elongated connector 204 , and slide plate 208 . The bolt 56 has lower portion 210 , mid portion 212 adjacent the shoulder 58 , the mid portion 212 having a smaller diameter than the diameter of the lower portion 210 , and upper portion 214 , the upper portion 214 of the bolt 56 having substantially the same diameter as the lower portion 210 , and having a slot 216 therethrough and a hole 218 therethrough, the slot 216 and the hole 218 substantially perpendicular one to the other.
[0271] The elongated connector 204 has end pin 220 , opposing hole 222 , and pin 224 therebetween, the end pin 220 and the pin 224 substantially perpendicular to the plane of the elongated connector 204 . The elongated connector 204 is sandwiched in the slot 216 of the upper portion 214 of the bolt 56 , the hole 218 and the hole 222 aligned one with the other, the bolt 56 and the elongated connector 204 pinned one to the other with pin 226 , the pin 226 therethrough the holes 222 and 218 .
[0272] The pull block 202 has longitudinal tracks 228 , retention tracks 230 and 232 , and channels 234 and 236 , the channels 234 between the longitudinal tracks 228 and the retention tracks 230 , and the channels 236 between the longitudinal tracks 230 and the retention tracks 232 . The pull block 202 is inserted into the longitudinal channel 182 of the astragal housing 180 , the channels 234 and 236 being adjacent to the retention guides 184 of the astragal housing 180 , the retention guides 184 slidably retaining the pull block 204 in the astragal housing 180 . The pull block 202 has substantially centrally disposed notch 238 at base 240 of the pull block 202 , notch 242 adjacent and substantially perpendicular to the substantially centrally disposed notch 238 , and bearing notches 244 . The substantially centrally disposed notch 238 is adjacent to and surrounds the elongated connector 204 adjacent the end pin 220 of the elongated connector 204 ; and sides 246 of the notch 242 surround and abut the end pin 220 , thus, pinning the elongated connector 204 to the pull block 202 one to the other. The pull block 202 also has lever arm receiving hole 248 .
[0273] The latching member 200 has lever arm 250 , which has trunnions 252 protruding therefrom, spring tail 254 , and latching dog 256 .
[0274] The slide plate 208 has retraction hole 260 , extension hole 262 , notches 264 , which form end tabs 266 , and projecting tabs 268 , which form projecting notch 270 therebetween, the projecting notch 270 for matingly slidably receiving the elongated connector 204 therebetween.
[0275] The elongated guide 52 is locked into the astragal housing 180 with the set screws 148 . The elongated guide 52 has notched recesses 280 opposing the recesses 130 , the notched recesses 280 matingly receiving the end tabs 266 of the slide plate 208 therein, and adjacent ends 282 , the notches 264 of the slide plate 208 matingly receiving the ends 282 of the elongated guide 52 therein, the slide plate 208 being sandwiched and locked between the elongated guide 52 and the channel base 185 of the astragal housing 180 . The projecting notch 270 of the slide plate 208 slidably guides the elongated connector 204 , which is located in the projecting notch 270 , substantially collinear with the center line of the elongated guide 52 .
[0276] The latching member 200 is sandwiched between the pull block 202 and the slide plate 208 , with the trunnions 252 in the bearing notches 244 of the pull block 202 and the lever arm 250 extending through the lever arm receiving hole 248 of the pull block 202 , thus facilitating operator control.
[0277] The retraction hole 260 and the extension hole 262 of the latching member 200 matingly receive the latching dog 256 of the latching member 200 therein.
[0278] The latching member 200 may be retracted to a latching member retracted position, when the lever arm 250 of the pull block 202 is depressed and pushed in the direction of pull block arrow marking 284 , which pulls the elongated connector 204 in the direction of the pull block arrow marking 284 , pulls the bolt 56 into the bolt retracted position, pulls the seal block 12 into the seal block retracted position, compresses the compression springs 18 , and compresses the compression spring 206 between the pin 224 of the elongated connector 204 and the projecting tabs 268 of the slide plate 208 . When the latching member 200 is retracted to the latching member retracted position, the spring tail 254 of the latching member 200 forces the latching dog 256 into the retraction hole 260 of the slide plate 208 , thus, locking the bolt 56 into the bolt retracted position and locking the seal block 12 into the seal block retracted position.
[0279] The latching member 200 may be released into a latching member extended position from the latching member retracted position, when the lever arm 250 of the pull block 202 is depressed and released, releasing compression from the compression spring 206 between the pin 224 of the elongated connector 204 and the projecting tabs 268 of the slide plate 268 , forcing the elongated connector 204 in the direction opposing the pull block arrow marking 284 , forcing the bolt 56 into the bolt extended position, releasing compression on the compression springs 18 , which forces the seal block 12 into the seal block extended position. When the latching member 200 is released, the latching member 200 snaps into latching member extended position, the latching dog 256 snaps into the extension hole 262 of the slide plate 208 , the spring tail 254 of the latching member 200 forcing the latching dog 256 into the extension hole 262 , thus, locking the bolt 56 into the bolt extended position with the seal block 12 in the seal block extended position, the seal block 12 automatically and independently self positioned with the end seal 20 abutting the sill 46 of the door frame 48 . The latching member 200 may alternatively be pushed into the latch member extended position.
[0280] The substantially centrally disposed longitudinal channel 54 of the elongated guide 52 has arcuate sides 286 and arcuate base 288 to slidably and matingly accommodate the bolt 56 , the lower portion 210 and the upper portion 214 of which are substantially cylindrical and have substantially the same diameter. The mid portion 212 of the bolt 56 is also substantially cylindrical, but has a smaller diameter than the diameter than that of the lower portion 210 and the upper portion 214 .
[0281] The elongated guide 52 also has oblique angled side portions 289 between the substantially planar side portions 138 and the arcuate sides 286 of the substantially centrally disposed longitudinal channel 54 . The longitudinally disposed side channels 142 have base walls 290 , which oppose the arcuate sides 286 of the substantially centrally disposed longitudinal channel 54 , and side walls 291 opposingly adjacent the substantially planar opposing side 136 .
[0282] Again, FIGS. 1 , 1 A- 1 C, 7 - 9 , and 16 show the bolt 56 locked into the bolt extended position with the lock 2 locked in the locked position, and FIGS. 2 , 2 A- 2 C, 17 , and 18 show the bolt 56 in the bolt retracted position with the lock 2 unlocked in the unlocked position. The elongated guide 52 has lock mounting hole 292 therethrough one of the substantially planar side portions 138 , the adjacent one of the oblique angled side portions 289 , the adjacent one of the arcuate sides 286 of the substantially centrally disposed longitudinal channel 54 and the adjacent one of the opposing longitudinally disposed side channel base walls 290 , and through the adjacent one of the longitudinally disposed side channel side walls 291 and the substantially planar opposing side 136 . The lock 2 is mounted in the lock mounting hole 292 .
[0283] The lock 2 comprises lock cylinder 293 , the lock cylinder 293 having an arcuate keyway 294 , arcuate tab 295 having lock stop 296 and unlock stop 297 , head 298 having slot 299 , mounting shoulder 400 , and bearing surface 402 . The lock 2 is rotatably mounted in the lock mounting hole 292 , with the mounting shoulder 400 rotatably mounted about the longitudinally disposed side channel side wall 291 adjacent the lock mounting hole 292 .
[0284] The astragal 30 has longitudinal wall 404 adjacent the edge 42 of the inactive door 44 . The lock 2 is rotatably mounted and held within the locking astragal with self positioning astragal seal 1 between the longitudinal wall 404 and the longitudinally disposed side channel side wall 291 adjacent the lock mounting hole 292 . The bearing surface 402 of the lock 2 is rotatably mounted abuttingly about the longitudinal wall 404 , and the mounting shoulder 400 is rotatably mounted abuttingly about the longitudinally disposed side channel side wall 291 adjacent the lock mounting hole 292 , thus, rotatably holding the lock 2 within the locking astragal with self positioning astragal seal 1 .
[0285] The arcuate tab 295 has a substantially ninety degree arc. The lock stop 296 and the unlock stop 297 are, thus, substantially perpendicular to each other, and thus, the locked position and the unlocked position of the lock 2 are substantially perpendicular to each other. The opposing longitudinally disposed side channel base wall 290 has lock contact area 406 and unlock contact area 408 , each adjacent to and on opposing sided of the lock mounting hole 292 . The lock stop 296 contacts the lock contact area 406 of the opposing longitudinally disposed side channel base wall 290 when the lock 2 is locked, and the unlock stop 297 contacts the unlock contact area 408 of the opposing longitudinally disposed side channel base wall 290 when the lock 2 is unlocked. The slot 299 at the head 298 of the lock 2 is substantially perpendicular to the axis of the bolt 56 , when the lock 2 is locked, the lock 2 is in the locked position and the lock stop 296 contacts the lock contact area 406 of the opposing longitudinally disposed side channel base wall 290 , indicating to a user that the bolt 56 is locked in the bolt extended position. The slot 299 at the head 298 of the lock 2 is substantially parallel to the axis of the bolt 56 , when the lock 2 is unlocked, the lock 2 is in the unlocked position and the unlock stop 297 contacts the unlock contact area 408 of the opposing longitudinally disposed side channel base wall 290 , indicating to the user that the bolt 56 is unlocked and may be moved from the bolt extended position to the bolt retracted position and vice versa, or the bolt 56 may be left in either the bolt extended position or the bolt retracted position, at the user's discretion. The lock 2 may be locked or unlocked by rotating the slot 299 at the head 298 of the lock 2 substantially ninety degrees from either unlocked to locked or substantially ninety degrees from locked to unlocked.
[0286] The lock cylinder 293 has wall 410 , and the bolt 56 has bolt top contact portion 412 and other bolt top portion 414 , the bolt top contact portion 412 being adjacent the wall 410 of the lock cylinder 293 , when the lock 2 is locked. When the lock 2 is locked, the lock 2 is in the locked position and the lock stop 296 contacts the lock contact area 406 of the opposing longitudinally disposed side channel base wall 290 , the bolt top contact portion 412 of the bolt 56 is blocked by the wall 410 of the lock cylinder 293 , which prevents the bolt 56 from moving from the bolt extended position to the bolt retracted position, thus, locking the bolt 56 in the bolt extended position. When the lock 2 is unlocked, the lock 2 is in the unlocked position and the unlock stop 297 contacts the unlock contact area 408 of the opposing longitudinally disposed side channel base wall 290 , the axis of the arcuate keyway 294 is substantially parallel to the axis of the bolt 56 , the bolt 56 is unlocked, and portion 416 of the bolt 56 adjacent the arcuate keyway 294 of the lock 2 may be slidably moved through the arcuate keyway 294 , thus, allowing movement of the bolt 56 from the bolt extended position to the bolt retracted position and vice versa, or the bolt 56 may be left in either the bolt extended position or the bolt retracted position.
[0287] A screwdriver or other suitable tool may be used to lock or unlock the lock 2 , by inserting the screwdriver or other suitable tool into the slot 299 and rotating the head 298 , and, thus, the lock 2 into the locked position or the unlocked position. Other suitable means may alternatively be used to rotate the lock 2 into the locked or unlocked position. The head 298 may, in lieu of or in addition to the slot 299 , which acts as a keyway, alternatively have a socket, a keyway, a protuberance, such as, for example, having a hex head, a knob, such as a knurled knob, or other suitable means adapted to facilitate rotating the lock 2 , in which case an alan wrench, a wrench, other suitable tool, or other suitable means may be used to rotate the lock 2 into the locked or unlocked position.
[0288] The lock 2 is preferably injection molded from an engineered plastic resin that has properties to provide strength, such as an acetal, although metal, such as aluminum or steel, thermoplastics, thermosetting polymers, rubber, or other suitable materials may be used.
[0289] The astragal housing 180 and the elongated guide 52 are preferably of metal, such as aluminum or steel, thermoplastics, thermosetting polymers, rubber, or other suitable material or combination thereof.
[0290] The seal block 12 and the latching member 200 are preferably injection molded from an engineered plastic resin that has properties to provide flexural strength, such as an acetal, although other suitable materials may be used. The end seal 20 and the face seal 156 are preferably of cellular material, such as closed cell neoprene sponge, although other suitable materials may be used.
[0291] FIG. 15 shows the latching member 200 with the lever arm 250 depressed and the latching dog 256 ready to be moved to the retraction hole 260 of the slide plate 208 , which is shown after being moved in FIGS. 17 and 18 . The seal block 12 is also retracted along with the bolt 56 , when the latching dog 256 is moved into the retraction hole 260 , as shown in FIGS. 17 and 18 .
[0292] The active door 162 and the inactive door 44 are “handed” as either right hand, in which the hinges of the active door 162 are on the right side of the active door 162 as viewed from the outside of the door frame 48 and left hand if the hinges of the active door 162 are on the left side of the door frame 48 as viewed from the outside of the door frame 48 . The elongated guide 52 and the self positioning astragal seal 10 may easily be reversed from left hand to right hand, and vice versa, by merely loosening the set screws 148 , removing the elongated guide 52 with the self positioning astragal seal 10 from the longitudinal channel 182 of the astragal housing 180 , and installing the elongated guide 52 with the self positioning astragal seal 10 on the end of the astragal housing 180 opposing that from which it was removed, thus, converting the astragal 30 from one hand to the other.
[0293] FIGS. 20-25 show alternate embodiments of astragals having astragal housings that the self positioning astragal 10 may be used with, although other suitable astragals having other suitable astragal housings may be used.
[0294] FIG. 20 shows an alternate embodiment of an astragal housing 300 , which has a saw-tooth recess 302 to retain finned tail 304 of a typical wrapped foam type weather strip 306 for sealing. The astragal housing 300 also has cavity 308 .
[0295] FIG. 21 shows an alternate embodiment of an astragal housing 310 , which is substantially the same as the astragal housing 300 , except that the astragal housing 310 has thermal break 312 , for installations in climates that experience extremely cold weather, in which the astragal housing 310 is fabricated from an aluminum extrusion, or other suitable material having substantially the same properties, which would otherwise readily lose heat to the outside and result in condensation, and in some cases even the formation of ice. The thermal break 312 is created by filling cavity 308 of the astragal housing 300 with a polyurethane thermal break compound, after which it is de-bridged by milling slot 314 , thus, separating outer and inner portions of the astragal housing 310 and preventing infiltration of the cold.
[0296] FIG. 22 shows an alternate embodiment of an astragal 320 , which may be used for installation on a pair of outwsinging rather than inswinging doors, which has astragal housing 322 , cover 324 that provides overlap, and outer seal 326 , and is used on the active leaf of the pair of out swinging doors. Inner seal 328 is of greater reach as the beveled edge of the active door is reversed, creating a greater gap at its inner edge.
[0297] FIG. 23 shows an alternate embodiment of an astragal 330 , which may be used for installation on a pair of outwsinging rather than inswinging doors, which is substantially the same as the astragal housing 320 , except that the astragal 330 has thermal break 332 .
[0298] FIG. 24 shows an alternate embodiment of an astragal 340 , which may be used for installation on a pair of outwsinging rather than inswinging doors, in which cover element 342 has saw-tooth recess 344 to accommodate finned tail 346 of a wrapped foam weather strip seal 348 . Inner seal 349 is of greater reach as the beveled edge of the active door is reversed, creating a greater gap at the inner edge.
[0299] FIG. 25 shows an alternate embodiment of an astragal 350 , which may be used for installation on a pair of outwsinging rather than inswinging doors, which is substantially the same as the astragal housing 340 , except that the astragal 350 has thermal break 352 .
[0300] FIGS. 26-29 show an alternate embodiment of a locking astragal 500 , which is substantially the same as the locking astragal with self positioning astragal seal 1 , except that the self positioning astragal seal has been removed from the locking astragal 500 . The locking astragal 500 has the lock 2 , as in the locking astragal with self positioning astragal seal 1 .
[0301] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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A locking astragal with self positioning seal that automatically positions at least one seal at the lower end of an astragal adjacent the threshold sill of a door frame, and prevents drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or automatically positions at least one seal at the upper end of the astragal adjacent the header of the door frame, and prevent drafts at the vicinity of the header. The self positioning seal independently positions itself abuttingly adjacent the sill and/or the header when the astragal's bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame, the astragal having locks for locking the bolts into the extended position, and can be used with a variety of thresholds, sills, headers, doors, and door frames
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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. 639,693, filed Dec. 11, 1975.
BACKGROUND OF THE INVENTION
This invention relates to a method and arrangement for automatically positioning a working implement, such as a drill bit, to predetermined positions and/or predetermined directions in space, wherein said predetermined positions and directions are defined by given values of respectively coordinates and an angle or angles in a system of coordinates.
The invention may to advantage be used for rock drilling, which means that the working implement is a drill bit. The invention, however, is applicable generally to positioning of different types of working implements, for instance for controlling of industrial robots.
When applying the invention to rock drilling it is, due to the irregularities of the rock surface intended to be worked, necessary to undertake measures in order to safeguard that the drill bit does not get stuck during movement from one predetermined position to another. According to one aspect of the invention the predetermined positions are programmed such that they are in an imaginary plane which is spaced from the rock surface.
A further object of the invention is to provide an automatic movement of the working implement to programmed positions according to a pattern, such as a drilling pattern, such that the working implement is moved to a predetermined position and/or is adjusted to a predetermined direction in shorter time than is obtainable in hitherto known constructions for automatic movement of a working implement.
To this end, the actual values of the coordinates and/or the angle or angles are sensed continuously. According to another aspect of the invention, the sensed actual values are adjusted simultaneously toward the values programmed in advance. In doing so, a considerable saving of time is achieved when comparing with constructions where the different means for moving the working implement are actuated in turn.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other purposes of the invention will become obvious from the following description with reference to the accompanying drawings, in which one embodiment is shown by way of example. It is to be understood that this embodiment is only illustrative of the invention and that various modifications thereof may be made within the scope of the claims following hereinafter.
FIG. 1 is a side view of a drill boom and a feed bar having a rock drilling machine movable to and fro therealong, in which the invention is applied.
FIG. 2 is a top view of the drill boom according to FIG. 1.
FIGS. 3, 4 and 5 show in block diagram form the control means for the hydraulic cylinders which determine the position of the drill boom and feed bar shown in FIGS. 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1, 2, a drill boom 10 is carried pivotally on a cross shaft 11 which is supported by a boom bracket 12. The pivotal angle α y of the drill boom 10 about the cross shaft 11 is adjusted by means of hydraulic elevating cylinders 13, 14, which are coupled pivotally between the boom bracket 12 and the drill boom 10. The drill boom 10 can be swung about a shaft 16 which is perpendicular to the cross shaft 11 by means of a hydraulic swing cylinder 15. The swing angle about the shaft 16 is depicted α x .
The drill boom 10 carries a boom head 17 at its distal end. A cross shaft 18 is journalled in the boom head 17. The cross shaft 18 carries a feed holder 19. A feed bar 20 is carried longitudinally slidably on the feed holder 19 by means of guides fixed thereon. The feed bar 20 carries in conventional manner a rock drilling machine 21 mechanically fed to and fro therealong. The rock drilling machine 21 rotates a drill steel 22 and delivers impacts thereagainst. The drill steel is guided by means of a drill steel centralizer 23 on the feed bar. The drill steel 22 carries a drill bit 24. A feed displacing hydraulic cylinder 48 is attached on the one hand to the feed holder 19, and on the other to the feed bar 20. The feed bar 20 is adjusted longitudinally relative to the drill boom 10 by extension or contraction of the hydraulic cylinder 48.
A hydraulic tilt cylinder 25 is coupled pivotally between the boom head 17 and the feed holder 19. By means of the hydraulic cylinder 28 the feed holder 19 can be swung about a shaft 27 which is perpendicular to the cross shaft 18. The swing angle relative to the drill boom 10 about the shaft 27 is depicted α k .
In order to define the position and direction of the drill bit 24 in an arbitrary point in space it is necessary to know the coordinates and angles of the drill bit 24 in a system of coordinates in space. In FIGS. 1, 2, a system of coordinates is marked having its origin in the intersection point of the geometric axis of the shaft 16 and a plane which is perpendicular to said geometric axis and which traverses the geometric axis of the cross shaft 11. The Y-axis coincides with the geometric axis of the shaft 16, the X-axis is parallel with the cross shaft 11 and the Z-axis is perpendicular to the X- and Y-axes and extends in the longitudinal direction of the drill boom 10. The distances along the X-axis and the Y-axis, respectively, from a reference point on the shaft 16 at the level of the cross shaft 11 to an imaginary line, which runs in the desired tunnel direction and intersects an imaginary plane 187 containing the predetermined positions, are depicted respectively X o and Y o . Z o depicts the distance between the abovementioned reference point and plane. The distance between the geometric axes of the cross shaft 11 and the cross shaft 18 is depicted L5. L8 depicts the distance between the geometric axis of the cross shaft 18 and the centre line of the drill steel 22. The distance between the geometric axis of the cross shaft 18 and the drill bit 24 is depicted L10. In FIG. 2, the distance between the geometric axes of the shaft 16 and the cross shaft 11 is depicted L4. In the same figure, L7 depicts the distance between the centre line of the drill boom 10, which line intersects the origin O, and the centre line of the drill steel 22.
By the abovementioned definitions, the coordinates of the drill bit 24 are as follows:
X - X.sub.o = L4 sin (α.sub.x + α.sub.o) + L5 cos α.sub.y sin (α.sub.x + α.sub.o) + L7 cos (α.sub.x + α.sub.o) + L8 sin (α.sub.y + α.sub.s) sin (α.sub.x + α.sub.o) - L10 [cos α.sub.k cos (α.sub.y + α.sub.s) sin (α.sub.x + α.sub.o) - sin α.sub.k cos (α.sub.x + α.sub.o)]
Y - Y.sub.o = L5 sin α.sub.y + L8 cos (α.sub.y + α.sub.s) + L10 cos α.sub.k sin (α.sub.y + α.sub.s)
Z - Z.sub.o = L4 cos (α.sub.x + α.sub.o) + L5 cos α.sub.y cos (α.sub.x + α.sub.o) - L7 sin (α.sub.x + α.sub.o) - L8 sin (α.sub.y + α.sub.s) cos (α.sub.x + α.sub.o) + L10 [cos α.sub.k cos (α.sub.y + α.sub.s) cos (α.sub.x + α.sub.o) + sin α.sub.k sin (α.sub.x + α.sub.o)]
In the above terms, α o depicts an angle in the XZ-plane for the drill boom 10 with respect to a given reference angle.
The direction of the drill steel 22 and thus also the direction of the drill bit 24 are defined as follows:
K = α.sub.o + α.sub.x + α.sub.k
S = α.sub.y + α.sub.s
The angle S depicts the direction of the drill steel 22 in a plane which traverses the centre line of the drill steel 22 and which is perpendicular to the shaft 18. K depicts the direction of the drill steel 22 in a plane which also traverses the centre line of the drill steel 22 and is perpendicular to said firstmentioned plane.
The angles α x , α y , α k and α s , respectively, are measured by connecting an angle sensing means, preferably a synchro, to respective swing shaft. The distance L10 is divided into two components, a fixed one L9 which depicts the distance when the feed displacing hydraulic cylinder 48 is entirely contracted, and a variable one, constant .α z , which depicts the extension of the hydraulic cylinder 48. For measuring the component constant .α z , a rack member is mounted on the feed bar 20. The rack member cooperates with a gear wheel, which is mounted on the feed holder 19. The turning of said gear wheel is transferred to a synchro, whereby also the distance L10 is represented as an angle.
In FIGS. 3, 4 and 5, a block diagram illustrates how the positioning of the drill boom shown in FIGS. 1, 2 is carried out. Synchros 29, 30, 31, 32 and 33 are in known manner provided with two unmovable windings, which are perpendicular to one another and one turnable winding. The turning of the turnable winding corresponds to the turning of the shaft connected thereto. The unmovable windings are energized with two sine-wave, 90° dephased, voltages, which are generated in oscillators 34, 35 and transmitted via leads 38, 39, 40 and power amplifiers 36, 37. When turning the shaft of a synchro, a sine-wave voltage having a constant amplitude is generated over the turnable winding. This sine-wave voltage is dephased with respect to the voltages generated in the oscillators 34, 35 such that the phase displacement is proportional to the turning angle. The oscillators 34, 35 are controlled in respect to frequency and phase angle from a generator 42 via a frequency divider 41.
The output signals from the synchros are transmitted to signal converters 43, 44, 45, 46, 47 in which the signals are converted to pulse duration signals having the same frequency as the sine-wave signal but a pulse duration, which is proportional to the respective angle. A high frequency is superposed the pulse duration signals so that a high-frequent pulse train is obtained having a number of pulses which is proportional to respective angle. These pulse trains appear in a frequency which corresponds to the sine-wave voltage originally transmitted to the synchros. In a preferred embodiment, all synchros are fed with 400 Hz. The high frequency transmitted to the converters, has a frequency of about 400. 2.π.2 11 , i.e. about 5.1 MHz, which frequency is doubled in the converters. This means that 2π . 2 12 pulses correspond to the turning angle of one revolution, i.e. 2 12 = 4096 pulses per radian. As regards the synchro 29 and the converter 43, the high frequency is given a value such that α Z gets the same scale constant as the other lengths, L4, L5, L7, L8 and L9. Said frequency value is obtained by means of a binary-rate-multiplier which transforms a frequency from the generator 42 to a frequency which is suitable for the scale factor.
L10 is obtained in binary form on the output of a counter 180 as the sum of L9 and the feed displacement corresponding to α Z . Signals of this type, i.e. signals where the number of pulses in a given time interval convey information of a particular measure, are here called rate-signals. The pulses can be spaced equally or unequally within the interval or a part thereof. The time interval must be so long that the pulses within two consecutive intervals will be refound in the same order and number when the information is unchanged. If the pulses are spaced equally within the whole interval they can be spoken of as a pulse frequency.
Separate leads from the converters 43, 44, 45, 46, 47 are given signals indicating whether the angles are positive or negative with respect to the reference direction.
Units 86 and 87 form the angular sums required in the positioning equations, viz.α x + α o and α y + α s .
α o , which is the angle of the boom bracket 12 relative to the Z-axis in the XZ-plane, is measured when the drill rig has taken up its position and is then set on a thumb wheel switch 181. The angular sum unit 87 comprises a special converter for converting the angle from the thumb wheel switch 181 from degrees to radians. The angular sum from the two units 86 and 87 is obtained as a pulse-rate-signal having 4096 pulses per radian in analogous manner as the signal from the converters 43, 44, 45, 46, 47.
In the above terms of the coordinates, sinus and cosinus of different angles are included. In order to get these values, the signals which represent the respective angles are transmitted to sin-cos-converters 82, 83, 84, 85. These converters give on its two outputs sinus and cosinus respectively of the angles and the angular sums in binary form and with 12 bit accuracy. Sinus 90°, thus, is represented by 2 12 .
In order to get signals representing the lengths L4, L5, L7, L8, L10, and signals representing sinus and cosinus of the angles α o , α x , α y , α k , α s , which signals can be added and multiplied, there are binary-rate-multipliers 55-81 in the control diagram.
The binary-rate-multipliers are designed such that if a rate signal is fed to the one input and a binary number to the other input there is obtained another rate-signal on its output representing the product of the two input measures.
There is the following relation:
r.sub.out = (r.sub.in × B.sub.in /4096)
where
r out = output rate-signal
r in = input rate-signal
B in = input binary number
4096 = 2 12 = maximum allowed input binary number
Consequently, r out is always less than r in .
The values of respectively L4, L5, L7, L8 and L9 corresponding to the dimensions of the drill rig are represented as binary numbers and are illustrated by 49, 50, 51, 52 and 53, respectively.
Units 88, 89, 90, 91, 92 for handling signals have inputs for rate-signals with sign transmitted from the binary-rate-multiplicators (the sign-leads are not shown), inputs for signals 123, 126, 135, 132, 129 representing set values of the measures X, Y, Z, K and S and inputs for administering the function of the unit. The rate-signals represent the instantaneous value of the coordinates X, Y, Z and the angles K and S. The ratesignals fed to one of these units are added with their signs and are compared with a signal from a data processing computer 93, the latter signal being transformed to a rate-signal and representing the set value. The difference is transformed to a pulse duration signal having a sign signal for X, Y, Z, S, K, respectively, which pulse duration signal is fed to leads 112-121.
In pulse-analogue- converters 160, 161, 162, 163, 164, these pulse duration signals are converted to an analogue voltage. The proportionality factor can be set by means of a binary signal from leads 124, 127, 136, 133, 130. Stabilizing nets being built-in optimize the dynamic characteristics of the different channels.
The signals treated in the above manner are then transmitted to control magnet amplifiers 165, 166, 167, 168, 169, wherein they are amplified and adapted to control magnets 170, 171, 172, 173, 174.
The control magnets actuate mechanically control valves 175, 176, 177, 178, 179, which give an oil flow being proportional to the input signal to the control magnet amplifiers. The speed of the hydraulic cylinders 15, 28, 48, 25, 14, thus, becomes proportional to the input signal to the control magnet amplifiers 165, 166, 167, 168, 169.
In the following, a positioning of a drill bit to a predetermined position is described. In the computer 93 are stored coordinates of the positions, where the drill bit is to be moved, and the desired drilling direction in these positions. The programmed positions are in an imaginary plane, which lies in front of the rock surface. The set value of the X-coordinate of the first position is transmitted to the counter unit 88 from the output 122 of the computer 93 via the lead 123. The product of L4 and sin (α x + α o ), the respective values taken from the multipliers 56 and 57 respectively, is transmitted via the lead 94 to the unit 88. Values of respectively L5, cos α y and sin (α x + α o ) are obtained from the multipliers 58, 59 and 60 respectively. The product of these values is transmitted to the unit 88 via the lead 95. Values of L7 and cos (α x × α o ) are obtained from the multipliers 61 and 62. The product of these values is transmitted to the unit 88 via the lead 96. The values of L8, sin (α y + α s ) and sin (α x + α o ) are from the multipliers 63, 64 and 65. The product of these values is transmitted to the unit 88 via the lead 97. The values of L10, cos α k , cos (α y + α s ) and sin (α x + α o ) are obtained from the multipliers 66, 67, 68 and 69. The product of these values is transmitted to the unit 88 via the lead 98. The values of L10, sin α k and cos (α x + α o ) are obtained from the multipliers 70, 71 and 72. The product of these values is transmitted to the unit 88 via the lead 99. The values fed into the unit 88 via the leads 94-99 are summed and the sum is the instantaneous actual X-coordinate value of the drill bit.
This actual value is compared with the set value from the lead 123. Any differences between the actual value and the set value cause correction signals to be fed to pulse-analogue-converter 160 via leads 112, 113. The lead 112 indicates the duration of the correction signal while the lead 113 indicates the sign of the correction signal, i.e. in which direction the hydraulic cylinder in question, in this case the swing cylinder 15, has to be activated. The signal from the pulse-analogue-converter 160 is amplified in the amplifier 165, whereupon the signal actuates the control magnet 170. The control magnet adjusts a valve 175. Due to in which direction the valve 175 is adjusted hydraulic fluid is supplied to either of the two chambers of the hydraulic cylinder 15. The drill boom 10 is then swung.
The set value of the Y-coordinate of the first position is transmitted to the counter unit 92 from the output 128 of the computer 93 via the lead 129. The product of the values of respectively L5 and sin α y obtained from the multipliers 58 and 78 respectively is transmitted to the unit 92 via the lead 109. The values of L8 and cos (α y + α s ) are obtained from the multipliers 63 and 79. The product of these values is transmitted to the unit 92 via the lead 110. The values of L10, cos α k and sin (α y +α s ) are obtained from respectively the multipliers 66, 67 and 80. The product of these values is transmitted to the unit 92 via the lead 111. The values fed into the unit 92 via the leads 109-111 are summed and the sum represents the instantaneous actual Y-coordinate value of the drill bit. This actual value is compared with the set value fed via the lead 129. Any differences between the actual value and the set value cause a correction signal, which is fed to the pulse-analogue- converter 164 via leads 120 and 121 respectively for respectively the duration and the sign of the signal. The signal is amplified in the amplifier 169 and is transmitted to the magnet 174. The magnet adjusts the valve 179, which controls the elevating cylinder 14. The drill boom 10 is then elevated or lowered.
The set value of the Z-coordinate of the first position is transmitted to the counter unit 90 from the output 134 of the computer 93 via the lead 135. The product of the values of L4 and cos (α x + α o ) from the multipliers 56 and 81 respectively is fed to the unit 90 via the lead 102. The values of L5 cos α y and cos (α x + α o ) are obtained from the multipliers 58, 59 and 73. The product of these values is transmitted to the unit 90 via the lead 103. The values of L7 and sin (α x + α o ) are obtained from the multipliers 61 and 74. The product of these values is transmitted to the unit 90 via the lead 104. The values of L8, sin (α y + α s ) and cos (α x + α o ) are obtained from the multipliers 63, 64 and 75. The product of these values is transmitted to the unit 90 via the lead 105. The values of L10, cos α k , cos (α y + α s ) and cos (α x + α o ) are obtained from the multipliers 66, 67, 68 and 76. The product of these values is transmitted to the unit 90 via the lead 106. The values of L10, sin α k and sin (α x + α o ) are obtained from the multipliers 70, 71 and 77. The product of these values is transmitted to the unit 90 via the lead 107. The values fed into the unit 90 via the leads 102 - 107 are summed and the sum is the instantaneous actual value of the Z-coordinate of the drill bit. This actual value is compared with the set value fed via the lead 135. Any differences between the actual value and the set value cause a correction signal, which is transmitted to the pulse-analogue-converter 162 via leads 116 and 117 respectively for respectively the duration and the sign of the signal. The signal is amplified in the amplifier 167 and is then fed to the magnet 172. The magnet adjusts the valve 177, which controls the feed displacing cylinder 48. The feed bar 20 is then displaced.
The set value of the angle K of the first drill hole is transmitted to the counter unit 89 from the output 125 of the computer 93 via the lead 126. The sum of α x , and α o is transmitted to the unit 93 via the lead 100. α k is fed into the unit 93 via the lead 101. α x and α o and α k are summed in the unit 89 and the sum is the instantaneous actual value of the angle K. This actual value is compared with the set value transmitted via the lead 126. Any differences between the actual value and the set value cause a correction signal, which is transmitted to the pulse-analogue-converter 161 via leads 114 and 115 for the duration and sign of the signal. The signal is amplified in the amplifier 166, whereupon it is transmitted to the magnet 171. The magnet adjusts the valve 176, which controls the swing cylinder 28. The feed bar 20 is then swung.
The set value of the angle S of the first drill hole is transmitted to the counter unit 91 from the output 131 of the computer 93 via the lead 132. (α y + α s ) is fed into the unit 91 via the lead 108. This value is the instantaneous actual value of the angle S. This actual value is compared with the set value transmitted via the lead 132. Any differences between the actual value and the set value cause a correction signal, which is fed to the pulse-analogue-converter 163 via the leads 118 and 119 for respectively the duration and the sign of the signal. The signal is amplified in the amplifier 168, and is then led to the magnet 173. The magnet adjusts the valve 178, which controls the tilt cylinder 25. The feed bar 20 is then tilted.
Between each of the leads 112-121 respectively a summation unit 147 is connected to a lead respectively 137-146. A lead 148 is connected between the summation unit 147 and the computer 93. The function of the summation unit 147 is to give order to the computer 93 when values of the next programmed point have to be taken out. Before this order is given, the values of X, Y, Z, K and S of the previous points have to be reached for a prescribed time. The condition for obtaining a signal from the summation unit 147 through the lead 148 is that all leads 137-146 have been without signal for a prescribed time. When the summation unit 147 has settled that the positioning is finished, the computer 93 gives order to lock the positioning, open the supply of flushing fluid, make a collaring and start the feed motor and rock drilling machine. The drill depth is measured by counting the number of pulses from a toothed wheel on the feed screw. A separate logical system, not shown in the block diagram, compares the actual drill depth with a drill depth programmed into the computer 93 via a lead 187. When similarity between measured and programmed drill depth is achieved, the drilling is stopped by reversing the feed motor.
Due to the irregularities of the rock surface, the Z-coordinates of the predetermined positions are defined such that they are in an imaginary plane, which is spaced from the rock surface, whereby safeguarding that the drill bit does not get stuck during movement from one position to another. When the summation unit 147 has stated that the positioning in the imaginary plane is finished, the computer 93 gives order to lock the drill boom and the feed bar against a turning about their axes, after a prescribed time delay displace the feed bar to rest against the rock, open the supply of flushing fluid, make a collaring and start the feed motor and the rock drilling machine. The displacement of the feed bar as well as the collaring can of course alternatively be carried out manually.
The desired values of the coordinates X, Y, and Z and the angles K, S and α are programmed starting from a given system of coordintes. Due to the face of country etc, it is not always possible to place the drill rig correctly in this system. In occurring cases, the given system of coordinates has to be transformed to one which coincides with the position in question of the drill rig. For this transformation there are correction units 181-186. The correction factors for respectively X, Y, Z, K and α are set by means of the respective unit or changer 181-186. The correction factors X o , Y o , Z o , K o , S o and α o are defined by directly measuring the position and inclination of the swing shaft 16 and the boom bracket 12 with respect to the geodetically determined line of the tunnel extension.
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A working implement such as a rock drilling apparatus is automatically positioned to predetermined positions and/or directions. Particularly, a drill bit is moved to an imaginary plane spaced from the surface to be worked upon completion of a drill hole by programming the predetermined positions such that they are in said imaginary plane. The actual values of the position and/or direction of the working implement may be adjusted simultaneously toward set values corresponding to the predetermined position and/or direction.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a window construction particularly adapted to resist conditions encountered during extreme storms. The window construction is used in an exterior window for a commercial or residential building, or a sliding glass door as typically leads between an interior room and a back porch or patio. The window construction functions as an integral part of the external protection for the building envelope, whether used as a window or sliding glass door, and includes high impact panes mounted in a structure of extruded frame parts in a manner that resists damage from pressure cycling and debris impact.
2. Prior Art
Exterior windows and/or sliding glass doors mounted in the walls of a commercial or residential buildings are intended to provide a weather-tight barrier against wind and rain. A window or sliding glass door also permits a view, and preferably has the capability of being opened during favorable conditions. It is possible to make a window or sliding glass door into a substantial barrier; however its viewing aspects and opening capabilities may suffer, and the expense of the window or door typically is increased. On the other hand, if the window or sliding glass door does not form a sufficient barrier, it may be damaged under extreme storm conditions.
Extreme storm conditions characterized by strong winds and rain, airborne debris and/or hail, occur yearly in various locales. Such conditions may occur in hurricanes or near tornadoes, or even in particularly strong thunderstorms. For example, in South Florida and along the Gulf Coast, hurricanes occur yearly or oftener.
In a strong storm, an exterior window or sliding glass door might be subject to winds of 75 mph (120 kph) or greater. Wind loading can be sustained, e.g., continuing for the greater part of a minute, or can occur in gusts and ripples. Both sustained and intermittent wind loading can cause structures to oscillate, and to withstand such loading, structures require both static strength and resilience.
Gale force winds load windows and/or sliding glass doors structurally and drive rain against the window or door and its seals. Moreover, such winds can carry debris. Smaller particles such as sand and gravel can damage window panes. In a strong storm, large missiles become airborne, such as pieces of roofing, loose lawn furniture and even structural parts of damaged buildings. A 9 foot (2.7 m) nominal 2×4 timber stud (5 cm×10 cm), weighing between 9 and 9.5 lbs (4.1 and 4.3 kgms) flung at a window at a speed of 34 mph (55 kph) or greater, for example, is a formidable missile. However wind borne debris of this type is not unusual in a hurricane.
Conventional windows and/or sliding glass doors for commercial and residential buildings generally have not been designed to withstand and/or resist such extreme weather. When subjected to high winds and debris, windows or sliding glass doors have failed or broken apart, allowing the weather and debris to invade the building envelope, and potentially leading to further structural damage due to a breach of structural integrity.
Experience has taught that hurricanes result in great losses, not only in property but in lives. What is needed is an improved window construction utilized in windows and sliding glass doors alike that better resists such extreme weather and/or storms. However, improved strength and debris resistance should be achieved without adversely affecting aesthetic aspects such as sufficient view and opening capability, and without unduly increasing costs.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a window construction, such as used in an exterior window or a sliding glass door, which is resistant to storms for improved effectiveness as an integral part of the external protection for a building envelope.
It is another object of the invention to make the above window construction from tough materials that can withstand substantial impact from windborne debris, yet are sufficiently resilient and resiliently connected so as to arch and twist for damping loads induced by wind and rain.
It is a further object of the invention to employ extruded aluminum parts in the above window construction, such that the window construction can be mass produced at a reasonable cost.
It is an additional object of the invention to form the extruded parts with C-shaped bosses so that a window frame, door frame, and/or a sash frame can be fastened together with screw fasteners.
It is yet another object of the invention to employ safety glass panes between adhesive and seals in the window construction, which in turn are mounted between parts that lock together without fasteners and induce substantial deformation in the adhesive and seals.
It is an optional object of the invention to incorporate the above window construction in a structure with at least one movable sash, such as vertically or horizontally slidable sash member in a window, or a horizontally slidable door panel in a sliding glass door, wherein the structure includes a fixed sash member as well to which the movable sash member can be latched by a latch mechanism.
These and other aspects and objects are provided according to the invention in a storm resistant window construction. The window construction has a window frame formed from left and right frame members connected to upper and lower frame members. These members are preferably extruded pieces, for example of aluminum. The frame members are formed with C-shaped bosses. These C-shaped bosses allow the frame members to be connected together by screws.
The frame members are formed with locking formations which permit engagement with an additional extruded part, namely extruded glazing beads. Each glazing bead includes complementary locking means for locking with the locking formations on the frame members such that a panel of safety glass, seals and adhesive are gripped therebetween, inducing deformation in the seals and adhesive for good sealing as well as a resilient structural connection.
The safety glass comprises at least one layer of annealed glass affixed to a multilayer composite of polymer materials. The safety glass is preferably oriented in the frame members such that the adhesive abuts a polymer layer and the resilient seal abuts the annealed glass. The multi-layer polymer composite preferably comprises an impact-resistant layer and a laceration-resistant layer, as chosen from the groups of polyvinylacetal polymers and polyvinylalchohol or polyethylene terephthalate polymers, respectively.
The frame members optionally are extrusions of alloys of aluminum, however extrusions of polymers are similarly advantageous. The adhesive can comprise silicone, or room temperature vinyl, glue or the like. A number of additional features and objects will be apparent in connection with the following discussion of preferred embodiments and examples.
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the embodiments disclosed as examples, and is capable of variation within the scope of the appended claims. In the drawings, FIG. 1 is an elevation view of a window construction in accordance with the invention, as used in a single-hung exterior window which is viewed from an outdoor vantage point;
FIG. 2a is an enlarged partial section view taken along line 2--2 in FIG. 1;
FIG. 2b is an exploded view corresponding to an upper portion of FIG. 2a;
FIG. 2c is an exploded view corresponding to a lower portion of FIG. 2a;
FIG. 3a is an partial section view taken along offset line 3--3 in FIG. 2a;
FIG. 3b is an exploded view corresponding to the left part of FIG. 3a, the right part being a mirror opposite; and,
FIG. 4 is an enlarged view of a detail of a lower sash rail in FIG. 2a, with portions broken away.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, an exterior window 10 incorporates the storm-resistant window construction aspects of the invention. The window 10 is representative of a single-hung window type because the window 10 includes a fixed frame and sash 12 and 14, respectively, and a movable, or vertically-slidable sash 16. The storm-resistant window construction aspects of the window 10 can be advantageously used in other window types, including but not being limited to skylights, double hung windows, horizontally slidable windows, and/or sliding glass doors. The window 10 is disclosed in particularity here merely for convenience in this description and does not exclude the storm-resistant window construction aspects being used in other types of windows in accordance with the invention.
The window 10 is mounted in a vertical wall (not shown) or like structure of a building, and is shown from the outdoor side (assuming the window 10 is mounted in an exterior wall). The storm-resistant window construction aspects of the window 10 is particularly advantageous for exterior walls of commercial and residential buildings; however the window 10 including the storm-resistant window construction aspects can be advantageously employed in other types of buildings and in other situations, such as a partition that subdivides indoor compartments, in a wall of an open garage or warehouse, in a wall in which both sides of the window 10 are exposed to the weather, and so on. Accordingly, terms like "inner" and "outer", "indoor" and "outdoor", and "left" and "right", are used merely for convenience in this description and do not limit the use or structural relationships of the window 10.
As previously stated, the window 10 comprises the frame 12, the upper preferably-fixed sash 14 and the lower movable sash 16 (upper and lower being relative to the positions shown in FIG. 1). Each sash 14 and 16 includes a panel of glazing 18 and 20 such as safety glass. Additionally, each sash 14 and 16 optionally carries a grid panel forming artificial muntins 26, fixed as shown to extend over an outdoor side of the glazing 18 or 20 for decorative purposes and to resemble a window of individual glass panes.
The window frame 12 comprises a pair of generally vertical jamb members 28 that have upper and lower ends flush against complementary portions of a generally horizontal head and sill members 30 and 32, respectively. The frame members 28-32 are segments of extruded pieces, preferably of aluminum although other materials are functionally equivalent, such as extrudable polymers, among others. The frame members 28-32 are preferably connected together via screw fasteners. Welded seams, among other connection options, are also possible and are not excluded. The window frame is subdivided by a fixed meeting rail 34, which extends generally horizontally between the spaced jamb members 28 and is likewise preferably connected by screw fasteners.
The glazing 18 of the fixed sash 14 is attached horizontally between the spaced jamb members 28 and vertically between the head member and meeting rail 30 and 34. The glazing 20 of the movable sash 16 is mounted in a sash frame 40 that is movably carried by the window frame 10. The sash frame 40 comprises spaced side rails 42 having upper and lower end portions flanking opposite ends of a top and bottom rail 44 and 46, respectively (for top rail 46, see, e.g.. FIG. 2a). The rails 42-46 of the sash frame 40, as well as the meeting rail 34, comprise extruded segments of aluminum, preferably, other similar materials also being possible. Rails 42-46 of the sash frame are preferably connected together by screw fasteners.
This general arrangement of a fixed sash 14 and movable sash 16 is known in the window art as a single-hung window. In a double-hung window embodiment, both sashes are movable. The window 10 of the invention can also be double-hung, a single-hung arrangement being shown for exemplary purposes only not to limit the invention to a single-hung embodiment only.
FIG. 2a is vertical section view of the window 10 and shows that the movable inner sash 16 moves in an inner vertical plane relative to a spaced outer plane extending through the fixed sash 14 (the outdoor-to-indoor direction being left to right in FIG. 2a). An optional screen sash 48 is shown in broken lines, mountable on the outdoor side of the movable sash. The top rail 44 carries a latch 50 with a sweeping hand-lever operative to drive a retractable tongue 50' to the left in FIG. 2a via a cam mechanism (not in view). The retractable tongue 50' is extendible into cooperatively sized recess 180 (see FIG. 2b) in the meeting rail 34 to lock the movable sash 16 in the position shown in FIG. 2a.
With general reference to FIGS. 2a-2c, head member 30 of window frame 12 includes an upstanding flange 52 for overlapping and anchoring to a structural member (not shown) of the building in which the window is installed. Preferably, anchors (not shown) like lag bolts or wood screws are used for fastening the upstanding flange 52 to structural members of the building such as adjacent studs. Head member 30 includes a web portion 54 that extends from the upstanding flange 52 to an inner depending flange 56. The head member 30 is formed with an intermediate flange 58 between inner depending flange 56 and outer upstanding flange 52. Web portion 54 has an upper surface formed with three parallel ribs that not only stiffen the frame but also act as spacers against the building structure to permit clearance for the heads of screws.
Intermediate flange 58 defines a glazing bearing surface 64 (see FIG. 2b) against which adhesive 62 supporting the glazing 18 is applied. An additional aspect of the head member 30 involves a pair of locking formations for receiving and securing a glazing bead 66. The glazing bead 66, like the frame and rail members 28-34 and 42-46, is preferably a segment of an extruded piece, such as extruded aluminum. An outer one of the locking formations is defined by a lip 68 on web portion 54, located below the upstanding flange 52, which lip 68 has an inclined surface. The inner one of the formations is defined partly by a tab 70 formed on the intermediate flange 58, as well as portions of the intermediate flange 58 and web portion 54, which cooperatively define a locking slot 72.
The sill member 32 (FIGS. 2a and 2c) includes an outer dependent flange 78 for overlapping and anchoring to a structural member of the building by anchors (not shown). Sill member 32 includes a web portion 80 that extends from the outer depending flange 78 to an inner upstanding flange 82 and is inclined downwardly for drainage to the outside. The web portion 80 has a lower surface formed with two parallel ribs that act as spacers against the building structure to permit clearance for the heads of screws, and an upper surface formed with a rib to catch screen sash 48. The inner upstanding flange 82 has an inner surface formed with a latching tab 86 (see FIG. 2c) to perform a latching function with movable sash 16.
The bottom rail 46 of the sash frame 40 has a box-like main portion, and an inner sidewall which has an upward extension 90 terminating in an inwardly extending flange 92. Flange 92 defines a manually graspable element of the sash frame 40 to permit a user to handle the movable sash 16 and to move it between open and shut positions (the shut position being shown in FIGS. 1 and 2a). Flange 92 has a lower surface formed with a C-shaped slot 94 that has an opening facing downwardly and inwardly. Slot 94 is sized and shaped to carry a pivoting latch bar 96 that can engage with tooth 86 of sill flange 82 when the sash 16 is closed.
The pivoting latch bar 96 is an alternative to the latch 50, to lock the movable sash 16 in the down position (as shown in FIG. 2a) in the window frame 12. The latch 50 is generally preferred over the latch bar 96. The latch bar 96 is preferred in special cases to meet the fire codes of some localities that require the window latching mechanism to be located within reach of rather small children.
Latch bar 96 extends left to right substantially between the left and right rails 42 (see FIG. 1). Latch bar 96 has a substantially cylindrical axle portion 98 pivotably carried in slot 94 and a hook portion 102 for catching the latching tab or tooth 86 on sill member 32, which results in the sash 16 being immovably secured in the down or shut position in the window frame 12. Latch bar 96 further includes a cantilever portion 104, the weight of which normally urges the latch bar 96 clockwise relative to the position shown in FIG. 2a, i.e., into a locking position at which hook portion 102 abuts upstanding flange 82 of sill member 32.
The hook portion 102 includes a tapered cam surface 106 (see FIG. 2c) facing downwardly, so that as the movable sash 16 is moved downwardly toward the shut position, the cam surface 106 slides over latching tab 86 on sill member 32, after which hook member 102 swings clockwise into the latched position shown in FIG. 2a. Thus, latch bar 96 automatically latches onto latching tab 86 when sash 16 is shut. Latch bar 96 is movable to an unlatched position by upward pressure on cantilever portion 104, typically by the user squeezing flange 92 and portion 104 together.
The bottom rail 46 has a lower sidewall with an external surface that is formed with a T-shaped groove 152 shaped and arranged to receive the T-shaped tongue 154 of a resilient seal or weatherstrip 156, and has a rib for abutting the sill member to limit the travel of the movable sash 16 at an extreme downward position.
FIG. 4 is a detail of the lower portion of the movable sash 16. The bottom rail 46 lower sidewall has an internal surface that is formed with a C-shaped boss 120. The upper sidewall has an internal surface likewise formed with a C-shaped boss 120, these bosses 120 being sized to accept the spiral threads of self-tapping screws 122 (FIG. 3b). Screws 122 are aligned through holes (not shown) in one or the other of the side rails 42 and tightened in the C-shaped bosses 120 (FIG. 4) to secure the side rails 42 (FIG. 1 ) and bottom rail 46 together in a butt-joint fashion.
In FIG. 4, the bottom rail 46 is formed with a locking lip 68. The upward extension 90 has a locking tab 70 which together with portions of the upward extension 90 and upper sidewall define a slot 72. The locking lip 68 and slot 72 are spaced and arranged to secure a glazing bead 66 in a fixed position as shown. The upward extension 90 of the bottom rail 46 has an outer surface defining a glazing bearing surface 64 against which adhesive 62 supporting the glazing 20 is applied, in a manner similar to that discussed above with reference to the fixed sash 14.
Glazing bead 66 (FIGS. 2c and 4) includes a channel-shaped base portion 130 (an inverted-U shape as shown) with opposite arms, one of which terminates in a locking lip 132 and the other of which terminates in a locking flange 134. Additionally, the glazing bead 66 includes a seal or weatherstrip-carrying flange 136. Flange 136 forms a T-shaped groove 110 for receiving a T-shaped tongue 112 of a resilient seal 114, the bearing part of which is resilient, e.g., hollow and tubular. Locking lip 132 and flange 134 are sized and arranged for engagement simultaneously with the locking lip 68 and slot 72, respectively, of the bottom rail 46, such that glazing part 66 is snapped into secure engagement. By these arrangements, glazing bead 66 can be press fit into engagement with rail 46 without requiring additional fasteners.
Glazing 20 preferably comprises a three-ply construction including an outer layer of annealed glass 142 (FIG. 4), a middle layer of a polymer 144, and an inner film 146 coating the polymer 144 for increased abrasion resistance. Polymer 144 can comprise any suitable variety of thermosetting or thermoplastic polymer for absorbing impacts and/or deforming forces, including but not limited to vinyl polymers, preferably polyvinylacetal polymers, and most preferably polyvinyl butyral and polyvinyl formal polymers. Film 146 can comprise any suitable variety polymer resistant to lacerating, including but not limited to groups chosen from polyvinylalchohol and polyethylene terephthalate polymers. The glazing 20 is oriented such that the glass side preferably faces outdoors and the polymer side faces indoors.
Glazing 20 is installed before glazing bead 66. Bottom rail 46 is prepared for the glazing 20 by application of a viscous bead of adhesive 62 such as silicone or room temperature cured vinyl glue, at the glazing bearing surface 64 of the bottom rail 46. Glazing 20 is placed against the viscous bead of adhesive or glue 62, and glazing bead 66 is readied for attachment to sill bottom 46. Locking flange 134 is guided into locking slot 72, and then the complementary locking lips 68 and 132 are forced together until they snap over one another to engage each other. As a result, glazing bead 66 is securely fixed. Additionally, the glazing 20 is sealingly and resiliently clamped across its sides between the combined adhesive bead and upward extension 62 and 90 on the inside, and the combined resilient weatherstrip and glazing bead 114 and 66 on the outside.
With more general reference to FIGS. 2a-2b, top rail 44 of sash frame 40 has a box-like main portion, and a graspable flange 160 extending from an upper and inner corner. The box-like main portion of top rail 44 has an outer sidewall formed with a T-shaped groove 162 (FIG. 2b) sized to receive a T-shaped tongue of a resilient seal or weatherstrip 164. The outer sidewall has a hook member 166 for hooking a complementary hook member 168 of the meeting rail 34, partly for limiting the downward travel of the sash 16 in the window frame 12, and partly for defining a closure for the window 10. The lower and upper sidewalls have internal surfaces formed with a C-shaped bosses 120, respectively, which permit fastening to the side rails 42 (FIG. 1) by screws 122 (FIG. 3b) in butt-joint fashion similar to that discussed above.
Meeting rail 34 similarly includes a box-like main portion, an upward extension 176 formed with a locking tab 70, a locking lip 68, and internal C-shaped bosses 120 which permit fastening between the jamb members 28 (FIG. 1) by screws 178 (FIGS. 3a and 3b) in butt-joint fashion. The locking lip and tab 68 and 70 (FIG. 2b) are spaced and arranged to secure a glazing bead 66 and glazing 18 in fixed positions as shown. Meeting rail 34 additionally includes an inner sidewall formed with a slot 180 that is sized and arranged for accepting the retractable latching tongue 50' of latch 50 on the top rail 44, which latch 50 is of a conventional cam-type window latch.
In FIGS. 3a and 3b, the left and right halves are mirror opposites, wherein the left jamb member 28 is described as representative of the right. Thus, the left jamb member 28 includes an outer flange 182 that extends in the distal direction (relative to the window's vertical center line, not shown). The outer flange 182 is arranged for overlapping and anchoring to the structural members of the building, preferably by anchors (not shown). Left jamb member 28 has a web portion 184 that extends from the outer flange 182 to an inner flange 186 that extends in the proximal direction. Web portion 184 is formed with two parallel ribs which, with a tab on the outer flange 182, space against the building structure to permit clearance for the heads of screws. C-shaped bosses 120 permit fastening between the head and sill members 30 and 32 (FIG. 1 ) via screws 188 (FIGS. 2a-2c) in butt-joints as above.
The jamb member 28 has an intermediate flange 190 (FIGS. 3a and 3b) that extends in the proximal direction, which intermediate flange 190 has an outer surface (the indoor-to-outdoor direction being up to down in FIGS. 3a and 3b) formed with a locking tab 70 (FIG. 3b). Left jamb member 28 has an outer proximal corner formed with a locking lip 68, the locking lip and tab 68 and 70 being spaced and arranged to secure a glazing bead 66 and glazing 18 in fixed positions as shown. The intermediate and inner flanges 190 and 186 are spaced apart to define a channel in which the sash 16 moves.
The left rail 42 of the sash 16, as representative of the right, is generally T-shaped, with an outer edge 192 of the left rail 42 defining a foot of the T-shape, and an inner end defining the head of the T-shape. The outer edge 192 is formed with a locking lip 68 on the proximal side and T-shaped groove on the distal side, sized to receive a T-shaped tongue of a resilient seal or weatherstrip 114. The weather strip 114 has a resilient, e.g., hollow, main body which slides along a surface of the intermediate flange 190 of the left jamb member 28.
The inner end of left side rail 42 comprises a proximal flange 196 formed with a locking tab 70, which coacts with the locking lip 68 to secure a glazing bead 66 and glazing 20 in fixed positions as shown. The distal flange carries a nylon slide 202 on an inner surface thereof for sliding against a surface of the inner flange 186 of the left jamb member 42. The distal flange of rail 42 terminates in the distal direction in a hook 204 to complement a hook 206 of a guide member 208. The guide member 208 is fastened to the left jamb member 28. The complementary hook portions 204 and 206 cooperate to guide the sash 16 in a preferred path during movement to avoid binding and the like.
FIGS. 3a and 3b additionally depict a balance cover 212 (FIG. 3a only) and balance top plate 214 for a sash balance (not shown) to counteract part of the weight of the movable sash 16 during movement thereof. The balance preferably comprises a coil tension spring (not shown), or another structure as known in the art.
Window 10 is particularly durable and has been successfully tested under conditions characteristic of strong storms such as hurricanes. More particularly, the window according to the invention has been found to meet criteria of the building code of Dade County, Fla., promulgated to provide standards for windows resistant to hurricane winds, windborne debris and the like, namely South Florida Building Code sections 2314.5 and 2315, as construed with the Building Code Compliance Office of Dade County's protocols PA 202-94, PA 201-94 and PA 203-94 (hereinafter called "the code provisions" collectively).
Briefly, compliance with the code provisions involved testing three specimen windows under test protocols involving subjecting each specimen to a static pressure test, an impact test, and a cyclical loading test, pursuant to protocols PA 202-94, PA 201-94 and PA 203-94, respectively.
Preliminarily, a specimen window is attached to a suitable fixture for mounting in a test chamber. The specimen window is supported by and secured to the respective fixture by the same number and type of anchors to be approved for normal installation of the window in a building. No sealing or construction material that is not normally used is employed to attach the specimen window to a fixture.
Under the static load test, the specimen window is subjected to a defined maximum static load, namely that equal to a static air pressure based on a wind velocity of 75 mph (120 kph). In addition to the static load there is water spray. One-half of the defined maximum load is applied to the outdoor side of the specimen window, sustained for 30 seconds and released. After a recovery of 10 seconds, one-half of the defined maximum load is applied to the indoor side of the specimen window, and sustained for 30 seconds before release. Next the specimen window is permitted a recovery period of between 1 and 5 minutes, after which the defined maximum load is applied to the outdoor side of the specimen window and sustained for 30 seconds. Following a recovery of 10 seconds, the defined maximum test load is applied to the indoor side of the specimen window and sustained for 30 seconds. Water is sprayed onto the outdoor side of the specimen window, at a minimum rate of 5 gph/ft 2 (200 lph/m 2 ) and at a pressure equal to not less than 15% of the full test load, sustained for not less than 15 minutes. Compliance requires that no water infiltration shall occur.
Under the impact testing protocol, an air cannon is arranged to launch missiles at a specimen window. A preferred missile is a combination of a timber of solid S4S nominal 2×4 #2 surface dry Southern Pine (nominal 5 cm×10 cm), between 7 and 9 feet long (2.1 and 2.7 m), with a sabot attached to a trailing edge of the timber to facilitate launching, the combined weight of the timber and sabot being between 9 and 9.5 lbs (4 and 4.3 kgs). The missile is launched at the specimen window to achieve a speed at impact of at 34 mph (55 kph).
Each specimen window receives two impacts. Specimen window number one is impacted once at the meeting rail, and once at the center of the glazing in the sash frame. Specimen window number two is impacted once at the center of the glazing in the sash frame, and once at the bottom rail of the sash frame, 6 inches (15 cm) from a bottom corner. Specimen window number three is impacted once at the bottom sash frame rail 6 inches (15 cm) from a bottom corner, and once at the meeting rail. After having been so impacted, and presumably dented, each specimen is subjected to the third protocol.
Each specimen window is returned to a pressure chamber, and cyclically loaded for 9000 cycles, at selected pressure differentials ranging up to a defined maximum of 70 lbs/ft 2 (3.35 Kpa). Indeed, all the samples constructed in accordance with the invention not only survived 70 lbs/ft 2 (3.35 Kpa) but also showed signs of being able to withstand more. Although, the test envelope was not actually extended beyond a maximum of 70 lbs/ft 2 (3.35 Kpa). The pressure differentials ramp up during one half the cycles and down during a second half. More particularly, 50% of the maximum defined differential applied to the outdoor side of the window at 3200 cycles, 100% is developed at 4500 cycles, immediately after which the pressure differential is reversed so that 100% of the maximum is applied to the indoor side of the specimen window, following which the pressure differential ramps down until as 50% of the maximum is applied to the indoor side at 7700 cycles, and so on.
The results for the three specimen windows are examined as to whether the three specimens collectively complied with the criteria defined in the code. Compliance with the code requirements, although not foolproof or representative of all possible storm conditions, is generally deemed to indicate that the window is a useful part of the external protection of a building envelope, likely to withstand expected storm emergencies such as hurricanes and the like.
During differential testing, specimen windows in accordance with the invention were observed to flex. A center of the meeting rail 34 was observed to arch out from a line intersecting its ends by up to 1.5 inches (3.8 cm); a center of geometry of the glazing 20 in sash frame 40 was observed to stretch away from a plane generally containing its four edges by up to 4 to 5 inches (10 to 12.7 cm); and, a center of sash bottom rail 46 simultaneously twisted together with the glazing to arch out by up to an inch (2.54 cm).
The window 10 of the invention has an overall structure that is durable enough to withstand anticipated impact, and is flexible and resilient for withstanding anticipated wind force and rain. Advantageous aspects of the overall structure include, among others, the hollow rails and thin frame members, the screw fastening system including the C-shaped bosses, the safety glass, and the means of attaching the glazing. Although durable, the window materials and their assembly as described can be accomplished at a reasonable expense for use in typical buildings.
The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed.
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A storm resistant window has a window frame and a window sash of preferably-aluminum extruded frame members, a glass and polymer safety glass, clamping glazing beads that bear sealingly on the glass, and a sash locking clasp arrangement. The window resists impacts characteristic of windblown hurricane debris, for example, and is resilient enough to damp wind loads induced by 75 mph (120 kph) winds, with resilient arching and twisting of the frame members. The clamping glazing beads are snap-fitted to lock tightly in the associated superstructure around the glazing, deforming resilient weatherseals against the outer surface of the safety glass. The safety glass has coextensive annealed glass and polymer layers. An additional polymer strip and a bead of adhesive affix the glazing on the inside for resisting abrasion of the polymer side against the frame. The window includes a latch for a positive locking connection between the frame and the sash within the frame.
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[0001] CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] This application claims priority to Provisional Application No. 60/484,829.
TECHNICAL FIELD
[0003] The present invention discloses a novel apparatus adapted to be positioned near a manhole and for pulling the water hoses used for cleaning sewer lines. This invention also relates to a method of using the disclosed portable hose puller. Although the hose puller is described in the context of cleaning sewer lines, one skilled in the art readily understands that the disclosed portable hose puller and method for using the portable hose puller may be used in a wide variety of applications that require hose, rope, electrical cord, or similar application.
BRIEF SUMMARY OF THE INVENTION
[0004] One embodiment of the present invention is directed to a portable hose puller comprising a frame; a pair of handle bars connected to the frame; a pair of ground wheels connected to the frame; a pair of puller wheels connected to the frame, wherein the puller wheel are operably positioned with respect to each other to grip a hose; an idler wheel operably located with respect to the puller wheels; and a motor connected to the puller wheels. The puller wheels are configured to have gripping surfaces, which may be made of rubber. Further, the puller wheels may be rounded.
[0005] The hose puller may further include an idler wheel is spring loaded to secure a hose in frictional association with the gripping surface of the puller wheels. The hose puller may also include a clutch that is connected to the puller wheels.
[0006] The hose puller may further include a control panel for controlling the speed of the motor.
[0007] The hose puller may further include a camera positioned with respect to the puller wheels to capture images of hose puller in operation.
[0008] The hose puller may further include a control panel for controlling the hose puller.
[0009] The hose puller may further include an upper and lower hose guide connected to the frame.
[0010] A further embodiment of the disclosed portable hose puller includes a hose puller comprising, a frame; a pair of handle bars connected to the frame; a pair of ground wheels connected to the frame; an upper puller wheel and a lower puller wheel connected to the frame, wherein the puller wheel are operably positioned with respect to each other to grip a hose; and a motor operably connected to the puller wheels. The hose puller may include puller wheels that are shaped to receive a hose. The puller wheels may be rubber. Further, the puller wheels may be shaped to grip a hose.
[0011] The hose puller may further comprise a chain connecting the puller wheels to the engine. The puller wheels are configured with a sprocket for receiving said chain. Further, the puller wheels and sprockets are sized such that puller wheels are traveling at the same rate.
[0012] The hose puller may further comprise a tensioning wheel to maintain tension in the chain.
[0013] The hose puller may further comprise a clutch operably connected to the motor and puller wheels.
[0014] The hose puller may further comprise a control panel configured to control the speed of the motor. The hose puller may also be configured to be controlled remotely.
[0015] The hose puller may further comprise comprises a camera positioned with respect to the puller wheels to capture images of hose puller in operation.
[0016] The hose puller may further comprise an upper and lower hose guide connected to the frame.
[0017] A further embodiment of the disclosed invention includes a method of using a hose puller comprising the steps of positioning a hose puller with respect to a manhole; running a hose from a water source to the hose puller; and gripping the hose with hose puller wheels.
[0018] The method further includes the steps of connecting the hose puller to an electrical power source and positioning the hose in frictional engagement with the hose puller.
[0019] The method further includes the step of engaging the hose puller to feed the hose into a manhole.
[0020] The method further includes the step of the step of positioning a camera to view the hose as it is fed into the manhole.
[0021] The method further includes the step of comprising the step of connecting a cleaning nozzle to the end of the hose.
[0022] The method further includes the step of feeding the cleaning nozzle and hose into a portion of pipe to be cleaned.
[0023] The method further includes the step of feeding the hose into the pipe using the hose puller and the cleaning nozzle.
[0024] The method may further include the step of remotely monitoring the speed and progress of the hose.
[0025] The method may further include the step of remotely controlling the speed and progress on the hose.
[0026] The method may further include the step of retracting the hose.
[0027] The method may further include the use of a hose puller comprises a frame; a pair of handle bars connected to the frame; a pair of ground wheels connected to the frame; a pair of puller wheels connected to the frame, wherein the puller wheel are operably positioned with respect to each other to grip a hose; and a motor operably connected to the puller wheels. The puller wheels may have a gripping surface. The gripping surface may be rubber. The gripping surface may also be rounded.
[0028] The method may further include the use of a hose puller that includes a clutch operably connected with the motor and puller wheels.
[0029] The method may further include the use of a hose puller that includes a control panel configured to control the speed of the motor.
[0030] The method may further include the use of a hose puller that includes a camera positioned with respect to the puller wheels to capture images of the hose puller in operation.
[0031] The method may further include the use of a hose puller that includes a control panel that can be controlled remotely.
[0032] The method may further include the use of a hose puller that includes an upper and lower hose guide connected to the frame.
[0033] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized that such equivalent constructions do not depart from the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The advantages, features, and details of the invention are explained in greater detail in the following description of the preferred embodiment, with the aid of drawings as listed below.
[0035] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
[0036] FIG. 1 is a portable hose puller;
[0037] FIG. 2 is the lower portion of the stand arms configured to seat inside a manhole;
[0038] FIG. 3 is the front of the hose puller showing the friction groove;
[0039] FIG. 4 is a wheel specially shaped to grip hose;
[0040] FIG. 5 is a hose puller configured with two puller wheels; and
[0041] FIG. 6 is a diagram showing the positioning and use of the portable hose puller.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Upon review of the detailed description and the accompanying drawings provided herein, it will be apparent to one of ordinary skill in the art that a portable hose puller may be used in a wide array of applications that require maneuvering of hoses or the like. Accordingly, the present invention shall not be limited to the structures and methods specifically described and illustrated herein, although the following description is particularly directed to a portable hose puller for use in sewer cleaning operations. The term “hose” with which the present invention is associated, includes various types of hoses, tubes, ropes, cables, chains, and the like. The term “portable” with which the present invention is associated describes an apparatus sized to be moved by one person. Further, the hose puller is light enough that it does not damage soft ground while being positioned. Portability makes the disclosed apparatus uniquely suited to be positioned near a work site. However, it is contemplated that the disclosed apparatus may be scaled for a particular application. For example, in large cable laying applications, the disclosed devise may be scaled to handle the increased loads associated with such applications.
[0043] FIG. 1 shows one aspect of portable hose puller 10 . The hose puller includes a frame 11 , which may be of metal, aluminum, plastic, or combinations thereof. The metal frame is configured with handles 13 and wheels 12 to allow for easy mobility. Handles 13 may be telescoping to provide greater leverage when moving the portable hose puller. Frame 11 is also configured with stand arms 14 . The lower portion of stand arms 14 include a gripping shape 15 . For grass and other soft surfaces, the gripping shape may be shovel shaped to dig into soft surfaces. However, it is readily understood that many different shapes may be used for different applications. For example, it is contemplated that rubber stoppers may also be used in some applications. The essential characteristic of all gripping shapes, however, is that they inhibit the movement of the hose puller 10 when it is in use. FIG. 2 shows a detailed view of the gripping shape 15 that is shaped to rest inside a manhole opening.
[0044] Also included on stand arms 14 are forward guide arms 16 . The forward guide arms 16 are sized to keep the hose in guided relation with the gripper wheels 17 . The forward guide arms 16 are shown as two separate extensions, which allows the hose to be easily fed into the gripper wheels 17 . However, it is contemplated that the arms may be connected to enclose the area in which the hose is located. It is further contemplated that the guide arms may be configured with rollers to reduce the friction between the hose and the forward guide arms 16 . alternatively, the forward guide arms 16 may include a material, such as Teflon, to reduce the friction between the hose and the forward guide arms. The guide arms are shown attached to stand arms 14 . However, it is readily understood that the guide arms may extend from handles 13 , extend from stand arms 14 to handles 13 , extend from some other frame element, or any combination thereof.
[0045] Attached to the hose puller frame 11 are puller wheels 17 . The puller wheels 17 are made from a soft material such as rubber. Although rubber is disclosed, one skilled in the art understands that any soft compound may be used. Additionally, the puller wheels 17 may be air filled. The puller wheels 17 are positioned to create a friction groove 18 between the wheels. FIG. 3 shows a front view of the hose puller to show the friction groove 18 . The puller wheels 17 are shown positioned side by side in a parallel configuration. In such a configuration, the curvature of the wheels form the side walls of the friction groove. Although a parallel positioning of puller wheels 17 is disclosed, it is contemplated that the space between the wheels may be adjusted to create a deeper groove. It is also contemplated that the angle between the wheels may be adjusted to change the depth of the friction groove 18 . Puller wheels 17 are connected to drive motor 21 . The drive motor 21 rotates the puller wheels 17 when power is applied. Alternatively, the frictional groove can be created by a single wheel 17 ′. FIG. 4 shows a wheel shaped for a frictional groove. The shaped wheel 17 ′ may be made out of any suitable material. The wheel shown in FIG. 4 is made out of aluminum. The puller wheels 17 are positioned relative to the man hole such that the weight of the hose pulls the hose into greater frictional engagement with the puller wheels 17 .
[0046] Attached to the hose puller frame 11 is an idler wheel 19 and idler wheel frame 20 . The idler wheel is configured to ensure that the hose being manipulated by the hose puller is maintained in frictional engagement with the frictional groove 18 . Like the puller wheels 17 , the idler wheel is made out of a soft material such as rubber or the like. The idler wheel may also be filled with air. Although the idler wheel 19 is shown a different size than the puller wheels 17 , it is understood that the idler wheel may be sized to suit a particular purpose. Additionally, the idler wheel may be any number of different shapes. For example, the idler wheel may actually be a flat surface that functions to keep the hose in frictional engagement with the puller wheels 17 . Alternatively, the idler wheel 19 may be shaped to complement the puller wheel 17 shown in FIG. 4 .
[0047] The disclosed hose puller is adapted to take advantage of the frictional force associated with redirecting a hose as it is being manipulated. For example, in the configuration shown, the hose is realigned from an orientation that is parallel to the surface to one that is perpendicular to the surface. Such realignment naturally seats the hose in the frictional groove. However, in other applications or in applications requiring greater frictional force, the idler wheel frame may be adapted to provide additional force to help seat the hose in the frictional groove. Additionally, the hose puller may be configured with multiple wheels 17 . In such a configuration the wheels are positioned to redirected the hose as it passes over each pair of wheels 17 . Redirecting the hose acts to increases the gripping friction provided by the gripping groove. A configuration with multiple sets of puller wheels is particularly adapted for straight line pulling applications where the hose direction is not changed as it passes through the hose puller 10 . One skilled in the art understands that the relationship between the puller wheels 17 can be changed to further increase the frictional forces. For example, all three puller wheels can be positioned in alignment to increase the amount of bend in the hose as it passes over each wheel.
[0048] The idler wheel 19 shown in FIG. 1 is attached to the idler wheel frame 20 . The idler wheel frame 20 may be selectively positionable or configured to apply rotational force such that the idler wheel 19 applies pressure to the puller wheels 17 . The rotational force may be the result of a spring or may be driven by some other means, such as pneumatically. Further, the spring tension can be adjusted using spring handle 25 .
[0049] The puller frame 11 includes aft guide arms 22 . The aft guide arms function similarly to the forward guide arms 16 and may be similarly shaped and configured.
[0050] The hose puller 10 may be controlled using control panel 23 or by remote control (not shown).
[0051] The hose puller 10 may also be configured with a camera 24 . The camera is positioned to capture images of the hose as it is feed into or retrieved from a sewer line. The camera may also be trained on the hose puller or any other aspect of interest. The hose puller may also be configured to view counter 37 . The counter 37 records the amount of hose that passes over wheel 17 . This information is used by the operator to control how far the cleaning nozzle is inserted into the sewer line. In a normal operation, once the length is established by visual inspection at the downhole manhole, the cleaning nozzle can then make multiple passes through the sewer line without additional visual inspections.
[0052] FIG. 5 depicts an alternative configuration in which the hose puller 10 is configured with two puller wheels 17 . Both puller wheels 17 are connected with chain 32 to drive motor 21 and drive motor sprocket 31 . The hose puller 10 also includes a tensioning wheel 33 . The tensioning wheel is designed to regulate the chain tension. The tensioning wheel may be a wheel, sprocket, or the like. The tension may be set manually or adjusted by way of a spring. The hose puller is hinged at point 35 such that different size hoses can be easily inserted into the hose puller. To the extent additional gripping is needed, a weight can be applied to the arm supporting the upper puller wheel 17 . Optimally, if a weight is needed, it is applied to the upper arm at end 34 . The hose puller configured as shown in FIG. 5 includes a camera and control box. Further, the hose puller of FIG. 5 is configured to be operated remotely. Puller wheels 17 may be made out of a hard rubber or other solid material that is also suited for gripping a hose.
[0053] FIG. 6 shows the hose puller positioned over a manhole. The hose puller 10 is shown as it is feeding a hose into a manhole for cleaning head 26 . The hose puller is shown connected to cleaning truck 27 . The cleaning truck supplies high pressure water to the cleaning head 26 . Although the cleaning truck is shown as the source of the water used by cleaning head 26 , it is understood that the cleaning truck 27 may be connected to a fire hydrant or other similar water source. Dashed line 28 shows a connection between the cleaning truck 27 and camera. Images from the video camera 24 are displayed on monitor 29 . Although the monitor is shown mounted to the back of cleaning truck 27 , it is understood that the monitor may also be located in the cab 30 . Additionally, FIG. 6 shows the cleaning truck 27 being located in close proximity to the hose puller 10 . In reality, the cleaning truck 27 is positioned much further away from the manhole. The hose puller engine may be gas powered or connected via a power line (not shown) to the cleaning truck 27 . Additionally, the hose puller is not show to scale. In particular, the hose puller is not scaled relative to cleaning truck 27 . In reality, the hose puller is much smaller relative to the cleaning truck.
[0054] The present invention is, therefore, well adapted to carry out the objects and attain the ends and the advantages mentioned, as well as others inherent therein. While presently preferred embodiments have been described, numerous changes to the details of construction, arrangement of the article's parts or components, and the steps to the processes may be made. For example, the frame may be reconfigured in a number of different ways. However, all such configurations allow for the frictional groove to provide the primary means whereby the hose puller manipulates hoses. Such changes will readily suggest themselves of those skilled in the art and are encompassed within the spirit of invention and in the scope of the appended claims.
[0055] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the machine, methods and steps described in the specification. As one will readily appreciate from the disclosure, machines, methods, and steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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A hose puller that includes puller wheels that are motorized and configured to grip, among other things, a high pressure water hose. The hose puller further includes an idler wheel that is positioned to oppose the puller wheels. The idler wheel is spring loaded to help ensure that the hose maintains frictional relation with the puller wheels. Alternatively, the hose puller may have puller wheels shaped to grip a high pressure water hose. The hose puller also includes a camera that is configured to show images that enable the operator to control the hose puller from a remote location.
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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 an improved particle sampling apparatus and hammer drill for use in efficiently drilling a bore hole while continuously taking core samples.
The object of the invention is to drill a hole without the use of a conventional drilling rig and to provide a continuous flow of broken particulate material to the surface.
SUMMARY OF THE INVENTION
In accordance with the present invention, apparatus for drilling a bore hole comprises a hammer and a series of dual wall drill tubes, the hammer being supplied with compressed air and being for use in applying successive percussive blows to a percussive drill cutting bit for taking core samples from the bottom end of the bore hole while drilling same, first means for indexing rotationally the bit for drilling purposes, said means being operable by a portion of the supply of air, second means to conduct from the bottom end of the bore hole the portion of air used by and exhausted from the percussive cutting bit and having core particles entrained therein, and third means to assist in conveying said exhausted air and core particles to the surface for collection.
Preferably, an upstanding rig is provided at surface level to support the hammer and drill tubes and to transmit push-down or pull-up movement thereto.
Preferably also, the portion of air actuating the first means is the same as that portion of air sequentially causing the hammer to apply the percussive blows.
Preferably further, the third means comprises an annular flushing jet to direct a portion of air upwardly through a sampling tube co-axial with the drill tube and hammer to induce a venturi to assist in conducting core particle entrained exhaust air upwardly. The flow of air through the jet is continuous and uninterrupted while the flow of exhausted air is intermittent and pulsating.
BRIEF DESCRIPTION OF THE DRAWING
An embodiment of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows a diagrammatic side elevation of an apparatus according to the present invention for use in drilling bore holes;
FIGS. 2 and 3 show, to a larger scale than FIG. 1, vertical cross-sectional views of a hammer and drill tubes;
FIG. 3 being an upright continuation of the view shown in FIG. 2;
FIG. 4 is an exploded view of a ratchet mechanism to a still larger scale;
FIG. 5 shows an exploded view of an alternative means of rotation for the cutting bit, the means incorporating a ratchet mechanism; and
FIG. 6 shows to a different scale a side elevation of alternative means of piston movement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, the apparatus comprises a rig 37 to be upstanding adjacent to where a bore hole is to be drilled. A drill tube head is carried on said rig 37 to be moved parallely of an upstand thereof by an arrangement of wire ropes 81 entrained around a set of pulleys 82, and the head 1 being moved by operation of extension or retraction of a hydraulically-operable ram 80. The drill head 1 supports a hammer 3 which is of a self-rotating sampling type and as the hammer 3 is progressed into the ground to form a bore hole, dual wall drill tubes 2 are added sequentially according to conventional practice to the hammer 3. The head 1 receives compressed air from a compressor (not shown) via a flexible hose 83. Thus air is fed therefrom to the cutting bit 27 of the hammer 3 to rotate same and drill the bore hole. Details of hammer 3 and the next adjacent drill tube 2 is shown in FIGS. 2 and 3 and will be described hereinunder in relation to the method of operation of the apparatus.
The method comprises the following sequence of events. High pressure compressed air (of the order of 100 psi or above), produced by the surface compressor, is channelled via the flexible hose 83 to the drill tube head 1. The high pressure compressed air then passes down the annular area within the dual wall drill tubes to enter the hammer. After passing through a shock absorber assembly 9, the high pressure compressed air is split at point 4, more than half the high pressure compressed air being directed past the hammer mechanism in the annular area between an inside piston liner 5 and a sample tube 6. This compressed air, which remains at high pressure, is then redirected at a high upward angle into the sample tube 6 by a flushing jet 7, to transport drill hole cuttings to the surface.
The remaining high pressure compressed air at point 4 passes through a water check valve 10 to enter an automatic valve block 11 of the hammer 3. This automatic valve 11 controls motion of a piston 12 of the hammer 3 and comprises six individual parts, i.e. valve cap 13 with air control grommets 14, and automatic valve chest top 15, a flap valve 16, and an automotive valve chest bottom 17 with `O` ring 18. The air control grommets 14 are fitted to the valve cap 13 to control the amount of air passing into the hammer system. By varying the number of grommets fitted, piston impact performance may be advanced or retarded. As the high pressure air passes through opened portholes 19 of the valve cap 13 and into the automatic valve check block comprising chest top 15, flap valve 16, and chest bottom 17 through an inlet passageway 22 of the chest top 15, the flap valve 16 moves upwards thus closing off outlet portholes 21 provided in the chest top 15. The high pressure compressed air is then channelled through portholes 23 of the automatic valve chest bottom and into a downstroke piston chamber 25. The piston 12 now travels to its maximum downward stroke, thus pushing a bit shank 26 and the cutting bit 27 out to their fully-extending position. The high pressure compressed air in the downstroke piston chamber 25 then exhausts out through exhaust portholes 28 and travels downwards in the annular area between an outside piston liner 29 and a hammer barrel 30. This exhaust air continues past a piston guide bush 31 and a ratchet assembly 32 and down the annular area between a splined drive tube 33 and the barrel 30. Because bit shank 26 and cutting bit 27 are fully-extended thus shutting-off exhaust port-holes 34 of the splined drive tube 33, the high pressure exhaust air is prohibited from escaping out via the exhaust portholes 35, of the cutting bit 27. The air, therefore, becomes trapped in the hammer system. Additional air is prohibited from entering the automatic valve block 11 and so all high pressure compressed air travelling down the dual wall drill string of tubes 2 is directed into a by-pass system 36. The air then passes down to the flushing jet 7 to flush the sample tube clean. Flushing jet 7 is air sealed with drill bit shank 26 by a cheveron type rubber seal 8.
When the sampling hammer 3 and dual wall drill string of tubes 2 are lowered to ground surface, or a bottom of an existing drill hole or whatever, by the rig 37, and the cutting bit 27, containing sintered tungsten carbide cutting teeth 38, comes into contact with resistant material, the cutting bit 27 and attached bit shank 26 are forced to retract inwards into the sampling hammer 3. The high pressure compressed air trapped in the downstroke piston chamber 25 is now allowed to escape through the splined drive tube exhaust portholes 34, past a bit retaining ring 39, a thrust bearing 53, chuck splines 40 and the cutting bit exhaust portholes 35. At the same time as piston 12 is pushed upwards by cutting bit 27 and bit shank 26, inlet portholes on the outside piston liner 41 are opened, and high pressure compressed air is thus allowed to flow into an upstroke piston chamber 42. This sudden reversal of air pressures within the downstroke piston chamber 25 and the upstroke piston chamber 42 causes the flap valve 16 to move downwards and close off the outlet portholes 23 in the automative valve chest bottom 17. High pressure compressed air then passes through the outlet portholes 21 in the automatic valve chest top 15.
As the high pressure compressed air flows into the upstroke piston chamber 42, the piston 12 is forced to move upwards. In so doing, the ratchet mechanism 32 (FIG. 4) locks. Pawls 43 which are held in by a pawl cap 44, and which protrudes outwardly vertically by means of a pawl spring 45 and a pawl plunger 46, lock against teeth of a ratchet gear 47. This ratchet gear 47 is in turn locked into an internal spiral bore 48. This internal spiral bore 48 is separated from the splined drive tube 33 by a thrust bearing 49. Both internal spiral bore 48 and splined drive tube 33 can rotate independent of each other. Because the ratchet mechanism 32 is locked, due to a locking key 50 located between a pawl cap 44 and the hammer barrel 30; the internal spiral bore 48 meshing with piston splines 51 causes the piston 12 to partially rotate on the piston's 12 upstroke. This in turn causes the splined drive tube 33 to partially rotate, owing to the piston splines 51 meshing with the splined drive tube 33. This partial rotation is transmitted to the bit shank 26 by way of splines 52 on the bit shank 26. In turn, the cutting bit 27 rotates partially by the same measure. A thrust bearing 53 exists between the retaining ring 39 and chuck splines 40. The bit retaining ring 39 contains needle bearings 72 which run freely against the inside of the hammer barrel 30.
As the piston 12 continues upwards and passes the outside piston linear exhaust portholes 28, the expanding air in the upstroke piston chamber 42 begins to exhaust out via the portholes 28, past piston guide bush 31, ratchet assembly 32, splined drive tube 33. Because bit shank 26 is now retracted, the splined drive tube exhaust portholes 34 are open and the exhaust air which is now at somewhat lower pressure, escapes past the bit retaining ring 39, thrust bearing 53, chuck splines 40 and cutting bit exhaust portholes 35.
As a result of the sudden pressure difference, the flap valve 16 moves back to close off outlet and inlet portholes 21, 20, in the automatic valve chest top 15. Compressed air now travels down the inlet passageway 22 and through the outlet portholes 23 of the automatic valve chest bottom 17. This compressed air begins to fill the downstroke piston chamber 25 and piston 12 begins its downstroke. Pawls 43 within the ratchet assembly 32 allow the ratchet gear 47 to turn, as piston travels downwards. Exhaust portholes 28 are shut off as piston 12 travels downwards to be opened again as piston 12 passes. Piston 12 continues downwards to strike top of bit shank 26, the impact shock being transmitted to the tungsten carbide cutting teeth 38 via bit shank 26 and cutting bit 27. Shock and some residual compressed air trapped in the upstroke piston chamber 42, bounce the piston 12 up slightly to uncover the bottom inlet portholes 41. Simultaneously, flap valve 16 moves down to close off outlet portholes 23 of the automatic valve chest bottom 17 and so opening the inlet and outlet portholes 20, 21 respectively, of the automatic valve chest top 15. The piston 12 then recommences its upward and downward cycle in rapid succession, and on each cycle, causes the cutting bit 27 and attached bit shank 26 to partially rotate, in the same direction. The air volume required for piston 12 movement in both upstroke and downstroke directions are similar. If V1 represents air volume for piston upstroke and V2 represents air volume for piston downstroke, then
V1 V2
Also, the active surface area for piston 12 downstroke is equal to the piston's downstroke total upper horizontal surface area. If A1 represents piston's active surface area and A2 represents piston's downstroke total upper horizontal surface area, then
A1=A2
With hammer motion in operation, compressed air from both downstroke and upstroke piston chambers 25, 42 respectively, exhausts out through the cutting bit exhaust portholes 35 at lower air pressure to the flushing air exhausted from the flushing jet 7. Because the high pressure compressed air is jetted at high upward angle into the sample tube 6 by the flushing jet 7, a venturi action is created between bit face surface 27 and the flushing jet 7, sucking in the hammer's lower pressure exhaust air with entrained bore hole cuttings. The high pressure compressed air jetted from the flushing jet 7 is a continuous uninterrupted air flow, while the lower pressure hammer exhaust air is an intermittent and pulsating flow.
The volume of high pressure compressed air jetted from the flushing jet 7 is equal to, or greater than, the hammer's exhaust volume release from the cutting bit exhaust portholes 35. If V3 represents by-pass flushing volume and V4 represents bit exhaust volume, then
V3≧V4
Flushing jet 7 orifice may be increased or decreased by vertical controlled movement of sample tube 6. The air passageway for both piston 12 impact and sample tube 6 flushing are separate and independent.
When a sub-terranean cavity is encountered, or hammer 3 and drill string 2 is pulled back from hole face, or the cutting bit 27 encounters little or no resistance, then the drill shank 26 and cutting bit 27 becomes fully extended, thus closing the splined drive tube exhaust portholes 34. Piston 12 motion will cease and flushing of the sample tube 6, by the flushing jet 7 continues at an accelerated rate due to the hammer's exhaust being redirected to sample tube 6.
The bit shank 26 and cutting bit 27 may be one piece or, alternatively, separate screw-fit parts. When the cutting bit 27 is separate from the bit shank 26, the cutting bit can be replaced without dismantling the hammer. The surface of the cutting bit 27 is set with sintered tungsten carbide cutting teeth 38 in either blade or button form, or in a combination of both. The cutting face of the bit 27 has an inward tapered face with hollow centre, through which pass the bit face drill hole cuttings, en route to sample tube 6. An eccentric breaking tooth 71 prohibits any rock core formation, breaking the core into smaller particle sizes. The broken particles travel up the sample tube 6 unobstructed, and are ejected with the flushing air out through the drill tube head 1. From here, the samples may pass through a flexible pipe to be collected and separated from the flushing air by a sample cyclone 54. The sample may then pass to a sample splitter 55 to be sized and quartered. Fitted to the top of the hammer barrel 30 is a water check valve assembly 10 and/or a shock absorber assembly 9. The shock absorber assembly 9 consists of a block of shock absorbent material 56 located between two halves of the shock absorber case 57, 58. A shock absorber locking nut 59 locks the two halves of shock absorber case together 57,58. Most of the shock resulting from the piston/bit impact will be absorbed by this assembly before being transmitted up along the dual wall drill tube 2. The water check valve prohibits ground water from entering the piston chambers 25, 42 and automatic valve block assembly 11 during stoppages in drilling such as changing dual wall drill tubes 2. It consists of a spring 60, a non-return valve 61, a water check valve top 62 and a water check valve bottom 63. While drilling is in operation, the high pressure compressed air passing through the water check valve assembly 10 causes it to remain open. Whenever the air supply is cut-off, however, the non-return valve 61 is closed by the water check valve spring 60 releasing tension, thus trapping air within the hammer assembly 3. This trapped air prohibits any ground water from creeping upwards into the hammer assembly 3, except sample tube 6.
Drill bit 27 rotation speed is controlled by the internal spiral bore 48. Rotational speed can be altered by fitting a different internal spiral bore, with differently angled splines. For depth, only the rig 37 is required, which raises or lowers the self-rotating sampling hammer 3 and dual wall tubes 2. Only the cutting bit 27, bit shank 26, piston 12, ratchet assembly 32, splined drive tube 33, bit retaining ring 39, and bearings 49,53,72, rotate.
With the above-described apparatus, there is less wear and abrasion to the hammer barrel 30 and dual wall drill tubes 2 than heretofore. Because the sampling hammer assembly 3 is self-rotating, there is no necessity to have a conventional drilling rig at the surface. No drill rig rotation motor is required, and the self-rotating sampling hammer 3 operates with the use of a conventional drilling rig or the rig 37 above-described.
In unstable ground and underwater conditions, sampling may proceed without the need for additional casing as the string of dual wall drill tubes 2 in effect act as casing. Underwater charging of holes with explosive or whatever, may be carried out using the sample tube 6, while equipment remains in hole. Sample tube 6 may also be used for pressure grouting, the sampling hammer 3 and dual wall drill tubes 2 being retracted as the bore hole becomes grouted under pressure.
Special lightweight dual wall drill tubes 2 may be used which utilize snap-on/bayonet type dual wall drill tube couplings 64. The sample tube 6 is held fixed, centrally within an outer drill tube wall 65 by a series of lugs 66. The bottom end of each length of sample tube is belled 67 and contains a rubber seal 68. As each length of dual wall drill tubes 2 is fixed to another, the top end of the sample tube 6 will slide tightly into the belled end 67 of another sample tube 6 with the rubber seal 68 forming an air tight seal. The outer drill tube 65 may be fixed with each other by male/female screw fixtures 69 or, alternatively, using the snap-on/bayonet type drill tube couplings 64 which use a locking device 70 to secure both couplings. If required, a suitable hammer-drill tube adaptor 73 can be fitted to the top of the hammer assembly to allow a chosen design of drill pipe 2 to be used.
Because the sample tube 6 diameter is large compared to diameter of the hole drilled, conventional or other downhole geophysical detection logging systems may be inserted down the sample tube 6 while drill string 2 and hammer system 3 remains in hole. For this purpose, the complete dual wall tubes 2, including sample tubes 6, may be made of durable, ultra-lighweight non-metallic materials, so allowing a wider range of downhole logging systems to be used. The sample tube 6 may also be used for water-well testing while complete drill string equipment remains in hole. This avoids re-entry of hole by drill string if hole is required to be deepened.
An alternative means of rotation of the cutting bit to that above-described can be used and this is shown in FIG. 5.
A helix spline on the lower portion of piston 84 causes a splined sleeve 86 containing an internal helix spline at its upper end, to rotate slightly as piston 84 travels downwards to strike a bit shank 91. Teeth on the lower end of the splined sleeve 86 slip against upper teeth of a ratchet 87. As the ratchet 87 is locked with the bit shank 91 by straight interlocking splines, only the splined sleeve 86 is caused to rotate in piston downstroke. The ratchet 87 is allowed to slip and move in the axial plane as it is cushioned by a mechanical spring 89 of variable design. Both the splined sleeve 86 and ratchet 87 are free to rotate being bounded at both ends by thrust bearings 85,88. As the movement of piston 84 reverses to upstroke due to valve poring previously described above and piston 84 begins travelling upwards, the piston's helix splines 84 engage with the internal helix splines of the splined sleeve 86, causing the splined sleeve 86 to rotate in the opposite direction by a small degree. Piston 84 is unable to rotate due to being locked with the outside piston liner 5 which in turn is locked to the rest of the hammer assembly. The drive teeth of the splined sleeve 86 lock with the opposing drive teeth of the ratchet 87. Because both teeth are locked together, there is no compression of spring 89. As the piston 84 continues its upstroke, rotation of the splined drive sleeve 86 takes place. This in turn causes ratchet 87 to rotate and thus the bit shank 91 and bit 27 rotate through the same distance via the ratchet 87 and bit shank 91 interlocking splines. Again bit 27 rotation takes place in between bit 27 impacts. The thrust collar 90 retains the bit shank 91, spring 89 lower thrust bearing 88 and ratchet 87 while locating with and allowing free movement with the splined sleeve 86. While allowing some axial movement of the bit shank 91 and attached bit 27, the thrust collar 90 prohibits bit shank 91 and attached bit 27 from falling out of hammer assembly 3.
The cutting bit 92 shown in FIG. 5 has straight external sides which protect the lower portion of the barrel from abrasion and wear.
An alternative means for locking bit shank 26 with bit 27 can be provided using a self locking mechanism, tapered or socket and pin 93 as shown in FIG. 5.
An independent slidable cradle positioned below the tube head and base of rig 37, positions, holds and aligns the dual wall drill tubes 2, for angle, vertical or horizontal drilling. The rig 37 is capable of vertical, horizontal or angle drilling.
The above-described embodiment is referred to conventionally as operating with a valve system. The present invention can also operate without valves i.e. conventionally referred to as a valveless system and FIG. 6 illustrates such a system. In this modification of the above-embodiment, the valve assembly 15, 16 and 18 are replaced by upper and lower liner support members 101, 102. The compressed air is directed into the upper piston chamber and with piston 12 or 84 in striking position, the air is free to escape via outside piston liner exhaust parts 28. Compressed air is also allowed to pass down between outside piston liner 29 and barrel 30 as in above embodiment and between inside piston liner 103 and by-pass tube 5 to enter the lower piston chamber via inlet port holes 41 or 104. Both the number and relative position to each other of the inlet and outlet port holes differ in this alternative "valveless" means to the "valve" means previously described. Because of this, the compressed air which builds up in the lower piston chamber, begins to push piston 12 or 84 upwards and will continue to do so until exhaust ports 28 become closed. Momentum carries the piston 12 or 84 still further until the driving air in the lower piston chamber also begins to exhaust out via ports 28. At the moment the balance is altered and piston 12 or 84 begins to descend in its downstroke, pushed by air building up in the upper piston chamber. So the cycle repeats itself in rapid succession.
An alternative means for air to drive piston 12 or 84 in its upstroke is a valve chest top which directs air inwards via a plurality of holes to be channeled down between by pass tube 5 and an inside piston liner 103.
An alternative means for advancing or retarding performance of hammer without affecting sample tube flushing can be provided. The control grommets 14 and valve cap 13 are replaced by upper and lower valve controls 106, 107. A locking pin 108 holds both together and allows a plurality of holes in both valve controls 106, 107 to align with each other in various degrees.
Sample tube locating pins 109 positioned throughout at convenient points to keep the sample tube 6 central.
By pass tube stop ring 110 fixes the by pass tube 5 centrally and from axial movement.
Liner end plug 111 is attached to lower end of inside piston liner 103 by means of circlip 112 or similar and contains seal member 113.
Flushing jet 7 may be part of by pass tube 5 or attached by means of a circlip or similar fastening.
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Apparatus for drilling a bore hole comprising a hammer and a dual walled drill tube. The hammer comprises a reciprocable piston, fluid flow control device for directing fluid under pressure to the hammer to reciprocally drive the piston, and cutting device coupled to the hammer which rotate upon reciprocation of the hammer to cut the bore hole. Rachets are coupled to the cutting device to permit rotation of the cutting means in one direction only and to prevent rotation in an opposite direction. A portion of the fluid under pressure is diverted to entrain and direct particulate material to the surface of the bore hole.
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This is a continuation-in-part of International Application PCT/GB01/05070, with an international filing date of Nov. 16, 2001, published in English under PCT Article 21(2) as International Publication Number WO 02/40785 A2.
BACKGROUND TO THE INVENTION
Field of the Invention
This invention relates to flood protection apparatus. In particular, it relates to flood protection apparatus that can be deployed to protect premises against inundation of floodwater through a toilet and to a flood protection aperture seal.
When a property occupier is presented with the prospect of preventing floodwater entering their property, one of the most daunting problems that they must face is the large number of and variety of the number of apertures that are formed through the walls of a typical building. All of these apertures must be sealed if ingress of floodwater is to be prevented.
Protection of door and window apertures has been addressed in our UK patent application No. 0102215.1 and International Patent Application No. PCT/GB01/04897, and protection of overflow pipes and toilet waste outlets is addressed in out UK patent applications filed on the same date as this application. However, there remain other apertures such as waste outlets and overflows of sinks and baths, and wall air vents that still require protection. It is protection of this latter type of apertures to which this application relates.
SUMMARY OF THE INVENTION
One aspect that is shared in common with the apertures to which this invention relates is that they are often spanned by one or more transverse members. These members may, for example, be a grille of a waste outlet, a support for a rising outlet plug of a waste outlet, or members of a grille of an airbrick. Alternatively or additionally, the aperture may have a periphery upon which a grip can be obtained. The inventors have realised that such a transverse member or the periphery of an aperture can be used to assist in sealing the aperture.
From a first aspect, this invention provides apparatus for sealing an aperture against ingress of floodwater comprising a cover portion for covering and forming a seal around an aperture, and location means for engaging with a fixed component associated with the aperture to retain the cover portion in place.
Such apparatus can be used to seal an aperture through which floodwater might otherwise enter a building.
The cover portion may carry a sealing element that, in use, forms a seal between the cover portion and material at the periphery of the aperture.
The location means may comprise an element that can be placed under tension to pull the cover portion into engagement with a peripheral region around an aperture to be sealed. The tension element may pass through the cover portion. For example, the tension element may be a bolt. In such cases, the locating means may further comprise a nut that is in threaded engagement with the bolt.
Additionally, the locating means may provide an engaging formation that can engage with and be retained by the fixed component. For example, the engaging formation may include a hook, for example, carried at an end region of an elongate element.
The fixed component with which apparatus embodying the invention may engage might be a periphery of the aperture or a component that extends across the aperture. As an example of the latter, the fixed component may be a grille, or a hole for the passage of fluid (e.g. water or ventilating air).
Apparatus embodying the invention may be provided in combination with additional mounting apparatus that can be disposed in relation to an aperture to provide a formation upon which the locating means can engage. Such additional mounting apparatus can be deployed where there is no existing formation for the location means to engage.
From a second aspect, the invention provides a flood protection kit including a plurality of apparatus for sealing an aperture against ingress of floodwater embodying the first aspect of the invention. These are typically suitable for application to a range of different apertures. A kit embodying this aspect of the invention may further include additional mounting apparatus as defined in the last-preceding paragraph.
In flood conditions, one of the most damaging and unpleasant routes for floodwater to enter premises is by reverse flow in the drainage system that causes water to emerge from a toilet bowl. This form of floodwater ingress cannot be prevented by the conventional measure of blocking doors and windows, for example with sandbags, nor by the door and window protection apparatus disclosed in our UK Patent Application No. 0102215.1. As the level of floodwater increases, it may enter the building through an overflow pipe that is normally provided for the cistern of a toilet.
Given that a toilet is an expensive installation that is often part of a suite, and for many, flooding is a rarity, the inventors have realised that it is unlikely that many householders would be tempted to install any flood protection measure that involved changing the toilet bowl or other apparatus. Therefore, they have concluded that a more effective solution is to provide apparatus that can be rapidly disposed, in the event of a flood warning, to guard against inundation in the event of a flood.
Therefore, from a third aspect, this invention provides flood protection apparatus comprising a sealing portion and a securing portion whereby the apparatus can be disposed for use in a toilet bowl such that the sealing portion is retained in position by the securing portion to substantially seal an outlet of the toilet bowl.
Such apparatus can be brought into use as and when there is a risk of flooding, and can subsequently be removed, leaving the toilet bowl unaltered from its original condition.
Most advantageously, the apparatus is adjustable such that it can be installed in a variety of different toilet bowls. In particular, the securing portion is advantageously adjustable to cooperate with a variety of toilet bowls.
In typical embodiments, the sealing portion is configured to form a seal within a waste outlet of a toilet bowl. For example, the sealing portion may have a tapering peripheral wall that can be accommodated within various waste outlets of different dimensions, a seal being formed between the peripheral wall and material of the toilet bowl.
Preferably, the sealing portion is formed of a resilient material that can be deflected so that it can conform to a surface of a toilet bowl against which it is to form a seal. This allows one configuration of a sealing portion to cooperate with a variety of differently shaped toilet bowls. Deflecting means may be provided, operation of the deflecting means causing resilient deformation of the sealing portion to enhance its sealing effectiveness. For example, the deflecting means may cause the sealing portion to compress in a first direction, and thereby expand in a transverse direction.
In a first arrangement, the securing portion may operate to pull the sealing portion into place. For example, it may cooperate with a suitably shaped part of the waste outlet of the toilet bowl, such as a part of the U-bend.
Alternatively or additionally, the securing portion may operate to press the sealing portion into place. In one preferred arrangement, the securing portion may engage with an underside of a rim portion of a toilet bowl. For example, the securing formation may comprise rim-engaging formations for engaging with a rim portion, the spacing between the rim-engaging formations being adjustable to conform to different sizes of toilet bowl. The rim-engaging formations may be carried on a bar of adjustable length. In such embodiments, the securing portion is preferably provided with a strut disposed to apply a force to the sealing portion. Advantageously, the strut is of adjustable length to accommodate variations in the configuration of the toilet bowl and to facilitate deployment of the apparatus.
The inventors have also realised that the presence of a toilet or other plumbing apparatus employing a cistern, especially in a lower floor of a building, can give rise to a further risk in the event of flooding. Such an installation will most usually incorporate an overflow to ensure that water can escape in the event that a level-controlling valve of the cistern fails to operate properly. It is common for such an overflow to include a pipe that exits to the exterior of the building. This can provide an entry path for floodwater.
From a second aspect, this invention provides apparatus for preventing floodwater for entering an overflow pipe in conditions of flooding, comprising a first component installed at an open end of the overflow pipe, and a second component, operably connectable to the first component, to seal the pipe in conditions in which flooding is expected. Apparatus embodying this aspect of the invention is most advantageously provided in combination with apparatus embodying the first aspect of the invention.
The first component of apparatus embodying this aspect of the invention may be permanently or semi-permanently installed on the overflow pipe. For example, it may be secured there by adhesive. The second component is typically removable from the first component when conditions of flooding have passed.
In a typical embodiment, the second component may be secured to the first component by mutually-engagement of threaded portions of the two components.
From a third aspect, the invention provides a flood protection system comprising flood protection apparatus according to the first aspect of the invention in combination with apparatus for preventing floodwater for entering an overflow pipe according to the second aspect of the invention.
The various aspects of the invention have been described above with reference to protection of buildings against flooding risks. However, it may also find application to protect boats from inundation. Many boats, from small yachts upwards in size, are equipped with flushing toilets. It is known that these can provide a route through which water can enter the vessel, either when it is moored, or when it is underway in rough conditions. Embodiments of the invention might therefore be deployed to prevent water entering the vessel under such circumstances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a wash-hand basin equipped with two sealing covers each being apparatus embodying the invention;
FIG. 2 is a transverse section of a sealing cover in place on the drain outlet in the wash-hand basin of FIG. 1 ;
FIG. 3 shows a component of securing means of the apparatus of FIG. 2 ;
FIG. 4 shows an airbrick upon which apparatus embodying the invention is to be mounted;
FIG. 5 is a transverse view of the airbrick of FIG. 4 having apparatus embodying the invention mounted upon it;
FIG. 6 is an external view of the apparatus of FIG. 4 in place on the airbrick;
FIG. 7 is a cross-section of apparatus embodying the invention deployed in conjunction with additional mounting apparatus;
FIG. 8 shows the additional mounting apparatus in FIG. 7 in greater detail;
FIG. 9 shows a toilet bowl with flood protection apparatus being another embodiment of the invention installed;
FIG. 10 is a cross-section of the toilet bowl of FIG. 9 ;
FIG. 11 shows a toilet bowl with flood protection apparatus being a further embodiment of the invention installed;
FIG. 12 shows a securing portion of the apparatus of FIG. 10 ;
FIG. 13 shows an end view of part of the securing portion of FIG. 12 ;
FIG. 14 shows apparatus being a further embodiment of the invention in place on a cistern overflow pipe; and
FIG. 15 shows the apparatus of FIG. 14 in cross-section; and
FIG. 16 shows the apparatus of FIG. 14 in place on an overflow pipe in cross-section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference first to FIG. 1 , a typical wash-hand basin 10 is shown. This has two apertures intended to let water out of the basin; a wastewater outlet and an overflow. However, in times of flooding, both of these can be potential points of entry for floodwater. As shown in FIG. 1 , two sealing covers 12 , 14 , each being an embodiment of the invention have been deployed to protect these two potential risk points.
The two covers shown in FIG. 1 are largely similar in construction, the principal difference between them being one of size. The cover 14 applied to the wastewater outlet is shown in FIG. 2 .
With reference to FIG. 2 , the sealing cover includes a cover portion 20 formed as a hollow frusto-conical moulding of stiff plastic material. At its end of lesser diameter, the cover portion 20 has a closing end wall 22 . It is open at its end of greater diameter. A central aperture is formed through the end wall 22 . A resilient annular seal 24 is provided at the open end of the cover portion 20 .
The sealing cover further includes securing means to secure it in place on the wastewater outlet. The securing means comprises an elongate bolt 30 that extends axially of the cover portion 20 through the aperture in the end wall 22 . A head 32 of the bolt 30 is shaped as a wingnut to enable it to be without the aid of tools. An annular sealing washer 34 of resilient material is disposed between the bolt heads 32 and the end wall 22 .
The securing means further includes a locating component 38 , shown in FIG. 3 . The locating component 38 includes a nut 40 from which two elongate resilient metal locating legs 42 project. Each locating leg 42 has a hook portion 44 formed at an end portion remote from the nut 40 . The nut 40 of the locating component 38 is carried in threaded engagement with the bolt 30 , such that the locating legs 42 project generally away from the end wall 22 of the cover portion.
The procedure to deploy the apparatus will now be described.
The locating component 38 is positioned such that its nut 40 is towards the free end of the bolt 30 . The hook portions 44 of the locating legs 42 are then located on a suitable structure. In this example, the structure chosen is a grid 50 provided to trap objects that are dropped into the wastewater outlet. However, in the case of apparatus applied to the overflow, the periphery of the overflow aperture may be used instead.
The bolt 30 is then turned to draw the nut 40 towards the end wall 22 . This, in turn, places the bolt 30 under tension and this urges the cover portion 20 towards the wastewater outlet. The seal 24 is compressed between the cover portion 20 and the periphery of the aperture so that a fluid-tight seal is formed between the cover portion 20 , the seal 24 and the periphery of the aperture. The sealing washer 34 is also compressed to form a seal at the end wall 22 of the cover portion 20 . In the case of a wastewater outlet, there is typically a bezel 52 at the periphery of the aperture that provides a surface against which a good seal can be formed.
An alternative embodiment is shown in FIGS. 4 to 6 . In this case, the sealing cover is intended to form a seal to cover an airbrick 60 .
An airbrick is typically built into a wall to provide a route for ventilating air to pass through the wall. The example shown in FIG. 4 is a simple airbrick with air holes 62 disposed in a regular rectangular array; however, there are many alternative patterns. The airbrick may be formed of ceramic (like a building brick), metal, plastic or other material.
This sealing cover has a cover portion 64 that has a generally rectangular outline shape. An outer wall 66 of the cover portion 64 is domed to confer the outer wall 66 with strength in compression. The outer wall 66 has a central aperture. A peripheral wall 68 of rectangular outline extends from the outer wall 66 . A resilient sealing element 70 is carried on an end surface of the peripheral wall 68 .
This embodiment has locating means substantially as described above, although it may be of a larger scale, if appropriate. The bolt 30 of the locating means passes through the central aperture of the outer wall 66 . This is shown most clearly in FIG. 5 .
To deploy this sealing cover, the legs 42 are each inserted through a hole 62 in the airbrick 60 . The bolt head 32 is then turned to rotate the bolt 30 and draw the nut along its length to clamp the cover portion 66 against the airbrick 60 . The sealing element 70 is then compressed between the airbrick 60 and the peripheral wall 68 to form a fluid-tight seal. The sealing washer 34 likewise is compressed to form a seal between the bolt head 32 and the outer wall 66 , the domed shape of the outer wall 66 resisting the compressive force applied to it.
As will be understood, deployment of the embodiment described above can meet with difficulties if the aperture has no suitable formation upon which the location means can engage. There may, for example, be no transverse element, or the aperture may be too deep for the legs to reach to form an engagement. With reference to FIGS. 7 & 8 , additional mounting apparatus is shown that presents a solution to this problem.
The additional mounting apparatus comprises a transverse metal bar 80 . A respective flat mounting pad 82 is carried at opposite end regions of the transverse bar, the mounting pads 82 being disposed substantially in a common plane. A slot 84 is formed through a central region of the bar 80 .
The additional mounting apparatus additionally includes a flat longitudinal metal bar 90 that extends through the slot 84 . One end portion of the longitudinal bar 90 is formed as a hook 92 . Several holes 94 are formed through the longitudinal bar 92 spaced along its length.
To deploy the additional mounting apparatus, the transverse bar 80 is placed across an aperture 96 to be sealed with the pads 82 being placed in contact with an inner surface of a wall 98 in which the aperture is formed, such that the longitudinal bar 90 is inserted into the aperture 96 , with its hook portion 92 within the aperture 96 . A locating pin 100 is then inserted through one of the holes 94 to secure the longitudinal bar 92 against removal from the slot 84 . The pin 100 has a head that cannot pass through the hole and a ring 102 that can be used to grip the pin 100 for removal.
Once the additional mounting apparatus is installed as discussed above, the sealing cover can then be deployed as shown in FIG. 7 . The hook portions 44 of the legs 44 can engage upon the hook portion 92 of the longitudinal bar 90 to secure the sealing cover in place.
The embodiments are described as being for installation in a building. However, the invention has equal applicability to application in boats (typically in yachts and larger boats) to prevent inundation of water through apertures such as drains or ventilators in the boat. It is likely that the embodiments for use in boats is likely to be very similar to those described above with little modification.
A property owner or a boat owner may be provided with a flood protection kit that includes several different embodiments, intended to cover a range of apertures in advance of a flood. The kit may also include additional mounting apparatus as described with reference to FIGS. 7 and 8 .
With reference first to FIGS. 9 & 10 , apparatus 112 being a first embodiment is shown for preventing inundation of floodwater through a waste outlet of a toilet bowl 110 .
The apparatus comprises a sealing body 114 . The body 114 is formed of a resilient material such as a high-density polymer. For example, a synthetic rubber material may be used. To enhance the sealing properties of the sealing body, it may be provided with a coating of a sealing material, such as compressible synthetic polymer foam. The sealing body 114 is formed with generally flat upper and lower surfaces, and a tapered peripheral surface. The peripheral surface is shaped to be as close as possible a fit within the waste outlet of a typical toilet bowl to form a fluid-tight seal. One or more voids 116 are formed within the sealing body. Thus, it is not solid, but has internal spaced containing air or other gas. This allows it to compress and distort when a force is applied to it. This enables the sealing body to conform to an opening into which it is urged, thereby ensuring that it can form a seal within a range of toilet bowls of differing sizes and shapes.
Securing means is carried on the sealing body 114 . The securing means comprises an elongate threaded rod 120 that passes through a bore formed through the sealing body 114 . At an end region of the rod 120 , there is provided a manipulation formation 122 that can be used by a person to turn the rod about a longitudinal axis. In this embodiment, the manipulation formation is shaped generally like a wingnut. The manipulation formation 122 has a flat lower surface that bears against a washer 124 carried on the upper surface of the sealing body 114 . The securing means further includes a bracket 126 . The bracket has a threaded boss 128 that is carried in threaded engagement upon the rod 120 . A hook portion 130 of the bracket 126 extends laterally from the boss 128 . The hook portion 130 is shaped and configured such that it can engage with a downwardly pointing projection at the U-bend of the toilet bowl.
An elongate bolt 132 extends through a bore in the sealing body 114 . A head 136 of the bolt 132 bears against a washer 134 that is carried on the lower surface of the sealing body 114 . A wingnut 138 is carried on the bolt 132 . Between the wingnut 138 and the upper surface of the sealing body 114 there is a washer 140 . The wingnut 138 , bolt 132 and washer 140 together constitute deflecting means for the sealing body 114 .
To deploy the apparatus in use, the bracket 126 is positioned towards the lower end of the rod 120 . The apparatus is then lowered into the toilet bowl 110 , and manipulated such that the hook portion 130 of the bracket 126 locates upon the projection (which will typically be below the level of water within the bowl). The manipulation formation 122 is then used to turn the rod 120 to draw the bracket along the rod 120 . The hook portion 130 engages with the protection, causing the rod 120 to be pulled downwards. Contact between the manipulation formation 122 and the washer 124 causes the sealing body to be urged downwards into the waste outlet of the toilet bowl, so securing it in place.
Once the sealing body is secured, the wingnut 138 is rotated to draw it along the bolt 132 . The wingnut 138 makes contact with the washer 140 . Continued rotation of the wingnut 138 causes the sealing body 114 to become compressed between the respective washers 134 , 140 on its lower and upper surfaces. Being of resilient material, this compression causes the sealing body 114 to bulge laterally, thereby urging its peripheral surface into contact with the material of the toilet bowl, thereby causing a fluid-resistant seal to form at the peripheral surface.
With reference now to FIGS. 11 , 12 and 13 , apparatus 112 being a second embodiment is shown. This apparatus comprises a sealing body 150 and a securing portion 152 , the latter being shown in FIG. 12 .
The sealing body 150 is of much the same construction as the corresponding component of the first embodiment, as described above, albeit without any bores being formed through it. In this embodiment, a metal plate 154 is carried on the upper surface of the sealing body 150 .
The securing portion 152 comprises a first and a second elongate bar metal portion 156 , 158 . The second bar portion 158 is of hollow section, such that the first bar portion 15 . 6 can be inserted within it. The bar portions 156 , 158 can then be slid with respect to one another to form a bar assembly of variable overall length. Two bolt and wingnut assemblies 160 are provided such that the bar assembly can be clamped at a selected length.
At an outer end region of each of the bar portions 156 , 158 is carried a respective rim-engaging locating pad 162 , formed of metal, and having a flat, upward-directed surface. The rim-engaging locating pads 162 are secured to the respective bar portions 156 , 158 such that they can move pivotally with respect to the bar portions. A pivotable means 165 for enabling pivotable rim-engaging pads 162 connected to the bar portions 156 , 158 may, for example, be achieved by connecting each pivotable rim-engaging locating pad 162 to the corresponding bar portion 156 , 158 by a ball and socket joint. This allows the upwardly-directed surface of the pads to pivot away from being parallel to the bar portions 156 , 158 .
Generally centrally of the bar assembly (of course, this will be approximate as the length of the assembly is changeable) there is carried a location assembly. The location assembly comprises an elongate threaded rod 148 that passes through a central aperture in the bar assembly. A wingnut 164 is carried on the threaded rod below the level of the bar assembly. A pressure body 166 is carried at a lower end portion of the threaded rod 148 . The pressure body 166 has a metal component that is secured to the threaded rod 148 , and a resilient polymer body carried on the metal component for engagement with the metal plate 154 of the sealing body 150 . The wingnut 164 , threaded rod 148 and pressure body together constitute deflecting means for the sealing body 150 .
To deploy the apparatus, the sealing body 150 is first located in the waste outlet of a toilet bowl. The length of the bar assembly is then adjusted such that its pads 162 can locate below opposite portions of the rim 168 of the toilet bowl. The wingnut 164 is then rotated to cause it to travel up the threaded rod 148 . The wingnut 164 bears against the bar assembly, urging the bar assembly upwards to locate the locating pads 162 against a lower surface of the rim 168 . The locating pads 162 will pivot such that they locate securely against the lower surface. At the same time, the rod 148 acts as a strut to urge the pressure body 166 against the meal plate 154 of the sealing body 150 , thereby urging the sealing body 150 downwardly into the waste outlet of the toilet bowl. The pressure thereby applied forms a seal between the peripheral surface of the sealing body 150 and the material of the toilet bowl.
To enhance protection against floodwater gaining entry to a building through a toilet installation, the invention provides apparatus for protecting the overflow that is commonly provided as part of the installation of a toilet cistern.
A typical arrangement of such an overflow is shown in FIGS. 14 & 15 . The overflow includes a pipe 170 , normally of plastic material, that extends from the toilet cistern through an external wall 172 of a building, to open at the building's exterior. This allows water to run away harmlessly in the event that the cistern is overfilled. The external outlet of the pipe 170 draws attention of a building owner to the leaking water. (Note that a similar overflow can be associated with other cisterns such a feed tank for a hot water cylinder, and this invention can be applied to such an overflow. It is, however, uncommon for these to be situated at a height that floodwater is likely to reach.)
The apparatus of this embodiment includes a spigot component 174 and a cap 176 , each being moulded of plastic material.
The spigot component 174 is tubular, and has an internal diameter that is a close sliding fit onto the overflow pipe 170 , 50 that a first end region of the spigot component 174 can be slid onto the pipe 170 , as shown in FIG. 15 . There is advantageously a radial projection 176 within the spigot component that engages with an end surface of the pipe 170 to limit the distance to which the pipe 170 can enter the spigot component 174 . (Note theta the radial projection should not project so far as to interfere with flow within the pipe.) An end region 178 of the spigot component 174 , opposite that into which the pipe 170 is received, is formed with an external thread.
The cap 176 has a head 182 shaped as a squat cylinder, and a boss 180 that projects axially from the head 182 . The boss 180 is tubular, and formed with an internal thread that can engage with the external thread of the spigot component 174 . A sealing member 184 is located within the boss 180 .
To deploy the apparatus, the spigot component 174 must first be located upon the overflow pipe 170 , and secured there. This is preferably done by way of adhesive. It is envisaged that the spigot component 174 be secured on the overflow pipe 170 in advance of the need for its use, and left in place permanently. The overflow can then function as normal. If flood conditions are expected, the cap 176 can be screwed into place on the spigot component 174 , its sealing member 184 forming a fluid-tight seal against an end surface of the spigot component 174 . Of course, the cap 176 must be removed once the flood risk passes to restore operation of the overflow. The embodiments are described as being for installation in a building. However, the invention has equal applicability to application in boats (typically in yachts and larger boats) to prevent inundation of water through a toilet installation in the boat. It is likely that the embodiments for use in boats is likely to be very similar to those described above with little modification.
Typically, a flood protection system may comprise a plurality of components each being various embodiments of the invention.
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Apparatus for sealing an aperture against ingress of floodwater is disclosed. The apparatus comprising a cover portion for covering and forming a seal around an aperture, and location means for engaging with a component associated with the aperture to retain the cover portion in place. For example, the locating means may include a securing element that engages with the fixed component, and screw threaded components to draw the cover portion into place. Embodiments of the invention may be applied to seal an aperture such as an airbrick, a wastewater outlet, an overflow, etc. Further apparatus comprises a sealing portion and a securing portion whereby the apparatus can be disposed for use in a toilet bowl such that the sealing portion is retained in position by the securing portion to substantially seal an outlet of the toilet bowl. Once the risk of flooding has passed, the apparatus can be removed.
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BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] A structural support beam for use in buildings, bridges, automotive frames and the like.
[0003] Description of the Prior Art
[0004] A beam is a structural element that is capable of withstanding load primarily by resisting bending. The bending force induced into the material of the beam as a result of the external loads, own weight, span and external reactions to these loads is called a bending moment.
[0005] Beams are traditionally descriptions of building or civil engineering structural elements, but smaller structures such as truck or automobile frames, machine frames, and other mechanical or structural systems contain beam structures that are designed and analyzed in a similar fashion.
[0006] In engineering, beams are of several types:
Simply supported—a beam supported on the ends which are free to rotate and have no moment resistance. Fixed—a beam supported on both ends and restrained from rotation. Over hanging—a simple beam extending beyond its support on one end. Double overhanging—a simple beam extending beyond its supports ends. Continuous—a beam extending over more than two supports. Cantilever—a projecting beam fixed only at one end. Trussed—a beam strengthened by adding a cable or rod to form a truss.
[0014] Most beams in reinforced concrete buildings have rectangular cross sections, but a more efficient cross section for a beam is an I or H section which is typically seen in steel construction. Because of the parallel axis theorem and the fact that most of the material is away from the neutral axis, the second moment of area of the beam increases, which in turn increases the stiffness.
[0015] An I-beam is only the most efficient shape in one direction of bending: up and down looking at the profile as an I. If the beam is bent side to side, it functions as an H where it is less efficient. The most efficient shape for both directions is a box (a square shell) or tube. But, however the most efficient shape for bending in any direction is a cylindrical shell or tube. But, for unidirectional bending, the I or wide flange beam is superior.
[0016] Cross-sectional views of more typical configurations or shapes are depicted in FIG. 1A through FIG. 1F .
[0017] Internally, beams experience compressive, tensile and shear stresses as a result of the loads applied to them. Typically, under gravity loads, the original length of the beam is slightly reduced to enclose a smaller radius arc at the top of the beam, resulting in compression, while the same original beam length at the bottom of the beam is slightly stretched to enclose a larger radius arc, and so is under tension. The same original length of the middle of the beam, generally halfway between the top and bottom, is the same as the radial arc of bending, and so it is under neither compression nor tension, and defines the neutral axis dotted line in the beam figure. Above the supports, the beam is exposed to shear stress. There are some reinforced concrete beams in which the concrete is entirely in compression with tensile forces taken by steel tendons. These beams are known as prestressed concrete beams, and are fabricated to produce a compression more than the expected tension under loading conditions. High strength steel tendons are stretched while the beam is cast over them. Then, when the concrete has cured, the tendons are slowly released and the beam is immediately under eccentric axial loads. This eccentric loading creates an internal moment, and, in turn, increases the moment carrying capacity of the beam. They are commonly used on highway bridges.
[0018] The following references illustrate the prior art.
[0019] U.S. Pat. No. 1,843,318 discloses an arch comprising a curved lower chord having reinforcing bars 24 and 24′ secured at each side of the lower curved edge of the arch to absorb the thrust (see FIG. 16).
[0020] U.S. Pat. No. 4,831,800 relates to a beam and reinforcing member comprising a longitudinally extending beam having a concrete upper flange, a web having greater tensile strength than concrete and rigidly connected to the upper flange with shear connectors. The web extends transversely downward from the upper flange longitudinally spaced apart leg portions with an intermediate arched portion extending between the leg portions.
[0021] U.S. Pat. No. 4,704,830 shows a flexible tension load bearing member such as a chain strung alongside an I-beam web portion end to end and hooked over the top flange. The mid-section of the chain is then attached in a load bearing capacity to the lower flange, preferably by a post tension controlling adjustable link controlling the chain tension.
[0022] Additional examples are found in U.S. Pat. No. 3,010,257; U.S. Pat. No. 3,101,272; U.S. Pat. No. 3,283,464; U.S. Pat. No. 3,300,839; U.S. Pat. No. 3,535,768; U.S. Pat. No. 4,424,652; U.S. Pat. No. 4,576,849 and U.S. Pat. No. 5,125,207.
SUMMARY OF THE INVENTION
[0023] Numerous different shapes and configurations of support beam structures have been designed for specific applications and strengths.
[0024] The present invention relates to a structural support beam configured for enhanced structural strength.
[0025] The structural support beam comprises a top flange held in fixed spaced relationship relative to a bottom concave flange by an interconnecting web including a lower concave surface having a radius of curvature substantially equal to the radius of curvature of the bottom concave flange such that when assembled the top flange, bottom concave flange and interconnecting web form an integral structural beam.
[0026] It has been observed that excessive tension forces exerted on opposite ends of the structure support beam may cause the bottom concave flange to separate from the interconnecting web. A lower stabilizer or retainer is secured to the structural support beam to prevent the bottom concave flange and the interconnecting web from separating. When the structural support beam and lower stabilizer or retainer are affixed together in the inner surface of each retainer member engages the corresponding end surface of the bottom concave flange, the corresponding end surface of the interconnecting web and the corresponding end surface of the top flange to secure the top flange, bottom concave flange, and interconnecting web together.
[0027] The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] For a fuller understanding of the nature and object of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
[0029] FIG. 1A is a cross-sectional end view of a T-shaped support beam of the present invention.
[0030] FIG. 1B is a cross-sectional end view of a T-shaped support beam of the present invention.
[0031] FIG. 1C is a cross-sectional end view of an I-shaped support beam of the present invention.
[0032] FIG. 1D is a cross-sectional end view of a triangular shaped support bias of the present invention.
[0033] FIG. 1E is a cross-sectional end view of a triangular shaped support beam of the present invention.
[0034] FIG. 1F is a cross-sectional end view of a C or U shaped beam of the present invention.
[0035] FIG. 2 is a side view of an I-beam under stress supported on pilings or pillars.
[0036] FIG. 3 is an exploded side view of the structural support beam of the present invention.
[0037] FIG. 4 is a partial side view of the structural support beam of the present invention.
[0038] FIG. 5 is a cross-sectional end view of the structural support beam of the present invention taken along line 5 - 5 of FIG. 4 .
[0039] FIG. 6 is an exploded side view of an alternate embodiment of the structural support beam of the present invention.
[0040] FIG. 7 is a side view of another alternate embodiment of the structural support beam of the present invention.
[0041] FIG. 8 is a top view of yet another embodiment of the structural support beam of the present invention.
[0042] FIG. 9 is a cross-sectional end view of the structural support beam of, the present invention taken along line 9 - 9 of FIG. 8 .
[0043] FIG. 10 is a top view of still another alternate embodiment of the structural support beam of the present invention.
[0044] FIG. 11 is a side view of the structural support beam of the present invention with an alternate embodiment of the lower stabilizer or retainer.
[0045] Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0046] Numerous shapes and configurations of support beam structures are exemplified in FIGS. 1A through 1F . Generally, these configurations are selected for specific application and strength. To provide additional strength different materials are employed. In addition, the gauge or thickness of the material used is varied to meet specific stress and strength requirement.
[0047] FIG. 2 illustrates the compression and tension forces exerted on a load bearing support I-beam.
[0048] These designs have inherent limitations due to the geometry of the beams in dealing with forces depicted in FIG. 2 .
[0049] The purpose of the present invention is to create a new geometry design that will provide greater strength while reducing weight in a single member unit to be used in load carrying applications similar to a beam.
[0050] Its function is to redirect the downward forces of gravity in such a manner as to cause the forces into compression on the load carrying top section thus causing the forces to be lateral or horizontal and then to transfer the forces to the ends where the connection will be made. The bottom section will not be connected except on the ends where connections will be made, and the downward forces will transfer. It should be noted the upper section and lower section are not connected except on the ends and thus remove the shear effect from the upper section and remove the deflection effects from the lower section and allow effects to be altered needed.
[0051] FIGS. 3 through 5 depict the structural support beam of the present invention generally indicated as 10 . The structural support beams described below may be constructed from a variety of materials such as metals including steel, aluminum or magnesium, fiberglass, concrete, wood, carbon fiber or generally used construction materials.
[0052] The structural support beam 10 comprises a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the bottom substantially concave flange 14 such that when assembled the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 form an integral structural beam as best shown in FIG. 4 .
[0053] As depicted in FIG. 5 , the substantially flat interconnecting web 16 is substantially perpendicular to the top substantially flat flange 12 and the bottom substantially concave flange 14 .
[0054] It has been observed that excessive tension forces exerted on opposite ends each generally indicated as 20 of the structural support beam 10 may cause the bottom substantially concave flange 14 to separate from the substantially flat interconnecting web 16 . A lower stabilizer or retainer generally indicated as 24 is secured to the structural support beam 10 to prevent the bottom substantially concave flange 14 and the substantially flat interconnecting web 16 from separating or substantially deflecting. Specifically, the lower stabilizer or retainer 24 comprises a substantially flat longitudinally disposed brace 26 having a substantially flat retainer member 28 formed at each end thereof. The substantially flat longitudinally disposed brace 26 is substantially parallel to the top substantially flat flange 12 ; while, the retainer members 28 are substantially perpendicular to the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 .
[0055] Thus, when the structural support beam 10 and lower stabilizer or retainer 24 are affixed together as shown in FIG. 4 , the inner surface 30 of each retainer member 28 engages the corresponding end surface 32 of the bottom substantially concave flange 14 , the corresponding end surface 34 of the substantially flat interconnecting web 16 and the corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 , and substantially flat interconnecting web 16 together.
[0056] FIG. 6 depicts an alternative embodiment of the structural support beam.
[0057] Specifically, the structural support beam 10 comprised a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 for an integral structural beam 10 similar to that best shown in FIGS. 4 and 5 .
[0058] In addition, a substantially flat retainer member 28 ′ is formed on each end of the substantially concave bottom flange 14 . The substantially flat retainer members 28 ′ are substantially perpendicular to the top substantially flat flange beam 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 such that when the structural support beam 10 is fully assembled the inner surface 30 ′ of each substantially flat retainer member 28 ′ engage the corresponding end surface 34 of the substantially flat interconnecting web 16 and corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 together as an integrated unit by welding or similar method.
[0059] FIG. 7 shows another alternate embodiment of the structural support beam 10 . Specifically, the structural support beam 10 comprises a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 form an integral structural beam 10 similar to that shown in FIG. 4 . Each end portion of the bottom substantially concave flange 14 comprises a flat end portion 15 .
[0060] As depicted in FIG. 7 , the substantially flat interconnecting web is substantially perpendicular to the top substantially flat flange 12 and the bottom substantially concave flange 14 .
[0061] A lower stabilizer or retainer generally indicated as 24 is secured to the structural support beam 10 to prevent the bottom substantially concave beam 18 and the substantially flat interconnecting web 16 from separating or substantially deflecting. Specifically, the lower stabilizer or retainer 24 comprises a substantially flat longitudinally disposed brace 26 having a substantially flat retainer member 28 formed at each end thereof. The substantially flat longitudinally disposed brace 26 is substantially parallel to the top substantially flat flange 12 ; while, the retainer members 28 are substantially perpendicular to the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 .
[0062] Thus, when the structural support flange 10 and lower stabilizer or retainer 24 are affixed together as shown in FIG. 7 , the inner surface 30 of each retainer member 28 engages the corresponding end surface 30 of the bottom substantially concave flange 14 , the corresponding end surface 34 of the substantially flat interconnecting web 16 and the corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 , and substantially flat interconnecting web 16 together. In addition, each flat end portion 15 is welded or otherwise affixed to the upper surface at each end of the substantially flat longitudinally disposed brace 26 .
[0063] FIGS. 8 and 9 depict yet another alternative embodiment of the structural support beam 10 similar to the structural support beam 10 shown in FIGS. 3 through 5 .
[0064] Specifically, the structural support beam 10 comprised a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 for an integral structural beam 10 similar to that best shown in FIGS. 4 and 5 .
[0065] In addition, a substantially flat reinforcing rib 38 is formed on and substantially perpendicular to each side portion 40 of the substantially flat longitudinally disposed brace 26 and each side portion 42 of each substantially flat retainer member 28 .
[0066] FIG. 10 depicts still another alternative embodiment of the structural support beam.
[0067] Specifically, the structural support beam 10 comprised a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 for an integral structural beam 10 similar to that best shown in FIGS. 4 and 5 .
[0068] In addition, a substantially flat reinforcing rib 44 is formed on and substantially perpendicular to the longitudinally mid portion 46 of the substantially flat longitudinally disposed brace 26 and the mid portion 48 of each substantially flat retainer member 28 .
[0069] FIG. 11 shows an alternate embodiment of the lower stabilizer or retainer 24 . Specifically, the lower stabilizer or retainer 24 comprises a pair of retainer members each generally indicated as 28 operatively coupled together by an intermediate longitudinally disposed brace 29 by a corresponding pair of coupling devices each generally indicated as 35 .
[0070] Each retainer member 28 comprises a first retainer leg 31 substantially parallel to the top substantially flat flange and a second retainer leg 33 disposed substantially perpendicular to the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 .
[0071] The intermediate longitudinally disposed brace 29 comprises a flexible member such as a cable or chain drawn tight or taut by the coupling devices each generally indicated as 35 such as a turn-buckle or the like.
[0072] When the structural support beam 10 and lower stabilizer or retainer 24 are affixed together, the inner surface 30 of each second retainer leg 33 engages the corresponding end surface 32 of the bottom substantially concave flange 14 , the corresponding end surface 34 of the substantially flat interconnecting web 16 and the corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 , and substantially flat interconnecting web 16 together.
[0073] Of course, each of the structural elements are welded or otherwise affixed together.
[0074] It will thus be seen that the objects set forth above, among those made apparent from the preceding description are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.
[0075] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
[0076] Now that the invention has been described,
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A structural support beam for use in buildings, bridges, mechanical frames and the like to resist bending due to gravitational and external forces comprising a top substantially flat flange disposed in fixed spaced relationship relative to a bottom substantially concave flange by an interconnecting web and a lower stabilizing brace disposed to engage the opposite end portions of the bottom substantially concave flange and the opposite end portions of the interconnecting web to reinforce the interconnection therebetween.
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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 an apparatus for producing liners for manholes, drainage pipes, sewer pipes and the like.
2. Description of the Prior Art
Liners for manholes and other drainage or sewer system are known in the art. Typically, a liner is applied to a deteriorating manhole in order to rehabilitate the manhole and return it to a safe and working condition. Application of such liner systems requires that the surfaces of the existing structure be thoroughly cleaned prior to application of the liner material to insure a strong bond between the material and the underlying structure. It is also common to seal the surface of the existing structure with a watertight sealant prior to application of the liner material to prevent water and other foreign substances from leaking between the liner and the structure, thereby causing the liner to disbond and fail.
One such liner system is described in U.S. Pat. No. 5,618,616 (Hume). There a multilayered liner system is provided for rehabilitating waste water system components. The existing, deteriorated structure is thoroughly cleaned to allow proper bonding of the liner material. A first primer layer is applied to seal the surface and then a plurality of additional foam and barrier layers are applied, as required. Each layer is sprayed applied. This method is time consuming, expensive and can be dangerous, as the personnel applying the liner may be exposed to harmful chemicals in a closed space with little or no air flow.
Systems have been developed whereby an entire manhole assembly may be constructed prior to installation. Such systems are useful for replacing deteriorated or non-functional manholes in existing waste water system or for providing a chemical and corrosion resistant manhole for use in new waste water system construction. Such a system is described in U.S. Pat. No. 5,303,518 (Strickland). A plastic liner having a provisions for creating mechanical lock with an outer shell of concrete is provided wherein the a plurality of projections extend outwardly from the liner into the concrete outer shell. The concrete flows around and between the projections thereby mechanically locking the liner to the concrete. The projections are integral to the liner and therefore, the liner material must be a material capable of being molded or shaped to form such projections, for instance, polyethylene or polyvinylchloride (PVC). In certain cases, additional processing may be required to provide a completed liner. Such processing may include cutting or milling the exterior surface of the liner to provide sufficient gaps or spaces for concrete to bond to the liner.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for producing a liner system around which a manhole, drainage system, sewer system or the like can be installed to create a lined, interior surface having a concrete outer shell. In this way, the outer shell of the manhole is protected from the harsh internal environment encountered in most sewer and drainage systems, yet the manhole does not require retrofitting to provide a liner. In addition, the liner will mechanically bond to the outer shell of the manhole to prevent separation and subsequent failure of the liner and manhole.
The apparatus of the present invention produces a liner for use in constructing manholes, drainage systems, sewer systems and the like. The apparatus typically includes a rotatable mandrel having a moving slide collar, at least one sprayer for applying liner material to the mandrel and a rock dropper capable of covering the entire length of the mandrel. The mandrel should be constructed such that the completed liner can be easily removed therefrom without breaking, cutting or otherwise damaging the integrity of the liner. For instance, the mandrel may be provided with a non-stick or reduced friction surface allowing a completed liner to simply slide off the mandrel when complete. The mandrel may be pre-sized in order to provide an adequate liner diameter. Therefore, depending on the specific application the mandrel will have varying diameter. For manhole liners, a mandrel with a 4′ diameter is common. The mandrel will be rotatable such that an even coating of liner materials may be disposed on the surface thereof. Any suitable apparatus for rotating the mandrel may be used. In order to supply varying lengths of liner, the mandrel may be provided with a moveable slide collar which can be adjusted to produce a liner of a specified length.
The liner producing apparatus of the present invention also includes at least one sprayer capable of applying an even coating of liner material along the length of the mandrel. Depending on the specific application, multiple liner materials may be sprayed onto the mandrel, a plurality of sprayers may be used to avoid problems which may be caused by mixing materials in the sprayer or delays required to clean the sprayer after each material is applied. Multiple sprayers may also be used where the desired length of the liner is such that a single sprayer cannot adequately cover the entire mandrel. The sprayers may be automated. The liner material may also be applied to the mandrel manually, using hand-held, compressed air driven sprayers.
The rock dropper of the present invention is used to apply a uniform layer of rocks or other suitable particles to the mandrel after at least one coat of liner material has been applied. The rocks, once deposited on the mandrel, will be bound in place in the liner material. An additional layer of liner material may be applied to at least partially cover the rocks and form bonding loops, protrusions or bonding particles thereon. The loops being capable of forming a mechanical bond with the outer shell.
Although a liner may be produced as a single extended tube, typically, the liner is typically composed of a plurality of shorter tubes or sections which are joined to form the complete liner. The individual sections may have a flange at one or both ends capable of engaging adjacent sections such that the adjoined sections for a sufficiently tight seal to prevent leakage through the joint. A gasket may be included between each section to further aid in creating an adequate seal.
Once a liner is produced and properly sized, the liner is inserted into a larger mold. The liner is appropriately positioned within the mold and the outer shell material is then poured or injected into the mold to form the outer shell around the pre-formed liner. The loops on the liner surface extend into the outer shell material, forming a mechanical bond therewith.
In another embodiment, the liner may be used to repair existing waste water or sewage structures by providing a liner which may be inserted into the existing structure. Concrete may then be poured between the liner and the existing structure for secure the liner in place. This both strengthens the structure and provides protection against future exposure to harsh chemicals or other deteriorating or corrosive substances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of an installed manhole liner system.
FIG. 2 is a schematic of a liner forming apparatus.
FIG. 3 is an isometric view of a portion of the liner of the present invention.
FIG. 4 is an enlarged view of a joint between two manhole sections.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the liner system L provides an internal liner structure 10 mechanically bonded to a concrete outer shell S to form a manhole M. The liner structure 10 may be a single, elongated tube or shaft, or may be a series of smaller tubes joined to form a single unit which extends from the upper or roof portion of the manhole 12 to the floor of the manhole 14 . To allow ingress and egress of water and other fluids and gases through the manhole, a pipe or other conduit 16 may be passed through a hole or opening 18 in the lower portion of the manhole. Preferably, the hole is bored through the concrete shell and liner after the manhole has been constructed. A molded hat section may be used to mount the pipe 16 in the bored hole 18 and to provide a suitable seal 20 between the hole 18 and the pipe. Benches and inverts may be added after the manhole has been installed, as required by the specific application for which the manhole is used.
FIG. 2 shows the liner forming apparatus A of the present invention. A mandrel 100 having a predetermined diameter is provided upon which the various liner materials may be applied. The mandrel 100 may be formed from any suitable material that will allow the liner 10 to slide from the mandrel once the liner is completely formed and dried. Preferably, the mandrel is formed primarily from polyurea. The mandrel 100 may be mounted on a hub 102 positioned at one end of the mandrel. The hub 102 may have a larger diameter than the mandrel 100 , thereby forming an end plate at the point of attachment between the hub and the mandrel and may be formed of any suitable material, such as stainless steel. The hub further provides a surface perpendicular to that of the mandrel, thereby providing a surface on which a flange may be formed at a first end of the liner. A shaft 104 is attached to the hub, away from the mandrel, such that the shaft is positioned along the central axis of the mandrel. The shaft 104 is attached, directly or indirectly, to a motor 106 or other apparatus capable of producing rotational motion capable of turning the entire rotating assembly, which includes the shaft 104 , hub 102 and mandrel 100 . The motor may be any commonly used in the industry. A slidable ring or collar 100 may be mounted along any point of the mandrel 100 , said collar 108 having a surface 110 which is perpendicular to the mandrel surface for forming a flange at an end of the liner opposite that of the hub 100 . The slidable collar 108 may be removed from the mandrel at an end opposite the hub to allow removal of the liner from the mandrel once the liner is completed.
The rotating assembly is rotated by the motor at a constant, predetermined speed, preferably 2-6 rpm. A spray nozzle or nozzles 112 are positioned above and at one end of the mandrel and are preferably designed to operate using compressed air. The nozzles 112 are mounted on a track to allow lateral movement of the nozzles during the application of the liner material. The nozzles are set to move a predetermined rate from one end of the mandrel to the other. The nozzles will further have a spray pattern 114 such that they are capable of completely covering a predetermined area of the mandrel on each rotation. The predetermined area is typically determined by the desired thickness of the liner material (i.e., a narrower coverage area will typically produce a thicker layer of liner material) and the speed the nozzles will move along the mandrel. The thickness of the coating material applied by the nozzles may, in part, be determined by the physical configuration of the nozzle, for instance, nozzle orifice size or diameter, and the pressure with which the liner material is supplied to the nozzle. For instance, a nozzle having a larger orifice will apply a thicker coating; likewise, providing the liner material at a higher pressure will also result in the thicker coating. The rate of movement of the nozzles along the track will depend primarily on the size and speed of rotation of the mandrel. As the mandrel 100 rotates under the nozzle 112 , a coating or liner material 116 is sprayed from the nozzles onto the mandrel creating an even and uniform cylinder of liner material. At each end, a collar or flange 118 will be formed where the liner material is sprayed onto the hub or the slidable collar.
In an alternative embodiment, the nozzles may be fixed and the rotating assembly may be configured to provide for lateral movement of mandrel such that the mandrel may move laterally below the nozzles.
In yet another embodiment, the spray nozzles may be hand held and an operator may apply the liner material manually by moving the nozzle along the mandrel as it rotates and ensuring that an even and uniform coating of liner material is applied.
A rock dispensing apparatus or rock dropper 120 is positioned above the mandrel. Preferably, the rock dropper is positioned directly above the mandre. As the nozzles 112 move along the length of the mandrel, the rock dropper 120 follows along a substantially parallel, lateral path dispensing a plurality of rocks 122 or other suitable material onto the wet surface of the liner material 116 . As the liner material dries, the rocks are bound or fixed in place and prevented from falling from the liner material as the mandrel rotates. The rocks create a plurality bumps or raised areas on the outer surface of the liner. The rocks may be of any suitable size, but preferably range in size from 0.5″ to 0.75″. In addition to rocks, any suitable material which will bond to the liner material create bumps or raised areas on the outer surface of the liner may be used.
After the rocks are dispensed and bound to the surface of the liner, a second nozzle or set of nozzles, travels from a first end of the mandrel, laterally to the second end of the mandrel, in similar fashion to the first nozzles. The second set of nozzles apply a second coat of liner material, covering the first layer of liner material and the rocks embedded therein. The thickness of the second coating layer may be changed or adjusted in the same manner as the first coating layer, i.e., by altering the size of the orifice in the injector or by providing the coating material to the nozzle at a higher pressure. As shown in FIG. 3, as the second coat of liner material is applied, loops, voids or tunnels 150 form in the second coating layer between adjacent rocks 122 . These loops, voids and tunnels 150 provide space wherein the concrete of the outer shell may flow, thereby creating a secure mechanical bond between the liner and the outer shell. It should be understood that the second coating layer may be applied using any of the methods of application of the first.
The liner material of the present invention is preferably a relatively quick drying polyurea. It should be understood, however, that any suitable material may be used as a liner material. The polyurea should be capable of setting before the mandrel has completed one revolution, but not before the rocks are applied. At the point in the revolution where the rocks are applied, the liner material should be tacky or sticky enough to hold the rocks in place.
The liner material may be formed as a single piece or may be formed in relatively shorter sections, depending on the specific application. Where multiple sections are used, each section may be joined mechanically, for instance, using screws, pins or the like and a gasket may be disposed between the flanges of the adjacent sections prior to joining. The sections may also be joined chemically, such as with a suitable adhesive.
To form a completed, preassembled manhole, the liner 10 is placed into the center of a mold. Preferably, an expandable support column is disposed in the center of the mold, around which the liner may be fitted. The column provides support for the liner while the concrete is poured into the mold around the liner. The area between the outer surface of the liner and the inner surface of the mold is then filled with concrete. The concrete flows completely around the liner and into the spaces formed thereon, creating a mechanical bond when the concrete is allowed to dry. Once dry, the support column may be collapsed and the entire manhole assembly may be transported to a required location. Where shorter liner segments are used, a specific application may require the stacking of more than one manhole segment. As shown in FIG. 4, a gasket material 184 may be disposed between the manhole segments 180 , 182 to prevent subsequent leakage when the manhole M is placed into service. Preferably, the gasket is a Ramnek gasket. A sealant layer or tape 186 may be placed over the joint 188 where two manhole segments meet to further prevent leakage of gas or liquid into or out of the manhole. Where necessary, a hole may be cut into the manhole, such as near the bottom for drainage, sewer or other lines to attach to the manhole.
The bottom or floor of the manhole 14 may be precast simultaneously and integrally with a lower section of lined manhole, or the floor may be formed in the field at the time of installation of the manhole. The floor may be lined or unlined and is preferably formed from concrete. Similarly, the top or roof of the manhole 12 may be cast simultaneously and integrally with a upper section of lined manhole or may be formed in the field at the time of installation. The roof 12 of the manhole M is typically formed from concrete and lined with a material of the same or similar composition as that used for the manhole walls. However, it should be understood that the roof may remain unlined as well. Any ring and cover assembly 22 maybe used on top of the manhole, as is common in the industry.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, and components, as well as in the details of the illustrated construction may be made without departing from the spirit of the invention.
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A method and apparatus for providing a liner for manholes, drainage systems, sewer system and the like, wherein multiple layers of liner material are sprayed onto the mandrel and outer shell engaging particles are embedded in and partially covered with the liner material. The liner is then placed into a mold and concrete or other suitable material is poured around the liner. The outer shell engaging particles form a mechanical bond between the liner and the concrete, thereby preventing future separation and failure of the liner.
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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 mine roof bolt assemblies and more particularly, to washers, bushings, gaskets and the like for sealing the interiors of mine roof bolt holes from ambient air present in mine shafts.
2. Description of the Prior Art
It has been found that certain layers of mine roof strata having a sufficient content of water absorbent clays such as montmorillonites, illites, etc., are very vulnerable to reaction with humid mine air. It has also been found that layers of roof strata containing certain minerals such as pyrite, calcite, etc. react adversely with either oxygen or a combination of moisture and oxygen and become greatly weakened by such reaction. If the roof bolt hole is not reliably sealed from the mine atmosphere, the roof bolt hole exposes the above-mentioned kinds of layers in the roof strata to a continually replenished supply of oxygen and/or water vapor, as subsequently explained. A vapor phase transfer reaction occurs wherein the moisture of the air with the above-mentioned water absorbent clays, or the reaction of the oxygen with the above-mentioned pyrites, calcites, etc., causes the corresponding layers of upper strata to weaken or oxidize. It has been found that as long as the supply of moist air and oxygen is replenished, the deterioration of the above kinds of layers extends laterally, eventually severely degrading the strength of the "laminated" mine roof strata configuration by causing lateral "slippage" between layers on either side of the degraded layer. The load bearing characteristics of such roof strata are believed to be greatly weakened even though the mine roof bolts remain tightly anchored in the upper strata. Diurnal barometric pressure changes, seasonal atmospheric pressure changes, pressure variations caused by pulsations of mine ventilation systems, variation in pressure caused by shooting and blasting, and variations in pressure due to extending and closing of working areas to mine ventilation all cause pressure changes in the ambient mine atmosphere which causes a "breathing" type of air exchange between the interior of roof bolt holes and the outside mine atmosphere if the roof bolt assemblies do not provide airtight sealing between the interior of the roof bolt hole and the mine.
Many of the known roof bolt assemblies do not provide reliable airtight sealing to prevent the above-mentioned "breathing," thus leaving the various above-mentioned strata exposed within the roof bolt holes and vulnerable to the above-described degradation due to the action of moisture and oxygen "inhaled" by the roof bolt holes. Therefore, a more detailed description of the action of the roof shales which are vulnerable to moisture is appropriate.
It has been found that shales are of sedimentary origin and composed of a mixture of fine grained sediments deposited in a layered type formation. The shales consist of hardened clays and silts possessing cleavage parallel to bedding. After deposition of the sediments the change from clay to shale is attended by a greater or less degree of recrystallization of the constituents and usually some enlargement of the particles. Many shales include a percentage of water absorbing clays such as the montmorillonite (smectite) group and to a lesser degree the illites, hallosites, etc., of the clay family of minerals. The clays may be finely dispersed throughout the shale formation or they may be deposited in very thin layers within the formation. The clay may vary in the concentration and location both vertically and laterally within the shale formation. A general observation of the shale roof strata of coal seams in the Midwest is that several inches of roof strata immediately above the coal, usually consisting of a dark siltstone (miner's slate) is more impervious to moisture than the upper portions of the immediate mine roof shale. The color of the roof shale is not a reliable indicator of the presence or absence of water absorbing clays.
The clays are very fine grained sedimentary deposits and generally consist of hydrated silicates of aluminum with various impurities. The water absorbent clays such as the montmorillonites, upon absorbing water, expand in volume and become plastic, which destroys their ability to resist stresses of both compression and tension. These clays have a high cation exchange capacity as compared to the less absorbent clays, they also have a flat pate-like crystalline structure. It is the interlayer water between the unit silicate layers of these minerals that causes their swelling and expanding characteristics. One important characteristic of the montmorillonites is that they absorb water up to a given point where equilibrium is reached, however, if allowed to dry, even a small amount, they will slake and swell immediately if again exposed to water. For this reason, it is important that bolt holes be sealed promptly against the drying of inherent and stabilized moisture of the clay and the reintroduction of moisture from the air. Clays that are water absorbent may expand as much as 1200% of their volume, and when confined, exert pressures in excess of 14,000 p.s.i.
Surface air taken into the mine contains moisture in the form of water vapor (gaseous state of water). The relative humidity of the air is measured as the ratio of the amount of water vapor actually present to the greatest amount possible at a given temperature. The total amount of vapor possible in the air varies with the temperature, the higher the temperature, the greater the capacity for holding vapor in the air. On a very humid day, the vapor content may be as much as 7% or more of the air. Water vapor expands in air space completely, equalizing the humidity of air within a bolt hole with the humidity of the air within the mine workings (Dalton's law of partial pressures and the kinetic molecular theory). Since the transfer of water from air to the clay in the shale takes place in a vapor phase transfer, restrictions to the entrance of mine air into a bolt hole can affect the volume and rate of vapor transfer into the bolt hole, and in turn, the time period involved in the clay-water reaction. The humidity of the air is constantly changing, during the day, in cycles, from day to day, and seasonal changes, the summer months being more humid than the winter months in the Central and Eastern United States.
A variety of mine roof bolt assemblies are known in the art. They usually include a bolt of from three to six feet in length, a roof plate or support plate through which the roof bolt extends, and an expansion shell threaded onto a threaded end of the roof bolt. A mine roof bolt hole is drilled, usually perpendicularly to the surface of the mine roof, with the expansion shell inserted into the roof bolt hole such that the support plate abuts the mine roof. The roof bolt is tightened, causing the expansion shell to expand, thereby anchoring the entire assembly into the mine roof strata and forcing the support plate inwardly against the mine roof. The mine roof strata described above is composed of various layers of different types of rock having varying strength characteristics. A plurality of spaced mine roof bolts installed in the mine roof tends to secure the various layers of mine roof strata together to prevent "slippage" therebetween, increasing the strength of the laminated strata, thereby preventing caving of the mine roof. However, up to now, the known mine roof bolt assemblies have not satisfactorily supported mine roofs wherein mine roof strata exposed by the roof bolt holes to ambient mine air and moisture has caused certain kinds of mine roof strata to weaken. Mine roof bolt assemblies are known to fall out of degraded roof bolt holes, eliminating the strata layer binding needed to prevent slippage between different layers of mine roof strata. It is also known that in certain cases, a mine roof may collapse even though all of the mine roof bolts therein are sufficiently tightly anchored in a hard layer, such as limestone.
This may be due to the fact that when a roof bolt hole is drilled into a shale roof it exposes the interior of the hole to mine air. Mechanical expansion shell-type bolt assemblies are not designed to provide airtight sealing of the bolt hole. When the roof bolt assembly is tightened in the hole, mine air can enter the hole, through the opening in the base plate and around the shank of the bolt and over the top of the base plate, particularly when the bolt is not installed perpendicular to the roof surface, or when the exposed roof surface is uneven. Vapor from humid mine air enters the bolt hole and comes in contact with the exposed shale strata in the interior of the bolt hole. If the exposed strata contains water absorbent type clays, then the vapor will react with the clay causing a deterioration of the strata. It is my belief that the progressive deterioration of the vulnerable strata takes place in cycles, viz the clay reacts with the water vapor until it reaches its equilibrium point, then a decrease in humidity permits a partial drying of the affected clay, then upon the next increase in humidity, the clay rapidly absorbs water until it again reaches its equilibrium point. The expansion and contraction of the clay in cycles affords an opportunity to extend the perimeter of the interface zone between the changed (by water) crystalline structure of the clay and the undisturbed crystalline portion of the clay formation. These water-clay cycles may be frequent or extended depending upon the variation in the humidity of the air, and the distribution of the water absorbent clays exposed in the bolt hole. As the affected (disturbed) area of the clay works its way outward from the hole, the rate of extension initially is greatly retarded due to the exponential increase in the area involved.
In a mine roof where the bolt holes are not sealed airtight, the vulnerable shales exposed within the hole interact with vapor from the air, the clay expands and becomes plastic and the stress resistance of the disturbed formation is destroyed, this causes a shift in the stress load carried by the roof strata which may cause overstressing in other areas of the mine roof. The strata beneath the disturbed clay zone may fail, unless the rock resistance of the lower strata is sufficient to offset the lost support of the disturbed upper zone. If the affected area is in the area of contact between the expansion shell and the wall of the bolt hole, the plasticity of the affected clay will relieve the stress imposed on the bolt hole wall by the expansion shell and the shell will become loosened and ineffective. If the area affected is below the area of contact with the expansion shell, then the strata below the affected zone may fall away from the bolt leaving the bolt dangling in the remaining portion of the roof. Where the upper part of a roof fall coincides with the top or upper part of the bolt holes, it is indicative that the cause of the fall may be due to the interaction of the humid mine air with the clay of the strata intersected by the bolt holes.
Many roof falls in shale roof in bolted areas are unpredictable on account of the many variables involved, including (1) the amount and location of water absorbent clays present in the roof shales, (2) the type of clays present, (3) restrictions to the entrance of mine air into the bolt holes due to the configuration of the surface of the roof and the positioning of the bolt and base plate with respect to the hole opening, and (4) the relative humidity of the mine air, particularly the seasonal variations in humidity.
U.S. Pat. No. 2,829,502 describes a mine roof bolt assembly for excluding mine air from a mine roof bolt hole to prevent spalling or crumbling of the side walls of the interior of the roof bolt hole by use of a large conical stopper-like washer on the shaft of a particular type of roof bolt. U.S. Pat. No. 3,651,651 shows a stabilizing bushing and a flat washer. U.S. Pat. No. 3,521,454 illustrates a flexible annular washer which accommodates variations in the surface surrounding the mount of a rock bolt hole. U.S. Pat. Nos. 4,183,699 and 4,188,158 disclose seals which contact the mine roof at the mouth of a roof bolt hole. In some instances, irregularity of the material around a roof bolt hole prevents these seals from being completely effective. The state of the art in roof bolt assemblies is believed to be further indicated by U.S. Pat. Nos. 4,162,133; 3,528,253; 4,103,498; 4,147,458 and 3,238,731. Thus, none of the known rock bolt or roof bolt assemblies provide reliable sealing of the interior of the mine roof bolt hole from mine air in certain practical instances, including the one set forth below.
Mine roof bolt holes ordinarily are drilled to a closed hole diameter tolerance in order to provide effective anchoring by means of the above-mentioned anchor shell assembly of conventional roof bolt assemblies. In certain instances, the roof strata is softer at the base portion than in the upper part whereat the anchor shell is to engage the strata comprising the walls of the roof bolt hole. Where such soft strata at the base portion of the hole is encountered, the drill bit utilized for drilling a standard diameter roof bolt hole rapidly penetrates the soft strata, making an irregularly shaped hole having a corkscrew-like pattern. Such holes, drilled by standard diameter drill bits in soft strata, usually are somewhat undersized. Consequently, considerable difficulty is frequently experienced in inserting the anchor shell of a roof bolt assembly into the lower portions of such roof bolt holes. In order to overcome this difficulty, it is common practice to first drill the lower part of the roof bolt hole in the soft strata with a drill bit having a diameter that is slightly oversized, and then change to the standard diameter drill bit as firmer strata into which the anchor shell will be anchored is encountered. The upper portion of the roof bolt hole is then drilled utilizing the standard diameter drill bit.
Although the foregoing technique avoids the difficulty of inserting the anchor shell into the roof bolt hole, it complicates sealing of the roof bolt hole to the roof bolt shafts, which, as explained above, is necessary to prevent deterioration in the strata to which the roof bolt is anchored. The complication referred to is the presence of substantial numbers of both standard diameter and oversized diameter roof bolt holes, requiring the use of at least several diameter roof bolt seal assemblies to effect the necessary sealing of the lower portion of the roof bolt hole from ambient mine air.
Therefore, it is an object of the invention to provide a bushing/seal assembly for sealing a roof bolt and roof bolt hole, which bushing/seal assembly effectively seals a roof bolt hole having any diameter within a predetermined range.
Although roof bolts are ordinarily axially aligned with the roof bolt holes when the roof bolt assemblies are inserted therein, anchoring of the anchor shells frequently result in "tilting" of the tightened roof bolt shaft within the roof bolt hole, causing a lower portion thereof to be "offset" or off-center with respect to the axis of the roof bolt hole. This condition frequently causes difficulty in obtaining an airtight seal of the roof bolt hole.
Therefore, another object of the invention is to provide a bushing/seal assembly for a roof bolt which avoids a sufficient amount of tilting of the roof bolt shaft after anchoring of the roof bolt assembly to prevent destruction of a seal of the roof bolt hole by means of a seal assembly through which the roof bolt shaft extends.
SUMMARY OF THE INVENTION
Briefly described, and in accordance with one embodiment thereof, the invention provides a bushing/seal assembly for providing a sealing relationship with a roof bolt shaft and a roof bolt hole having a diameter within a predetermined range, the bushing/seal assembly including a flexible body having first and second flexible skirts, one flexible skirt having a diameter selected to form an airtight seal with a standard size roof bolt hole and a second flexible skirt having a diameter and resilience selected to form an airtight seal with an oversize roof bolt hole. In the described embodiment of the invention, a rigid, stabilizing washer element engages the flexible body of the bushing/seal assembly. A roof bolt shaft extends through the body of the bushing/seal assembly and an opening in the rigid stabilizing washer. The periphery of the stabilizing washer engages the walls of a roof bolt hole to prevent an amount of tilting of the roof bolt shaft which will significantly reduce the level of sealing of either the first or second flange with the wall of a roof bolt hole. In one embodiment of the invention, the stabilizing washer includes a flat rigid metal washer having a plurality of notches for receiving lugs which extend from an end of the flexible body against which the rigid stabilizing washer rests. In another embodiment of the invention, the stabilizing washer includes a cylindrical upper section and a cylindrical lower section, the diameter of the cylindrical upper section being substantially greater than the diameter of the cylindrical lower section. The upper portion of the body of the flexible bushing/seal includes a cylindrically shaped portion integral therewith having a cylindrical opening for snugly receiving the lower cylindrical portion of the stabilizing washer, the stabilizing washer having a hole which closely fits the roof bolt shaft, thereby preventing tilting of the stabilizing washer.
A variety of interior sphincter flanges are provided in several embodiments of the body of the flexible bushing/seal for providing an airtight relationship with the surface of the roof bolt shaft. In one embodiment of the invention, a metal spring clip disposed around the flexible body of the bushing/seal assembly clamps the interior wall of the bushing/seal body tightly against the outer surface of the roof bolt shaft to produce an airtight seal therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the bushing/seal assembly of the present invention.
FIG. 2 is an alternate perspective view of the body of bushing/seal assembly of FIG. 1.
FIG. 3 is a sectional view taken along section line 3--3 of FIG. 1.
FIG. 4 is a partial sectional view illustrating the working of the bushing/seal assembly of FIG. 1 in an oversized side mine roof bolt hole.
FIG. 5 is a partial sectional view illustrating the working of the bushing/seal assembly of FIG. 1 in a standard size mine roof bolt hole.
FIG. 6 is a perspective view of another embodiment of the invention.
FIG. 7 is an alternate perspective view of the embodiment of the invention shown in FIG. 6.
FIG. 8 is a sectional view taken along section line 8--8 of FIG. 6.
FIG. 9 is a partial sectional view useful in explaining the operation of the bushing/seal assembly of FIG. 6 in a standard size roof bolt hole.
FIG. 10 is a perspective view of the variation of the bushing/seal assembly of FIG. 8.
FIG. 11 is a sectional view taken along section line 11--11 of FIG. 10.
FIG. 12 is a perspective view illustrating another embodiment of the invention.
FIG. 13 is a partial sectional view of the embodiment of the invention shown in FIG. 12.
DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-5, bushing/seal assembly 1 includes a tubular body section 5 having a hollow interior 6. A stem of a conventional mine roof bolt shaft 23 passes through hollow interior 6, which snugly grips the stem surface. A sphincter, having a diameter less than a diameter of hollow interior 6, is disposed at the lower end of tubular body 5 for tightly gripping the stem or shaft of roof bolt 23 to provide an airtight seal therewith. An upper skirt 9 extends radially from the upper outer surface of tubular body 5. A lower skirt 7, which has a larger diameter than the diameter of upper skirt 9, extends radially from the outer surface of tubular body 5 and is based below upper skirt 9. Tubular body 5 and upper and lower skirts 9 and 7, which are integrally formed with tubular body 5, can preferably be composed of an elastomer, such as neoprene.
A flat upper surface of tubular body 5 is designated by reference numeral 11, and serves as a platform from which two lugs 13 extend upward. A steel stabilizing washer 3 having flat, parallel upper and lower surfaces has a pair of lug-receiving semicircular notches 17 therein for snugly receiving lugs 13.
As best seen in FIG. 5, bushing/seal 1, when disposed about the stem of a roof bolt 23 and positioned in a roof bolt hole 19' having a standard-sized diameter, provides an airtight seal with the walls of roof bolt hole 19' due to the outward pressure exerted by upper skirt 9 against the walls of roof bolt hole 19. The diameter of upper skirt 9 and the thickness and resiliency thereof are selected so that the outward pressure exerted by upper skirt 9 against the walls of roof bolt hole 19' ensures an airtight seal therewith which prevents moist mine air from entering the portion of the roof bolt hole above bushing/seal assembly 1, even if roof bolt 23 is not perfectly centered in roof bolt hole 19'.
Referring now to FIG. 4, if a slightly oversized roof bolt hole 19 is encountered, the same bushing/seal assembly 1 can be utilized to obtain the desired airtight seal. In this instance, larger diameter lower skirt 7 flexes outward to contact the walls of oversized roof bolt hole 19 providing an airtight seal therewith, despite the fact that upper skirt 9 may not make an airtight seal therewith, especially if roof bolt 23 is slightly off-center with respect to roof bolt hole 19.
Stabilizing washer 3, when oriented so that its plane is perpendicular so the axis of roof bolt 23 and is maintained in that position by platform 11 and lugs 13 of tubular body 5, prevents roof bolt 23 from deviating too far away from the center of either oversized roof bolt hole 19 or standard sized roof bolt hole 19'. (However, if stabilizing washer 3 were tilted, it would be possible for roof bolt 23 to be displaced further off-center than if stabilizing washer 3 is perpendicular to the axis of roof bolt 23).
It should be noted that the lower skirt 7 must have more flexibility than upper skirt 9, since lower skirt 7 must be compressed into the smaller diameter of standard roof bolt hole 19', wherein upper skirt 9 is mainly relied upon to provide an airtight seal.
The spacing between upper skirt 9 and lower skirt 7 is selected so that when upper skirt 9 is fully flexed downward, it will not overlap any portion of lower skirt 7. It should be noted that tubular body 5 has a lower extension portion which extends a sufficient distance below lower skirt 7 that when the bushing/seal assembly 1 is forced into a roof bolt hole by a mine roof bolt support plate, both upper skirt 9 and lower skirt 7 will be forced a sufficient distance into the roof bolt hole to avoid minor irregularities in the wall of the roof bolt hole adjacent to the mouth thereof, which irregularities might prevent the lower skirt 7 from making firm contact with the complete inner circumference of the bolt hole, thereby preventing an airtight seal from being accomplished.
As mentioned above, unless stabilizing washer 3 is installed at substantially a right angle relative to roof bolt 23, stabilizing washer 3 becomes relatively ineffective in protecting the flexible bushing/seal from being crushed against one wall of a roof bolt hole (thereby preventing an airtight seal from being accomplished) if roof bolt 23 is forced to tilt as it is tightened to achieve anchoring thereof.
For use in conjunction with a conventional 5/8 inch diameter roof bolt (which has a shaft diameter of 9/16 inch, the 5/8 inch dimension referring to the threaded portion), the inside diameter of hollow interior 6 is preferably 5/8 of an inch, and the outside diameter thereof is preferably 7/8 inch. The outside diameter of upper skirt 9 is preferably 1 and 5/8 inches and the maximum thickness thereof is one-fourth of an inch. A sloped surface 9' on the upper surface of upper skirt 9 has an outside diameter of 1 and 1/4 inches at its upper portion and an outside diameter of 1 and 5/8 inches at its lower portion, the minimum thickness of upper skirt 9 being approximately one-eighths of an inch.
The height of each of sphincter portions 25 and 25' of the embodiment of the invention shown in FIG. 1 is approximately one-fourth of an inch, the minimum inside diameter thereof being approximately 3/8 of an inch.
The outside diameter of lower skirt 7 is one and 3/4 inches, the thickness thereof being one eighth of an inch. The spacing between upper skirt 9 and lower skirt 7 is one-half inch, tubular body 5 extending 3/4 of an inch below lower skirt 7.
The overall height of bushing/seal assembly 1 is preferably one and 3/4 inches for the embodiment of the invention shown in FIGS. 1-5.
Another embodiment of the invention is shown in FIGS. 6-9, this embodiment being different from the embodiment of FIG. 1 in that the lower portion of tubular body 5 flares outward, and lower skirt 7 extends or flares outward at the same slope. A lower sphincter 25 is provided at the lower end of tubular body 5. The illustrated arrangement provides for increased pressure applied to the outer circumferential portion of sphincter 25 by lower skirt 7 as lower skirt 7 is flexed inward by the walls of roof bolt hole 19', as shown in FIG. 9. For this embodiment of the bushing/seal assembly, upper skirt 9 preferably has a greater diameter than lower skirt 7 for sealably engaging walls of an oversized roof bolt hole.
A different configuration of stabilizing washer 3 is shown in the arrangement of FIGS. 6-9, wherein stabilizing washer 3 has a flat, relatively shallow upper section 27 and a relatively longer lower "sleeve" section 31 having a substantially smaller diameter than upper section 27. Sleeve portion 31 fits within a mating recess 33 formed by an upper washer-receiving section 3' disposed on the upper end of tubular body 5. The elongated sleeve section 31 prevents stabilizing washer 3 from tilting on the stem of roof bolt 23, thereby ensuring that roof bolt 23 will move no further from the center of the roof bolt hole than a distance equal to the difference between the radii of the roof bolt hole and the upper portion 27 of stabilizing washer 3. As in the embodiment of FIGS. 1-5, tubular body 5 and upper and lower skirts 9 and 7 and washer receiving section 3' are all integrally formed of an elastomer, such as neoprene. As before, stabilizing washer 27 is preferably formed of steel.
Another variation of the structure shown in the embodiments of FIGS. 6-9 is shown in the embodiment of the invention illustrated in FIGS. 10 and 11. This embodiment of the invention differs from that shown in FIGS. 6-9 only in the configuration of sphincter portion 25, which has a triangular shape similar to that shown in the embodiment of FIG. 1.
Yet another embodiment of the bushing/seal of the present invention is shown in FIGS. 12 and 13, which combines certain features of the embodiments of FIGS. 1 and 7. The stabilizing washer 3 and washer/receiving section 3' of the embodiment of FIG. 6 utilized, while the skirt structure of the embodiment of FIG. 1 are utilized. A somewhat different symmetrical sphincter arrangement 25 having an isosceles triangular cross-section is utilized. As indicated in FIG. 12, a very effective sealing relationship between sphincter 25 and the stem of roof bolt 23 can be achieved by utilizing a spring clip 45 disposed around the outside of tubular body 5 over sphincter 25. In certain instances, if spring clip 45 is utilized it would be possible to obtain an airtight seal with respect to roof bolt 23 even if sphincter 25 is omitted.
While the invention has been described with reference to several particular embodiments thereof, those skilled in the art will be able to make various modifications to the disclosed embodiment of the invention without departing from the true spirit and scope thereof, as set forth in the appended claims.
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A bushing/seal assembly for providing an airtight seal between the shaft of a mine roof bolt and a roof bolt hole includes a body having first and second flexible skirts extending outwardly from the body, the diameter of the first skirt being less than the diameter of the second skirt in order to facilitate adequate sealing with both standard size and slightly overside roof bolt holes. A rigid stabilizing washer engages the flexible body, the roof bolt shaft and the wall of the roof bolt hole in order to prevent excessive tilting of the roof bolt assembly after anchoring thereof in the roof bolt hole.
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This application is a division of application Ser. No. 08/191,071, filed Feb. 3, 1994 now U.S. Pat. No. 5,511,761.
BACKGROUND OF THE INVENTION
The present invention described herein is related generally to a concrete wall forming system for use in primarily residential and light commercial building construction. More particularly, the present invention is related to prefabricated monolithic footing and wall forming members or panels which are relatively light weight for manageability, but rigidly constructed and gang formed or interconnected to form complete integral footing and wall forming units which are substantially self-straightening and non-sagging.
Perhaps the greatest cost in new home construction is the cost of labor. The cost of labor is generally based upon an estimation of the time required to complete a given job. Therefore, there exists a continuing desire to lessen the time required for performing such work, and thereby increase the efficiency of the operation. Concrete contractors continually struggle with this problem because of the extreme difficulty which they encounter in trying to find and keep personnel that are capable of lifting and handling concrete forms in excess of 80 pounds on a daily basis, in adverse conditions. The physical wear on the personnel causes slowdowns in production as well as a relatively high rate of turnover in personnel, which in turn leads to an inefficient operation. Thus, concrete contractors are continually seeking methods by which the heavy physical labor involved in this work may be lessened.
When a poured concrete foundation for a home or other building is being constructed, a substantial amount of time and heavy physical labor is generally required for assembling footing form members, and thereafter assembling the foundation wall forming members which rest upon the concrete footings that have been previously formed and poured. Frequently, the footing forms and wall forming panels are separately constructed on the job site, by hand, and often times by separate contractors. Because each contractor will generally do its own layout work, more time is consumed and the owner of the building consequently pays twice for the same layout work.
Also, hand assembled concrete forms require numerous braces and support members to hold the same in an aligned upright position to receive the concrete therebetween. Such hand assembled wall forming panels frequently have surface irregularities and are constructed such that pillowing (outward bowing of inner surface panel) and alignment problems may occur. All of the above, along with the heavy physical labor involved, greatly increases the necessary time and labor cost involved in constructing the foundation of such a building.
Alternatively, once the conventional footing forms are assembled and the concrete footings are poured, the foundation walls may be hand assembled by laying concrete blocks, which also requires a substantial amount of time and heavy physical labor. In fact, this is still the most prevalent method of constructing foundation walls in the residental housing industry.
The substantial amount of time and heavy physical labor involved with either of the above methods has led the construction industry to seek new methods of constructing such footings and foundation walls which are less physically taxing, more efficient, and less costly. For example, the Steel-Ply form system, which was developed by Symons Corporation, consists of a plurality of prefabricated 2'×8' wall forming panels that are uniform and symmetrical in construction, and can be hand assembled on-site, or gang formed into larger wall forming units which are set in place and stripped via the use of a crane.
The advent of the Steel-Ply wall forming system reduced the amount of time necessary in constructing poured foundation walls, once the footings were properly constructed. However, such a system still requires additional time and labor to assemble the footing forms and pour the concrete footings prior to the assembly and setting of the prefabricated wall forming panels. Such footing forms must also be disassembled separately, which also adds additional cost to a project. Additionally, whether such Steel-Ply panels are hand assembled on-site or ganged formed, additional walers and strongbacks must be secured across the backside thereof in order to gain proper alignment of such panels so as to ensure that the resulting poured concrete wall is straight within the required specification therefor. For such reasons, it can be seen that costly time and heavy physical labor is still required both for assembly and disassembly of the required footing forms, and for assembly and disassembly of the interconnected panels and their required walers and strongbacks which are used to properly align the interconnected panels.
There have also been other wall forming systems developed in the past which allow the footings and foundation walls to be poured simultaneously. However, such conventional wall forming systems require on-site hand assembly which, as already pointed out, is extremely time consuming and labor intensive. In addition, the footing forms for such a system support the wall forming panels, and are therefore generally reinforced by interconnecting members which extend between opposing footing forms, and are ultimately buried within the footings once the concrete hardens. This creates substantial material waste and makes such forming systems more difficult to disassemble and strip once the foundation walls have hardened. This, of course, again increases the time, labor and cost involved in the construction of foundation walls, which is undesirable.
From the above, it can be seen that there is a definite need in the building industry, and particularly in new home construction, for a more efficient, less costly means of constructing the necessary footings and foundation walls for housing projects. More particularly, there is a distinct need for a wall forming system which has relatively light-weight prefabricated wall forming panels that include means for monolithically forming associated footings of desired width. Such panels must be constructed uniformally and symmetrically so as to be capable of being gang formed for setting in position or stripped as an integral monolithic footing and wall forming unit, and must be rigidly constructed and interconnected in such manner as to be self-straightening and non-sagging, without the need for additional walers and strongbacks. Such panels must support the footing forming members attached thereto so that no wasteful interconnecting members between opposing footing forms are necessary, thereby allowing such monolithic footing and wall forming units to be stripped as an integral one-piece structure. These advantages and more are provided by my new wall forming system, which is described and shown in more detail hereinafter.
BRIEF SUMMARY OF THE INVENTION
It is the principal object of this invention to provide a plurality of relatively light-weight, easy to handle rigid wall forming panels, each having a monolithic footing forming member adjustably mounted thereto in supported relation. Such wall forming panels are to be uniformally and symmetrically constructed for ease of manipulation, and for purposes of facilitating gang forming thereof into integral unitary monolithic footing and wall forming units which are self-straightening and non-sagging, and capable of being readily set in position and stripped as an integral one-piece unit through the use of a crane or other suitable hoisting device.
To accomplish the above objectives, I have developed a wall forming apparatus for constructing monolithic concrete footings and foundation walls which includes a plurality of relatively light-weight prefabricated wall forming panels, each of which has a rigid peripheral framework constructed of metal onto which a rigid inner planar surface member is connected. Depending in supported relation from the lower peripheral frame section of each panel, and adjustably attached thereto, is a rigid footing forming member which is preferably constructed of an extruded metal, but may be fabricated in a machine shop, depending on the number of footing and wall forming units needed.
A plurality of such panels and attached footing forms may be gang formed by rigidly interconnecting the same, and hoisted into desired position via the use of a crane or other suitable method so as to form a plurality of opposing monolithic footing and wall forming units which define the outer confines of the building foundation to be formed. Such monolithic footing and wall forming units may be set in position and stripped easily as integral units, since no interconnecting members are required to extend between opposing footing forms. Moreover, the construction of the peripheral framework of each panel eliminates the need for additional walers and strongbacks for proper alignment of adjacent panels.
Each footing forming member includes a plurality of mounting holes located adjacent opposite ends thereof, which allows the same to be adjusted inwardly or outwardly relative to the inner planar surface of the wall forming panel to which it is connected. By adjusting the footing forms inwardly and outwardly, footings of varying widths may be formed relative to the desired wall thickness.
Each footing forming member is also constructed in such manner that the means for connecting such footing forming members to the respective wall forming panels does not extend within the concrete receiving cavity defined between opposing footing and wall forming units. To accomplish this, the portion of each footing forming member which abuts the lower peripheral frame section of each respective wall forming panel is formed to define an open area immediately beneath the wall forming panel into which the connecting means may extend without entering the concrete receiving cavity between opposing wall panels. In the preferred embodiment of my invention, the abutting portion of each footing forming member includes an angularly disposed portion which extends downwardly and outwardly from the inner planar surface of the wall forming panel to which it is connected, thereby defining an open area between the abutting portion of the footing forming member and the angularly disposed portion thereof.
Because the connecting means between the footing forms and wall forming panels do not extend within the concrete receiving cavity, and because opposing footing forms are devoid of any interconnecting supports therebetween, the only portion of my wall forming apparatus which extends within the concrete receiving cavity are the ties which hold such opposing footing and wall forming units in proper spaced relation. Thus, by avoiding the extension of any unnecessary parts within the concrete receiving cavity formed between opposing footing and wall forming units, such units may be easily stripped as integral one-piece units once the concrete has hardened.
As described above, each wall forming panel is constructed uniformly and symmetrically such that adjacent panels can be rigidly interconnected or gang formed to form opposing footing and wall forming units. Such panels may be placed face down with their inner planar surface laying on a large substantially flat surface, such as that provided by a flatbed truck or trailer, and adjacent panels may be rigidly interconnected to form the monolithic footing and wall forming units which may be used and reused between different job sites.
The peripheral frame sections of each wall forming panel are constructed of a rigid metal and have a cross-sectional width which is sufficient to prevent canting and consequent misalignment between adjacent panels when such panels are rigidly connected immediately adjacent their upper and lower peripheral frame sections. The abutting portions of each adjacent wall forming panel are milled flat so that such rigid interconnection thereof will ensure proper alignment of such panels. There is no need for additional walers and strongbacks due to the relatively wide cross section of the frame sections, and their rigid interconnection adjacent the upper and lower frame sections thereof.
Interconnection of such panels immediately adjacent to the upper and lower peripheral frame sections also helps to prevent sagging or bowing of such wall forming panels from the substantial weight which is created by gang forming such panels. Preferably, each wall forming panel is constructed to be 4'×8' in dimensions, and weighs no more than about 180 pounds, but preferably 140 pounds or less, to facilitate ease of manipulation and maneuverability. Once gang formed, it is preferable that each footing and wall forming unit not exceed 40' in length, and should not weigh more than approximately 2400 pounds, including accessory hardware, so that a smaller, less costly crane may be used for positioning and stripping the same.
By constructing and interconnecting the wall forming panels in the above manner, rigid monolithic footing and wall forming units may be formed which are self-straightening and non-sagging, without the need for additional walers and strongbacks to support the same. Each individual wall forming panel is light enough for fairly easy hand maneuverability, if necessary, and each monolithic footing and wall forming unit which is constructed may be used and reused without disassembly thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention more fully appear from the following description, made in connection with the accompanying drawings, wherein like reference characters refer to the same or similar parts throughout the several views, and in which:
FIG. 1 is a perspective view of a portion of my improved concrete wall forming apparatus, showing the individual construction of each monolithic footing and wall forming panel, and showing the gang forming and positioning of such panels to form spaced opposing integral monolithic footing and wall forming units which receive the poured concrete therebetween;
FIG. 2 is a vertical cross sectional view of my improved concrete wall forming apparatus, showing the apparatus as used with interconnecting tieing members and adjustable monolithic footing forming members attached to the wall forming panels thereof;
FIG. 3 is a partial side elevational view of the lower portion of a wall forming panel, showing the preferred construction of the footing forming member which attaches to the wall forming panel;
FIG. 4 is a partial side elevational view of the lower portion of a wall forming panel, showing an alternative embodiment of a footing forming member wherein a drain tile seat form is constructed integrally therewith;
FIG. 5 is a partial side elevational view of the lower portion of a wall forming panel, showing another alternative embodiment of the footing forming member wherein a drain tile seat form may be constructed via the attachment of an accessory piece for forming the same;
FIG. 6 is a partial side elevational view of the lower portion of a wall forming panel, showing the adjustability of the footing forming member relative to the wall forming panel to which it is attached;
FIG. 7 is a top plan view of a footing forming member which attaches to a wall forming panel, showing a plurality of openings at each end for adjustability thereof;
FIG. 8 is a rear elevational view of an integral monolithic footing and wall forming unit, having vertical break lines to represent the interconnection of a plurality of wall forming panels to form the integral unit, and showing the means by which such integral footing and wall forming units may be hoisted and moved into a desired position;
FIG. 9 is a perspective view of a plurality of wall forming panels prefabricated into an integral monolithic footing and wall forming unit in accordance with my invention on a substantially flat surface, such as a flatbed truck or trailer.
DETAILED DESCRIPTION OF THE INVENTION
Shown in FIG. 1 of the enclosed drawings is my improved concrete wall forming apparatus 1 which is generally comprised of a pair of spaced opposing integral monolithic footing and wall forming units 3 and 5. Each of the monolithic footing and wall forming units 3 and 5 is comprised of a plurality of interconnecting uniformly and symmetrically constructed light weight prefabricated wall forming members 7, each of which carrys at its lower end an adjustable footing forming member 9. Each wall forming member 7 is constructed of a rigid framework comprising an upper peripheral frame section 11, a lower peripheral frame section 13, and opposite side frame sections 15 and 17 extending between and interconnecting the upper and lower peripheral frame sections 11 and 13. Extending laterally between opposite side frame sections 15 and 17, and disposed parallel with upper and lower frame sections 11 and 13, are a plurality of spaced central rigid support members 19 which add rigidity to each wall forming panel. Attached to the inner surface of the framework of each wall forming member 7 is a panel 21 having an inner planar surface 23.
As mentioned previously, all such integral monolithic footing and wall forming units such as that shown by numerals 3 and 5 in FIG. 1 are substantially self-straightening and non-sagging. In order to accomplish the same, the framework of each wall forming member 7 is generally constructed of metal or other sufficiently rigid material. Each side peripheral frame section 15 and 17 are constructed with a plurality of reinforced raised connecting blocks 25 which are milled substantially flat and perpendicular to a plane defined by the inner surface of the framework to which panel 21 is connected, thereby defining a substantially straight-line along the upper and lower horizontal edges of peripheral frame sections 11 and 13. Preferably, blocks 25 should be milled flat as described above to within a tolerance of about 0.010 inch. Also, reinforced connecting blocks 25 are preferably disposed at least immediately adjacent the upper frame section 11 and lower frame section 13 of the framework for each wall forming member 7, therefor allowing rigid interconnection of adjacent wall forming members 7 immediately adjacent the upper and lower ends thereof. Interconnection of such adjacent wall forming members 7 is accomplished through the use of rigid bolt 27 which passes through openings 29 in the reinforced connecting blocks of each peripheral side frame section 15 and 17.
At least the upper and lower peripheral frame sections 11 and 13, and adjacent connecting blocks 25 are constructed such that the width from its rearmost surface 31 to the inner surface to which panel 21 is connected is not less than approximately 3 inches, thereby providing a much broader framework than that used in conventional residential wall forming systems. The advantage in constructing the framework of wall forming members 7 with substantially broader connecting portions immediately adjacent the upper and lower peripheral frame sections 11 and 13, and milling connecting blocks 25 to within the approximate tolerance set forth above, is that rigid side-by-side interconnection of such wall forming members 7 adjacent the upper and lower ends thereof will substantially eliminate any inward or outward canting of one wall forming member 7 relative to another. Consequently, such interconnected wall forming members 7 become subtantially self-straightening, without the need for additional walers and strongbacks for increased support and alignment. Moreover, the additional strength provided by the reinforced connecting blocks 25 causes the integral monolithic footing and wall forming units 3 and 5 to be substantially non-sagging when hoisted via a crane in the manner as shown in FIG. 9.
As shown in FIG. 2, once each integral wall forming unit 3 and 5 have been set in place in their desired spaced relation within an excavated ditch, a tieing means 33 is used to interconnect the opposing wall forming units and retain the same in proper spaced relation. As shown in FIG. 2, a coil tieing arrangement is used, although there are many other tieing arrangements which can be employed to accomplish the same result. As shown best in FIG. 1, coil tieing members 33 are disposed between side-by-side interconnected wall forming members 7 and are properly positioned and seated within notches 35 which are formed on opposite side edges of panel 21. Each tieing means 33 is comprised of a coil tie 37 which threadingly receives within each of its opposite ends a coil bolt 39. Coil bolt 39 bears against washer 41 which, in turn, bears against the rear surface 31 of the interconnected side peripheral frame sections of adjacent wall forming members 7. Generally a plurality of tieing members 33 are utilized at each joint between interconnecting wall forming members 7 to hold the opposing monolithic wall forming units 3 and 5 in proper spaced relation. An additional overhead tie (not shown) may be used to secure the top ends of opposing footing and wall forming units 3 and 5 together by seating such a tieing means 33 within notches 34 of upper tie brackets 36. Once all tieing members 33 are properly connected, concrete 43 may be poured into the concrete receiving cavity 45 which is formed between opposing monolithic footing and wall forming units 3 and 5.
As is best shown in FIGS. 2-6, the footing forming member 9 which is attached to the lower peripheral frame section 13 of each footing forming member 7 includes an abutting mounting portion 47 which includes a plurality of mounting holes 48 disposed at opposite ends thereof (FIG. 7) which allow for adjustable connection thereof to a wall forming member 7, as shown in FIG. 6. From the point of the abutting portion 47 which is most inwardly disposed and adjacent to the inner planar surface 23 of panel 21, footing forming member 9 preferably extends angularly downward and outward, thereby forming an open area 49 disposed between abutting portion 47 and angularly disposed portion 51 of forming member 9. The joint between abutting portion 47 and angular portion 51 is reinforced or gusseted at point 53 to provide added strength for support of the weight of wall forming member 7, and for withstanding the pressure from the poured liquid concrete. Footing forming member 9 extends downwardly from the outer terminal end of angular portion 51 to its bottom terminal portion 55. Although the preferred construction is as shown in the accompanying drawings, it is conceivable that other configurations of footing forming member 9 may be used, so long as an open area 49 is formed thereby.
The importance of open area 49 in footing forming member 9 lies in the fact that it is important that no portion of the wall forming apparatus extend within-the concrete receiving cavity 45, other than the tieing means 33, which is accessibly disposed above the lower peripheral frame section 13 of a wall forming member 7. This facilitates ease in stripping the integral monolithic footing and wall forming units once the concrete has set and hardened. By forming open area 49, the interconnecting bolt 57 between footing forming member 9 and wall forming member 7 to which it is connected does not extend within the concrete receiving cavity 45, and will therefore not become lodged within the concrete 43 so as to prohibit easy and efficient stripping of the forms therefrom once the concrete has hardened. It also prevents the threads of the connecting nuts and bolts from becoming coated with concrete, thereby facilitating ease in adjustment of the footing forming members 9 when such an adjustment is desired.
Another significant advantage resulting from the prefabrication of such monolithic footing and wall forming units is that the footing forming members 9 are built down from the wall forming members 7, rather than the wall forming members being built up from the footing forms, as in conventional wall forming systems which are constructed in a piecemeal manner on the job site. Because each wall forming member 7 carries its respective footing forming member 9, there is no need for interconnecting members between opposing footing forming members 9 when set into position prior to the pouring of concrete. As such, stripping of the monolithic footing and wall forming members 3 and 5 after the concrete has hardened only requires disconnection of the accessible tieing means 33 disposed above the lower peripheral frame section 13 of the wall forming members 7 thereof. This is a significant time savings over conventional footing wall forming systems which are constructed at the job site.
As best shown in FIGS. 4 and 5, the footing forming members may be alternatively designed so as to form a drain tile seat in the resulting concrete footing formed thereby. As shown in FIG. 4, angular portion 51 of footing forming member 10 may be constructed with an integral inwardly protruding arcuate portion 59 which, upon pouring of the concrete, will form a seat upon which drain tile (shown in phantom lines) may rest prior to backfilling dirt against the formed concrete wall. Alternatively, as shown in FIG. 5, a standard footing forming member 9 may be modified to carry an arcuately shaped attachment 61 which serves the same purpose as the integrally formed arcuate portion 59 in FIG. 4. Use of the arcuate attachment 61 is advantageous in that the standard footing forming member 9, as shown in FIG. 3, may be utilized without the need for manufacturing a complete separate line of footing forming members in the configuration as shown in FIG. 4.
In operation, as shown in FIG. 9, a plurality of integral monolithic footing and wall forming units such as that designated as 3 and 5 in the instant disclosure may be constructed on a substantially flat surface, such as a flatbed truck or trailer 63, which may also be used for transportation of the same. Once constructed, such integral monolithic wall forming units may be transported from job site to job site without disassembly thereof. Therefore, use of a flatbed truck or trailer 63 allows for both prefabrication and transportation of the monolithic footing and wall forming units, which greatly reduces the amount of assembly time for the same.
To construct such units 3 and 5, a plurality of wall forming members 7 having monolithic footing forming members 9 attached to the lower peripheral frame section 13 thereof are laid face down with inner planar surface 23 of panel 21 lying on the flat surface of the flatbed truck or trailer 63, or on other panels disposed therebelow. Such wall forming panels are abutted together in side-by-side relation and rigidly interconnected at least at points immediately adjacent the upper and lower ends thereof, as shown in FIG. 9. Preferably, no more than approximately ten wall forming panels 7 are interconnected in side-by-side relation, so that each integral monolithic footing and wall forming unit 3 or 5 extends only approximately 40 feet in length, and does not exceed approximately 2,400 pounds in weight. If such limitations are adhered to, a smaller and less costly crane may be used to manuever and set the same.
Once such integral monolithic footing and wall forming units are constructed, appropriate rigging 65 is connected to such units 3 and 5, and a crane, knuckleboom or other suitable device is used to hoist such units as shown in FIG. 8 of the enclosed drawing. Such units may be readily set in desired position within an excavated trench, and appropriately supported until further footing and wall formings units are put in place and tied together so as to form the entire wall forming apparatus for the desired foundation.
It will, of course, be understood that various changes may be made in the form, details, arrangement and proportions of the parts without departing from the scope of the invention which comprises the matter shown and described herein and set forth in the appended claims.
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A wall forming apparatus for constructing monolithic concrete footings and walls of a building foundation which includes a plurality of relatively light-weight prefabricated wall forming panels connected together and positioned to form a plurality of opposing monolithic footing and wall forming units, each panel having an outer rigid framework from which an adjustable footing form depends, the opposing footing forms of the opposing footing and wall forming units being devoid of any structure extending directly therebetween, and the framework of each panel being constructed of sufficient rigidity and with sufficient cross-sectional dimensions so as to prevent canting and sagging of the footing and wall forming units formed by the panels when interconnected. Construction and proper placement of the integral footing and wall forming units is accomplished by placing the panels side-by-side on a flat surface and rigidly interconnecting the same at the adjacent upper and lower corners thereof, and thereafter hoisting each constructed footing and wall forming unit into desired position through the use of a crane or other suitable hoisting device.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD AND BACKGROUND OF THE INVENTION
[0001] The present invention relates to a cartridge device for introducing chemical supplements to a toilet cistern and, more particularly, to a cartridge device for introducing chemical supplements to a toilet cistern without having to displace the cover of the toilet cistern.
[0002] There are various ways of adding supplements such as detergent to water in a toilet cistern. One simple way is to put a solid block of cleaning material containing an adsorbed dye into a holder disposed within the cistern. The cleaning material is then slowly dissolved in the water within the cistern. A weakening color of the water indicates that the cleaning material is running out and that the block of cleaning material needs to be replaced. However, the block of cleaning material gives off cleaning material at a rate that depends primarily on the surface area of the block, such that the concentration of cleaning material in water is far from constant, and is highly dependent on the time elapsed since the toilet was last flushed.
[0003] A more sophisticated way of introducing detergent to water in a toilet cistern is to place a dispenser containing a cleaning liquid inside the cistern. When the water level in the cistern changes, cleaning liquid from the dispensing container is dispensed by any of various types of dispensing systems. In many of these dispensing systems, the discharge of the cleaning liquid is effected by means of a change in the water level within the cistern.
[0004] One drawback of such dispensers is that the cover of the toilet cistern has to be temporarily removed or displaced in order for the cleaning material (solid or liquid) or a cartridge containing the cleaning material, to be replenished periodically.
[0005] This drawback is largely overcome by Patent Application PCT/IL02/00827 to Eshel, et al., which discloses a chemical dispenser, for use with a flush toilet, which is mounted externally to the toilet cistern using an existing opening in the cistern. It is observed in the above-referenced application that most toilet cisterns are produced with two holes, one on each end of the cistern, to provide for alternative positioning of the water input valve, hence, the chemical dispenser is readily installed on most cisterns without having to drill a new hole therein.
[0006] One deficiency in the art taught by the PCT Application to Eshel, et al., is that the chemical dispenser takes up considerable space proximate to the housing of the toilet cistern. In many bathrooms, the allotment of space for such a dispenser is impractical, or even impossible. Moreover, the chemical dispenser provides a large surface area for the collection of dust and dirt, a distinct disadvantage both for home and public bathrooms. The disposition of the chemical dispenser external to the cistern, while simplifying the refilling procedure, also makes the dispenser prone to breakage due to accidental knocks as well as vandalism. The chemical dispenser taught by Patent Application PCT/IL02/00827 is particularly susceptible to vandalism because the bulky dispenser is disposed in plain view.
[0007] Hence, there is therefore a recognized need for, and it would be highly advantageous to have, a chemical dispensing device that enables a simple refilling procedure, i.e., without having to displace the cover of the toilet cistern, and yet is largely free of the substantial deficiencies of the known external dispensers. It would be of further advantage if such a device would be compact, aesthetically pleasing, and inexpensive to produce.
SUMMARY OF THE INVENTION
[0008] The present invention is a dispenser for introducing chemical supplements to a toilet cistern without having to displace the cover of the toilet cistern.
[0009] According to the teachings of the present invention there is provided a device for introducing a chemical supplement to a toilet cistern without having to displace a cover of the toilet cistern, including: (a) a dispensing unit having a releasing mechanism, disposed within the cistern, for releasing the chemical supplement into the cistern, and (b) a housing, associated with the releasing mechanism and disposed within the cistern, for receiving a cartridge containing the chemical supplement, and (c) an attachment mechanism for securing the device to a surface of the toilet cistern.
[0010] According to another aspect of the present invention there is provided a cartridge device for containing a chemical supplement to a toilet cistern, including: (a) a housing for containing the chemical supplement, and (b) a securing mechanism, at least part of which is disposed on the housing, for securing the housing within the cistern, the housing being designed and configured to at least partially fit through an opening in a surface of the cistern, and such that the housing can be inserted through the opening without having to displace a cover of the cistern.
[0011] According to yet another aspect of the present invention there is provided a method of introducing a chemical supplement to a toilet cistern, including the steps of: (a) providing a cartridge device including: (i) a housing for containing the chemical supplement, and (ii) a securing mechanism, at least part of which is disposed on the housing, for securing the housing within the cistern; (b) inserting the cartridge device through an opening in a surface of the toilet cistern, and (c) securing the cartridge device with respect to the toilet cistern, using the securing mechanism.
[0012] According to still further features in the described preferred embodiments, the device further includes: (d) a protruding element, disposed within the housing, and designed and configured to penetrate the cartridge when the cartridge is inserted into the housing.
[0013] According to still further features in the described preferred embodiments, the releasing mechanism includes a buoyant plug.
[0014] According to still further features in the described preferred embodiments, the plug is a bi-directional buoyant plug.
[0015] According to still further features in the described preferred embodiments, the attachment mechanism includes a fitting that fits around the surface.
[0016] According to still further features in the described preferred embodiments, the cartridge has a structurally-weakened surface, and wherein the protruding element is designed and configured to penetrate the cartridge in a vicinity of the structurally-weakened surface.
[0017] According to still further features in the described preferred embodiments, the releasing mechanism includes a buoyant plug, and wherein the protruding element is disposed on the plug.
[0018] According to still further features in the described preferred embodiments, the opening is disposed in the cover of the cistern.
[0019] According to still further features in the described preferred embodiments, the opening is disposed in a wall of the cistern.
[0020] According to still further features in the described preferred embodiments, the cartridge is designed and configured such that at least a portion of the cartridge can pass through an opening in the cover of the toilet cistern, such that the chemical supplement can be introduced to the cistern without having to displace the cover of the cistern.
[0021] According to still further features in the described preferred embodiments, the cartridge is equipped with a handle for facilitating an insertion of the cartridge into the housing, and for securing the cartridge within the cistern.
[0022] According to still further features in the described preferred embodiments, the cartridge is equipped with a scent chamber for containing a solid scent for providing a scent to an environment external to the cistern.
[0023] According to still further features in the described preferred embodiments, the scent chamber has a disposable covering for covering the solid scent, the disposable covering for removing before the solid scent is activated.
[0024] According to still further features in the described preferred embodiments, a surface within the housing includes a securing mechanism for securing the cartridge thereto.
[0025] According to still further features in the described preferred embodiments, the securing mechanism includes a first threaded surface that is complementary to a second threaded surface disposed on the cartridge.
[0026] According to still further features in the described preferred embodiments, the housing is designed and configured with respect to the opening such that upon insertion of the cartridge device into the opening, the chemical supplement is disposed completely, or at least partially, within the toilet cistern.
[0027] According to still further features in the described preferred embodiments, the housing includes a structurally-weakened surface designed and configured such that upon insertion of the cartridge into the opening, the structurally-weakened surface is penetrated by a protruding element within the toilet cistern.
[0028] According to still further features in the described preferred embodiments, the cartridge device further includes: (c) a scent chamber, associated with the housing, for containing a solid scent, the chamber designed and configured such that upon insertion of the device into the opening, the chamber is disposed outside the toilet cistern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. Throughout the drawings, like-referenced characters are used to designate like elements.
[0030] In the drawings:
[0031] FIGS. 1 a and 1 b are schematic views of the cartridge device of the present invention according to a first preferred embodiment, in which the cartridge is inserted via the cistern lid, wherein:
[0032] FIG. 1 a shows the cartridge completely inserted within the cistern, and
[0033] FIG. 1 b shows the cartridge in a partially-inserted disposition;
[0034] FIGS. 2 a - 2 b are schematic illustrations of the buoyant plug in an open position and in a closed position, respectively, and
[0035] FIG. 3 is a schematic illustration of the cartridge device of the present invention according to another preferred embodiment, in which the cartridge is inserted via an opening in a wall of the cistern.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] The present invention is a dispenser for introducing chemical supplements to a toilet cistern without having to displace the cover of the toilet cistern.
[0037] The principles and operation of the dispenser of the present invention may be better understood with reference to the drawings and the accompanying description.
[0038] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawing. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
[0039] The major innovation of the present invention is the replenishment of the supplement from the exterior of the toilet cistern without having to displace the lid of the cistern. This is achieved by utilizing a hole in the toilet cistern that is disposed anywhere above the water level (when the cistern is full). The hole, which can be an existing hole or a dedicated hole built into the toilet cistern for this purpose, can be disposed in the lid or on any side of the cistern.
[0040] Referring now to the drawings, FIG. 1 a is a schematic view of the cartridge device 10 of the present invention according to a first preferred embodiment, in which a tube-shaped cartridge 12 containing a chemical supplement is completely inserted in cistern 14 via an opening in cistern lid 16 .
[0041] As can be seen with greater clarity in FIG. 1 b , the side of cartridge 12 has a threaded area 18 , and opening 20 in cistern lid 16 (or in cartridge chamber 24 ) is equipped with threaded area 22 that is complementary to threaded area 18 . The top of cartridge 12 is equipped with a handle 24 , which facilitates both the insertion of cartridge 12 into cistern 14 and the securing of cartridge 12 to cistern lid 16 by means of complementary threaded areas 18 , 22 .
[0042] Inside cistern 14 is disposed a cartridge chamber 24 for housing cartridge 12 . Cartridge chamber 24 is firmly affixed to cistern lid 16 by housing adaptor 26 , which preferably fits snugly around both the inside and outside surfaces of cistern lid 16 .
[0043] It is evident that many alternatives for securing the cartridge 12 to cartridge chamber 24 or to cistern lid 16 or to cistern wall 112 (shown in FIG. 3 hereinbelow) will be apparent to those skilled in the art.
[0044] Disposed below cartridge chamber 24 is dispensing chamber 28 , which serves to dispense the chemical supplement from cartridge chamber 24 into cistern 14 , as will be explained in greater detail hereinbelow. Cartridge chamber 24 and dispensing chamber 28 fluidly communicate through upper ring 30 . Within dispensing chamber 28 is disposed buoyant plug 32 , which is designed to alternatively block fluid communication in two directions:
(1) between dispensing chamber 28 and lower ring (or orifice) 34 , such that the chemical supplement is able to flow into dispensing chamber 28 (“down position”, or “open position”), but water from cistern 14 is blocked from flowing into dispensing chamber 28 ; (2) between cartridge chamber 24 (and/or cartridge 12 ) and dispensing chamber 28 , such that the chemical supplement is not introduced into cistern 14 via dispensing chamber 28 (“up position”, or “closed position”).
[0047] An air hole 64 is advantageously disposed in a wall of cartridge chamber 24 (in the event that the wall fluidly seals between the inside and outside of cartridge chamber 24 ), or possibly in a wall of cartridge 12 (in the event that the cartridge wall fluidly seals between the inside and outside of cartridge 12 ).
[0048] FIGS. 2 a - 2 b are schematic illustrations showing the buoyant plug in an open position ( FIG. 2 a ), and in a closed position ( FIG. 2 b ). Upon flushing the toilet, there is no water to support the device, hence buoyant plug 32 falls to a down or open position, such that the chemical supplement flows from cartridge chamber 24 into dispensing chamber 28 (see arrows 36 in FIG. 2 a ).
[0049] During the filling of the water cistern, buoyant plug 32 is buoyed by the water, and is reelevated. Once buoyant plug 32 has reattained its starting position ( FIG. 2 b ), such that the communication between cartridge chamber 24 and dispensing chamber 28 has been sealed, the chemical supplement, which is substantially incompressible, is released from dispensing chamber 28 via lower ring 34 , into the water tank (see arrows 38 in FIG. 2 b ).
[0050] FIG. 3 is a schematic view of a cartridge device 100 of the present invention according to another preferred embodiment, in which a cartridge 102 is inserted via an opening 110 in a wall 112 of cistern 14 . Since most toilet cisterns are produced with two holes, one on each end of the cistern, to provide for alternative positioning of the water input valve, cartridge device 100 is readily installed on most cisterns without having to drill a new hole therein.
[0051] Referring back to FIG. 1 b , cartridge 12 is advantageously equipped with a structurally-weakened surface 40 , typically disposed in the bottom surface of cartridge 12 . Upon insertion of cartridge 12 into cartridge chamber 24 , structurally-weakened surface 40 is penetrated by a sharp surface 33 within cartridge chamber 24 . In FIG. 1 b , the sharp surface is disposed on buoyant plug 32 . In FIG. 3 , structurally-weakened surface 41 and sharp surface 43 within cartridge chamber 24 are designed and configured such that structurally-weakened surface 41 is penetrated by sharp surface 43 , preferably while cartridge 12 is being screwed into place.
[0052] In another preferred embodiment of the present invention, shown in FIG. 1 a , handle 24 of cartridge 12 is at least partially hollow, so as to serve as a scent container 44 for containing a perfume, deodorizer, or the like. Preferably, the solid scent material in scent container 44 is covered by a foil or other disposable covering 46 . Thus, after cartridge 12 is installed in cistern 14 , disposable covering 46 is removed from scent container 44 , exposing the active material therein to the environment, and initiating the scenting of the air.
[0053] It must be emphasized that in addition to enabling the user to provide a chemical supplement to the water cistern without having to remove the cistern lid, the present invention enables the user to utilize a liquid chemical supplement without having to store the supplement outside the water cistern, and without having to deal directly with the liquid (and the spilling thereof). The liquid is introduced within a cartridge, and is not exposed to the environment outside of the cistern.
[0054] It must be further emphasized that the present invention provides a mechanism for firmly securing the container for holding the chemical supplement to the lid or wall of the cistern. Furthermore, the present invention serves to contain the chemical supplement within the cistern, while also containing a solid scent material for scenting the environment around the cistern. The solid scent material is firmly fixed to the lid or external wall of the cistern, such that no additional device is required for holding the material, and moreover, the scent material does not take up additional space on top of the cistern lid (or on another surface in the bathroom), nor is the scent material subject to being moved around, knocked over, etc., as with conventional containers for holding such materials.
[0055] As used herein in the specification and in the claims section that follows, the term “internal surface of the toilet cistern” refers to an internal surface of the cistern body or to an internal surface of the cistern lid.
[0056] 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 spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.
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A device for introducing a chemical supplement to a toilet cistern without having to displace a cover of the toilet cistern, including: (a) a dispensing unit having a releasing mechanism, disposed within the cistern, for releasing the chemical supplement into the cistern, and (b) a housing, associated with the releasing mechanism and disposed within the cistern, for receiving a cartridge containing the chemical supplement, and (c) an attachment mechanism for securing the device to a surface of the toilet cistern.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
The present invention relates to a device for the connection of a miniature electric motor with at least two electric conductor tracks of a printed-circuit board, particularly with regard to the housing of a central locking device of an automotive vehicle, the miniature motor presenting one socket per conductor track end to be inserted.
BACKGROUND OF THE INVENTION
Today miniature motors are applied in connection with different servo devices. In the automobile industry there are many applications of such servo devices, e.g. for opening and closing the windows or also for actuating a central locking device. The miniature motor or even several miniature motors have to be connected in the designated way with conductor tracks of a printed-circuit board or the like.
Originally, each motor was provided with a cable connection and the cable was connected with the conductor tracks of the printed-circuit board by plugging or soldering it. Attempts have also been made to connect contact sheets of the motor with flat plugs. These connections are expensive and time consuming since they have to be realized manually. Furthermore it is often undesirable to lay cables in the housing of the device because the cable can hinder the motion of the moving components. This applies especially when the device provided with one or more motors is exposed to vibrations, as is always the case in automobiles.
In another known version, such miniature motors are provided with slide connectors which protrude from the motor like the contact sheets do. These slide connectors are pushed into the openings of the conductor tracks and soldered directly to them. Although in this case no cable is involved, the miniature motors must have a precisely defined position in relation to the printed-circuit board or the conductor tracks in question. This defined position often does not correspond to the desired mounting position of the motor. This is especially true when the motor is not provided with a circular, but an oval or similar non circular housing. Furthermore the layout of the conductor tracks depends on the conformation of the motor. Modifications of the motor generally leads to a corresponding modification of the conductor tracks. This is time consuming and usually also very expensive.
The object of the present invention is therefore to develop the device mentioned at the beginning in such a way, that the motor can be mounted simply and quickly despite the absence of a cable connection and that small modifications of the motor do not involve any or at least any important adaptation to the connection of the printed-circuit board.
This object is achieved according to the present invention by putting the adapter between the end pieces of the conductor tracks and sockets of the motor. This arrangement provides for an electrically conductive connection between the motor and the conductor tracks and permits the quick adaptation to a slightly modified motor and/or modified end pieces of the conductor tracks. In addition to this, the connection of the motor with the adapter as well as the connection of the adapter with the end pieces of the conductor tracks is pluggable, so that cables are no longer necessary. The respective plug-in connections can be designed as already known. Therefore the miniature motor, e.g. coupled with the adapter, can be connected easily, quickly and safely with the end pieces of the conductor tracks, or in the specific case, with the central locking device, all prerequisites for an automatic assembly being given.
In another improvement of the present invention, the ends of the electrically conductive elements close to the motor are formed as plug pins which are retained in the sockets of the miniature motor in a clamped way. In this case the sockets have a flat plug-in opening in which the electrically conductive elements are plugged in an elastically clamped manner.
In another aspect of the present invention, the lateral distance of the ends of the electrically conductive elements close to the motor corresponds to the lateral distance of the sockets of the miniature motor so that both can be coupled by a linear motion and at the same time be connected in an electrically conductive way.
For reasons of cost and weight, the material thickness of the electrically conductive elements should be as small as possible. Stamped parts, however, must present a minimum thickness because of the stamping procedure. If the sockets after a modification of the miniature motor are provided with somewhat wider insertion slots for the electrically conductive elements, it may be possible that a tight fit of the electrically conductive elements in the sockets can no longer be ensured. In another embodiment of the present invention, an improvement is achieved in that the flat sides of the electrically conductive elements are parallel and each one shows a depression, particularly extending in the plug-in direction, which leads to enlarged ends of these electrically conductive elements to be inserted so that, at least in case of elastically expanding sockets, also small dimensional tolerances near the sockets can be compensated within certain limits.
The depressions of the two electrically conductive elements are directed towards each other in a particularly preferred manner. Since the form of the two electrically conductive elements is, apart from that, essentially similar, the different position of the depressions with regard to their flat sides provides for a certain identification which permits an automatic sorting. This is the prerequisite for an automatic or at least semi-automatic assembly. As for the rest, the electrically conductive elements can be retained in the base member of their adapter in one of the known ways, e.g. by jamming or by extrusion if the adapter, as foreseen in the present embodiment, is made of plastic material.
Preferably, the electrically conductive elements have an essentially angular shape. This means that when the electrically conductive elements abut loosely on a surface, one leg is parallel to the one of the other electrically conductive elements and their depressions point upwards, the other leg points into the opposite direction. This can be exploited for the identification of the single parts.
As already mentioned, the electrically conductive elements can be plugged into the base member or extruded with its material. In a variant of the present invention, preferred in this regard, clamping engagement is easily achieved by the depression, nipple provided the insertion slot or the material in this area is sufficiently yielding so that the depression or nipple can penetrate to some extent. A favorable variant is also to clamp the electrically conductive element by means of a snap connection in which the nipple snaps in behind a projection or undercut.
As already mentioned, the adapter and the end parts of the conductor track can be connected in a pluggable manner. In to ensure that this plug-in connection is vibration proof and to secure it, it is advisable to make each end piece of the conductor track engage between two fork prongs on the leg of the angle which is remote from the motor. The length of the parallel part of the fork prongs and therefore the constant width of the insertion slot corresponds to the width of the conductor track.
A particularly preferred variant of the present invention ensures that the unit consisting of the adapter and the miniature motor can be slipped onto the end pieces of the conductor track by a simple linear movement which permits a fully automatic assembly and excludes wrong electrical connections in each of the two connecting points.
In order to ensure a safe electrical connection between the end pieces of the conductor track and the adapter or its electrically conductive elements, an enlargement at the insertion end of each end piece of the conductor track is provided for, in particular a depression extending in the plug-in direction, which is associated with the space between the parallel parts of the fork prongs. By this it is also possible to achieve a tight mechanical connection which certainly leads to a high electrical safety of these connecting points.
Developments being of particular advantage to the fully automatic connection of the adapter or the unit consisting of adapter and miniature motor with the end pieces of the conductor track, are described. First of all, the insertion slopes permit a safe connection between the adapter and the end pieces of the conductor track even if there is a slight deviation from the correct position. By means of the insertion slopes, they are introduced safely into the insertion slots on the inside of which are positioned the forks of the two electrically conducting elements which are coupled mechanically and in an electrically conductive manner to the end pieces of the conductor track when the adapter is slipped onto these end pieces.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the top view of a central locking device of the present invention with fitted miniature motor which is connected electrically by means of the device being object of the present invention, the cover being partly broken away.
FIG. 2 is a top view of the adapter surface close to the motor with fitted electrically conductive elements, on an enlarged scale.
FIG. 3 is a cross-sectional view of FIG. 2 taken along line III--III.
FIG. 4 is an enlarged view of an electrically conductive element.
FIG. 5 is a front view of this element, partly cut along line V--V.
FIG. 6 is a top view of the other electrically conductive element.
FIG. 7 is a representation corresponding to FIG. 5, partly cut along line VII--VII of FIG. 6.
FIG. 8 is a representation according to FIG. 2 without the electrically conductive elements.
FIG. 9 is a cross-sectional view along line IX--IX of FIG. 8.
FIG. 10 is a side view of the adapter in the direction of arrow X of FIG. 8.
FIG. 11 is a view of the adapter in the direction of arrow XI of FIG. 10.
FIG. 12 is a view of the adapter in the direction of arrow X of FIG. 8.
FIG. 13 is a view of the adapter in the direction of arrow XIII of FIG. 12.
FIG. 14 is a cross-section along line XIV--XIV of FIG. 13.
FIG. 15 is a cross-section along line XV--XV of FIG. 8.
FIG. 16 is a cross-section along line XVI--XVI of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the housing 1 of a central locking device for an automotive vehicle, there is a miniature electric motor 2 driving a worm 3. This worm meshes with a worm wheel 4. According to the present invention, the miniature electric motor 2--hereinafter referred to as "motor"--is connected in an electrically conductive way with two electrical conductor tracks 6 and 7 by means of an adapter 5, the conductor tracks being attached to a printed-circuit board 8 which is not represented in detail and which in this embodiment is fixed at the bottom on the inside of the device housing 9 or is made of the bottom itself being the carrier of the punched conductor tracks. The device housing 9 is closed to the outside by means of a cover 10. The end pieces of the conductor tracks on which in FIG. 1 the adapter 5 is slipped perpendicularly from above to the bottom, extend therefore from the bottom of the housing 1 perpendicularly towards the top and the person who looks at the drawing.
In FIGS. 8 to 14 the adapter 5 is represented in detail. FIGS. 2 and 3 show the adapter 5 equipped with the electrically conductive elements which are represented on an enlarged scale in FIGS. 4 to 7.
According to e.g. FIGS. 10 and 12, the adapter 5 is essentially bow-shaped or groove-shaped. This depends on the motor 2 showing a regular cylindrical section with two parallel flat portions and the adapter 5, according to FIG. 12, being attached to one of these flat portions. Its two legs 11 and 12 each are associated with one of the curved housing walls or encompass these in part.
The electrically conductive elements 13 and 14 showing, according to FIGS. 4 and 6, an essentially angular shape, in the present embodiment are simply plugged into the base member 15 of the adapter 5, but could also be embedded into the plastic material of the base member 15, i.e. extruded by it. From FIGS. 4 and 6 further discloses electrically conductive elements having a different size. With regard to the geometrical dimensions, leg 16 of the electrically conductive element 13 corresponds to leg 17 of the electrically conductive element 14. Each leg 16 or 17 is provided with a depression 19 or 20 extending in its longitudinal direction and therefore also in the direction 18 in which the adapter 5 is slipped on the motor 2. In FIGS. 4 and 6 the projections of the depressions are pointing upwards, i.e. towards the person who looks at the drawing. When mounted, the ends 21 or 22 of the electrically conductive elements 13 and 14 being close to the motor, point in the same direction so that the two depressions 19 and 20 are directed towards each other. This explains why the arrows for the slip-on direction 18 are opposite to each other in FIGS. 4 and 6.
Approximately in the transition point from one leg 16 or 17 to the other one 23 or 24 there is a further indentation or depression 25 or 26 which in the embodiment is circularly limited on the outside. It extends in relation to the depression 19 or 20 in the opposite direction, i.e. in FIG. 4 or 6 downward, and serves for clamping the referred electrically conductive elements 13 or 14 in the base member 15 by means of a snap connection which will subsequently be described more in detail.
The free end of the other leg 23 or 24 has a forked shape, i.e. it is provided with an open slot 27 or 28. In order to form a throat, the free ends of the fork prongs 29 and 30 are deflected towards each other or the sides of the slot are bulged towards the inside. In FIG. 4 the throat is indicated with 31.
Every leg 16 or 17 of the electrically conductive element 13 or 14 provided with a depression 19 or 20 projects from the surface 32 of the base member 15 of the adapter 5 being close to the motor 2 or adjacent to it and extends also perpendicularly to this surface. Both legs 16 and 17 are parallel to each other and thus also to the drawing plane and protrude from the surface 32 to an equal extent. Each leg can be inserted into a socket of the electric motor 2 which is not illustrated, the depression 19 or 20 providing for a good electrical contact and a retaining of the adapter 5 by jamming it to the motor 2. The sockets are provided with a slot and can also be formed, e.g., by a U-formed element, leg 16 or 17 engaging between its legs.
When the adapter is mounted, the end piece of the conductor track, indicated with 33 in FIG. 3, is positioned inside the throat 31, i.e. at the point where the open slot 27 or 28 is limited by two parallel borders. In FIG. 3 it extends perpendicularly to the drawing plane. This means that the adapter 5 being fixed to the miniature electric motor is slipped, perpendicularly to the drawing plane in FIG. 3, from above to the bottom onto the end pieces of the conductor track. In order to illustrate this, in FIG. 3 also the other end piece of conductor track 34 is drawn with a dashed line. But it does not extend upward as much as the end piece of conductor track 33, because the electrically conductive element 14 with the shorter leg 24 that is remote from the motor, is positioned underneath leg 23. In FIG. 3 can also be seen why the other leg 24 is shorter than leg 23 of the electrically conductive element 13. The distance between the electrically conductive elements 13 and 14 can be learned from FIG. 2.
At the plug-in or push-in end of each end piece of the conductor tracks, 32, 34, there is an enlargement (a depression) extending in the plug-in direction, which corresponds to depression 19 or 20 of the electrically conductive elements 13, 14. For the sake of clarity it is not indicated in FIG. 3. This depression is exactly associated with the forked area of the electrically conductive elements, so that the fork prongs can be expanded elastically providing a good mechanical and electrically conductive contact.
The other leg 23 or 24, which is remote from the motor, is inserted in a slot 35 or 36 (FIGS. 12 and 3) and retained in this slot by clamping it with depression 25 or 26, the slot having an angular form according to FIG. 3, so that the whole electrically conductive element 13 or 14, with the exception of the free end of leg 16 or 17, is entirely accommodated in the base member 15 made of plastic material and is therefore stored safely from an electrical point of view.
Each slot 35 and 36 is crossed by another slot 37 or 38 (FIG. 12). Furthermore each slot accommodates an end piece of a conductor track. The open slot 27 or 28 of the leg 23 or 24 remote from the motor, is in alignment with the slot 37 or 38 so that the end pieces of the conductor tracks can be pushed through in the direction of arrow 39 when the adapter 5 is mounted. In practice, however, the adapter 5 with the electric motor 2 will be slipped onto the end pieces of the conductor tracks, 33, 34, in the opposite direction to arrow 39. In order to permit a good insertion of the end pieces of the conductor track, the end portion, i.e. at the point where slot 37 passes into slot 38, is provided with insertion slopes 40, 41. Certainly, slot 38 in direction of arrow 39 is shorter than slot 37 which has to accommodate the longer end piece of conductor track 33. According to FIG. 13, this is also true for the slots 35 and 36.
FIG. 12 indicates also shoulders 42 which engage in corresponding recesses of the motor housing and therefore improve safe positioning as well as mounting. A center groove 43 can engage with a spring shaped at the motor housing.
From the above details, it can be easily seen that the two electrically conductive elements 13 and 14 can be identified by means of a sorting device and the above mentioned identification and can be inserted into the base member 15 or into the foreseen slot in fully automatic way. However, it is not only possible to mount the electrically conductive elements 13 and 14 to the adapter 5 in fully automatic way, but also to slip the adapter automatically onto the electric motor 2. Finally, the unit consisting of the miniature electric motor 2 and the adapter 5 can also be slipped onto the end pieces of the conductor tracks, 33 and 34, in an automatic procedure. This leads without doubt to a reduction of the assembly costs and contributes to an increased production and a reduced rejection rate. Small modifications of the miniature electric motor can be compensated easily by modifying the base member 15 and/or the electrically conductive elements 13, 14, slight changes at the plug-in sockets of the electric motor being compensated, if necessary, already only by the depressions 19 and 20 of the electrically conductive elements 13, 14.
Often the electric motor 2 does not have a circular, but a non circular cross-section. By means of adapter 5, designed in the form described above, such a motor can be mounted on edge in housing 1 of the central locking device and thus be accommodated saving much space.
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A pluggable adapter for connecting a miniature electric motor, especially of a central locking device of an automotive vehicle, with the end pieces of conductor tracks and to accommodate the motor in the housing. Soldering is no longer necessary and there aren't any disturbing cables.
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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 division of application Ser. No. 09/058,477 filed on Apr. 10, 1998, now U.S. Pat. No. 6,079,490.
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The subject invention generally pertains to equipment used for repairing wells that have already been drilled, and more specifically pertains to mobile repair units that frequently travel from one site to another.
2. Description Of Related Art
After an oil rig drills a well and installs the well casing, the rig is dismantled and removed from the site. From that point on, a mobile repair unit is typically used to service the well. Servicing includes installing and removing inner tubing strings, sucker rods, and pumps. The variety of work requires a myriad of tools. When the tooling is not closely associated with the mobile repair unit, the right equipment may not be available when needed.
Moreover, the work is carried out by a company that typically owns and operates several mobile repair units. The units are often operating at the same time at various remote sites. Some sites may be separated by hundreds of miles. This makes it difficult to stay abreast of the status at each of the sites.
Typically, a supervisor will travel from site to site. However, this is inefficient and often critical steps of an operation get carried out unsupervised. At times, accidents occur in the absence of an unbiased witness.
SUMMARY OF THE INVENTION
To avoid the problems of today's mobile repair units, a first object of the invention is to closely associate hydraulic and pneumatic systems with a mobile repair unit by having them share a common power supply and monitoring system.
A second object of the invention is to provide a remotely accessible mobile repair unit with the necessary equipment to make it universally adaptable to do a variety of work such as removing and installing an inner tubing string, sucker rods, and pumps.
A third object is to provide a mobile repair unit that senses and transmits, to a remote home base, data that identifies the extent to which an inner tubing string was stretched prior to flooding the well bore with fluid.
A fourth object is to identify from a remote location key events, such as the time of transition of installing steel sucker rods to installing fiberglass ones.
A fifth object is to restrict local operator access to a system that monitors the operation of a mobile repair unit so an unbiased and unaltered record can be recorded and maintained of the complete system and activity of the mobile repair unit.
A sixth object is to convey to a remote location a record that helps explain events that led to an accident at the work site. When the information is conveyed to a remote site, it is not likely to be destroyed by the accident itself, such as a fire.
A seventh object is to remotely identify an imbalance of a mobile repair unit caused by wind or leaning inner tubing segments against its derrick.
An eighth object is to remotely distinguish between the raising and lowering of an inner tubing string to help establish the cause of an accident. An added benefit is to be able to place the proper predetermined tension on a packer or tubing anchor being set.
A ninth object is to enable one to remotely identify when a mobile repair unit is operating for the purpose of determining the amounts to be invoiced for the work performed.
A tenth object is to provide a method of alerting a home base of a hazardous level of hydrogen sulfide gas present at a remote work site.
These and other objects of the invention are provided by a self-contained mobile repair unit having a universal set of hydraulic and pneumatic tooling for servicing well equipment such as an inner pipe string, a sucker rod and a pump. The repair unit and tooling share a common engine. An extendible derrick supporting a hoist is pivotally coupled to the frame of the repair unit. A monitor senses the load on the derrick and conveys that information to a remote home base where the time of critical events is identified.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a mobile repair unit with its derrick extended.
FIG. 2 is a schematic view of a pneumatic slip in a locked position.
FIG. 3 is a schematic view of a pneumatic slip in an open position.
FIG. 4 is a schematic illustration of a set of hydraulic tongs.
FIG. 5 is a side view of a mobile repair unit with its derrick retracted.
FIG. 6 is an electrical schematic of a monitor circuit.
FIG. 7 is an end view of an imbalanced derrick.
FIG. 8 shows digital data associated with a time stamp.
FIG. 9 illustrates the raising and lowering of an inner tubing string.
FIG. 10 shows an inner tubing being lowered.
FIG. 11 shows an inner tubing stopped at a predetermined depth.
FIG. 12 shows an inner tubing being locked in a conventional manner to another casing.
FIG. 13 shows an inner tubing being stretched.
FIG. 14 shows pre-stretched inner tubing locked within an outer casing.
FIG. 15 shows a first steel sucker rod (with a pump) being lowered into an inner tubing string.
FIG. 16 shows a second steel sucker rod being lowered into an inner tubing string.
FIG. 17 shows a first fiberglass sucker rod being lowered into an inner tubing string.
FIG. 18 shows a second fiberglass sucker rod being lowered into an inner tubing string.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a retractable, self-contained mobile repair unit 20 is shown to include a truck frame 22 supported on wheels 24 , an engine 26 , a hydraulic pump 28 , an air compressor 30 , a first transmission 32 , a second transmission 34 , a variable speed hoist 36 , a block 38 , an extendible derrick 40 , a first hydraulic cylinder 42 , a second hydraulic cylinder 44 , a first transducer 46 , a monitor 48 , and retractable feet 50 .
Engine 32 selectively couples to wheels 24 and hoist 36 by way of transmissions 34 and 32 , respectively. Engine 26 also drives hydraulic pump 28 via line 29 and air compressor 30 via line 31 . Compressor 30 powers a pneumatic slip 84 (FIGS. 2 and 3 ), and pump 28 powers a set of hydraulic tongs 52 (FIG. 4 ). Pump 28 also powers cylinders 42 and 44 which respectively extend and pivot derrick 40 to selectively place derrick 40 in a working position (FIG. 1) and in a lowered position (FIG. 5 ). In the working position, derrick 40 is pointed upward, but its longitudinal centerline 54 is angularly offset from vertical as indicated by angle 56 . The angular offset provides block 38 access to a well bore 58 without interference with derrick pivot point 60 . With angular offset 56 , the derrick framework does not interfere with the typically rapid installation and removal of numerous inner pipe segments (known as an innerpipe string 62 ) and sucker rods 64 (FIG. 16 ).
Individual pipe segments (of string 62 ) and sucker rods 64 are screwed to themselves using hydraulic tongs 66 which are schematically illustrated in FIG. 4 . The term “hydraulic tongs” used herein and below refer to any hydraulic tool that can screw together two pipes or sucker rods. An example would include those provided by B. J. Hughes company of Houston, Tex. In operation, pump 28 drives a hydraulic motor 68 forward and reverse by way of valve 70 . Conceptually, motor 68 drives pinions 72 which turn wrench element 74 relative to clamp 76 . Element 74 and clamp 76 engage flats 81 on mating couplings 78 of a sucker rod or inner pipe string of one conceived embodiment of the invention. However, it is well within the scope of the invention to have rotational jaws or grippers that clamp on to a round pipe (i.e., no flats) similar in concept to a conventional pipe wrench, but with hydraulic clamping. The rotational direction of motor 68 determines assembly or disassembly of couplings 78 . Transducer 80 is used to provide a 0-5 VDC signal 82 that in one embodiment of the invention indicates the applied torque to couplings 78 .
Referring to FIGS. 2 and 3, when installing inner pipe string 62 , pneumatic slip 84 is used to hold pipe string of pipe 62 while the next segment 62 ′ is screwed on using tongs 66 . Compressor 30 provides pressurized air through valve 86 to rapidly clamp and release slip 84 (FIGS. 2 and 3, respectively). A tank 88 helps maintain a constant air pressure. Pressure switch 90 provides monitor 48 with a signal that indirectly indicates that repair unit 20 is in operation.
Referring back to FIG. 1, weight applied to block 38 is sensed by way of a hydraulic pad 92 that supports the weight of derrick 40 . Hydraulic pad 92 is basically a piston within a cylinder (alternatively a diaphragm) such as those provided M. D. Totco company of Cedar Park, Tex. Hydraulic pressure in pad 92 increases with increasing weight on block 38 . In FIG. 6, first transducer 46 converts the hydraulic pressure to a 0-5 VDC signal 94 that is conveyed to monitor 48 . Monitor 48 converts signal 94 to a digital value, stores it in a memory 96 , associates it with a real time stamp, and eventually communicates the data to a remote home base 100 by way of a modem 98 .
In the embodiment of FIG. 7, two pads 92 associated with two transducers 46 and 102 are used. An integrator 104 separates pads 92 hydraulically. The rod side of pistons 106 and 108 each have a pressure exposed area that is half the full face area of piston 108 . Thus chamber 110 develops a pressure that is an average of the pressures in pads 92 . One type of integrator 104 is provided by M. D. Totco company of Cedar Park, Tex. In one embodiment of the invention, just one transducer 46 is used and it is connected to port 112 . In another embodiment of the invention, two transducers 46 and 102 are used, with transducer 102 on the right side of unit 20 coupled to port 114 and transducer 46 on the left side coupled to port 116 . Such an arrangement allows one to identify an imbalance between the two pads 92 .
Returning to FIG. 6, transducers 46 and 102 are shown coupled monitor 48 . Transducer 46 indicates the pressure on left pad 92 and transducer 102 indicates the pressure on the right pad 92 . A generator 118 driven by engine 26 provides an output voltage proportional to the engine speed. This output voltage is applied across a dual-resistor voltage divider to provide a 0-5 VDC signal at point 120 and then passes through an amplifier 122 . Generator 118 represents just one of many various tachometers that provide a feedback signal proportional to the engine speed. Another example of a techometer would be to have engine 26 drive an alternator and measure its frequency. Transducer 80 provides a signal proportional to the pressure of hydraulic pump 28 , and thus proportional to the torque of tongs 66 .
A telephone accessible circuit 124 , referred to as a “POCKET LOGGER” by Pace Scientific, Inc. of Charlotte, N.C., includes four input channels 126 , 128 , 130 and 132 ; a memory 96 and a clock 134 . Circuit 124 periodically samples inputs 126 , 128 , 130 and 132 at a user selectable sampling rate; digitizes the readings; stores the digitized values; and stores the time of day that the inputs were sampled. It should be appreciated by those skilled in the art that with the appropriate circuit, any number of inputs can be sampled. Page Scientific provides circuits that employ multiplexing to provide twelve input channels.
An operator at a home base 100 remote from the work site at which repair unit 20 is operating accesses the data stored in circuit 124 by way of a PC-based modem 98 and a cellular phone 136 . Phone 136 reads the data stored in circuit 124 via lines 138 (RJ11 telephone industry standard) and transmits the data to modem 98 by way of antennas 140 and 142 . In one embodiment of the invention, phone 136 includes a CELLULAR CONNECTIONTM™ provided by Motorola Incorporated of Schaumburg, Ill. (a model S1936C for Series II cellular transceivers and a model S1688E for older cellular transceivers).
Some details worth noting about monitor 48 is that its access by way of a modem makes monitor 48 relatively inaccessible to the crew at the job site itself. Amplifiers 122 , 144 , 146 and 148 condition their input signals to provide corresponding inputs 126 , 128 , 130 and 132 having an appropriate power and amplitude range, Sufficient power is needed for RC circuits 150 which briefly (e.g., 2-10 seconds) sustain the amplitude of inputs 126 , 128 , 130 and 132 even after the outputs from transducers 46 , 102 and 80 and the output of generator 118 drop off. This ensures the capturing of brief spikes without having to sample and store an excessive amount of data. A DC power supply 152 provides a clean and precise excitation voltage to transducers 46 , 102 and 80 ; and also supplies circuit 24 with an appropriate voltage by way of voltage divider 154 . Pressure switch 90 enables power supply 152 by way of relay 156 whose contacts 158 close by coil 160 being energized by battery 162 .
FIG. 8 shows an example of the data extracted from circuit 124 and remotely displayed at PC 164 . The values plotted at a point in time indicated by numeral 166 represent repair unit 20 at rest with engine 26 idling as shown in FIG. 1 . Numeral 168 showing weight on block 38 and high engine speed indicates the raising of an inner pipe string 62 as represented by arrow 170 of FIG. 9 . Numeral 172 showing weight on block 38 and low engine speed indicates the lowering of inner pipe string 62 as represented by arrow 174 of FIG. 9 . Points 176 , 178 , 180 , 182 and 184 correspond to the conditions illustrated in FIGS. 10, 11 , 12 , 13 and 14 , respectively. In FIG. 10, an inner pipe string 62 is being lowered into an outer casing 186 . In FIG. 11, tubing string is stopped at a predetermined depth. In FIG. 12 pipe string 62 is rotated in a conventional manner to lock its lower end 188 to outer casing 186 (note slight torque at point 190 ). In FIG. 13 an upper end 192 of string 62 is raised until the pressure parameter at right and left pads 92 reach the predetermined limit indicated by numeral 194 . In FIG. 14 wedge 196 locks upper end 192 to casing 186 , and block 38 is disconnected from pipe string 62 . Points 198 , 200 , 202 and 204 correspond to the conditions illustrated in FIGS. 15, 16 , 17 and 18 , respectively, which depict the lowering of a string of sucker rods having a pump 77 at its lower end. Intermediate points 199 , 201 and 203 indicate tongs 66 screwing onto the first steel sucker rod 64 a second steel sucker rods 206 , a fiberglass sucker rod 208 , and a second fiberglass sucker rod 210 , respectively. Note the difference in torque and the incremental weight difference at pads 92 when changing over from steel rods to fiberglass ones. Points 212 correspond to the windy conditions illustrated by arrow 214 of FIG. 7 . The absence of data points beyond 12:00 indicates that the windy conditions prevented the crew from continuing, or it was Friday afternoon.
Referring back to FIG. 4, it should be noted that transducer 80 represents any one of a variety of devices that produce an electrical signal in response to a change in a sensed condition. In one embodiment of the invention, transducer 80 is actually a hydrogen sulfide gas detector with signal 82 serving as a gas detection signal that varies with a varying concentration of hydrogen sulfide gas 250 . An example of a hydrogen sulfide gas detector is a CONTROLLER 8000 provided by Industrial Scientific Corporation of Oakdale, Pa.
Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those skilled in the art. Therefore, the scope of the invention is to be determined by reference to the claims which follow.
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A self-contained mobile repair unit for repairing wells includes the hydraulic and pneumatic tooling required to do a variety of jobs including the installation and removal of an inner pipe string, sucker rods and a pump. The repair unit, hydraulic tooling and pneumatic tooling share a common engine and a common process monitor. Access to data gathered by the monitor is restricted at the job site itself. Instead, the data is transmitted to a remote home base for the purpose of monitoring operations form a central location.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to BR PI 1100148-8, filed 22 Feb. 2011, the entire contents of which, including specification, claims and drawings, are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an end fitting for flexible risers. The device enables the assembly procedure to be carried out with no need to bend the tensile armour. The assembly procedure in the present invention eliminates the residual tensions produced due to plastic deformation of the tensile armour and also the modifications in microstructural properties of the steel, imposed by common end fittings and their respective assembly techniques.
BASIS OF THE INVENTION
[0003] In offshore production systems, crude oil produced in wells on the ocean floor is conveyed to a stationary production unit (SPU) by means of pipelines. These pipelines of electro-hydraulic umbilicals for injecting water and for pumping oil and gas are commonly referred to as collection and production lines.
[0004] This set of pipelines constituting the collection and production lines is basically subdivided into two distinct parts:
The first portion, preponderantly horizontal, denominated: the horizontal segment. This portion is conventionally static and also specifically known in the technical terminology as “flowline”. The second portion, constituted by a preponderantly vertical pipe connected to the extremity of the horizontal segment and which ascends from the sea floor to the platform whereat it is connected, denominated: the vertical segment. The second portion is also known, and hereinafter denominated, by the technical terminology of “riser”
[0007] The term vertical as used here should not be interpreted in the strict sense, since the distance between the platform and the point of connection to the “flowline”, together with the weight of the riser itself, means that this stretch has to take a substantially curved shape known as catenary.
[0008] There are basically two types of riser on the market: rigid and flexible, which are fixed to a platform by means of supporting structures specially designed to support and to resist the stresses applied therein, which can be due to the weight thereof as well as movement thereof due to ocean currents, for example.
[0009] Like the supporting structures, the end fitting must also be designed to support and to resist the stress from weight and movement of the riser.
RELATED ART
[0010] Adopting the system of flexible risers adds several more difficulties, due to the need for solutions related to anchorage, because flexible risers, due to their construction, are more sensitive than rigid risers to the various different stresses to which they are submitted.
[0011] These flexible risers are constituted by superimposing at least six interdependent layers with totally different compositions: the first, innermost layer is the inner casing, followed by a polymeric pressure layer. These are followed by the pressure armour, the inner layer of tensile armour, and the outer layer of tensile armour, comprising braided steel wire. All of the foregoing are further covered with an outer polymer layer.
[0012] Currently, to fix the upper end of a flexible riser to the corresponding support in the SPU, the end of the riser has to be fixed to a device, which serves as the engaging and supporting means between the riser as such and the support. This device is known in the art as the “end fitting”.
[0013] This results in a situation in which the stresses due to the weight and movement of a riser are concentrated in a single region. This region is represented by three components of a collection and production line, namely: the support, the end fitting and the free end of the flexible riser.
[0014] The three components interact differently with each other. While the support shows restricted freedom of movement with respect to the corresponding end fitting, the end fitting itself can only interact in a fixed manner with respect to the six components that form the flexible riser.
[0015] As regards this aspect of fixing, the end fittings are designed and manufactured so as to offer the best means for uniting the components for supporting the flexible riser and at the same time they also offer reliable means for hydraulic insulation as regards the inner polymeric pressure layer. Currently, this union is basically obtained as follows:
First the inner and outer layers of the tensile armour, which are made of steel and confer axial strength to resist the tensile stresses to which the flexible riser is submitted, are exposed. In order to achieve transfer of the tensile stresses from the riser to the end fitting, and then to the support on the platform, adhesion of the wire of the tensile armour is promoted by a resin in a section inside the end fitting. This adhesion is carried out inside the end fitting, in the vicinity of the opening, known in the art as the wedge region or canula.
[0018] This is a critical region due to the change of geometry imposed on the steel wire of tensile armour. The current assembly procedure used to bend the wire in the opening region of the end fitting requires the plastic deformation of the tensile armour.
[0019] According to the practice currently adopted, the internal sealing and anchoring of the armour are carried out in the same region of the end fitting, which necessarily entails bending of the tensile armour in order to access the inner sealing layer in order to subsequently seal the same.
[0020] Over the years, those skilled in the art have noted that most of the problems related to flexible risers occur precisely in the vicinity of the end fitting, which is the critical region of the structure where the tensile stresses on the collection and production line are greatest.
[0021] Experience of dissection of end fittings for risers which have been in operation, or which have been subjected to evaluation tests, show that there is a critical section as regards faults in risers inside the end fitting, and this is precisely the section in which the tensile armour undergoes plastic deformation during the process of assembling the end fittings.
[0022] The existence of a section predominantly associated with failure is principally because, although the flexible riser undergoes rigid quality control during manufacture, the end fitting is assembled manually by an assembler in the factory or on board a ship.
[0023] As currently designed by the manufacturers, in the process of assembling an end fitting the assembler needs to bend (“pull away”) the wire of the tensile armour so as to be able to reach the layers further inside the pipe and seal the inner layer, and then bond the steel wire, both in the same region of the end fitting.
[0024] This forcible bending of the wire of the tensile armour causes plastic deformation of the steel of the wire, inducing considerable residual tension in the armour. Plastic deformation and the geometrical discontinuities caused by reassembling the armour to inject the resin occur precisely in the section of the armour of which most is demanded: close to the opening of the end fitting, at the beginning of the resin region, where this whole process of bending and unbending the tensile armour, together with the concentration of tension that occurs in this region, accelerates the process of fatigue in the wire.
[0025] The problems outlined above are described in various documents in the specialist technical literature. Document U.S. Pat. No. 6,273,142, published 14, Aug. 2001, relates to a flexible pipe with an end fitting; document U.S. Pat. No. 6,923,477, published 02, Aug. 2005, relates to a terminal end fitting for multilayer flexible pipes with an internal seal; and document U.S. Pat. No. 6,592,153, published 15, Jul. 2003, describes a terminal end fitting for flexible pipes; document PI 0704349-2, published 05, May 2009, relates to an end fitting for flexible pipes; and document PI 0703202-1, published 28, Apr. 2009, relates to a terminal for a flexible riser with a conical fitting. These are all examples of the various different models of end fittings currently on the market, which invariably require that the steel armour layer be bended in order to carry out the appropriate internal sealing and to complete the assembly thereof.
[0026] The present invention has been developed for carrying out assembly of the flexible riser at the end fitting without submitting the tensile armour to plastic deformation.
[0027] To this end we have developed an end fitting for the flexible riser and the method of assembly without deforming the armour, which is the object of the present invention, the aim of which is to simplify the assembly procedure, to improve the precision of adhesion between the end fitting and the riser, to eliminate residual plastic tension, and also to maintain the original geometry of the wire armour of the flexible risers in the vicinity of the opening of the end fitting.
[0028] It also aims to provide a novel concept of connection, which can be adopted as the base for new designs.
[0029] Other objectives which the end fitting for the flexible riser and method of assembly without deforming the armour, which are the object of the present invention, are intended to achieve are enumerated below:
1. to enable an increase in the service life of the ends of flexible risers; 2. to make it possible to use flexible risers in deeper waters; 3. to simplify considerably the assembly procedure; 4. to improve significantly the structural performance of the flexible riser especially as regards increasing its fatigue life.
SUMMARY OF THE INVENTION
[0034] In a first aspect, the invention pertains to an end fitting for the flexible riser constituted by three distinct parts, namely: a core, an outer casing, and a termination.
[0035] The core is composed of a predominantly cylindrical piece provided at one of its ends with a main flange, with the other end thereof having a conical shape. The conical end has a diameter large enough for the core, when directed against the riser, to fit between the pressure armour and the two superimposed layers of tensile armour of said riser. The main flange, at the end of the core, is provided with an inner chamfer which accommodates a frontal seal ring in the form of a wedge, with an activation flange superimposed thereon.
[0036] A supporting flange is provided close to the main flange of said core, so as to be able to shield the free ends of the two superimposed layers of tensile armour within the limit of the inside diameter of a cylindrical outer casing.
[0037] The outer casing comprises a substantially cylindrical piece which has a constant outside diameter, with one end thereof fixed to the main flange, the size of which is equivalent to the inside diameter thereof. The free end of the cylindrical outer casing is provided with an inner chamfer which accommodates a rear seal ring in the form of a wedge, also with an activation flange superimposed thereon. Inside, between the cylindrical outer casing and the conical portion of the core, a chamber is formed, which is filled with resin.
[0038] Finally, the termination is fixed to the main flange of the core.
[0039] In a second aspect, the invention pertains to a method to ensure that the device is assembled on the risers, without deforming the tensile armour of the same, by following basically the following steps:
cutting the outer covering of a riser so that the layers of tensile armour are exposed for a length sufficient for anchoring the same; positioning the core of the end fitting under the layers of tensile armour; fitting the free ends of the layers of tensile armour; into the supporting flange so that they are shielded on the body of the core, and within the limit of the inside diameter of a cylindrical outer casing; fixing the cylindrical outer casing to the core; securing the outer covering by fitting a first activation flange; sealing and securing the inner sealing layer, by fitting a second activation flange; fixing the termination to the main flange of the core; filling resin into the chamber where the tensile armour is anchored to the body of the end fitting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The invention will be described below in more detail together with the drawings discussed below which, solely as examples, accompany the present report, of which they are an integral part, and in which:
[0049] FIG. 1 is a cross-sectional view of an end fitting of the prior art.
[0050] FIG. 2 is a cross-sectional view of the end fitting of the present invention.
[0051] FIG. 3 is a cross-sectional view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0052] The end fitting for a flexible riser and method of assembly without deforming the armour, which are the object of the present invention, have been developed from studies primarily intended to eliminate residual tensions and modification of the microstructural properties of steel caused during the current procedure for connecting the end fitting and the tensile armour of a flexible riser.
[0053] The present invention provides means for altering the assembly procedure in relation to that currently employed, eliminating the need to bend the wire of the armour.
[0054] As can be seen from FIG. 1 this shows in schematic cross-section how the six basic layers of a riser ( 150 ) are fixed by adhesion to a standard type of end fitting ( 100 ), in accordance with the prior art.
[0055] In one way or another the end fittings ( 100 ) in the prior art always show a main termination ( 101 ) in which the polymeric pressure layer ( 152 ) is sealed by the inner seal ring ( 157 ) and the anterior seal activation flange ( 159 ). The inner ( 154 ) and outer ( 155 ) layer of armour of the riser ( 150 ) are adhered by means of the resin in the chamber ( 158 ), the opening of which is close to and directed in the same sense as the body of said main termination ( 101 ).
[0056] Thus, this standard structure entails bending backwards the layers of tensile armour ( 154 ) and ( 155 ), usually known as the wire of the tensile armour, during the assembly procedure, so that the assembler can reach the polymeric pressure layer ( 152 ) and position the inner seal ring ( 157 ) and then fix the anterior seal activation flange ( 159 ). Subsequently, the layers of tensile armour ( 154 ) and ( 155 ) are unbent, so that these can be adhered inside the chamber ( 158 ), by injecting resin, in the outermost section of the riser ( 150 ).
[0057] The end fitting ( 200 ) for a flexible riser and method of assembly without deforming the armour, proposed herein, have been developed from the basic configuration of the end fittings ( 100 ) currently on the market, but use a novel approach of fitting the riser ( 150 ).
[0058] As can be seen in FIG. 2 , in this novel inventive concept, the main body of the end fitting ( 200 ) is constituted by three distinct parts, namely: a termination ( 210 ), a core ( 220 ), and an outer casing ( 260 ).
[0059] As will be shown below, and can be readily visualized with the aid of the figures, this novel structural concept enables the assembler to adhere the inner polymeric pressure layer ( 152 ) without the need to change the direction of the layers of tensile armour ( 154 ) and ( 155 ) of the riser ( 150 ) by bending, because the sealing zone of the inner polymeric pressure layer ( 152 ) and the zone of adhesion and anchoring of the tensile armour ( 154 ) and ( 155 ) are located in different, independent, points in the end fitting ( 200 ).
[0060] The core ( 220 ) is constituted by a predominantly cylindrical piece provided with a flange ( 221 ) at one of the ends thereof and having a conical shape at the other end ( 222 ) thereof.
[0061] The conical end ( 222 ) has a diameter sufficient for said core ( 220 ), when directed against the riser ( 150 ), to fit between the pressure armour ( 153 ) of said riser ( 150 ) and the two superimposed layers ( 154 ) and ( 155 ) of the tensile armour.
[0062] The flange ( 221 ) at the end of the core ( 220 ) is provided with an internal chamfer, which accommodates a frontal seal ring ( 230 ) in the form of a wedge, overlaid by a first activation flange ( 240 ). When pressed by the first activation flange ( 240 ), said frontal seal ring ( 230 ) in the form of a wedge squeezes the polymeric pressure layer ( 152 ) forming an internal seal.
[0063] Optionally in order to facilitate manufacture, the core ( 220 ) can be made up of two independent pieces, fitted together by some fitting means; one of these, the anterior core ( 220 ′), being constituted by a section provided with the flange ( 221 ), and the other, the posterior core ( 220 ″), being constituted by a section provided with a wedge-shaped conical end ( 222 ).
[0064] A support flange ( 250 ) is provided close to the flange ( 221 ) of said core, so as to be able to support the free ends of the two superimposed layers ( 154 ) and ( 155 ) of tensile armour within the limit of the inside diameter of a cylindrical outer casing ( 260 ).
[0065] The cylindrical outer casing ( 260 ) has a constant outside diameter and one of the ends thereof is fixed to the flange ( 221 ), which has a size equivalent to the inside diameter thereof. Inside, the diameter of the cylindrical outer casing ( 260 ) is constant from the end thereof fixed to said flange ( 221 ) to close to the beginning of the conical portion of the core ( 220 ), when the diameter starts to get smaller, following the conical shape of said portion of the core, but being longer, until the inside diameter reaches the outer covering ( 156 ) of the riser ( 150 ).
[0066] The outer covering ( 156 ) of the riser ( 150 ) is shielded and separated from the other layers of the riser ( 150 ) by an expansion ring ( 300 ), which is placed between said outer covering ( 156 ) and the superimposed layers of tensile armour ( 154 ) and ( 155 ).
[0067] The free end of the cylindrical outer casing ( 260 ) has an internal chamfer, which accommodates a posterior seal ring ( 270 ) in the form of a wedge, overlaid by a second activation flange ( 280 ), which, when pressed against the free end of said cylindrical outer casing ( 260 ), causes the posterior seal ring ( 270 ) to squeeze the outer covering ( 156 ) of the riser ( 150 ) against the expansion ring ( 300 ).
[0068] Inside, between the cylindrical outer casing ( 260 ) and the conical portion of the core ( 220 ) a chamber ( 290 ) is formed, which is filled with epoxy resin or the like, resulting in sustaining adhesion between the end fitting ( 200 ) and the superimposed layers of tensile armour ( 154 ) and ( 155 ). This zone of adhesion occurs in a portion in which the tensile armour ( 154 ) and ( 155 ) is not subject to any type of plastic deformation or change in the composition of the strands thereof or even the angle with respect to the axis of the riser ( 150 ).
[0069] Finally, the termination ( 210 ) is fixed to the flange ( 221 ) of the core ( 220 ), to give the final configuration of the end fitting ( 200 ).
[0070] Other proposals for effecting the inner or outer seal can be presented without deviating from the inventive concept, such as, for example, the alternative embodiment presented in FIG. 3 , in which the inner seal is effected by a seal ring ( 230 ′) and an activation flange ( 240 ′) which act against the body of the termination ( 210 ).
[0071] The invention also pertains to a rapid method of assembly without needing to bend the layers of tensile armour of the riser.
[0072] The method will be described with reference to FIG. 2 , but it should be emphasized that the inventive concept described below is not restrictive, and a person skilled in the art will recognize that it is possible to alter the sequence in order to include or eliminate certain steps of the method to suit new configurations of the basic end fitting ( 200 ) shown both in FIG. 2 and in FIG. 3 , these alterations being included within the scope of the method of the invention.
[0073] With the help of FIG. 2 it is possible to see the procedure for initiating the assembly of the riser ( 150 ), following the following steps:
[0074] 1—Cutting the outer covering ( 156 ) of the riser ( 150 ) so that the layers of tensile armour ( 154 ) and ( 155 ) are exposed for a length sufficient for anchoring the same;
[0075] 2—Placing an expansion ring ( 300 ) under the outer covering ( 156 );
[0076] 3—Positioning the core ( 220 ) of the end fitting under the layers of tensile armour ( 154 ) and ( 155 );
[0077] 4—Fixing the support flange ( 250 ) of the wire, preferably by means of screws, to the flange ( 221 ) of the core;
[0078] 5—Fitting the free ends of the layers of tensile armour ( 154 ) and ( 155 ) into the support flange ( 250 ) so that they are shielded on the body of the core ( 220 ), and within the limit of the inside diameter of a cylindrical outer casing ( 260 );
[0079] 6—Fixing the cylindrical outer casing ( 260 ) to the core ( 220 ), preferably by a screw thread, but which can also be by means of a flange;
[0080] 7—Positioning the posterior seal ring ( 270 ) in the form of a wedge behind the cylindrical outer casing ( 260 ), and then securing the outer covering ( 156 ), by means of fitting an activation flange ( 280 );
[0081] 8—Positioning the frontal seal ring ( 230 ) on the polymeric pressure layer ( 152 ), in the form of a wedge and sealing and securing said layer ( 152 ), by fitting an activation flange ( 240 ), preferably by means of screws, to the top of the flange ( 221 ) of the core ( 220 );
[0082] 9—Fixing the termination ( 210 ) to the flange ( 221 ) of the core ( 220 ), preferably by means of screws;
[0083] 10—Filling with resin the chamber ( 290 ), where the tensile armour ( 154 ) and ( 155 ) is anchored to the body of the end fitting ( 200 ).
[0084] Alternatively, this last step can be carried out shortly after the seventh step.
[0085] It can be easily appreciated that the current invention not only eliminates the need to bend the tensile armour of the riser, but more especially it also makes the assembly procedure much more simple and rapid.
[0086] However, one of the main factors which makes the present proposal feasible is not limited to ease of assembly, but above all to eliminating residual plastic tension left during assembly using available end fittings according to the prior art.
[0087] Thus, one of the unquestionable advantages of the proposed invention is, therefore, to raise the reliability of the connection and establish new parameters for operational stresses in flexible risers, in order to ensure lower levels of failure.
[0088] The invention has been described here with reference to preferred embodiments thereof. However, it should be clear that the invention is not restricted to these embodiments, and those skilled in the art will immediately perceive which alterations and substitutions can be adopted without deviating from the inventive concept described herein.
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The present invention relates to an end fitting of a flexible riser. The device makes it possible to carry out the assembly procedure without the need to bend the tensile armour. By means of the assembly procedure thereof, the technique proposed eliminates residual tension due to plastic deformation of the tensile armour and modifications in the microstructural properties of the steel, imposed by current end fittings and the corresponding techniques for assembling the same.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to marine platforms for offshore installation as for example on the sea bed or river bed to provide ship and/or barge docking facilities.
2. Description of the Prior Art
Prior structures of this type have generally related to fixed and/or floating docks or platforms. U.S. Pat. No. 3,672,178 discloses a circular floating dock in a protected environment and rotatable about a fixed piling or the like. Variations include radially extending docks forming boat slips therebetween. A similar arrangement in a floating platform is seen in U.S. Pat. No. 3,521,588 and a fixed offshore ship mooring installation may be seen in U.S. Pat. No. 3,563,041.
This invention provides a marine platform with the advantages of a fixed or stationary platform on which a crane or the like may be positioned.
SUMMARY OF THE INVENTION
A marine platform takes the form of a stationary cylindrical structure having a closed upper end with annular guides thereabout together with a plurality of arcuate shaped floating platforms defining a circle in assembly individually secured by flexible means to the annular guides about the stationary cylindrical structure, the arrangement being such that the arcuate shaped floating platforms can be rotated about the stationary cylindrical support and they are free to rise and fall individually responsive to wave motion or water level changes. Each of the floating platforms provides docking space for ships or barges and means is included in the stationary cylindrical structure for rotating the floating platforms thereabout so as to enable the ships or barges secured to the floating platforms to be desirably positioned upstream, downstream or down wind as the case may be.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation with parts in cross section and parts broken away illustrating the marine platform embodying the present invention;
FIG. 2 is a top plan view of the marine platform seen in FIG. 1 with parts broken away and in cross section;
FIG. 3 is an enlarged cross sectional detail on line 3--3 of FIG. 2; and
FIG. 4 is an enlarged horizontal section on line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the form of the invention chosen for illustration herein, the marine platform as best illustrated in FIG. 1 of the drawings comprises a stationary center platform 10 preferably cylindrical in structure and having a closed top 11 and an enlarged under water base 12 positioned on or in the sea bed or river bed. The height of the stationary central platform 10 is greater than the normal water level L. A pair of oppositely disposed vertically spaced guide rails 13 and 14 extend continuously in an annular pattern around the upper side walls of the stationary central platform 10 at a point above the normal water level L and a plurality of floating dock units 15 are positioned in a circle around the stationary central platform 10 and flexibly secured thereto by a plurality of devices 16, each of which includes at least one flanged rotary member 17 positioned between and engaged upon the annular guide rails 13 and 14.
By referring now to FIG. 2 of the drawings, it will be seen that each of the floating dock units 15 is arcuate in shape and defines a segment of a circle and is arranged in the circle about the stationary central platform 10 with the respective ends 18 of the floating dock units 15 in spaced relation to one another.
By referring again to FIG. 1 of the drawings, it will be seen that the outermost sides of the floating dock units 15 are provided with attachment devices 19 by which a ship or a barge 20 or the like can be secured thereto by a coupling device 21.
In FIG. 1 of the drawings a crane, including a vertical support 22, is shown centrally located on the stationary central platform 10, the crane including a horizontal support 23, a vertically movable hook 24 and mechanism 25 for moving the same together with a counter weight 26 as customary in crane constructions. It will occur to those skilled in the art that such a crane can swing around the marine platform disclosed herein and load and unload cargo from ships or barges secured thereto. Alternately the crane may comprise an overhead tramway extending shoreward as will occur to those skilled in the art.
The flexible devices 16 which connect the floating dock units 15 to the stationary central platform 10 by way of the annular guide rails 13 and 14 are such that they permit the floating dock units 15 to move responsive to wave motion and changes in water level. A detail of one form of such a device may be seen in FIG. 3 of the drawings, and by referring thereto it will be noted that the flanged rotary member 17 is doubly flanged with the flanges being spaced and engaged on the inner and outer surfaces of the vertically spaced guide rails 13 and 14. The rotary member 17 has an axle bracket 27 to which an extensible arm 28 is pivotally affixed. A swivel coupling 29 or the like is carried on the a part of the extensible arm 28 and is attached to the near side of one of the floating dock units 15.
As seen in FIG. 2 of the drawings, a plurality of these flexible connectors generally indicated at 16 extend between the several floating dock units 15 and the annular guide rails 13 and 14. Means not shown is preferably incorporated in the stationary central platform 10 for imparting motion to the rotary members 17 and so as to make possible the rotation of the floating dock units 15 about the stationary central platform 10. Such rotation will move boats or barges tied up to the floating dock units 15 relative to the stationary central platform 10 as may obviously be desirable to position the ships or barges down wind with respect thereto or to move them inunder the crane heretofore described or its tramway alternate.
It will occur to those skilled in the art that if no apparatus is provided for imparting rotary motion to the floating dock units 15, a power boat, tug or the like can be used to rotate the assembly of floating dock units 15 and ships or barges tied thereto.
It will also occur to those skilled in the art that the stationary central platform 10 may be formed of steel or concrete, it may be solid or hollow and that the floating dock units 15 may be similarly formed of steel or concrete or alternately buoyant materials.
The above described marine platform provides a practical, relatively inexpensive offshore docking facility for ships or barges or the like, and makes possible the relocation of the ships or barges as may be desirable and at the same time accommodates changes in the sea or water level and provides for yielding resistance to wave motion and the like. It may be formed in various sizes and heights for various specific functions.
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A marine platform for offshore installation has a fixed central platform and an annular arrangement of floating dock units positioned thereabout arranged for movement therearound and vertical movement responsive to wave and water level changes. The annular arrangement of floating dock units accommodate the docking of ships and barges which may be rotated about the marine platform by rotary motion imparted the dock units.
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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. 12,934, filed Feb. 16, 1979.
BACKGROUND OF THE INVENTION
There are many thousands of oil wells over the surface of the earth that are drilled and completed in unconsolidated sand, i.e. crumbly sandstone. In such wells, sand does not necessarily precipitate to the bottom of the well, but instead may remain in suspension and is pumped up, if not free flowing, with the oil. As a result, most mechanical parts as valves, bearings, pistons, cylinders, etc. wear out prematurely under such conditions. Accordingly, the sand must be filtered out from the oil, preferably in the well. Petroleum companies have spent large sums of money in trying to find a suitable solution to the sand problem, but heretofore there has been no satisfactory method or long lasting device for preventing the entry of sand into the tube string and eventually into the suction pipe of the pump, or other works, and for cleaning sand screens quickly without bringing the screen to the surface for cleaning and then returning it to the bottom of the well.
In the construction of the present day sand screen, the mode of operation is such that the sand screen must be replaced for one of two reasons. The first occurs when the sand screen has developed limited flow capacity as a result of screen gauge reduction from plugging or scale build-up. The second occurs when the gauge of the sand screen becomes larger than the original design which allows sand into the production string. The disclosed invention eliminates the need to replace the sand screen when it has limited flow capacity. Thus, the intent of this sand screen cleaning system is to eliminate the cost of loss in production and the cost of re-work operation which include equipment and manpower in removing and replacing a sand screen with limited flow capacity.
U.S. Pat. No. 2,837,032 discloses an oil well foam and wire coil filter, but that filter is quite sophisticated and expensive to manufacture, and is not adjustable to be opened for backwashing a cleaning liquid, as water, to clean the clogged filter. Another attempted solution was a spring filter as disclosed in U.S. Pat. No. 3,754,651, but because no spacers are apparent between the helical filter elements, the elements would have to be held in slight tension to separate the helical filter elements during filtering. Thus that filter could not be used as an oil well filter on which high compressive loads may be placed. Likewise no spring valve can be utilized therein to strengthen the compressive capabilities for converting the filter to one for use in wells. Also, the spring filter of U.S. Pat. No. 3,179,116 is incapable of being strengthened to use in wells. Any compressive force on the triangular spring elements would cause them to collapse, and further the coined depressions for separating the spring elements would cause the spring elements to flex with a load thereon causing displacement of the adjacent coils and variations of the gauge therebetween.
Thus, new and better methods for forming and assembling helical spring sand filters, and better self-cleaning helical spring sand filters are required for mounting on the lower end of a tubing string extending down into a well to the oil containing sand strata.
The disclosed inventions are improvements over those of Assignee's U.S. Pat. Nos. 3,901,320 (166-311) and 3,937,281 (166-233).
OBJECTS OF THE INVENTION
Accordingly, a primary object of this invention is to provide a new and better self-cleaning helical spring sand screen.
A further object of this invention is to provide a self-cleaning helical spring sand screen that is easy to operate, is of simple configuration, is economical to build and assemble, and is of greater efficiency for the filtering of sand out of oil deep in an oil well.
Other objects and various advantages of the disclosed new self-cleaning helical sand screen will be apparent from the following detailed description, together with the accompanying drawings, submitted for purposes of illustration only and not intended to define the scope of the invention, reference being made for that purpose to the subjoined claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings diagrammatically illustrate by way of example, not by way of limitation, one form of the invention wherein like reference numerals designate corresponding parts in the several views in which:
FIG. 1 is a schematic diagrammatic view with parts in section of the new sand screen as mounted in a typical oil well;
FIG. 2 is a schematic diagrammatic longitudinal cross-section of the self-cleaning helical spring sand screen in the producing position;
FIG. 3 is a view similar to FIG. 2, but with the helical spring sand screen illustrated in the pressurized and expanded position for spring cleaning; and
FIG. 4 is a schematic diagrammatic view with parts in section of a modification of FIG. 2.
The invention disclosed herein, the scope of which being defined in the appended claims is not limited in its application to the details of construction and arrangements of parts shown and described, since the invention is capable of other embodiments and of being practiced or carried out in various other ways. Also, it is to be understood that the phraseology or terminology employed here is for the purpose of description and not of limitation. Further, many modifications and variations of the invention as hereinbefore set forth will occur to those skilled in the art. Therefore all such modifications and variations which are within the spirit and scope of the invention herein are included and only such limitations should be imposed as are indicated in the appended claims.
DESCRIPTION OF THE INVENTION
This patent includes an apparatus comprising a new self-cleaning helical spring sand screen, particularly for use in an oil well.
A self-cleaning helical spring sand screen is disclosed in the drawings that may be made by various methods, as by hand.
FIG. 1 is a schematic diagrammatic view of a typical producing oil well with its casing 10 having pumping equipment 11 comprising motor means 12 for actuating walking beam 13 with horse head 14 for operating pump 15 in the well. A crude oil pump is utilized after free flow has ceased for raising the oil that has passed through the screen 16 from the petroliferous unconsolidated sand 17 up to the surface to exit from production or discharge pipe 18. Except for the valve (23) screen 16 combination, all of the above parts may be conventional elements.
FIG. 2 illustrates a schematic enlarged sectional view of the preferred modification of the new self-cleaning helical spring screen 16 for performing the above described methods. This screen 16, FIG. 2, comprises a helical square spring 19, as shown in Assignee's U.S. Pat. No. 3,937,281, the bottom of which is secured, as by welding, to a valve housing 20. A perforated, helical spring stretching frame 21 supports the helical spring screen comprising interlinked portions 21a, 21b, and 21c. The slot in each of links 21a, 21b, and 21c, consecutively, is made of equal length so that the helical spring will be stretched evenly. The upper end of the spring 19 is secured, as by welding, to lower screen frame portion 21c which is fastened, as with screw threads, for example, to the bottom of a spool valve 23.
While various shapes may be utilized for the wire or bar stock for forming the spring 11, square bar stock is preferred in this case.
Spool valve 23, FIG. 2, is slideable and reciprocal in the portion of the valve housing 20 positioned just above the oil sand strata 17 with upper and lower packers 25a, 25b, respectively.
The spool valve 23 comprises a fluid passage tube 24 with both upper and lower ends slideably mounted in suitable fluid tight seals (not shown) spaced apart upper and lower flanges 26 and 27, respectively, of valve housing 20 for receiving sand-free liquid from the top of the helical spring sand screen 16 and passing it upwards through production tube 28 for emptying from discharge pipe 18 at the surface. Three spaced apart flanges, 29, 30, and 31 are fixed on the spool valve fluid passage tube 24 and have fluid tight sliding contact with the internal walls of the valve housing 20 between its flanges 26 and 27. A compression spring 32 is inserted between the valve housing upper flange 26 and the spool valve upper flange 29 for urging the valve down against a suitable stop 33 where the helical spring sand screen is positioned in a contracted or sand-free liquid producing mode.
For by-passing the liquid to the various chambers formed by the above-identified flanges in the valve housing 20, by-pass passages 34 and 35, FIG. 2, are formed in the valve housing wall. By-pass passage 34 interconnects the upper annular chamber A between flanges 26 and 29 with annular chamber B between flanges 29 and 30. By-pass passage 35 interconnects annular chamber B with annular chamber C. Chamber C likewise has a passage 36 in the wall of the tube 24 for interconnecting the chamber with the fluid passage tube 24. Chamber E is formed between the valve housing lower flange 27 and the upper perforated wall 37 of the helical spring screen perforated frame section 21a. Annular chamber D between flanges 31 and 27 has an interconnecting passage or opening 38 from an outer high pressure liquid annulus F formed between the well casing 10 and the valve housing 20.
At the surface, a pump 39, FIG. 2, is mounted for supplying, when desired, liquid under high pressure to the annulus F. The packer 25a seals the bottom of the annulus so that the only outlet is the passage 38 from the high pressure liquid annulus F to the annular chamber D. A conventional valve 41 is likewise mounted at the top of the production tube 28 in outlet pipe 18 for sealing off the upper end of the production tube, when desired, during backwashing, as will be explained hereinafter.
When the conventional sand screen becomes clogged with sand or other foreign material, it is raised to the top of the well, cleaned, and then lowered again, often requiring a few days to make such a trip. But the disclosed helical spring sand screen is self-cleaning in the bottom of the well in a few moments of high pressure liquid backwashing as shown below.
Briefly, in operation for cleaning of the above described helical spring sand screen after it has gradually become clogged with sand or other foreign material and after having producing sand-free oil, for example, from an unconsolidated petroliferous sand strata 17, FIG. 2, the valve 41 on the production tube discharge pipe 18 is closed and the high pressure pump 39 at the surface is started soon after, if not simultaneously. Liquid under high pressure is pumped down the annulus F and through the opening 38 into chamber D for actuating the spool valve 23 upwardly from the producing position of FIG. 2 to the cleaning position of FIG. 3. As the spool valve 23 is forced upwardly compressing spring 32 in chamber A, the liquid in chamber A passes down through the by-pass passage 34 in the wall of the valve housing into chamber B. Liquid in chamber B passes through the by-pass passage 35 into chamber C. High pressure liquid in chamber C from the beginning of the rise of valve 23 is forced out the passage or openings 36 into tube 24 down into chamber E, and then through the perforated interlinked sections 21a, 21b, and 21c of the screen frame. This reverse flow of high pressure liquid through the helical spring screen 16 squirts the high pressure liquid out backwards through or between the convolutions of the screen for cleaning it with the high pressure liquid by removing all sand and foreign material from therebetween the coils.
After a relatively short period of time, the liquid pressure in chamber A begins to equalize with the pressure in chamber C. This is due to the vent or flow passage 42 between chamber A and the large chamber C forming the upper portion of the production tube, and the compression spring 32 pressing against flange 29 in chamber A to thus force the spool valve 23 downwardly from the position of FIG. 3 to that of FIG. 2. This time period is usually sufficient to provide thorough cleaning of the clogged helical spring sand screen with the high pressure liquid back flow. The above cycle may be repeated, if so desired, until the screen is cleaned adequately and the resistance to flow therethrough is reduced.
Likewise, this raising of the spool valve may be accelerated by opening of the production valve 41, FIGS. 2 and 3, and simultaneously shutting down the high pressure pump sooner after the spool valve has reached its lower-most position. As the spring urges the valve down, liquid flows from chamber D both through passage 35 back into chamber C, and back out into the annulus and out on exhaust vent (not shown) at the surface, and from chamber C the liquid flows through passage 35 momentarily to chamber D and then back to chamber B and fluid flows through passage 36 to tube 24, and liquid from chamber B flows through passage 34 back to chamber A, there always being free passage of liquid through passage 42 in the upper valve flange 26.
FIG. 4 is a schematic diagrammatic drawing of a modification of the control system of the self-cleaning helical spring sand spring of FIGS. 2 and 3. Here high pressure pump 39a has a control lever 43 and production valve 41a has a handle 44, both handles being interconnected with a link 45. Thus with 90° counterclockwise rotation of control lever 43 to the position illustrated in FIG. 4, the pump 39a starts pumping and supplying liquid under high pressure and simultaneously valve handle 44 is rotated 90° counter-clockwise from the valve open position to the position illustrated in FIG. 4 to close the production tube valve 41a. Opposite clockwise rotation opens the valve 41a, FIG. 4, and ceases flow of liquid under pressure from pump 39a. Pump control lever 43 of pump 39a, FIG. 4, like in pump 39 of FIG. 2, relieves the pressure in annular chamber F by venting or bleeding off liquid (not shown) when in inactive, no-pumping state.
Obviously other methods may be utilized for cleaning or assembling a helical spring sand screen with the embodiments of FIGS. 2, 3, and 4 than those listed above, depending on the particular well conditions.
Accordingly, it will be seen that while a self-cleaning helical sand screen is new and different, each will operate in a manner which meets each of the objects set forth hereinbefore.
While only one exemplary mechanism has been disclosed, it will be evident that various other modifications are possible in the arrangement and construction of the disclosed self-cleaning helical spring sand screen without departing from the scope of the invention and it is accordingly desired to comprehend within the purview of this invention such modifications as may be considered to fall within the scope of the appended claims.
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A self-cleaning helical spring sand screen for use at the petroliferous unconsolidated sand strata of an oil well are disclosed. The sand screen comprises a hydraulically actuated, spring based spool valve connected to the upper end of the sand screen for receiving liquid under high pressure, for storing energy in the spring, for expanding the helical spring sand screen, and for ejecting liquid into the helical spring sand screen for cleaning thereof. Then upon ceasing of flow of the high pressure liquid, the stored energy in another spring contracts the helical spring sand screen for restorating production of sand-free oil from the production tube. A second modification is disclosed.
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This Application is the U.S. National Phase Application of PCT International Application No PCT/GB03/01022 filed Mar. 11, 2003.
This Application relates to a centraliser for an oil well tubular.
DESCRIPTION OF THE RELATED ART
Expandable centralisers are known, such as the bow-spring centraliser, which employs resilient bow-springs that are biased into an expanded configuration, and forced into a narrower bore so that the springs deform between the body of the centraliser and the borehole to space the centraliser body apart from the borehole.
BRIEF SUMMART OF THE INVENTION
According to the present invention there is provided a slotted expandable centralizer.
Typically the centraliser has a body with a bore to accept a tubular, and is radially expandable to an expanded configuration on application of a force in a radial direction.
Preferably, the centraliser has blades that can project radially outward from the body of the centraliser in a non-expanded configuration.
Preferably, the blades and the centraliser are made from a metal such as steel, and can be of the same thickness.
Optionally, the blades can project outwardly from the body of the centraliser in the expanded configuration. Alternatively, the blades can change configuration during expansion of the centraliser so that the expanded configuration can have a more uniform radius.
Preferably, the centraliser has at least two slots. Preferably, the slots are longitudinal in the non-expanded configuration, and open to generally diamond-shaped apertures in the expanded configuration. Typically, slots are arranged in longitudinally aligned rows with slots in adjacent rows being axially offset with respect to one another, so that the ends of circumferentially adjacent slots overlap. The rows and the slots themselves need not be axially aligned; this is merely a preferred option.
Alternatively, the slots are C-shaped in the non-expanded configuration. Other shapes of slots are possible, such as Z-shapes.
Preferably, the slots are of uniform dimension, but this is not necessary.
Optionally, slots are uniformly distributed over the body and the blades. Alternatively, the centraliser has slotted portions circumferentially adjacent to non-slotted portions.
Optionally, the non-slotted portions include at least one blade.
Optionally, all of the blades are located in non-slotted portions.
Typically, the centraliser is made from a material which is capable of plastic and/or elastic deformation.
Typically the centraliser is adapted to receive an expandable tubular within its bore and is adapted to deform radially with the expandable tubular during expansion.
According to another aspect of the present invention, there is provided a centraliser assembly comprising a slotted expandable centraliser which has a body with a bore to accept a tubular, and is radially expandable on application of a force in a radial direction to an expanded configuration; and an expandable tubular, located in the bore of the centraliser.
The tubular can comprise production tubing, casing, liner, drill pipe, screen, perforation guns or any other kind of downhole tubular.
Preferably, the force to expand the centraliser is provided by an expander device such as an expansion cone being pushed or pulled through the tubular.
The slots can have a typical length of between 1 and 5 cm, but this is only optional, and other lengths of slot can be used.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
An embodiment of the invention will now be described by way of example only and with reference to the accompanying drawings, in which:
FIG. 1A shows a perspective view of a centraliser in an initial, non-expanded configuration;
FIG. 1B shows the centraliser of FIG. 1A in an expanded configuration;
FIG. 2A shows an alternative embodiment of a centraliser in a non-expanded configuration; and
FIG. 2B shows the centraliser of FIG. 2A in an expanded configuration.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1A shows a steel centraliser 10 in a non-expanded configuration, attached to a slotted expandable steel tubular 12 . The slotted expandable steel tubular 12 is well known in the art. Both the centraliser 10 and the tubular 12 have many slots 18 , distributed approximately uniformly over the surface.
The centraliser 10 comprises a body 14 and blades 16 which project radially outwards from the body 14 in the non-expanded configuration shown in FIG. 1A . In this embodiment the blades 16 are hollow projections formed by pressing the blade shape from the body 14 , and are of the same thickness and material as the body of the centraliser 10 . The blades 16 each comprise an outer face 16 A, side walls 16 B and end walls 16 C.
The slots 18 are typically between 1–5 cm in length and are arranged in parallel rows that are aligned with the axis of the tubular 12 and the centraliser 10 . Slots in circumferentially adjacent rows are axially offset with respect to one another, so that the ends of the circumferentially adjacent slots overlap, leaving a web of metal between the ends of axially adjacent slots, and their circumferentially adjacent neighbours. Each slot 18 has a much shorter length than the axial length of the centraliser 10 . The slots 18 cover both the body 14 and the blades 16 .
All of the slots 18 may be of uniform size and shape, or alternatively, the slots on the blades 16 could be differently shaped to the slots on the body 14 .
In use, an unexpanded centraliser 10 is fitted onto a string of expandable tubulars 12 , with the tubular 12 received within the bore of the centraliser as shown in FIG. 1A . The string is lowered into a borehole to the depth where expansion of the tubular 12 is desired. An expander device (not shown) is then pulled or pushed through the tubular 12 . A possible expander device is an expander cone, which is typically pulled/pushed by a hydraulic ram or by fluid pressure. The expander device expands the tubular 12 as it passes through it, and as the tubular expands this expands the centraliser 10 located on the outer surface of the tubular 12 .
The largest end of the cone has a greater cross-sectional area than that of the non-expanded centraliser, so as the cone passes the centraliser 10 , the centraliser 10 experiences a radial expansion force from the expander cone (transmitted via the expandable tubular 12 ). The two sides of each slot on the centraliser 10 are pushed apart from each other, which widens the slot to the extent permitted by the web of metal between adjacent slots. Thus, the slots change shape; from being long and thin, they become shorter, fatter diamond-shaped apertures. The centraliser radially expands to the size of the widest part of the expander cone. The shape of the final aperture in the expanded centraliser 10 is determined by the size, shape and strength of the web between the slots.
The blades 16 do not need to expand as much as the body 14 of the centraliser 10 in order to accommodate the expander cone, as they have already been pressed out of the body of the centraliser 10 . Thus, the slots of the outer faces 16 A may adopt a different shape (e.g. narrower) on expansion as compared with the slots on the body of the centraliser 10 . Likewise, parts of the side walls 16 B and end walls 16 C need to expand more than other parts, so there can optionally be a non-uniform pattern of apertures on the expanded centraliser, which can be used to influence the shape and strength characteristics of the expanded centraliser 10 . After the cone has passed the centraliser 10 , the whole centraliser 10 adopts approximately the same inner diameter as the outer diameter of the tubular 12 .
FIG. 1B shows the centraliser 10 of FIG. 1A in an expanded configuration. The outer faces 16 A of the arms 16 have expanded less than the body of the centraliser 10 , so that the expanded centraliser 10 has a generally uniform radius.
This embodiment is useful for inserting expandable tubulars such as screens into a borehole, where the blades 16 of the centraliser 10 are required to ease entry of the string into the hole but are not required after expansion of the screen against the borehole wall. With slotted blades as in this embodiment, the centraliser can ease the passage of the string into the hole, reducing friction between the screen and the hole, and spacing the screen from the wall to enhance insertion, and after expansion of the string can virtually disappear against the borehole wall.
In this embodiment the pattern of the slots on the blades and the body are substantially the same and this can give rise to a non-uniform pattern of apertures on the expanded centraliser. In other embodiments, the pattern or shape of the slots on the blades 16 can differ from the pattern or shape of the slots on the body of the centraliser 10 , so as to adopt a more uniform pattern of apertures after expansion of the centraliser 10 .
FIG. 2A shows an alternative embodiment of a centraliser 10 A. The centraliser 10 A has a body 24 and longitudinal strips 20 , which are not slotted. Blades 25 are positioned on the longitudinal non-slotted strips 20 . The rest of the centraliser 10 A is slotted, as in the embodiment of FIGS. 1A and 1B .
Slots 28 are aligned axially in rows, as in the embodiment of FIGS. 1A and 1B . Slots 28 in adjacent rows are axially offset with respect to one another. Each slot 28 has a much shorter length than the axial length of the centraliser 10 A.
In use, the centraliser 10 A is attached to a portion of slotted pipe and expanded in the same way as the centraliser 10 of FIGS. 1A and 1B , i.e. by means of an expander cone. The slotted parts of the centraliser 10 A expand in the way described above: the two sides of each slot are pushed apart from each other, which widens the slot. The long thin slots become shorter, fatter diamond-shaped apertures.
The non-slotted strips 20 do not substantially expand (apart from possibly some plastic/elastic deformation). Thus, the non-slotted strips 20 do not change their shape substantially, and the blades 25 remain protruding from the expanded body 24 . They may become further circumferentially spaced apart from each other, due to the expansion of the slotted parts of the body 24 between the blades 25 . FIG. 2B shows the centraliser 10 A of FIG. 2A in an expanded configuration.
This embodiment is suitable for expandable casing strings that still require a centraliser function after expansion, for example to provide an annulus for cement, or to wash out debris or other material from the well after insertion of the casing.
It should be noted that it is possible to provide some embodiments with intermediate properties, for example a slotted body and blades with comparatively fewer slots, so that the blades can expand less than the body, and a small blade structure is left after expansion.
Modifications and improvements can be incorporated without departing from the scope of the invention.
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This invention relates to a slotted expandable centraliser. In preferred embodiments, the centraliser is adapted to be used in conjunction with slotted casing, and can expand with the casing when an expander cone is propelled through the casing.
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FIELD OF THE INVENTION
This invention relates to gutter guards used to prevent debris from clogging a rain gutter.
BACKGROUND OF THE INVENTION
Gutter guards include a perforated planar surface that spans the rain gutter opening to allow water to drain into the gutter while preventing debris from doing so. The front of the guard is usually secured or retained on the front lip of the gutter, for example by means of fasteners, a clip system or by shaping the front edge of the guard such that it is physically engaged on or under the lip.
In some cases, such as disclosed in U.S. Pat. No. 7,614,185 to Brochu, the guard is designed to seat in a recessed position in the gutter. Such an arrangement creates a lip or wall at the front of the guard to stop fast moving water from simply flowing across the guard and to the ground, which risks defeating the purpose of the gutter. Despite the front lip or wall formed by a recessed gutter guard, large quantities of fast-flowing water from the roof can overwhelm the apertures in the forward portion of the guard where accumulating water can spill over the front lip of the recessed gutter guard before it can drain through the apertures.
Older-style prior art rain gutters are typically secured to the fascia of the building by a spike and ferrule system in which a nail or spike is inserted into a ferrule extending from the front of the gutter and through the rear wall of the gutter, so as to embed in the fascia. Spike and ferrule systems usually involve unthreaded nails or spikes that may not provide a secure fastening to the fascia and are sometimes difficult to install, particularly for do-it-yourselfers. More recently, the use of gutter hangers has become the preferred means of installing gutters. Gutter hangers extend between the front and rear walls of the gutter and a wall screw is inserted through the hanger, through its rear wall and into the fascia. Gutter hangers are provided at spaced locations along the length of the gutter as illustrated in FIG. 1 . The present applicant supplies gutter hangers with a pre-installed threaded fastener to facilitate installation.
However, gutter hangers present a potential obstacle to installation of recessed gutter guards. Guards are typically manufactured in predetermined lengths of roll-formed product having a uniform profile along their lengths. As some gutter hangers have shoulders near the top rear of the gutter, the presence of the shoulders inhibits the ability to install a guard any deeper into the gutter than the height of the gutter hangers. For example, Canadian Patent No. 2,597,976 to Brochu discloses a guard that includes a planar top portion and a rear wall that extends along the rear of the gutter to support the guard on the bottom of the gutter. The presence of the rear wall renders the disclosed system unusable with gutter hangers that have a shoulder as the rear wall of the guard would be impeded by the hangers.
The rear of the guard may be secured by fasteners or it may passively abut either the rear of the gutter, the fascia or in some cases be wedged under the shingles of the roof. The use of fasteners at the rear of the guard increases the chance of water seepage into the underlying fascia of the building. US Patent Publication No. US 2009/0031638 to lannelli avoids the use of fasteners at the rear of the guard by wedging the guard between the roof structure and the roof shingles. That approach is obviously labour intensive, requires skill, risks snapping the shingles if they are brittle and may be difficult to achieve after construction of the roof has been completed. It is also limited by the proximity of the roof line to the gutter, which may vary from building to building and allows rainwater to shoot off the front of the gutters.
US Patent Publication No. US 2009/0108144 to Brochu discloses a passive abutment of an angled rear portion of the guard against the fascia or a hook that engages the rear wall of the gutter. Such passive support systems have the advantage of being easy to install and of not requiring additional fasteners or specialized tools. However such systems run the risk of improper installation if the rear of the guard is pushed down hard enough to seat the rear of the guard below its most effective height. The same result can follow from the weight of snow or ice. This can result in bending of the guard along its length or if installed too low, obstruction of the flow of water along the gutter.
It is an object of the present invention to provide a partially recessed roll-formable gutter guard that is easy to install in conjunction with gutter hangers. Another object of the invention is to avoid the use of fasteners at the rear of the guard. It is a further object of the invention to minimize the accumulation of water at the front of the gutter guard.
These and other objects of the invention will be better understood by reference to the detailed description of the preferred embodiment which follows. Note that not all of the objects are necessarily met by all embodiments of the invention described below or by the invention defined by each of the claims.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a gutter guard comprises a downwardly extending support leg that is designed to rest on all styles of gutter hangers and to provide longitudinal rigidity to the guard. In a related aspect, the leg is omitted for a short distance adjacent a side edge of the guard or the side edge is provided with a notch to accommodate the support leg, thereby permitting lengths of gutter guard to be joined in partially overlapping relationship in the gutter.
The support leg also serves to provide longitudinal rigidity to the guard which facilitates handling and facilitates the use of a friction fit of the rear of the guard with the fascia.
According to an aspect of the invention, the friction fit is facilitated by an upwardly angled rear end of the guard, the upward angle also contributing to directing water away from the fascia.
In another aspect of the invention, the guard includes a rear shoulder portion to accommodate the shoulder of the gutter hangers in the event that the gutter hangers have a rear shoulder, while still allowing the principal planar surface of the guard to be recessed or partially recessed within the gutter. In a more particular aspect, the invention comprises the arrangement of the walls forming the shoulder.
In another aspect, a flat attachment face is provided at the front of the guard for overlying and securing it to the front lip of the gutter.
In a further aspect, the central planar portion of the guard has a slight rearward sloping angle to flow water away from the front lip of the guard to avoid the accumulation of water near the front lip and an upstanding wall is provided between the central portion and the attachment flap to discourage water from flushing over the front lip of the gutter.
The attachment flap is angled slightly downward from back to front to direct water off the attachment face and to maintain a more closely flush line when viewed from the front of the building. A forward downward angle to the top wall of the rear shoulder assists in isolating the connection between the fascia and the hanger wall screw from water.
In yet another aspect, the invention comprises a rain gutter guard adapted for use in a recessed position within a gutter that is mounted to a building wall by a series of spaced gutter hangers. The gutter guard comprises a porous surface for substantially spanning the width of the gutter and includes a leg extending downward from the surface and is adapted to rest on the gutter hangers when the gutter guard is urged downward within the gutter.
In another aspect, the invention is an assembly of a rain gutter and a gutter guard comprising a series of spaced gutter hangers for mounting a gutter to a vertical building surface. The gutter guard has a porous surface that substantially spans the width of the gutter and a leg extending downward from the surface and adapted to rest on the gutter hangers when the gutter guard is urged downward within the gutter. The support leg extends downward a distance substantially less than the depth of said gutter.
In a method aspect, the invention comprises a method of installing a gutter guard on a rain gutter that is secured to a vertical building surface by a series of spaced gutter hangers. A gutter guard as described above is installed such that the leg rests on the gutter hangers and a rear edge of the gutter guard is substantially proximal to a rear edge of said gutter.
Other aspects of the invention relate to the presence of an upwardly angled segment at the rearmost end of the guard for resilient abutment against the building wall, the particular inclination of the central portion, an angle provided to the attachment flap, an angle provided to a second wall forming a part of the shoulder, and an angle provided for a rearmost segment of the guard.
The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the exemplary preferred embodiment and to the claims by which the invention is defined.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by reference to the detailed description of the preferred embodiment and to the drawings thereof in which:
FIG. 1 is a perspective front view of a typical gutter showing a plurality of gutter hangers according to the prior art;
FIG. 2 is a perspective view of a gutter, a gutter hanger and a gutter guard according to the preferred embodiment, installed in the gutter;
FIG. 3 is a side elevation of the gutter guard of the preferred embodiment;
FIG. 4 is a cross-sectional view of a gutter, gutter hanger and a gutter guard according to the preferred embodiment installed in the gutter. For clarity, the apertures in the guard are not shown in this view; and,
FIG. 5 is a plan view of the guard.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following describes a preferred implementation of the inventive concepts of the invention. There may of course be various other manners of embodying the same inventive concepts and this section of the specification therefore does not purport to describe the full extent or scope of the invention but merely to illustrate the preferred embodiment thereof.
FIG. 1 is a perspective view of a prior art gutter 10 with gutter hangers 12 , 14 , 16 being provided at spaced locations to secure the gutter to the fascia of a building. The preferred embodiment of gutter hangers are available with pre-installed wall screws 18 , 20 , 22 that are screwed through the rear wall 24 of the gutter and into the fascia of the building (the fascia is not shown in the drawings). A fastening shoulder 36 is provided in the gutter hanger to retain and align the wall screws to the rear of the gutter 10 . While not all gutter hangers have such a shoulder, one feature of the preferred embodiment of the invention is best appreciated by reference to gutter hangers having shoulders as shown.
FIGS. 2 and 4 are views of a gutter 10 with gutter hangers 12 , 14 , 16 , and a gutter guard 26 according to the preferred embodiment while FIG. 3 is a side elevation of the gutter guard 26 according to the preferred embodiment.
In this description, the portion of the guard and gutter that are adjacent the fascia of the building will be referred to as the “back” or “rear” and the portions distal from the fascia will be referred to as the “front” or “forward” portions.
Guard 26 , which is formed as a single piece of extruded or roll-formed material, includes a downwardly extending leg 28 adapted to either rest directly on the gutter hangers 12 , 14 , 16 or to abut them when the guard is urged down into the gutter (for example by the installer, during cleaning or under the weight of snow or ice). Leg 28 also serves to provide longitudinal rigidity to the guard that facilitates handling of long segments of guard and facilitates a friction fit installation of the guard by pressing its rearmost end against the fascia of the building. The support leg 28 extends downward a distance substantially less than the depth of the gutter 10 .
The rear of the guard 26 forms a shoulder 34 to provide clearance for the fastening shoulders 36 of the gutter hangers and their associated wall screws. Shoulder 34 is formed by a first upwardly inclined wall 30 and a second upwardly inclined top wall 32 extending rearward from the first inclined wall 30 .
According to the preferred embodiment, leg 28 is formed at the juncture between the central planar surface 42 and the upwardly inclined wall 30 .
The guard 26 is therefore adapted to be easily positioned in the gutter by resting leg 28 on the gutter hangers 12 , 14 , 16 so as to recess the guard within the gutter without interference from the hanger shoulders 36 while also avoiding the risk of inserting it too deep into the gutter 10 during installation. During installation, the rearmost end of the guard is disposed such that it is substantially proximal to a rear edge of the gutter 10 .
The front end of the guard 26 is formed to provide a flat attachment flap 34 that provides a surface for securement to the underlying gutter lip 37 , for example by means of a screw 38 . At the rear of the guard, top wall 32 terminates in a segment 40 that is angled upward at about 45° to allow bending and resilient abutment for a friction fit to the fascia boards.
In the preferred embodiment, central planar portion 42 extends forwardly from leg 28 . Central portion 42 , diagonal wall 30 and top wall 32 are each provided with a regular pattern of apertures 46 to create a porous surface. Central portion 42 acts as the principal drainage surface of the guard 26 . Preferably an upstanding wall 44 is provided between planar portion 42 and attachment flap 34 to contain water flowing from the roof and to prevent it from spilling over the forward lip 37 of the gutter.
Planar portion 42 has a slight (between 1° and 3°, preferably 1.5°) rearward incline to promote the rearward flow of water. Top wall 32 is inclined upward at an angle of between 1.5° and 4°, preferably 3°, from front to back. The slight incline of the top wall 32 is designed to keep water from migrating toward the fascia of the building.
The attachment flap 34 extends downwardly from back to front at an angle of between 3° and 7°, preferably about 5°, in order to direct water to the front of the gutter and to provide an approximately flush line when viewed from in front of the building.
In order to avoid the risk posed by sharp edges during handling, the attachment flap 34 is folded over at its end to provide a smooth forward edge. Similarly the tip 48 of rear edge 40 is preferably rounded for the same reason and to avoid scoring of the fascia.
In installing gutter guards end to end along a gutter, gaps between the guards should be avoided. In the case of gutter guards that are flush stackable, this is achieved by simply overlapping the guards. However, the presence of leg 28 prevents the guards from overlapping in a flush relationship. In order to accommodate partial overlapping of the ends of the guards, the leg 28 is omitted from a short segment of at least one end of the guard and is replaced by a slot 50 of sufficient width to accommodate the leg of an adjacent guard, as illustrated in FIG. 5 . This allows partial flush overlapping of the guards during installation in a gutter. Alternatively, the leg 28 can simply be omitted from a short segment and the gutter guard from which the leg 28 is omitted can be simply overlaid on the side adjacent guard.
Similarly, a portion of the upstanding wall 44 and the attachment flap 34 is omitted along a short segment 52 to allow overlapping of end to end adjacent guards.
It will be appreciated by those skilled in the art that the preferred and alternative embodiments have been described in some detail but that certain modifications may be practiced without departing from the principles of the invention, the scope of which is defined principally by the claims.
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A rain gutter guard comprises a downward leg for abutting gutter hangers when the guard is urged down into the gutter. A shoulder of the guard accommodates the shoulder of the gutter hangers. A front attachment flap secures the front of the guard to the gutter while the rear is retained by friction fit of an angled segment against the building fascia. An upstanding wall separates the central portion from the attachment flap. The central portion is inclined rearward and the attachment flap inclines to the front.
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RELATED APPLICATIONS
This application is a continuation of utility patent application Ser. No. 11/216,929 entitled Plastic Expandable Utility Shed filed Aug. 30, 2005, now U.S. Pat. No. 7,581,357 the contents of which are herein incorporated by reference in their entirety. This application is also related to Ser. No. 29/230,885 filed May 27, 2008, now U.S. Design Pat. No. D529,623, and Ser. No. 29/230,978 filed May 27, 2005, now U.S. Design Pat. No. D525,715, the contents of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
This invention relates generally to plastic utility sheds, and more specifically to a modular roof system constructed of injection molded plastic panels for creating plastic utility shed roofs of various sizes from standardized components.
BACKGROUND OF THE INVENTION
Utility sheds are necessary for lawn and garden care, as well as general all-around home storage space. Typically, items such as garden tractors, snow blowers, tillers, ATVs, motorcycles, lawn tools and the like are stored within utility sheds for the convenience of the homeowner.
The prior art has proposed a number of different panel systems, or kits, comprising blow molded and/or extruded panels which are combined with connector members for forming storage structures, e.g. utility sheds. Unfortunately, blow molding and/or extrusion of panels for utility sheds has resulted in shortcomings within the state of the art products. For example, due to the nature of the manufacturing process, blow molded and/or extruded plastic components cannot be formed with the intricate shapes and/or sharp corners required for integrated connectors. Therefore, these systems require extruded metal or plastic connector members having a specific cross-sectional geometry that facilitates an engagement between the blow molded or extruded panels to complete the structure.
A particularly common structure for the connector members is one having an I-beam cross section. The I-beam defines free edge portions of the connector member which fit within appropriately dimensioned and located slots in the panel members. U.S. Pat. No. D-371,208 teaches a corner extrusion for a building sidewall that is representative of the state of the art I-beam connector members. The I-beam sides of the connector engage with the peripheral edge channels of a respective panel and thereby serve to join such panels together at right angles. Straight or in-line versions of the connector members are also included in the kits to join panels in a coplanar relationship to create walls of varying length.
Another drawback associated with blow molded panels is the requirement of an inner and an outer wall. The inner and outer walls are a necessary product of the blow molding manufacturing process. While the inner wall may add some rigidity to the panels, it also adds a significant amount of weight and dramatically increases the volume of plastic necessary to form a panel of a given size when compared to other methods of manufacturing, such as injection molding.
A further drawback associated with blow molded panels relates to accurate control of wall thickness throughout the panels. The blow molding process does not allow the wall thickness of the panels to be accurately controlled. Once the molten plastic is conveyed to the tooling, there is minimal control over where the plastic flows during formation of the panel. Also, the blow molding process does not allow the intentional formation of thick and thin sections within a single panel for engineered rigidity at the points of high stress or high load concentration.
Extruded panels generally require hollow longitudinal conduits for strength. Due to the nature of the manufacturing process, the conduits are difficult to extrude in long sections for structural panels. Thus, they also require connectors to achieve adequate length for utility shed roofs. A common structure for connecting extruded members has a center I-beam with upper and lower protrusions for engaging the conduits. Wall panels utilizing these connectors are vulnerable to buckling under loads and may have an aesthetically unpleasing appearance. Moreover, roof loads from snow and the like may cause such walls to bow outwardly due to the clearances required between the connectors and the internal bores of the conduits. U.S. Pat. No. 6,250,022 discloses an extendable shed utilizing side wall connector members representing the state of the art. The connectors have a center strip with hollow protrusions extending from its upper and lower surfaces along its length; the protrusions being situated to slidably engage the conduits located in the side panel sections to create the height needed for utility shed walls.
The aforementioned systems can also incorporate roof and floor panels to form a freestanding enclosed structure such as a small utility shed. U.S. Pat. Nos. 3,866,381; 5,036,634; and 4,557,091 disclose various systems having inter-fitting panel and connector components. Such prior art systems, while working well, have not met all of the needs of consumers to provide the structural integrity required to construct larger sized structures.
Larger structures must perform differently than small structures. Large structures must withstand increased wind and snow loads when compared to smaller structures. Paramount to achieving these needs is a panel system which eliminates the need for extruded connectors to create enclosure walls which resist panel separation, buckling, and racking. A further problem is that the wall formed by the panels must tie into the roof and floor in such a way as to unify the entire enclosure. Also, from a structural standpoint, the enclosure should include components capable of withstanding the increased wind, snow, and storage loads required by large structures.
Therefore, what is needed in the art is an injection molded modular roof system for utility enclosures. The modular roof system should achieve objectives such as light weight single wall construction. The construction of the panels should eliminate the need for extruded I-beam connectors to create a roof assembly which resists panel separation, buckling, and racking. The roof assembly should be capable of withstanding the wind and snow loads typically associated with utility enclosure roofs.
There are also commercial considerations that must be satisfied by any viable utility shed enclosure system or kit; considerations which are not entirely satisfied by state of the art products. The roof assembly must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The roof assembly must also be capable of being packaged and shipped in a knocked-down state. In addition, the roof assembly must be modular and facilitate the creation of a family of roof assemblies that vary in size but which share common, interchangeable components.
Finally there are ergonomic needs that a roof assembly must satisfy to achieve acceptance by the end user. The roof assembly must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. In addition, the roof assembly must not require excessive strength to assemble or include heavy component parts. Moreover, the roof assembly must assemble together in such a way so as to not detract from the internal storage volume of the resulting enclosure or otherwise negatively affect the utility of the structure.
SUMMARY OF THE INVENTION
The present invention provides a system including injection molded roof panels, headers, and ridge caps having integrated connectors which combine to form a family of variously sized roofs for utility enclosures. The roof panels, headers, and ridge caps are formed of injection molded plastic to create light-weight components having integrally formed ribs and gussets for strength and integrity. The injection molding also facilitates integrally formed connectors so that the panels, headers and ridge caps interlock with one another without the need for separate connectors. In addition, the ridge caps and/or roof panels may be formed of translucent plastic for natural lighting.
Accordingly, it is a primary objective of the instant invention to provide a plastic utility roof assembly.
It is a further objective of the instant invention to provide a plastic roof assembly which utilizes roof panels and ridge caps having single wall construction with integrally formed ribs and gussets for a lightweight yet robust roof assembly.
It is yet another objective of the instant invention to provide a plastic roof assembly which accommodates injection molding plastic formation of the components for increased structural integrity.
It is a still further objective of the invention to provide a modular header system which allows standard components to be utilized for different width roofs.
Still another objective of the instant invention is to provide a roof system in which the components include integrally formed connectors.
Yet another objective of the instant invention is to provide a roof system which includes components having predetermined sizes for creating roofs of varying dimensions using common components.
Still yet another objective of the instant invention is to provide a roof assembly which reduces the number of components required to assemble a roof and simplifies construction.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein 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 FIGURES
FIG. 1 is a front perspective view of an enclosure comprising an assembled wall system, roof headers, and a ridge cap.
FIG. 2 is a front perspective view of an enclosure comprising an assembled wall system, headers and the left half of the roof assembly.
FIG. 3 is an exploded view of a complete roof assembly.
FIG. 4 is a front perspective view of a two piece header.
FIG. 5 is a rear perspective view of a two piece header.
FIG. 6 is a front perspective exploded view of a two piece header with a strap support.
FIG. 7 is a front perspective view of a three piece header.
FIG. 8 is a rear perspective view of a three piece header.
FIG. 9 is a front perspective exploded view of a three piece header with a strap support.
FIG. 10 is a bottom view of a three piece header.
FIG. 11 is a perspective view of the back side of a header and the underside of the roof panels.
FIG. 12 is a perspective view of the front side of a header and the underside of roof panels.
FIG. 12A is an enlarged view of the connection between the header and a roof panel.
FIG. 13 is a perspective view of the top of the roof panels and a section of the ridge cap.
FIG. 14 is a perspective view of the underside of the roof panels and a section of the ridge cap.
FIG. 15 is an enlarged view taken along line 2 - 2 of FIG. 14 illustrating the connection between the ridge cap and a roof panel.
FIG. 16 is a perspective view of the connection between a roof panel and a wall panel.
FIG. 16A is an enlarged view taken along line 3 - 3 of FIG. 16 illustrating the connector which joins a roof panel to a wall panel.
FIG. 17 is a perspective view of an assembled roof and wall panel.
FIG. 17A is an enlarged view taken along line 4 - 4 of FIG. 17 illustrating the assembled connection between a roof panel and a wall panel.
FIG. 18 is a perspective view of an assembled roof and wall panel including a roof support.
FIG. 18A is a enlarged view of the connector between a roof panel and the roof support.
FIG. 19 is a perspective view of two different roof panels utilized for enclosures of different widths.
FIG. 20 is an enlarged view of the connection between two roof panels.
FIG. 21 is an enlarged view of one roof panel of the connection shown in FIG. 20 .
FIG. 22 is a section view taken along line 1 - 1 of FIG. 13 illustrating the overlapping connection between the roof panels.
DETAILED DESCRIPTION OF THE INVENTION
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
FIGS. 1-3 show perspective views of a heavy duty plastic utility enclosure, generally referenced as 10 , constructed according to a preferred embodiment of the present invention. The roof assembly generally includes header assemblies 410 , roof panels 460 , roof supports 520 , and a ridge cap assembly 530 which are shown in an exploded view in FIG. 3 . The header assembly is a truss like structure molded with an aesthetically pleasing generally smooth wall 412 on its outer surface (FIGS. 3 , 6 , 7 , and 9 ) and integrally formed box bracing 414 ( FIGS. 4-9 ) and a plurality of pockets 416 constructed and arranged to accept roof support members 470 on its inner surface. In the preferred embodiment the header assembly is constructed of a center member 418 and a pair of outer members 420 ( FIG. 3 ). This type of construction permits the center member to be added or removed to construct different size enclosures while the outer members remain the same. Each member of the header assembly includes an upper surface 422 and a lower surface 424 . The lower surface 424 includes a plurality of inwardly extending engagement sockets 426 constructed and arranged to cooperate with removable and replaceable bosses 428 and/or door hinge pins 430 . The bosses 428 or hinge pins 430 are slid into their respective engagement sockets 426 until the integrally formed spring tabs 432 ( FIGS. 6 and 9 ) engage corresponding apertures formed in the engagement sockets. The end surfaces 434 , 436 of the header members includes means to connect them together illustrated herein as a plurality of outwardly extending, inter-fitting tubes 438 . The tubes are constructed and arranged to extend into a socket 439 formed in an adjacently positioned header member until integrally formed spring locks 440 ( FIG. 8 ) engage a corresponding aperture. This construction provides a load distributing connection between the header members that prevents separation and bowing of the assembly under load. In addition, the design provides a sealed connection between the panels preventing weather and insect infiltration. The resultant header created by the combination of the interlocking members benefits from high structural integrity and reliable operation.
Referring to FIGS. 4-6 , a two piece header embodiment is illustrated. With this embodiment additional means are provided for attaching the header members together illustrated herein as a C-shaped clip 444 . The C-shaped clip is inserted into apertures 446 provided in each of the header members ( FIG. 5 ). The C-shaped clip is provided to prevent separation and provide load support integrity to the header assembly. For additional support ad rigidity the header assembly is constructed and arranged to cooperate with a metal support member 448 . The metal support member is attached to the header members with fasteners 450 and anchors 452 . The anchors are inserted through the apertures 454 on the rear side of the header members ( FIG. 5 ). In this manner FIGS. 8 and 9 show how the strap is employed with a three piece header assembly.
The headers are attached to the wall assemblies by sliding the bosses 428 into sockets (not shown) positioned in the top portion of the wall panels until the integrally formed spring clips 442 ( FIG. 3 ) engage apertures formed in the sockets. The result is a positive lock that maintains alignment of the wall panels in the same plane and prevents bowing or bending of one panel relative to another one.
Referring to FIGS. 1-3 and 5 , at least three roof supports 520 are inserted into their respective pockets 416 in each of the headers and may optionally be secured in place with suitable fasteners. The roof supports are preferably constructed of a metal such as steel, but may be constructed of other materials well known in the art capable of providing structural support to the roof assembly. Such materials may include but are not limited to wood and/or plastic as well a suitable combinations thereof. FIG. 1 illustrates the placement of the support beams in the headers of the preferred embodiment.
Referring to FIGS. 3 and 13 roof panels 460 are formed as either a central roof panel 462 or an end roof panel 464 . Each central roof panel has a top surface 466 , a bottom surface 468 , a first locking edge 470 , a second locking edge 472 , a third locking edge 474 and a closed edge 476 . Along the bottom surface 468 adjacent to the closed edge 476 is another connection means illustrated herein as a plurality of sockets 478 constructed and arranged to receive roof connectors 480 ( FIGS. 16 and 17 ). The roof connectors are constructed and arranged to cooperate with pockets (not shown) located in the top portion of the wall panels as well as the sockets 478 located on the lower surface of the roof panels. A series of spaced apart structural ribs 482 extend across the bottom surface of each roof panel to provide rigidity and increased weight carrying capacity to the roof assembly. The first 470 and second 472 locking edges of the roof panel include another connection means illustrated herein as a W-shaped overlapping connection 484 ( FIG. 22 ). The distal portion 486 of the first locking edge 470 of the overlapping connection includes a plurality of ramp-locks 488 constructed and arranged to cooperate with apertures 490 formed into the second locking edge overlapping connection. The W-shaped overlapping connection provides a water resistant seal between the panels and prevents the panels from bowing or separating under wind or snow loads. The second locking edge 472 further includes a downwardly extending wave shaped rib 492 ( FIG. 21 ). This rib is constructed and arranged to fit into a corresponding trough 494 formed on the first locking edge 470 ( FIG. 20 ). The connection of the wave shaped rib 492 and corresponding trough 494 provides an additional water resistant seal between the panels. Any water that may enter the trough flows downwardly along the trough and out through drain 496 ( FIG. 20 ). Drain 496 is located outside of the walls so that water is prevented from entering the enclosure.
Sockets 478 located on the lower surface of the roof panels comprise two sockets members ( FIG. 20 ). Each socket member is located along a locking edge of a roof panel (FIGS. 16 , 17 , and 20 ). Roof connectors 480 are formed with two upwardly extending members 500 and a lower member 502 which spans members 500 . The upwardly extending members are provided with ramp-locks 504 and the lower member is provided with two ramp-locks 506 . The connectors 480 are constructed and arranged to allow the upwardly extending members to slide into sockets 478 and the lower member to slide into a socket on the top portion of a wall panel ( FIGS. 16 and 17 ). The ramp-locks engage apertures 508 in socket 478 and ramp-locks 506 engage apertures 510 in the wall panel socket. Another type of roof connector 512 also slides into sockets 478 which are located on the lower side of the roof panel and spaced between the ends of the roof panels as shown in FIG. 18 . The lower portion of connector 512 is provided with a groove which engages roof supports 520 to provide support for the roof panel along its length. Connectors 512 are provided with ramp locks 514 which engage apertures 508 in sockets 478 to provide a locking connection. The connectors 512 and roof supports 520 provide roof support for additional snow loads.
The end roof panels 464 are similar to the central roof panels in that they have a top surface, a bottom surface, sockets 478 on the bottom surface located along either a first or second locking edge, a third locking edge and a closed end. They differ from the central roof panels in that they are not as wide and have a channel 516 located along either a first or second locking edge. In place of a locking edge adjacent the channel there is a smooth edge surface 518 ( FIGS. 3 and 12 ). This edge extends beyond the header and presents an aesthetically pleasing surface. The width of channel 516 is the same as the depth of the header assemblies 410 so as to form a connection between the roof and the header assemblies and create a weather resistant seal between the two members. Channels 516 are also include apertures 522 which engage ramp-locks 524 located along the upper edge of the header assemblies ( FIG. 12 ) to secure the end roof panels to the header assemblies.
The central and end roof panels are available in at least two different lengths as shown in FIG. 19 . The pattern of the structural ribs 482 on the bottom surface of the roof panels is selected so that the shorter roof panel can be formed without retooling. As can be seen in FIG. 14 if the formation of the roof panel is stopped at the transverse rib 482 a shorter roof panel, with the proper structural elements, will be the result.
The roof assembly also includes a ridge cap assembly 530 which is formed from a plurality of like constructed ridge cap members 531 ( FIG. 13 ). Each ridge cap member includes an integrally formed tubular connector 533 at one end thereof and an integrally formed aperture 532 at the opposite end thereof. The tubular connector 533 of one ridge cap member engages the aperture 532 of an adjacent ridge cap member thereby interlocking the members together. There are also two ridge cap members which cooperate with the end roof panels and header assemblies ( FIG. 3 ) and include apertures 536 which cooperate with ramp-locks 524 formed on the header assemblies ( FIG. 12 ) to secure the ridge cap members to the header assemblies. Each of these ridge cap members is formed with an end portion which corresponds to the edge surface 518 of the end roof panels so as to present an aesthetically pleasing edge surface when located adjacent thereto. The ridge cap members may be made from a translucent material to enhance natural lighting of said enclosure.
The third locking edge of each roof panel includes an interlocking tubular connection 526 which is constructed and arranged to cooperate with a conjugately shaped receiver 528 formed in the ridge cap members 531 ( FIG. 3 ) to join roof panels on opposite sides of the roof and to create a weather resistant seal. The tubular connection 526 includes integrally formed ramp-locks 534 which engage corresponding apertures 536 in the ridge cap members ( FIG. 15 ). The length of each ridge cap corresponds to the width of a roof panel.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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The present invention provides a system which includes injection molded roof panels, header assemblies and ridge caps having integrated connectors which combine to form a family of variously sized roof assemblies for utility enclosures. The injection molding facilitates integrally formed connectors so that the roof panels, header assemblies and ridge caps interlock with one another without the need for separate connectors.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device and method for protecting a tool such as a measuring instrument (probe) or a specialized working tool in a well, this tool being fixed to the end of a drill string.
2. Description of the Prior Art
In the devices and methods of the prior art, the tool or instrument is caused to leave its protective casing or jacket by a movement of the tool or instrument relatively to the drill string and to the casing, the casing being fixed relative to the drill string.
Such an operating mode has numerous drawbacks. In fact, very often the specialized tools, such as well logging probes, require an electric connection with the surface of the well. This connection is generally provided by a cable and it therefore advisable to provide members which ensure the electric continuity of the connection during movement of the tool. Such members are particularly fragile and present difficulties in use.
Moreover, very often, the devices of the prior art move the tool by pumping liquid inside a hollow string. This results in violently propelling the probe with the risks of damage thereto, particularly if the well is obstructed.
The prior art may be illustrated by the French Pat. No. FR-A-2 547 861, European Pat. No. EP-A-0 122 839 and the U.S. Pat. No. 4,349,072.
The present invention overcomes these drawbacks by providing a retractable protective device for a specialized instrument or tool working in a well, this tool or instrument being fixed to the end of a drill string.
SUMMARY OF THE INVENTION
The device of the invention comprises a casing or jacket for protecting said tool or instrument and is characterized in that the drill string has, substantially at its end and before said tool or instrument, a first guide member and in that the casing has a second guide member, these first and second guide members being adapted for cooperating together so as to allow movement of the casing relative to the tool or instrument.
The device of the present invention may include means for anchoring and locking the casing relatively to the assembly formed by said drill string and said tool or instrument.
These anchoring means may be adapted for immobilizing the casing when the casing protects the tool or instrument, or when the casing does not protect said tool or instrument. The casing may include means for centering in the well.
The device of the present invention may include means for moving the casing relatively to the assembly formed by said drill string column and said tool or instrument.
The present invention also provides a method of protection using a protective casing or jacket for a specialized instrument or tool working in a well, this tool or instrument being fixed to the end of a drill string.
The method of the invention is characterized in that the casing is mounted for sliding relatively to the assembly formed by the tool or instrument and the drill string.
According to the present invention, the assembly formed by the drill string and the tool or instrument may be moved for removing the tool from its protective casing. Thus, the casing remains substantially immobile relatively to the well.
Still within the scope of the present invention, for working with the tool or instrument in a given zone of the well, the assembly formed by the drill string and the casing is moved beyond this zone while the casing is in the position protecting the tool or instrument and the tool is uncovered during the movement, or just before the movement of this assembly in the opposite direction and before again reaching the working zone.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood and its advantages will be clear from the following description of examples which are in no wise limitative, illustrated by the accompanying drawings in which:
FIGS. 1 and 2 illustrate a simple embodiment of the device of the invention,
FIGS. 3 and 4 illustrate a second embodiment in which the device of the invention includes means for centering the casing in a well, and
FIGS. 5 and 6 show a third embodiment in which said casing is moved by hydraulic means.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a simple embodiment of the device of the invention.
Reference 1 designates a tool or instrument to be uncovered temporarily. This tool, which may be a well logging probe or any other tool, is fixed to a drill string 2 which may be a drill pipe string, by means of a first guide member 3 which in the case of FIG. 1 is a cylinder.
Reference 4 designates a protective casing or jacket. This casing includes a second guide member 5, such as bearings which may slide over the first guide member 3.
FIG. 1 shows the casing 4 in a position protecting the tool 1.
Casing 4 may be held in this position by anchoring or locking means 6. In FIG. 1 these locking means comprise retractable dogs 7. These dogs may be remote controlled electromagnetically.
Since such anchoring means are well known to a man versed in the art, they will not be described here in detail.
When it is desired to uncover tool 1, as is shown in FIG. 2, the dogs 7 are retracted and the casing 4 is moved so as to uncover the tool to be protected 1 which may then be activated for carrying out the operation for which it is designed.
In the example shown in FIG. 1, the tool to be protected as well as the means 6 for locking the casing to the guide member require an electric connection with the equipment situated for example on the surface.
A male connector 8 fixed to the inside of the column will allow this connectio. A female connector 9 fixed to the end of the cable 10 is adapted for cooperating with the male connector 8. The female connector 9 may be lowered into the drill string by gravity and/or possibly by pumping.
The projection and retraction of dog 7 may be controlled by electric signals transmitted through conductors incorporated in a drill string.
Movement of the casing may be produced in several ways.
In what follows, several moving methods will be mentioned which in no wise limit the scope of the present invention.
In the case where the friction of the casing on the walls of the well is sufficiently higher than that of the casing on the probe, it will be possible to have locking means 6 which immobilize the probe in its protective position illustrated in FIG. 1. Thus, during lowering of the tool, this latter remains protected.
When it is desired to uncover the tool retraction of the locking means 6 is controlled for example by means of electric signals transmitted through cable 10 and the connectors 8 and 9. It is then sufficient to push on the drill string to cause the tool 1 to leave the casing 4, as is the case in FIGS. 2 and 4.
The casing 4 will not advance if the forces which retain it and which are due to the forces between the casing and the walls of the well are sufficient to overcome the drive forces which result from the forces due to the friction of the casing on the probe and possibly to the weight of the casing. Of course, the forces due to the weight of the casing do not come into play when the probe is brought out in a horizontal portion of a well.
It is obvious that if the tool is to be moved in the direction of a deeper and deeper penetration into the well, while out of its casing, it will not be necessary to lock the casing 4 in the tool extended position.
On the other hand, if the tool is to be moved in the opposite direction, while out of its casing, it will be necessary to lock the casing in the extended tool position.
This may be achieved for example by means of second anchoring and locking means which may comprise dogs 11 (FIG. 4). Of course, still without departing from the scope of the present invention, a single anchoring or locking means may be used adapted for immobilizing the casing in the tool extended position and in the tool retracted position.
FIGS. 3 and 4 show the case where the protective casing 4 is equipped with centering tools 12 and 13. This centering tool may be of the blade type.
The use of centering tools maintains the casing in the center of the well, and consequently the tool in the case where the tool is centered with respect to the casing.
In addition, in some cases, it is the centering tools which induce a friction force between the casing and the well 14.
Moreover, the embodiment shown in FIGS. 3 and 4 illustrates a device of the invention having first means 7 for anchoring or locking the casing in the probe protected position and second means 11 for anchoring and locking the casing 4 in the probe 1 extended position (FIG. 4).
The first locking means comprise dogs 7 which cooperate with an axial bearing surface 15 integral with tool 1 for defining a space which will limit the movement of the second guide member 5 which, in this case, will also play the role of axial stop.
The same goes for the second locking means. The movement of the second guide members 5 which serve as axial stops is limited on the one hand by an axial bearing surface 16 integral with the drill string and by the dogs 11.
The dogs of the first and second locking means are included in the space defined by the bearing surface integral with the tool and by the bearing surfaces integral with the drill string.
FIGS. 5 and 6 show the casing in the probe protected position and in the probe extended position respectively.
In the case of these Figures, movement of the casing is obtained by hydraulic means.
The device shown in FIGS. 5 and 6 includes a hollow drill string 2 and a passage 17 passing through the first guide member 3.
The passage 17 opens at one of its ends into the drill string 2 through an orifice 18 and at its other end into a chamber 19 defined by the second guide member 5 and the bearing surface 15 integral with the tool through an orifice 20.
In the upper part of the casing a clearance 21 has been provided so as to better allow the pressure forces to cause movement of casing 4 in the probe extended position, when the anchoring or locking means 7 are retracted.
Thus, when fluid is pumped inside the drill string, it passes through passage 17, arrives in clearance 21 and causes chamber 19 to expand casing 4 to rise. This operation is equivalent to that of a hydraulic cylinder.
Casing 4 may include orifices 22 situated in the lower part of the casing 4 so that these orifices are uncovered when the probe is extended. This will allow the pumped fluid to flow.
The device shown in FIG. 6 includes means 11 for locking or anchoring the casing in the tool extended position.
For moving the casing in the probe protected position, after stopping pumping of the fluid the means 11 for locking the casing may be retracted and a pull exerted on the drill string 2 until the casing 4 covers tool 1 again, then the first locking means 7 may be tripped.
Of course, other means may be used for moving the casing into the tool protected position, particularly hydraulic systems the reverse of those described above whose operations will be equivalent to that of a double acting cylinder.
The control of the different valves required for operating such a device equivalent to a double acting cylinder could be provided by electric signals or by information transmitted by the fluid flowing in the drill string, particularly by inserting flow rate or pressure sensors.
It is evident that if the female connector 9 is lowered by pumping a flow orifice may be provided in the low part of the column. This orifice may be closed when the female connector is in place.
In one embodiment of the device of the invention it will be possible, when it is desired to work in a given zone of the well, to lower the tool and the casing beyond the working zone, the casing then being in the tool protected position, then to extract the tool and return to the working zone.
Such a method of operation avoids penetrating into the well with the tool extended and so avoids destruction of the tool against an obstructing element in the well such as cave-ins.
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The present invention provides a device and method for protecting, by means of a casing, a measuring instrument or a specialzied tool fixed to the end of a drill string. Said drill string has substantially at is end and before said tool a first guide member and said casing has a second guide member, said first and second guide member being adapted for cooperating together so as to allow movement of said casing relatively to said tool or instrument.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF INVENTION
[0001] The invention relates to lift systems for raising and lowering window blinds that have lift cords such as pleated shades, roman shades and venetian blinds.
BACKGROUND OF THE INVENTION
[0002] Venetian type blinds have a series of slats hung on ladders that extend from a headrail to a bottomrail. In most venetian blinds a pair of lift cords is provided each having one end attached to the bottomrail and then passing through elongated holes in the slats up to and through the headrail. When the lift cords are pulled downward the blind is raised and when the lift cords are released the blind is lowered. A cord lock is usually provided in the headrail through which the lift cords pass. The cord lock allows the user to maintain the blind in any desired position from fully raised to fully lowered. Pleated shades and roman shades are also raised and lowered by lift cords running from the bottom of the shade into a headrail. The cord lock system and other cord lift systems used in venetian blinds can also be used in pleated shades and roman shades. Another type of lift system for window blinds utilizes a take-up tube for each lift cord. These tubes are contained on a common shaft within the headrail. Each lift cord is attached to one end of a tube. The tubes are rotated to wind or unwind the lift cord around tubes. This system is generally known as a tube lift system. Some tube lift systems are operated by a continuous loop cord that passes over one end of the axle and extends from the headrail.
[0003] In recent years the art has been concerned that cords, particularly looped cords, pose a strangulation threat to children who may become entangled in the cords. Consequently, there has been much interest in cordless blinds. These blinds rely on electric motors or spring motors to raise and lower the lift cord. One common cordless blind simply contains a motor connected to a tube collection system within the headrail. Another cordless blind relies upon a constant force spring motor attached to a spool or spools on which the lift cords are collected. This type of cordless blind is disclosed by Coslett in U.S. Pat. No. 5,105,867 and by Kuhar in U.S. Pat. Nos. 5,482,100; 5,531,257 and 6,079,471.
[0004] Coslett discloses a sun shade having a series of blades connected together to form a serrated shape like a pleated shade. The upper blade is mounted within a hollow housing and the lower blade is secured to a plate member. A constant force spring plate is wound around a spring spool member and further engaged to an output spool, both of which are within a hollow handle secured to the hollow housing. A cord is connected to the output spool and passed from the handle through the housing and the blades and is connected to the plate member. Such a cording arrangement is similar to that of a lift cord in a pleated shade or venetian blind. The spring retains the blades in a folded closed position. When the shade is extended the spring exerts tension on the cord. Consequently, Coslett teaches the user to fix the plate member along one side of the window and to provide a hook to retain the hollow housing at the opposite side of the window when the shade is covering the window. Thus, Coslett's shade can be in only one of two positions, fully extended to cover the window or fully retracted. Furthermore, Coslett's blind is not suitable for installation in an orientation in which one rail is fixed at the top of the window frame as is done for most building windows. That is so because when the blind is fully retracted most people could not reach the handle to extend or close the blind without standing on a stool or ladder.
[0005] Kuhar discloses a cordless, balanced blind that contains at least one constant variable force spring motor in the headrail. The springs in these motors vary in thickness or in width along their length as they are wound around storage drums. A cord spool is coupled to one or more spring drums. The lift cords of the blind are wound about the spool. Thus, the spring winds or unwinds as the blind is raised or lowered. The difference in width or thickness of the spring compensates for the increasing weight of the blind on the cords as the window covering is raised and the decreasing weight as the blind is lowered. Kuhar teaches that much effort be made to select and couple the spring motor to the cords so that the bottomrail is balanced at any and every position. Kuhar further teaches that several spring motors may be coupled together.
[0006] Placing the spring motors in the headrail as taught by Kuhar requires that the headrail be tall enough and wide enough to accommodate the spring motors. Consequently, the headrail must be larger than would be required if no spring motors were in the headrail. If one placed the spring motors in the bottomrail, a smaller headrail could be used; however, the weight of the bottomrail would be increased. Increasing the weight of the bottomrail would make it much more expensive to balance the bottomrail in any and every position as Kuhar teaches is critical. Perhaps this could be accomplished with more or larger spring motors, but that would change the dynamics of the blind. For that reason one following the teachings of Kuhar would be lead away from putting spring motors in the bottomrail.
SUMMARY OF THE INVENTION
[0007] I provide a cordless blind containing one or more springs in the bottomrail of the blind. Preferably the spring is a constant force spring motor of the type disclosed by Coslett and Kuhar. The spring motor is connected to at least one cord collector in a manner to maintain tension on the cord collector. The tension causes the lift cords to be collected on the cord collector when the cord collector and the lift cords are free to move, thereby moving the bottomrail toward the headrail. I further provide a lock mechanism attached to the cord collector or the lift cords. The lock mechanism has a locked position wherein the lift cords are restrained from being collected on the cord collector and has an unlocked position that allows the cord collector and plurality of lift cords to move freely. I prefer that the lock mechanism be biased toward a locked position. However, a two position, i.e. locked or unlocked, lock mechanism could be used. I further prefer to provide a button on the bottomrail to operate the lock mechanism.
[0008] The cordless blind of the present invention is easy to operate. A user simply presses the button to release the lock and either pulls the bottomrail down or allows the spring motor to raise the bottomrail. When the button is released the lock engages if the lock is of the type that is biased to a locked position. If a two position lock is used the user presses the button, moves the bottomrail to a desired position and presses the button again to lock the lock mechanism. Because the lift cords and cord collector are no longer free to move, the bottomrail stays in the position where it was when the button was released.
[0009] This cordless blind could be a pleated shade, a cellular shade, a roman shade or a venetian blind. If the shade is a venetian blind I prefer to provide ladders in which the rails of the ladders are connected to form a continuous loop. Then the slats can be tilted with a conventional tilt mechanism in the headrail.
BRIEF DESCRIPTION OF THE FIGURES
[0010] [0010]FIG. 1 is a rear perspective view of a present preferred embodiment of my cordless blind.
[0011] [0011]FIG. 2 is a sectional view taken along the line II-II of FIG. 1 wherein a portion of the front wall of the bottomrail has been cut away.
[0012] [0012]FIG. 3 is an enlarged view of the spring motor in the embodiment shown in FIGS. 1 and 2.
[0013] [0013]FIG. 4 is a perspective view similar to FIG. 3 of an alternative spring motor that can be used in the cordless blind of the present invention.
[0014] [0014]FIG. 5 is a front view of three interconnected spring motors that can be used in the cordless blind of the present invention.
[0015] [0015]FIG. 6 is a front view of two interconnected spring motors that can be used in the cordless blind of the present invention.
[0016] [0016]FIG. 7 is an end view of a ladder and associated pulleys that can be used when the cordless blind of the present invention is configured as a venetian blind.
[0017] [0017]FIG. 8 is a front view of an alternative motor and lock mechanism for a second present preferred embodiment of my cordless blind.
[0018] [0018]FIG. 9 is a perspective view of a bottomrail partially cut away to show for a third present preferred embodiment of my cordless blind.
[0019] [0019]FIG. 10 is a schematic representation of a fourth present preferred embodiment of my cordless blind.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] A present preferred embodiment of my cordless blind shown in FIG. 1 is comprised of a headrail 2 , a bottomrail 4 and a window covering material such as cellular material 6 connected between the headrail and the bottomrail. The window covering material could also be a single panel of pleated material, roman shade material or a set of slats carried on ladders as in a venetian blind. The blind could be any width or length and likely would be larger than the blind shown in FIG. 1. Lift cords 8 are fixed within the headrail, pass through the window covering material and into the bottomrail. Although only two lift cords 8 are shown in FIG. 2 it should be understood that the cordless blind could have more lift cords with the number of lift cords being related to the width of the blind. The lift cords 8 are collected on cones 10 within the bottomrail The cones each have a central bore that enables them to be mounted on a common axle 12 . The axle 12 is coupled to a spring motor 20 shown in detail in FIG. 3. If desired the cones could be omitted and the cords could be wrapped on the axle.
[0021] In a standard tube lift the lift cord is wound about a cylindrical tube or cylindrical axle. Consequently, each rotation of the axle will collect or release a length of cord equal to the circumference of the tube which can be calculated from the equation L=π dn where d is the outside diameter of the tube plus the diameter of the cord and n is the number of revolutions. In blinds for standard residential and commercial windows the axle may rotate 40 or more times to fully raise or lower the blind. All window blinds that have lift cords will have at least two lift cords and each lift cord is wound on a separate tube. Although all tubes and cords are supposed to be the same diameter, one tube or cord often is larger than the diameter of another tube or cord with differences in diameters often being 0.005 inches and may be as much as 0.010 inches. Since the spool will rotate as many as eighty to over a hundred times to fully lower the blind, that means one lift cord will be lowered 0.4 inches more than the other lift cord. A difference of 0.25 inches is noticeable to a person looking at the blind or shade. Hence, if there is a difference in diameters in the cords or the axles the bottom of the shade will appear to be tilted. If the blind has more than two cords and the short cord is in the middle the bottomrail acts like a teeter-totter pivoting about the short middle cord and the whole blind oscillates as the blind is being raised or lowered.
[0022] In the lift system shown in FIG. 2 the total length of lift cord that will be released is determined by the equation:
L = π d 1 - d 2 2
[0023] Because a cone offers a series of different diameters a fabricator can position the cones on the axle so that the lift cords begin wrapping at different locations on the cones. Consequently, the fabricator can compensate for variations among cones and cords. The result is that every blind can be fabricated so that the bottom of the blind is level when the blind is fully lowered. The fabricator can adjust the position of the cord simply by rotating the cone relative to the axle.
[0024] Referring to FIGS. 2 and 3 the spring motor 20 has a bracket 21 on which a storage drum 22 and an output drum 24 are rotatably mounted in a spaced apart relationship. The storage drum is free to rotate about axle 23 . When the output drum 24 rotates it turns axle 25 and attached worm gear 26 . Output drum 24 has gear teeth or an attached gear 27 that engages gear 30 . When worm gear 26 turns, worm gear 28 on shaft 12 will also turn turning the shaft 12 . A spring 29 is coupled between the storage drum 22 and the output drum 24 . The spring provides a constant tension on the lift cords acting through the axles 23 and 12 and gears 26 and 28 . The spring 29 may be configured in one of several ways to provide the desired tension. The first configuration has a constant thickness throughout the length of the spring. One end of the spring is narrower than the opposite end of the spring with the width gradually increasing or decreasing form one end to the other end. The narrow end is attached to the center of the storage drum 22 and the wider end attached to the center of the output drum. The spring is wound from one drum to the other in an opposite coil orientation. As the spring 29 is transferred from the storage drum 22 to the output drum 24 , the width of the spring between the two drums will decrease and the spring will be wound oppositely to its original coil shape. Another embodiment of the spring varies in thickness from one end to the other end but has a constant width. The thinner end is attached at the core of the storage drum. The thicker end is attached to the core of the output drum. As in the first configuration, the orientation of the spring as it is transferred from the storage drum to the output drum is reversed. A third possible configuration is for the spring to vary in both width and thickness. Also, a laminated coil spring could be used.
[0025] A control shaft 32 extends from hub 31 to a control box 34 . The control shaft carries a pawl 30 having teeth that will mesh with gear teeth 27 on drum 24 . Control shaft 32 does not rotate but can move transversely along its centerline. Consequently, when pawl 30 engages the teeth 27 on drum 24 , the drum as well as the spring motor and the lift cords will not move. Button 36 controls movement of control shaft 32 . In one configuration a spring is provided within hub 31 or control box 34 that biases the shaft to a locked position in which the pawl 30 engages the teeth on drum 24 . Consequently, The drum, spring motor and lift cord will not move until and unless button 36 is pressed. To operate the blind a user simply presses the button to release the lock mechanism and either pulls the headrail down or allows the spring motor to raise the bottomrail. While the lock is in this unlocked position the spring motor will cause axle 12 to turn collecting the lift cords on the cones. This force is such that a person can easily overcome the spring motors by pulling down on the bottomrail. The downward force will cause the axle 12 to rotate in an opposite direction playing out the lift cords and winding the spring in the spring motors in an opposite direction. When the button is released the lock engages. Because the lift cords and cord collector are no longer free to move, the bottomrail stays in the position where it was when the button was released. An alternative is to provide a two position button such that pushing the button once will cause the pawl to move away from the teeth on drum 24 . The pawl will stay in that unlocked position until the button is pressed again. The second push of the button moves shaft 32 returning the pawl 30 to the locked position in engagement with teeth 27 on drum 24 .
[0026] Several other configurations of spring motors can be used. The spring motor of FIG. 4 has a storage drum 22 and a take up drum 24 carried on a bracket 41 with a spring 43 connected between them. This spring can be any of the springs described as suitable for use in the first embodiment and operates in the same manner. In this embodiment the lift cords 8 are collected on a spool 44 carried on a common axle 42 with the take up drum 24 . Consequently, the take up drum 24 and the spool 44 will turn together in the same direction. As in the first embodiment there is a lock mechanism (not shown) that is connected to the take up drum through a gear mechanism or other suitable means.
[0027] Another spring motor configuration is illustrated in FIG. 5. This spring motor 50 has three take-up drums 52 each carrying a spring that is also connected to an associated storage drum 54 . A link 56 connects the take up drums together. The lift cords are wound on spools connected to a respective storage drum. This spool and take up drum configuration is similar to the spool 42 and take up drum 24 shown in FIG. 4. In the embodiment of FIG. 5 the spools are behind the take up drums and thus are not visible in the figure. A spring 59 is connected between each storage drum 54 and take up drum 52 pair. This spring can be any of the springs described as suitable for use in the first embodiment and operates in the same manner. A lock mechanism (not shown) is connected to at least one of the storage drums. The lock mechanism operates in the same manner as the lock mechanism described in the embodiment of FIGS. 1, 2 and 3 .
[0028] Yet another spring motor configuration is shown in FIG. 6. The spring motor 60 has two take-up drums 62 each carrying a spring 69 that is also connected to an associated storage drum 64 . This spring can be any of the springs described as suitable for use in the other embodiments and operates in the same manner. The two storage drums have gear teeth or an associated gear that meshes with gear 66 . Thus, the two storage drums will turn simultaneously but in opposite directions. A lock mechanism (not shown) is connected to the gear 66 or to at least one of the storage drums. The lock mechanism operates in the same manner as the lock mechanism described in the embodiment of FIGS. 1, 2 and 3 .
[0029] In the event that the cordless blind is a venetian type blind I prefer to configure the ladders as shown in FIG. 7. Those ladders 70 have opposite rails 71 , 72 having rungs between them that carry slats 73 . The ends of the rungs 71 , 72 are connected together to form a loop. Pulleys 74 and 75 in the headrail 2 and the bottomrail 4 are positioned at either end of the loop and support the ladder. The slats can be tilted by pulling one of the ladder rails up or down as indicated by the double-headed arrow or a conventional tilt mechanism can be provided in the headrail.
[0030] Second and third present preferred embodiments of my cordless blind utilize a cord lock in conjunction with one or more spring motors. The spring motor and lock mechanism for the second embodiment shown in FIG. 8 has a single spring motor with a take up drum 24 and storage drum 22 . A cord collector spool 42 is carried on the same axle that carries take up drum 42 . Consequently, the spring motor will try to wind the lift cords 8 onto the spool 42 . The lift cords are routed through a cord lock 44 . When the cord lock is in a locked position, the lift cords cannot be wound onto the spool. When the cord lock is unlocked the spring motor will wind the lift cords onto the spool raising the blind. Furthermore, while the cord lock is unlocked a user could pull the bottomrail down overcoming the force of the spring motor and lowering the blind. The cord lock could be biased to a locked position of could require manual operation to lock and unlock the cord lock. The third present preferred embodiment has a bottomrail illustrated in FIG. 9 containing two spring motors 40 similar to the motor shown in FIGS. 4 and 8. The lift cords 8 are routed through the bottomrail, over a pulley 45 , through a cord lock 44 to a spool on the spring motor 40 .
[0031] A fourth present preferred embodiment of my cordless blind is illustrated by the schematic of FIG. 10. That blind 80 has a headrail 82 , bottomrail 84 and window covering material 86 connected between the headrail and bottomrail. Spring motors 81 and 83 are provided in both the headrail and the bottomrail. The spring motors 81 in the headrail are sized so as to be unable to lift the blind without the help of the spring motors 83 in the bottomrail 84 . Lift cords 88 are connected to the spring motors 81 in the headrail as well as the spring motors in the bottomrail 84 . The lift cords 88 pass through a cord lock 85 that operates like the cord lock in the embodiments of FIGS. 8 and 9.
[0032] It should be noted that in all of the embodiments the button that operates the lock mechanism is within the bottomrail. Consequently, no operator cords or wands are needed to operate the blind. The button is easily reached when the blind is partially lowered or in a finally lowered position.
[0033] While I prefer to provide a lock mechanism to control movement of the spring motors and the lift cords, a cordless blind could be made with the spring motors only in the bottomrail and without a lock mechanism by carefully choosing the spring motors to balance the bottomrail when the bottomrail is at selected positions such as would correspond to a fully open or half open blind. That cordless blind could have a cording arrangement of the types shown in FIGS. 2, 8 or 9 without the cord lock.
[0034] Although I have shown certain present preferred embodiments of my cordless blind it should be distinctly understood that the invention is not limited thereto, but may be variously embodied within the scope of the following claims.
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A cordless blind contains one or more springs in the bottomrail of the blind. Preferably the spring is a constant force spring motor and is connected to at least one cord collector in a manner to maintain tension on the cord collector. The tension causes the lift cords to be collected on the cord collector when the cord collector and the lift cords are free to move, thereby moving the bottomrail toward the headrail. Preferably, a lock mechanism is attached to the cord collector or the lift cords. The lock mechanism has a locked position wherein the lift cords are restrained from being collected on the cord collector and has an unlocked position that allows the lift cords and cord collector to move.
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FIELD OF THE INVENTION
The present invention relates generally to a building construction system, the components thereof, and method therefore. More specifically, the present invention relates to a building construction system that utilizes specifically designed component parts that fit together, such as by male/female connections, and are permanently attached through the use of an adhesive, or bonding glue, to create an extra strong and uniformly tight structure. In effect, the end result is equivalent to a one-piece construction since all components are permanently “chemically welded” to each other with all components being made from the same type of materials.
BACKGROUND
Construction of private dwellings, both in the United States and abroad, has been substantially limited by the relatively low availability of skilled labor and high strength building materials. Furthermore, the construction of dwellings is often influenced by frequently encountered high/low heats and humidities at the construction sites, combined with the resultant biological attacks on the structure from mildew, insects and organisms which thrive in hot and/or humid environments. In third world countries, one solution that has existed for ages in such locations is to make the housing out of relatively flimsy, locally available materials, such as palm fronds or straw and the like, combined with mud and clay infused into a bare structure. However, such structures, while certainly economical, provide little in the way of genuine protection from the elements and provide extensive cover for insects and vermin. Thus, it is very difficult to prevent the spread of disease in and among such dwellings, and the quality of daily life in such structures is necessarily low. Furthermore, such construction is not amenable to housing modem equipment or perishables, offers little shelter from the elements and thus severely limits their use for business purposes.
Important in the consideration in building construction, especially in the United States, are the high cost of construction because of the large amount of skilled labor required in the construction process. Therefore, it would be useful to provide a construction design that would not use expensive materials and does not require large amounts of skilled labor, and is easily erected at the site where the housing is desired.
Normal construction of buildings requires the use of many different and varied construction labor techniques and skills. Often it requires carpenters, for wood construction, masons, for cement and brick construction, roofers, drywall installers, and others. Furthermore, normal conventional construction requires the use of many and varied materials, such as plywood, wood rafters, drywall, bricks or concrete blocks, roofing materials, to name a few. These materials are typically connected together using a variety of connectors, such as nails, screws, staples, pegs and the like. While the resulting building provides shelter or housing, it is expensive due to the various materials and various different skills required to complete the construction. In addition, it takes a considerable amount of time to complete the construction due to the coordination required between the various labor skills and material application processes. In summary, the resulting cost for constructing any structure is high and the length of time until completion is long.
Furthermore, the strength of different buildings will vary substantially based on the quality of the materials used and the skills of the individual work specialists performing their specific duties. Currently, there is no uniformity in the building strength as compared to other buildings. Therefore, it is useful to provide a building system that requires only one type of material and can use the same labor force for all facets of construction.
Moreover, existing building construction systems also result in wide variances as far energy efficiency is concerned. One building may be very cost effective as far as the costs of heating and air conditioning are concerned where another of the same size, by comparison, may be very expensive for such costs. It would be useful for a construction system to provide uniform and equal energy costs that will also be very low.
An object of the present invention is to alleviate the above described disadvantages of the prior art, by alleviating the problems of uneven and high energy costs, time delays in the construction process, lack of uniformity in the final building's physical strength, and the high financial cost of construction. In addition, since all components of the present invention are “pre-made” to fit the individual building pattern, then waste and unnecessary material are at an absolute minimum as compared to considerable wasted materials in all current building construction systems.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a unique construction system that uses unique building materials that are specifically designed for this process so that the resulting construction is simpler and more economical than conventional and other construction systems that are currently being used for “on-site” construction of residential and all other building construction projects. This system is primarily orientated to one or two levels in height.
It is another object of the present invention to have this new system available for use, with some modifications, for the construction of pemanent and mobile home construction.
It is a further object of the present invention to improve the physical strength and safety of the final construction project substantially over the physical strength of buildings that are built using currently acceptable methods.
It is yet another object of the present invention to provide a construction process that is so simple that almost anyone can construct a safe and usable building even if they are not highly educated or trained in the fields of construction. Thus allowing a substantial increase in labor resources that can be used to build the buildings according to the present system.
It is yet a further object of the present invention to provide a construction process that uses unique materials, which can be mass-produced on a very economical basis.
It is yet a further object of the present invention to provide a building process that is flexible enough to allow for unlimited construction design applications and to accomplish attractive esthetic exterior and interior designing.
It is still yet a further object of the present invention to provide an end product that is substantially energy efficient and that requires little or no maintenance regardless of weather conditions or the physical location of the building.
It is another object of the present invention to provide a construction process that requires the use of only a specialized glue for all permanent connections, as opposed to most construction processes that currently require nails, screws, or other forms of hardware to be used to inter-connect the materials used in the construction process.
It is a further object of the present invention to provide a building process that uses the same materials, and thus available from a single supplier, as opposed to conventional building processes that require several different types of materials, such as wood studs, plywood, drywall, various ceiling tiles, masonry products, roofing materials and the like.
The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its structure and its operation together with the additional object and advantages thereof will best be understood from the following description of the preferred embodiment of the present invention when read in conjunction with the accompanying drawings. Unless specifically noted, it is intended that the words and phrases in the specification and claims be given the ordinary and accustomed meaning to those of ordinary skill in the applicable art or arts. If any other meaning is intended, the specification will specifically state that a special meaning is being applied to a word or phrase. Likewise, the use of the words “function” or “means” in the Description of Preferred Embodiments is not intended to indicate a desire to invoke the special provision of 35 U.S.C. §112, paragraph 6 to define the invention. To the contrary, if the provisions of 35 U.S.C. §112, paragraph 6, are sought to be invoked to define the invention(s), the claims will specifically state the phrases “means for” or “step for” and a function, without also reciting in such phrases any structure, material, or act in support of the function. Even when the claims recite a “means for” or “step for” performing a function, if they also recite any structure, material or acts in support of that means of step, then the intention is not to invoke the provisions of 35 U.S.C. §112, paragraph 6. Moreover, even if the provisions of 35 U.S.C. §112, paragraph 6, are invoked to define the inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function, along with any and all known or later-developed equivalent structures, materials or acts for performing the claimed function.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a pillar support according to the present invention.
FIG. 2 is a bundle of pillar supports according to the present invention.
FIG. 3 illustrates how a pillar support is inserted into a pre-dug hole and onto a REBAR structure according to the present invention.
FIG. 4 illustrates the pillar support after insertion into the pre-dug hole, according to the present invention.
FIG. 5 illustrates the pillar support top according to the present invention.
FIG. 6 illustrates the main support beam according to the present invention.
FIG. 7 illustrates how the main support beam attaches to the pillar support tops according to the present invention.
FIG. 8 illustrates the main support beam after attachment to the pillar support tops.
FIG. 9 illustrates how a vertical support attaches to the basic support beam according to the present invention.
FIG. 10 illustrates several vertical supports attached to a main support beam.
FIG. 11 illustrates how wall panels according to the present invention are attached to the vertical supports and major support beam.
FIG. 12 illustrates an exterior wall with wall panels in place.
FIG. 13 illustrates the installation of floor panels according to the present invention.
FIG. 14 illustrates the installation of the wall top plate according to the present invention.
FIG. 15 illustrates the wall top plate after installation according to the present invention.
FIG. 16 illustrates a wall that includes special supports for plumbing and electrical needs.
FIG. 17 illustrates the how the floor joists are placed to support the floor panels.
FIG. 18 illustrates a second wall (in dashed lines) connected to a corner post.
FIG. 19 shows the addition of an interior wall (in dashed lines).
FIG. 20 shows the addition of ceiling rafters and ceiling panels.
FIG. 21 illustrates the ceiling rafters and panels in place.
FIG. 22 illustrates the placement of roof rafters for a typical roof structure.
FIG. 23 illustrates how roof panels are attached to the roof rafters.
FIG. 24 illustrates a more detailed view of use of the roof rafters and roof panels.
FIG. 25 illustrates a more detailed view including a portion of the ceiling in place.
FIG. 26 illustrates a corner joist.
FIG. 27 is a top perspective view of a ceiling panel.
FIG. 28 is a bottom perspective view of a ceiling panel.
FIG. 29 illustrates how the connectors are used to splice two supports together end-to-end.
FIG. 30 a is flat roof framing embodiment.
FIG. 30 b is a peaked roof framing embodiment.
FIG. 30 c is a high peaked roof framing embodiment.
FIG. 31 a illustrates the framing of a window opening.
FIG. 31 b illustrates the framing of a door opening.
FIG. 32 is a groove cover according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is a building system and components that are useful for the quick and easy construction of buildings and the like. The process starts with a foundation for the structure and works upwards in a logical and systematic manor developing the framework, walls, floors, basic utility service connections, ceilings and roofing system progressively and logically so that when the structure's roof is finished there is nothing else to do except install the utilities, such as plumbing, electric, ventilation, and the like, and the decorating features, such as painting, paneling, interior closets, and the like. In a preferred embodiment, the system uses “color coded” building materials and the simple design of the “special building materials” that are described herein.
There are several benefits of the present invention over prior art systems. The cost of materials are less than the cumulative costs for the materials necessary for conventional wood framed construction because there are a lot of different types of products necessary for existing constructions but only one type of material is required for the present invention. The “time factor” for current construction is much longer than that which applies to the present design, because the present design is extremely simplified and all the materials are already exactly the proper lengths. The amount of time required for construction will be at least 50% less than that required for current construction methods. And the design of the present invention is not limited to housing construction, but applies to any type of building from barns and garages to five story apartment complexes.
Referring now to the drawings for a more complete understanding of the invention, FIG. 1 is a view of a pillar support 10 according to the present invention. The pillar support 10 a hollow tubular structure, preferably a hollow tube with a generally square or rectangular cross section. Most preferably, the pillar supports 10 are 8 inches by 8 inches square hollow tube-like structures and come in 8 foot long (or longer) sections. Both ends of the pillar support 10 are open to receive inserted materials. As illustrated in FIG. 2, these pillar supports may be conveniently packaged in space saving bundles for easy shipment. The building ultimately constructed will be secured to the ground by use these pillar-supports 10 . The pillar supports 10 are cut to the required length on site.
As illustrated in FIGS. 3 and 4, the pillar supports 10 are installed into pre-dug holes into the ground, said holes being at least 3 feet in depth and having reinforcing bars 5 or (REBAR) steel rods wired together to form an “anchor”. The hole, with the pillar support 10 and REBAR structure 5 in place, is then filled with concrete leaving at least 5 inches of the top of the pillar support 10 exposed for the attachment of a pillar support top 15 . See FIG. 5 .
After the pillar supports 10 have been properly installed at all major stress and support points in the building plans, the pillar support tops 15 , illustrated in FIG. 5, are attached to the pillar supports 10 . The pillar support tops 15 are caps that have a receiving cavity that closely matches the outside size and shape of the top of the pillar supports 10 . Located on a top surface of the pillar support tops 15 are vertical ribs 20 that extend between two opposite sides of the pillar support top 15 . The ribs 20 are preferably 1 inch by 1 inch in cross sectional size. The pillar support tops 15 are attached to the pillar supports 10 by gluing them onto the pillar supports 10 with the vertical 1 inch by 1 inch ribs 20 running parallel to the intended wall's borders. This assures a secure attachment to the ground.
Next, main support beams 25 are attached by an adhesive onto the top of the pillar support tops, FIGS. 6, 7 , 8 , and 9 . The main support beams 25 are substantially rectangular in cross section. There are two bottom grooves 30 that extend longitudinally from one end of the main support beam 25 to the opposite end, on a bottom surface. The two bottom grooves 30 are preferably symmetrically located on the bottom surface. Located on a top surface are two top grooves 35 . The two top grooves 35 , like the two bottom grooves 30 , extend from one end of the main support beam 25 to the opposite end, but on the top surface. The two top grooves 35 , however, are not symmetrically located on the top surface, but are located predominantly to an outside edge. The ribs 20 on the pillar support tops 15 fit into two bottom grooves 30 located in the main support beams 25 in such as way that the two top grooves 35 are located on the outer-most side of the building's wall. This forms the “foundation for the building's structure”. This also provides for the secure attachment of the rest of the building's structure to the pillar supports 10 and therefore to the ground.
Next, all basic vertical supports 40 , which are preferably 4 inches by 4 inches, and special supports 45 , as illustrated in FIGS. 10 and 16, that are designated in the building plans for utility, such as electric and plumbing, connections are attached to the main support beams 25 at 2 foot intervals, on-center, by means such as adhesives. The basic vertical supports 40 are substantially rectangular in shape with two sets of grooves 42 , on opposite sides, that extend from one end of the basic vertical support 40 to the opposite end. Additionally there are two sets of ribs 44 , one set located on each opposite end of the vertical support 40 . The special vertical supports 45 have the grooves 42 and the ribs 44 and include a structure for plumbing connections, which have a plumbing conduit installed in the center with a universal connector on top and in a plumbing outlet junction box that opens to the interior of the building. Another embodiment of the special vertical supports 45 is for electrical connections. This embodiment includes an electrical outlet box that may be located either adjacent to one end or substantially in the middle of the special support 45 . As with the plumbing version, there is a conduit installed in the center with a universal connector on top and in the electrical outlet junction box. When attaching the vertical supports 40 and 45 to the basic support 25 , the ribs 44 located at one end of the vertical supports 40 and 45 are fit into the two top grooves 35 located on the top surface of the main support beam 25 and glued into place. This provides the vertical support for the building as well as the receptacles (the grooves 42 ) for interior and exterior wall panels, 50 and 55 .
As illustrated in FIGS. 11 and 12, the internal as well as exterior wall panels, 50 and 55 , are then attached to the walls by applying glue to the grooves 42 and 35 , aligning a male “lip” 53 located on the edges of the panels, 50 and 55 , with the grooves 42 located on the sides of the vertical and special vertical supports 40 and 45 , and “sliding” the wall panels 50 and 55 place. This increases stability and building strength as well as providing an insulated wall system with all basic utility service connections already in place. Further, since there is a space between the internal and exterior wall panels, 50 and 55 , additional insulation or support materials may be incorporated into the structure.
Exterior corners are created using a corner post 47 at the corner of the structure, as illustrated in FIG. 18 . The corner post 47 , shown in FIG. 26, has two sets of grooves 42 and ribs 44 , like the vertical support 40 , however instead of being on opposite sides, the grooves 42 of the corner post 47 are on adjacent sides. In this manner, a 90-degree corner may be constructed. Shapes other than square or rectangular may be used for the corner post 47 to create corners with different angles and still fall within the scope of the present invention. In order to complete the corner structure a matching corner cap (not illustrated) with matching grooves and ribs is used to fill in the three-sided gap at the top of the corner. This corner cap may have any shape, as long as it snugly fits into, and seals, the top corner void.
Next, floor joists 60 , as illustrated in FIG. 17, are installed by laying the floor joists 60 laterally across the main support beams 25 and gluing into place. The floor joists 60 are secured into place on 2-foot centers starting in the right front corner of each room. The floor joists 60 provide the strength and support for floor panels 65 and create an even more secure building structure that is firmly attached to the ground. The floor joists 60 are pieces that have substantially rectangular cross section, said pieces have two bottom grooves 30 that extend longitudinally from one end to the opposite end on a bottom surface and two top grooves 35 that extend from one end to the opposite end on a top surface, said two bottom grooves 30 further adapted to receive the two ribs 20 on the pillar support tops 15 .
After the floor joists 60 are installed and secured into place, the floor panels 65 are positions over the floor joists 60 and glued into place, starting in the right front corner of each room, see FIG. 13 . The floor panels 65 , which preferably have a first lip near a top surface along one edge and a second lip near a bottom surface along an opposite edge such that the two lips are adapted to overlap when placed upon the floor joists 60 , are secured by gluing, to the floor joists 60 and to adjacent floor panels 65 as they are installed. The resulting floor structure is designed to be very strong and thermally comfortable, due to the insulation that is incorporated into the floor panels 65 at the factory. The floor panels 65 provide a quality surface for any covering that the owner chooses and will never squeak or crack as some conventional floor systems do.
After the floor panels 65 are installed, a wall top plate 70 is attached to the walls by simply securing the wall top plate 70 laterally on top of the vertical supports 40 and 45 and projecting lip of the wall panels 50 and 55 and attaching them in place over the lips on the wall panels 65 , see FIGS. 14 and 15. The wall top plate is preferably the same structure as the main support beams 25 , previously described above. All seams and connections are glued in place thus making for an extremely strong structure. This results in a totally sealed and connected structure from the ground to the roof. By using glue to secure all seams of the structure, or other sealants, there is no room for insects, rodents or even large volumes of air to penetrate the building.
As illustrated in FIG. 19, additional interior walls may be added attaching vertical supports 40 along the interior wall line and using interior wall panels 50 , on both sides. A wall top plate 70 is also added to seal the top of the interior wall.
Next, the ceiling for the structure is installed, illustrated in FIGS. 20 and 21. This is accomplished by attaching ceiling rafters 80 on top of the wall top plates 70 between the walls for each room. The ceiling rafters 80 are basically I-shaped joists with a wider lower section than upper section. The ceiling rafters 80 are installed 2 feet on-center starting in the right front corner of each room. The ceiling rafters 80 can come in lengths of up to 24 feet and can be attached to the roof structure with support cables, or by other systems, if necessary to prevent sagging over long spans. Preferably, the ceiling rafters 80 are secured, by glue, to the top plates 70 at all points of contact.
After the ceiling rafters 80 are in place, the ceiling panels 85 are installed in between the ceiling rafters 80 and are glued into place on top of the bottom section of the I-beam and are further glued to adjacent ceiling panels 85 wherever they overlap. The ceiling panels 85 are hollow core and filled with insulation. The ceiling panels 85 have a recess that extends around three sides that are glued to the ceiling rafters 80 . The recess is designed such that the projecting portion of the ceiling panels 85 fits between the ceiling rafters 80 . The basic house framing, floors, utility connection services and ceilings are now completed. The final attachment of the roof is the next step.
Since there can be any number of roof designs, the present description will focus on the simple connection of the roof to the main building and the connection of the roof panels to the roof rafters 90 . The framing structure chosen to fit the roof design would be built using the grooved wall top plates 70 and 1 inch by ¾ inch insert connectors 120 . These would be connected together and attached to the building's frame with the usual gluing process at all points of contact. The roof rafters 90 , illustrated in FIG. 22, are preferably 4 inch by 4 inch hollow square tubular structures that have 1 inch by 1 inch grooves 95 located every 12 inches laterally across the rafter to allow for the attachment of the roof panels 100 . The roof panels 100 are installed from the outside wall top plate 70 and extend to the center roof rafter 90 of the roof and are mounted on 2 foot centers starting with the right side of the building. They are simply glued to the top plates and center rafter at all points of contact. This is illustrated in FIGS. 23, 24 , and 25 .
As illustrative examples, for flat roofs, the roof rafters 90 are placed onto the main support beams 25 on the outside walls and securely attached by glue. For pitch roofs, the roof rafters 90 are notched with a saw at the position where the roof rafter makes contact with the main support beams 25 of the outside walls. The main support beams 25 is then fit into the notch and the rafter 90 is then glued into place. For highly pitched roofs, upright posts cut from 4×4 posts are used as well as side glued cross supports to further strengthen the roof rafter system. The cross supports are glued onto the sides of the upright roof raters. This is done so as to be unobtrusive to any outside coverings. The ends of the roof are paneled using regular wall panels and uprights. However, roof panels may be substituted for the wall panels.
The roof panels 100 are overlapping insulated panels that are installed on top of the roof rafters 90 horizontally so that lips 105 on the panels 100 fit into the grooves 95 on the roof rafters. The roof panels 100 have an overhanging lip 107 that extends substantially around two adjacent edges. There is also a recess 109 located on a top surface that also extends substantially around two adjacent edges, but different edges that those of the overhanging lip 107 . The roof panels 100 are installed starting at the right bottom of the roof section and are glued to the roof rafters 90 and to each other at all points of contact. The resulting roof construction is a roof that is totally water proof, resistant to thermal changes, and extremely strong.
The final step in constructing the basic house package requires the attachment of a roof apex or general purpose overlap panel 110 . The overlap panels 110 are preferably two 4 inch wide connectors that pivot on a hinge joint such that any angle may be achieved through the flexible hinge. The overlap panels 110 are glued onto one roof rafter 90 and then bent and glued to a second roof rafter 90 . The overlap panels 110 cover any seams that may result where two or more roof lines intersect. The overlap panel can also be used to cover outside corners of the structure, door seams, or any other seam that is a result of two or more sections joining together. The overlap panel is secured and sealed, such as by an adhesive, over the seam to secure the junction and to eliminate any possible leaks by air or water.
The present invention is a framing design and only allows for the spaces where traditional doors and windows may be attached. Vertical supports 40 and wall top plates 70 are used to frame openings that are then further framed with wood to the appropriate size for whatever is applied, such as a door or window, by the construction personnel. Any “tracked edges” that are exposed inside the door or window frame are filled in using cover pieces. For example, when framing a window opening, a vertical support 40 is cut to allow for a window box frame opening. When framing a door opening, 1 or 2 upright supports may be cut short from the top and the door opening boxed with a wall top plate 70 to form out the door opening frame.
The basic structure is now completed and is totally inter-connected and secured to the ground. Due to the flexibility of the materials used, and the fact that the preferred adhesive effectively chemically welds the components together into one uniformly strong unit, any outside force, such as wind, water, or even ground movement, will be resisted as if it were affecting a natural single piece structure.
As used in this application, the preferred embodiment of all ribs and channels has length and width measurements that are generally 1 inch by 1 inch. All horizontal beams and rafters will come from the factory marked every 2 feet to facilitate locating proper attachment of vertical supports or panels.
Internal walls are provided by attaching interior wall supports 120 to the structure. The interior wall supports 120 are illustrated in FIG. 24 and are generally rectangular in cross section with two grooves 125 , one located each on opposite sides of the interior wall supports 120 . The two grooves 125 receive interior wall panels 55 , similar to the exterior walls.
Finally, where necessary, there are 1 inch by 2 inch connectors 130 that are substantially flat pieces that are adapted to fit within and between adjacent grooves and that may be used to connect 4×4 structures to created 4×8 or 8×8 composite structures, or interconnect other grooved structures. See FIG. 25 . There are flat end caps 140 that are substantially flat surfaces with four projecting ribs 145 that complementarily fit with the end portions of the grooves of a support structure, such as the vertical supports 40 and provide a flat end surface. See FIG. 26 . Also, there are floor internal base and top panel holders 150 . See FIG. 27 . These are used on the top of floors panels 65 or the bottom the ceiling panels 85 for small partitions, such as closets and the like.
The color code system is generally as follows: interior and exterior wall panels 50 and 55 will have the same color. However, the side that is to face outwards will be the side that is colored; the vertical supports 40 and 45 will have one color and the horizontal beams or supports 25 will have another color, even if they are manufactured from the same building materials; roof panels 100 will always have a reflective color and the reflective color will be on the upside.
The preferred embodiment of the invention is described above in the Drawings and Description of Preferred Embodiments. While these descriptions directly describe the above embodiments, it is understood that those skilled in the art may conceive modifications and/or variations to the specific embodiments shown and described herein. Any such modifications or variations that fall within the purview of this description are intended to be included therein as well. Unless specifically noted, it is the intention of the inventors that the words and phrases in the specification and claims be given the ordinary and accustomed meanings to those of ordinary skill in the applicable art(s). The foregoing description of a preferred embodiment and best mode of the invention known to the applicant at the time of filing the application has been presented and is intended for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and many modifications and variations are possible in the light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application and to enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
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The present invention relates generally to a building construction system, the components thereof, and method therefore. More specifically, the present invention relates to a building construction system that utilizes specifically designed component parts that fit together, such as by male/female connections, and are permanently attached through the use of an adhesive, or bonding glue, to create an extra strong and uniformly tight structure. If effect, the end result is equivalent to a one-piece construction since all components are permanently “chemically welded” to each other with all components being made from the same type of materials.
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The present invention concerns a furniture hinge comprising a fitment portion and a hinge cup hingedly connected thereto for fixing to furniture parts, and a damping device for damping a relative movement between the fitment portion and the hinge cup, wherein the damping device is arranged in or on the hinge cup.
The invention further concerns an article of furniture having at least one furniture hinge of the kind to be described.
Furniture hinges comprising a hinge cup and a damping device arranged in or on the hinge cup are already known in the state of the art. As an example in that respect mention is to be made of AT 6499 to the present applicant, DE 25 39 954 A1, DE 10 2007 047 287 A1, DE 10 2006 047 315 A1 or EP 1 469 153 A1. Damping devices having a piston which has a linear damping stroke usually have a travel-dependent damping function, that is to say the degree of damping is dependent on the available damping stroke of the piston. Therefore a sufficient damping travel is to be provided to achieve the desired soft cushioning of a relative movement of the two fitment portions. A particular requirement is therefore that of arranging the damping device in as space-saving a fashion as possible, but at the same time also ensuring an adequate damping stroke and thus a satisfactory damping action for the furniture hinge.
WO 2007/131933 A1 discloses a furniture hinge having a damping device, wherein the housing of the damping device is held within the hinge cup by way of co-operating fixing means (in the form of a tab and an abutment surface). As a consequence of a hinge lever of the hinge being connected to a slider of the damping device, the damping device already has to be fitted into and fixed in the hinge cup, as from the factory.
WO 2009/094272 A1 which is of earlier priority but published after the relevant date describes a furniture hinge having a damping device which is fitted into the hinge cup and fixed by way of snap-action holding means relative to the hinge cup bottom. That publication does not show a hinge in which the damping device can be inserted from above into the hinge cup, with the fitment portion and the hinge cup hingedly connected together. For retro-fitting of the damping device it is obviously necessary to dismantle the hinge.
The object of the present invention is to propose a furniture hinge of the general kind referred to in the opening part of this specification, wherein the damping device saves space, is efficient and can be fitted at a later stage.
According to the invention in an advantageous configuration that is achieved in that the damping device has a housing having first fixing means and second fixing means are arranged on the hinge cup, wherein the housing of the damping device can be inserted from above into the hinge cup and in the mounted position is arranged substantially completely within the hinge cup, wherein the housing of the damping device and the hinge cup can be connected together in said mounted position by way of the first and second fixing means.
The definition ‘can be inserted from above into the hinge cup’ is intended to mean insertion of the housing of the damping device in a direction of movement substantially perpendicular to the bottom of the hinge cup.
It is therefore possible with the proposed invention to arrange the housing of the damping device completely within the hinge cup, wherein the housing in that mounted condition preferably does not project beyond the hinge cup, that is to say the entire component unit of the damping device in the mounted condition is completely between the bottom of the hinge cup and the plane formed by the hinge cup opening. The housing of the damping device can be mounted relative to the hinge cup and removed therefrom by way of the first and second fixing means. In an embodiment of the invention it can be provided that the housing of the damping device can be releasably fixed on or in the hinge cup by the first and the second fixing means, preferably it can be fitted without the use of a tool and can preferably be dismantled without the use of a tool.
The damping device can include a slider movable relative to the housing, wherein the first fixing means are provided on the slider so that the housing of the damping device can be connected to the hinge cup releasably indirectly by way of the slider.
In a preferred embodiment of the invention it can be provided that the first and second fixing means are in the form of a self-latching latching connection. Such a latching connection permits automatic latching between the housing of the damping device and the hinge cup in the course of introducing the housing into the hinge cup without in that case the user having to actuate additional locking means for fixing purposes. The first and second fixing means can together form a snap-action connection so that the damping device can be clipped into the hinge cup in the form of a complete unit. In a possible embodiment of the invention, the first or second fixing means can include at least one movable or mobile arresting element by which the housing can be fixed relative to the hinge cup. A desirable configuration is characterised in that the arresting element is of a resilient nature, wherein the connection between the first and second fixing means is releasable by pressure against the resilient action of the arresting element.
In a possible embodiment it can be provided that the arresting element is arranged on the housing of the damping device and in the mounted position engages into an opening or at a latching edge of the hinge cup. In a kinematic reversal it is also possible that the arresting element is mounted on the hinge cup and in the mounted position engages into an opening or latching edge arranged on the housing of the damping device.
It can be provided that the first and second fixing means are operative between the housing of the damping device and a side wall of the hinge cup. Alternatively or supplemental thereto it may also be possible that the first and second fixing means are operative between the housing of the damping device and the bottom of the hinge cup or a support portion (in particular a fixing projection) associated with the hinge cup.
In that respect it is possible that the fixing projection is provided for mounting a spring which urges the hinge cup relative to the fitment portion into the completely closed position and/or into the completely open position. That fixing projection can thus also be used as a support element for the housing of the damping device. The fixing projection can extend at least portion-wise within the hinge cup, the fixing projection having a recess provided for receiving the housing of the damping device—in particular for receiving and guiding a linearly displaceable slider of the damping device.
In a preferred configuration of the invention it can be provided that the housing has a peripheral surface, the shape of which is adapted portion-wise to the inner shape of the hinge cup. In other words, the external shape and size of the housing of the damping device are adapted to the shape and size of the internal space in the hinge cup. That permits defined preliminary positioning of the housing, wherein after positioning has been effected the first and second fixing means can be connected together, wherein the housing of the damping device can be fixed relative to the hinge cup in positively locking relationship and/or force-locking relationship. Due to the contour of the housing of the damping device, that is adapted to the hinge cup, it bears in the mounted position for the greatest part directly against the inside wall of the hinge cup, wherein arranging it within the hinge cup is effected in a visually very inconspicuous fashion and the risk of dirt deposits between the housing of the damping device and the inside wall of the hinge cup is also reduced.
For easy dismantling of the damping device relative to the hinge cup there can be provided a release portion, by which the connection between the first and second fixing means is releasable, whereupon the housing of the damping device can be dismantled from the hinge cup. In that respect it may be advantageous if the release portion is arranged on the housing of the damping device. The release portion can be moved into a release position manually and/or by means of a tool whereby the housing of the damping device can be dismantled from the hinge cup.
Due to the first and second fixing means, hinge arrangements which already exist can be subsequently retro-fitted with a damping device, wherein the retro-fitting operation can already be effected in the factory. When the damping device is already fitted in the factory, production lines which are already there can be retained so that mounting the damping device only requires a very low level of complication and expenditure. It will be appreciated that subsequent fitting and/or dismantling of the damping device on already existing hinge arrangements can also be effected by a user. The damping device can also be inserted into the hinge cup and fixed relative to the hinge cup by way of the first and second fixing means when the hinge lever of the hinge is hingedly connected to the hinge cup.
To achieve a particularly compact structure it may be desirable if the damping device has a first and a second fluid chamber which are filled with damping fluid and which are connected together by way of a passage. In that case it may be desirable if a piston can be engaged in the first fluid chamber and thereby the volume of the first fluid chamber can be changed, and wherein arranged in the second fluid chamber is a device which is deformable or movable by a flow of damping fluid into and out of the second fluid chamber for changing the volume of the second fluid chamber.
The two fluid chambers are therefore connected in serial relationship and are in fluid-conducting communication by way of at least one passage. The damping fluid of the first fluid chamber, that is displaced during the damping stroke by the first piston, also has to flow through the passage into the second fluid chamber—apart from possible residual compressibility of the damping fluid—, wherein the volume of the second fluid chamber can be changed by the fluid pressure. The second fluid chamber therefore forms a compensation space for the displaced damping fluid, that is variable during compression or decompression respectively. The second fluid chamber can be arranged in a very compact structure relative to the first fluid chamber whereby particularly small damping device constructions can be implemented.
In an embodiment of the invention the said device can have a deformable material portion arranged in the second fluid chamber or a piston displaceable in the second fluid chamber, whereby the volume of the second fluid chamber can be changed when damping fluid flows in or out. Thus instead of the second piston in the second fluid chamber, it is also possible to employ a deformable material portion made from a compressible material such as for example foam rubber. The arrangement of the second piston can—but does not have to—be omitted as the return movement of the first piston produces a reduced pressure and thus a suction effect so that the damping fluid present in the second fluid chamber is at least partially caused to flow back into the first fluid chamber again after damping has taken place.
In an embodiment of the invention the first fluid chamber has a first longitudinal axis and the second fluid chamber has a second longitudinal axis, wherein the first longitudinal axis and the second longitudinal axis of the fluid chambers extend parallel to each other or can also extend transversely relative to each other. The passage connecting the two fluid chambers can in principle also be of a very short length (for example in the form of a hole in the function as an overflow opening). It is preferably provided that the passage connecting the two fluid chambers extends from the bottom region of the first fluid chamber to the inlet region of the second fluid chamber.
In a possible embodiment of the invention it can be provided that the damping device has a first piston and at least one second piston with a linear damping stroke, wherein the direction of the linear damping stroke of the first piston extends substantially parallel or transversely relative to the linear damping stroke of the second piston.
The first and second pistons can each be guided displaceably in a fluid chamber, wherein the two fluid chambers are connected in serial relationship and are in flow communication by way of the at least one passage. In that way it is possible to reduce the damping stroke of the first piston and therewith the structural size of the damping device. The damping medium of the first fluid chamber, that is displaced during the damping stroke of the first piston, flows through the narrowed passage into the second fluid chamber whereby the flow resistance of the damping fluid present in the first fluid chamber is increased. By virtue of the resulting small structure for the damping device, it can be particularly easily accommodated within the hinge cup.
In a possible embodiment of the invention it can be provided that the direction of the linear damping stroke of the first piston relative to the linear damping stroke of the second piston includes an angle α, wherein the angle α is between 70 and 110°. In a preferred configuration of the invention it can also be provided that the direction of the linear damping stroke of the first piston relative to the linear damping stroke of the second piston extends at a right angle.
In a possible embodiment the two fluid chambers can be respectively formed by the internal space of a fluid cylinder. It is however particularly preferred for the fluid chambers to be provided in a housing of the damping device so that the additional provision of fluid cylinders is not absolutely necessary. In that way the damping device can be implemented with a reduced number of components to be employed.
The damping device can have an actuating element, by which the force can be applied to the damping device, wherein the actuating element can be acted upon by one of the fitment portions or by a hinge lever arranged between the fitment portions, during the hinge movement. The hinge lever which is pivotable during the hinge movement can be caused to immerse into the hinge cup towards the end of the closing movement of the furniture hinge. In that respect a possible configuration provides that at least one of the two pistons is integrally connected to the actuating element. The integral configuration of the actuating element with one of the pistons reduces the number of components, while in addition force can be applied directly to the damping device.
In a possible embodiment the actuating element can have a linearly displaceable slider which can be acted upon by one of the fitment portions or by a hinge lever arranged between the fitment portions as from a predetermined relative position of the fitment portions with respect to each other. The slider can be in the form of a sliding wedge having an inclined surface which can be acted upon by one of the fitment portions or by the hinge lever towards the end of the closing movement and/or the end of the opening movement.
To avoid unwanted tilting of the sliding slider during the damping operation it may be advantageous if the slider has a guide—preferably in the form of a slot—, whereby the slider is displaceable relative to a fixing projection arranged on the hinge cup. The fixing projection can be provided at the same time for mounting a spring device which urges the two fitment portions into an end position. In that case the spring device can urge the fitment portions in the direction of the completely open position and/or in the direction of the completely closed position, wherein the spring action begins only towards the end of the closing process and/or towards the end of the opening process. The proposed damping device is therefore desirably provided to damp an opening movement and/or a closing movement over a portion of the total opening angle range of the two fitment portions relative to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the present invention will be described by means of the specific description hereinafter. In the drawings:
FIG. 1 shows a perspective view of an article of furniture having a movable furniture part which is pivotally mounted to the furniture carcass by way of furniture hinges according to the invention,
FIG. 2 shows a perspective view of a furniture hinge having a damping device integrated in the hinge cup,
FIGS. 3 a , 3 b show a side view of the furniture hinge mounted to the furniture parts in an open position and a cross-sectional view thereof,
FIGS. 4 a , 4 b show a side view of the furniture hinge mounted to the furniture parts in an intermediate position and a cross-sectional view thereof,
FIGS. 5 a , 5 b show a side view of the furniture hinge mounted to the furniture parts in a closed position and a cross-sectional view thereof,
FIG. 6 shows a perspective view of the damping device,
FIGS. 7 a - 7 c show views in horizontal section illustrating positions of the two pistons during the damping stroke and during the return stroke,
FIGS. 8 a , 8 b show an alternative embodiment of a damping device, wherein a deformable material portion is arranged in the second fluid chamber for changing the volume of the second fluid chamber,
FIGS. 9 a , 9 b show a possible embodiment of a damping device which can be mounted and/or removed on the hinge cup without a tool, having a fixing device for fixing to the furniture hinge,
FIGS. 10 a , 10 b show a further embodiment of a damping device which can be releasably fixed within the hinge cup,
FIGS. 11 a - 11 d show various views of a further embodiment of a damping device having a release portion for dismantling purposes,
FIGS. 12 a - 12 d show a damping device having various configurations of a release portion for dismantling the damping device,
FIG. 13 shows a highly diagrammatic view of a hinge cup countersunk in a standard bore, wherein the fixing means for fixing the damping device are operative between the housing of the damping device and the bottom and/or a side wall of the hinge cup, and
FIGS. 14 a - 14 c show the damping device to be inserted into the hinge cup in a dismantled position and in the mounted position and a slider of the damping device with fixing means provided thereon.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective view of an article of furniture 1 having a furniture carcass 2 , wherein a movable furniture part 3 in the form of a pivotable door is fixed by way of furniture hinges 4 according to the invention to a frame 2 a provided or arranged on the furniture carcass 2 . The movable furniture part 3 is mounted pivotably between a closed position of closing the furniture carcass 2 and an open position.
FIG. 2 shows a possible embodiment of a furniture hinge 4 , wherein a first fitment portion 5 is associated with the furniture carcass 2 and a second fitment portion 6 is associated with the movable furniture part 3 . As shown in the Figure, the carcass fitment portion 5 can be L-shaped or U-shaped and in the mounted position can at least partially embrace the frame 2 a shown in FIG. 1 . It will be appreciated that the fitment portion 5 may also be in the form of a hinge arm. The second fitment portion 6 has a hinge cup 6 a which can be sunk in a bore on the movable furniture part 3 . The hinge cup 6 a has a flange 6 b which in the mounted position bears against the inside of the movable furniture part 3 . Arranged between the fitment portion 5 and the hinge cup 6 a is a hinge lever 7 which is mounted displaceably and/or tiltably relative to the first fitment portion 5 by way of an adjusting device 8 . The hinge lever 7 is mounted pivotably to the hinge cup 6 a at an axis of rotation on the other side. In the illustrated embodiment therefore the furniture hinge 4 is in the form of a single-axis hinge. It is possible to see a spring device 9 which urges the two fitment portions 5 , 6 in the direction of the closed position or holds the fitment portions 5 , 6 in a closed position. A damping device 10 is arranged substantially completely within the hinge cup 6 a , wherein the damping device 10 is provided for damping a relative movement of the two fitment portions 5 , 6 relative to each other over a part of the movement through the maximum opening angle of the two fitment portions 5 , 6 . The damping device 10 has an actuating element 11 in the form of a linearly displaceable slider 11 a which is acted upon by the hinge lever 7 towards the end of the closing movement of the furniture hinge 6 and thereby applies the force to the damping device 10 .
FIG. 3 a shows a side view of the open furniture hinge 4 in the mounted condition. The first fitment portion 5 is fixed to the frame 2 a of the furniture carcass 2 while the second fitment portion 6 is mounted with the hinge cup 6 a to the movable furniture part 3 . It is possible to see the damping device 10 whose arcuate peripheral edge is at least partially adapted to the contour of the inside wall of the hinge cup 6 a . The housing of the damping device 10 can be for example at least approximately of a mushroom-shaped configuration in plan view. The hinge lever 7 which is pivoted during the hinge movement acts on the linearly displaceable slider 11 a towards the end of the closing movement whereby the damping process is initiated. The Figure also shows the spring device 9 which in the illustrated embodiment performs the function of a closing spring.
FIG. 3 b shows a vertical section along the arrows shown in FIG. 3 a . The carcass fitment portion 5 is fixed to the frame 2 a by way of a screw 12 . The hinge cup 6 a is sunk in the movable furniture part 3 , the damping device 10 with the slider 11 a being completely integrated in the hinge cup 6 a . The slider 11 a has an inclined surface 15 which is acted upon by the hinge lever 7 as from a predetermined relative position of the fitment portions 5 and 6 with respect to each other. The slider 11 a has a slot 13 so that the slider 11 a is displaceable guidedly during the damping process relative to a fixing projection 14 arranged stationarily on the hinge cup. In the illustrated Figure the hinge lever 7 is in a position of being spaced from the inclined surface 15 of the slider 11 a.
FIG. 4 a shows a view similar to FIG. 3 a , with the difference that the movable furniture part 3 has been further moved in the closing direction and the hinge lever 7 now encounters the slider 11 a of the damping device 10 , which can be particularly clearly seen from the sectional view in FIG. 4 b . The cranked hinge lever 7 now abuts against the inclined surface 15 of the slider 11 a whereby the damping process is initiated.
FIG. 5 a shows the completely closed position of the movable furniture part 3 relative to the frame 2 a , the damping process already being concluded. It can be seen from the sectional view in FIG. 5 b that the hinge lever 7 has displaced the slider 11 a by way of the inclined surface 15 thereof so that the stationary fixing projection 14 , in comparison with FIG. 4 b , bears against the opposite end of the slot 13 . The movement to be damped has been applied to the damping device 14 by the movement of the slider 11 a.
FIG. 6 shows the damping device 10 which can be completely integrated into the hinge cup 6 a and the housing 10 a of which is at least portion-wise adapted to the inside shape of the hinge cup 6 a . The housing 10 a has an arcuate peripheral edge which in the mounted position bears at least region-wise against the inside wall of the hinge cup 6 a . The slider 11 a with its inclined surface 15 and its slot 13 is mounted displaceably relative to the housing 10 a during the damping stroke and during the return stroke.
FIG. 7 a shows a perspective view in horizontal section of the damping device 10 , with reference to which the operating principle of the damping device 10 is to be described. The Figure shows a first fluid chamber 16 in which a first piston 16 a is linearly displaceably guided. The damping device 10 is in the form of a fluid damper, the first fluid chamber 16 being filled with a damping fluid (for example a liquid, an oil or, with a suitable structural size, also with air). A seal 17 a seals the first piston 16 a with respect to the inside wall of the first fluid chamber 16 . Associated with the first fluid chamber 16 is a return mechanism 18 a in the form of a spring which, after the damping stroke has been effected, moves the piston 16 a back into a position for the next damping stroke again. The return mechanism 18 a can also be arranged outside the fluid chamber 16 . The slider 11 a is preferably integrally connected to the first piston 16 a so that a movement of the slider 11 a at the same time also leads to movement of the first piston 16 a into the first fluid chamber 16 . The device 25 arranged in the second fluid chamber 21 for altering the volume in that second fluid chamber, in the illustrated embodiment, includes a displaceable piston 21 a , by which the volume of the second chamber 21 can be changed when damping fluid flows in or out.
The damping fluid is pressed through the passage 19 and through a through opening 20 a in a switching blade 20 into the second fluid chamber 21 by the first piston 16 a being pushed into the fluid chamber 16 . The seal 17 b seals the piston 21 a with respect to the second fluid chamber 21 a . The second piston 21 a is also displaced into a rearward end position by the damping fluid being pressed from the first fluid chamber 16 into the second fluid chamber 21 . The damping fluid is exclusively between the first piston 16 a and the second piston 21 a . It can be seen that the direction of movement A of the first piston 16 a extends transversely relative to the direction of movement B of the second piston 21 a . The direction of movement A of the first piston 16 a includes an angle α which is preferably between 70° and 110° with the direction of movement B of the second piston 21 a . Preferably the directions of movement A and B of the first piston 16 a and the second piston 21 a are at a right angle to each other. The directions of movement A, B can also extend in mutually parallel spaced relationship.
FIG. 7 b shows the first piston 16 a pushed completely into the first fluid chamber 16 , that is to say the damping process is already concluded. The fact that the piston 16 a was pushed into the first fluid chamber 16 provided that the damping fluid in the first fluid chamber 16 was pressed through the passage 19 , the opening 20 a in the switching blade 20 and the through-flow opening 22 a into the second fluid chamber 21 , whereupon the second piston 21 a was displaced within the second fluid chamber 21 into the rearward end position shown. The size of the through opening 20 a in the switching blade 20 increases with increasing pressure actuation by the damping fluid, whereby the flow cross-section of the through opening 20 a can be increased. The switching blade 20 is preferably made from rubber-elastic material.
In FIG. 7 c the two pistons 16 a , 21 a have been partially returned again by the two return mechanisms 18 a , 18 b so that the pistons 16 a , 21 a are moved in the direction of the readiness position shown in FIG. 7 a again. The return mechanism 18 b therefore moves the second piston 21 a in the opposite direction again, in which case the damping fluid in the second fluid chamber 21 can flow back through the two through-flow openings 21 a and 21 b . Starting from the first position shown in FIG. 7 b (in which the damping fluid flows exclusively through the through opening 20 a into the second fluid chamber 21 ) the switching blade 20 was moved into a second position as shown in FIG. 7 c in which the switching blade 20 lifts off the through-flow openings 22 a , 22 b so that, in the return stroke, the damping fluid can also flow back around the switching blade 20 in the direction of the first fluid chamber 16 . In that way the damping device 10 can be very quickly moved into a readiness position for the next damping stroke again. At the same time the first piston 16 a of the first fluid chamber 16 is also moved back by the return mechanism 18 a and can again assume the readiness position. It can also be provided that the arrangement of the second return mechanism 18 b can be omitted and only the first return mechanism 18 a is provided. In that way the return movement of the first piston 16 a results in a reduced pressure being produced in the first fluid chamber 16 , by which the damping fluid coming from the second fluid chamber 21 due to a suction effect passes into the first fluid chamber 16 again. Starting from FIG. 7 c the two pistons 16 a , 21 a can again be moved back into the starting position shown in FIG. 7 a.
The switching blade 20 therefore performs a triple function, more specifically a) for building up the pressure of the damping medium in the first fluid chamber 16 , b) overload safeguard by radial expansion of the through opening 20 so that the flow cross-section can be increased, and c) damping return by lifting the switching blade 20 off the through-flow openings 22 a and 22 b.
In an embodiment of the invention it is provided that the piston surface of the first piston 60 and the piston surface of the second piston 21 have an operative piston surface of the same size. It is however also possible for the effective piston surface of the first piston 16 a and that of the second piston 21 a to be of differing sizes so that it is possible to provide a travel step-down effect in respect of the second piston 21 . When therefore the effective piston surface of the second piston 21 is larger than that of the first piston 16 , a damping stroke of the first piston 16 a also leads to a reduced damping stroke of the second piston 21 a . The length of the second fluid chamber 21 and thus the size of the housing 10 a can possibly also be reduced by virtue of the reduced damping stroke of the second piston 21 a.
FIG. 8 a shows an alternative embodiment of a damping device 10 . Similarly to the embodiment of FIGS. 7 a - 7 c , there is provided a slider 11 a which is integrally connected to the first piston 16 a so that the first piston 16 a engages into the first fluid chamber 16 in the damping stroke. A seal 17 a seals off the first piston 16 a relative to the first fluid chamber 16 . In the damping stroke the damping fluid displaced by the first piston 16 a can flow by way of the through opening 20 a in the switching blade 20 and through the through-flow opening 22 a into the second fluid chamber 21 . In the illustrated embodiment the device 25 arranged in the second fluid chamber 21 includes a compressible deformable material portion, by which the volume of the second fluid chamber 21 can be altered when damping fluid flows in or out. FIG. 8 a shows the first piston 16 a in a readiness position for the damping stroke. In FIG. 8 b the fact of the first piston 16 a being pushed into the first fluid chamber 16 provided that the damping fluid was urged into the second fluid chamber 25 by way of the above-described common paths, whereby the device 25 was deformed and the volume of the second fluid chamber 21 increased. When the slider 11 a is no longer acted upon by the hinge lever 17 of the furniture hinge 4 then the first piston 16 a of the first fluid chamber 16 is moved back into the position shown in FIG. 8 a again by the return mechanism 18 a . As a result, a reduced pressure is produced in the first fluid chamber 16 , whereby the suction effect causes the fluid in the second fluid chamber 21 to be drawn back through the through-flow openings 22 a , 22 b and around the switching blade 20 into the first fluid chamber 16 again, whereupon the device 25 of the second fluid chamber 21 also expands again and again assumes the FIG. 8 a position. It is therefore not absolutely necessary for a displaceable second piston 21 a having its own return mechanism 18 b also to be provided in the second fluid chamber 21 . The device 25 can have a compressible material portion (for example a TPU plastic portion or a foam rubber). It will be appreciated that the device 25 can also include a second piston 21 a as described hereinbefore, which is supported displaceably within the second fluid chamber 21 .
FIGS. 9 a and 9 b show a possible embodiment illustrating how the furniture hinge 4 can also be fitted with a damping device 10 subsequently (that is to say retro-fitted either at the factory or also by a user). FIG. 9 a shows the carcass fitment portion 5 and the door fitment portion 6 with the hinge cup 6 a connected pivotably to the carcass fitment portion 5 by way of the hinge lever 7 . The hinge lever 7 is mounted to the hinge cup 6 a at the axis of rotation S. Provided on the hinge cup 6 a are diagrammatically shown fixing means 23 (for example in the form of a recess, a latching edge or an opening 23 a ) while the housing 10 a of the damping device 10 is provided with corresponding fixing means 24 (for example in the form of a resilient arresting element 24 a ). The housing 10 a of the damping device 10 can therefore be releasably connected to the hinge cup in the illustrated mounting position by way of the first and second fixing means 23 , 24 , preferably being automatically latchable.
FIG. 9 b shows the damping device 10 with the housing 10 a and the slider 11 a displaceable relative thereto. For fixing to the furniture hinge 4 the housing 10 a has fixing means 24 with at least one arresting element 24 a which is in engagement in the mounted position with the opening 23 a , shown in FIG. 9 a , of the hinge cup 6 a . In that way the housing 10 a of the damping device 10 can be fixed relative to the hinge cup 6 a . In contrast to the slot 13 shown in FIG. 6 the slot 13 in FIG. 9 b is open downwardly in order thereby to fit the slider 11 a and therewith the damping device 10 subsequently to the fixing projection 14 shown in FIGS. 3 b , 4 b and 5 b respectively. In the mounted condition of the housing 10 a the arcuate peripheral surface thereof bears against the inside wall of the hinge cup 6 a and does not project beyond the hinge cup 6 a . The arresting element 24 a is resilient, is acted upon by a spring or is formed directly by a spring and can be moved from the mounted position on the hinge cup 6 a into a release position by applying pressure in opposition to the spring force of the arresting element 24 a so that the housing 10 a of the damping device 10 can be removed again from the hinge cup 6 a . The fixing means 24 with the arresting element 24 a and the opening 23 a on or in the hinge cup 6 a is only shown by way of example, it will be appreciated that other possible forms of mounting and removal are also possible. In a kinematic reversal it is also possible for the resilient arresting element to be arranged on the hinge cup 6 a and for the opening 23 a or latching edge also to be arranged on the housing 10 a of the damping device 10 .
FIG. 10 a shows a further possible way of fixing a damping device 10 which can be arranged in the mounted position entirely within a hinge cup 6 a . The damping device 10 includes a housing 10 a which can be fitted into the hinge cup 6 a from above (therefore substantially at a right angle to the bottom of the hinge cup). The housing 10 a of the damping device 10 has a first fixing means 24 in the form of a clip-like or circlip-like spring while the hinge cup 6 a is provided with second fixing means 23 in the form of an elongate recess 23 a , wherein the housing 10 a of the damping device 10 and the hinge cup 6 a can be releasably connected together in the mounted position by way of the first and second fixing means 23 , 24 . It is also possible to see a fixing projection 14 arranged within the hinge cup 6 a and extending substantially parallel to an axis of rotation S of the furniture hinge 4 . In the interior of the hinge cup 6 a the fixing projection 14 has a recess 40 provided for receiving and guiding the linearly displaceable slider 11 a . The flattening afforded by the recess 40 , or the lower position of the fixing projection 14 , permits an enlarged structural space for the housing 10 a of the damping device 10 .
FIG. 10 b shows the mounted position of the damping device 10 within the hinge cup 6 a . In that position the damping device 10 does not project beyond the plane of the opening of the hinge cup 6 a . The housing 10 a has a shoulder-shaped abutment 25 a which in the mounted position is supported against a corresponding counterpart abutment 25 b of the hinge cup 6 a . The peripheral surface of the damping device 10 is adapted to the contour of the internal space in the hinge cup 6 a . Towards the end of the closing movement of the movable furniture part 3 relative to the stationary furniture carcass 2 the hinge lever 7 bears against the slider 11 a of the damping device 10 , whereby the damping process is initiated.
FIG. 11 a shows a possible way of removing the damping device 10 fixed in the hinge cup 6 a . The housing 10 a of the damping device 10 has at least one release portion 26 , by which the connection between the first and second fixing means 23 , 24 is releasable so that the housing 10 a can be completely removed. The housing 10 a can be levered out of the hinge cup 6 a by applying a screwdriver 27 to the release portion 26 and the carcass abutment portion 5 . Removal is of relevance in that respect as a damping effect for the mobile hinge 4 is sometimes not wanted at all. If for example the movable furniture part 3 is pivotably mounted to the furniture carcass 2 by way of a plurality of furniture hinges 4 , it may be sufficient for only one furniture hinge 4 to be fitted with a damping device 10 , while the other furniture hinges 4 do not have any damping device in order thereby to ensure reliable closure of lighter movable furniture parts 3 . FIG. 11 b shows a perspective view from the front of the damping device 10 , from which it is possible to see the housing 10 a with the shoulder-shaped abutment 25 a and the linearly displaceable slider 11 a . In the illustrated embodiment the release portion 26 for dismantling of the damping device 10 is provided in one piece on the housing 10 a . FIG. 11 c shows a perspective view from the front of the damping device 10 while FIG. 11 d shows a perspective view from the front of the damping device 10 .
FIG. 12 a shows a further possible way of dismantling the damping device 10 by means of a slot-type screwdriver 27 which in the illustrated embodiment can engage the linearly displaceable slider 11 a . Various configurations of the release portion 26 are shown in FIGS. 12 through 12 d . In FIG. 12 b the release portion 26 is in the form of a bar projecting upwardly from the housing 10 a . In FIG. 12 c the release portion 26 is in the form of a recess in the displaceable slider 11 a , the release portion 26 being adapted to receive a cross-head screwdriver. In FIG. 12 d the release portion 26 is also provided on the slider 11 a and the release portion 26 with the slider 11 a jointly provide a slot-shaped recess in which a slot-type screwdriver can engage for dismantling of the damping device 10 .
FIG. 13 shows a highly diagrammatic view of a hinge cup 6 a sunk in a provided standard bore 30 in the movable furniture part 3 . The hinge cup 6 a has a bottom 31 and a side wall 29 extending therearound. The damping device 10 with the housing 10 a and the linearly displaceable slider 11 a includes first fixing means 24 while second fixing means 23 are associated with the hinge cup 6 a , wherein the housing 10 a of the damping device 10 can be releasably connected together in the intended mounted position by way of the first and second fixing means 23 , 24 . The second fixing means 24 of the housing 10 a can therefore be releasably connected to the bottom 31 of the hinge cup 6 a and/or to a side wall 29 thereof. The hinge lever 7 mounted at the axis of rotation S acts on the linearly displaceable slider 11 a as from a predetermined relative position of the hinge cup 6 a whereby the slider is pushed into the housing 10 a and initiates the damping process.
FIG. 14 a shows a perspective view of the furniture hinge 4 , wherein the fitment portion 5 in the form of the hinge arm is hingedly connected to the hinge cup 6 a by way of at least one hinge lever 7 . The housing 10 a of the damping device 10 can be fitted into the hinge cup 6 a from above when the hinge levers 7 and the hinge arm 5 are mounted, and can be releasably fixed therein. The damping device 10 has a slider 11 a movable relative to the housing 10 a , wherein the first fixing means 24 are provided on the slider 11 a so that the housing 10 a of the damping device 10 can be releasably connected to the hinge cup 6 a indirectly by way of the slider 11 a . In the illustrated Figure the second fixing means 23 of the hinge cup 6 a are formed by a fixing projection 14 which projects laterally inwardly from an inside wall of the hinge cup 6 a and is provided for connection to the slider 11 a . The fixing projection 14 can pass through the side wall of the hinge cup 6 a and in so doing also serve to receive the spring device 9 , by which the furniture hinge 4 is movable into the completely closed position.
FIG. 14 b shows the damping device 10 when subsequently fitted into the hinge cup 6 a . The housing 10 a of the damping device 10 has an arcuate peripheral edge adapted to the inside shape of the hinge cup 6 a . The housing 10 a of the damping device 10 has at least one preferably shoulder-shaped abutment 25 a which is additionally supported at an inside wall of the hinge cup 6 a so that the housing 10 a is held at least partially in positively locking relationship within the hinge cup 6 a . Towards the end of the closing movement of the hinge 4 the hinge lever 7 encounters the slider 11 a , whereupon it is pushed into the housing 10 a and the closing movement of the hinge 4 is thus damped.
FIG. 14 c shows a highly diagrammatic perspective view of a possible embodiment of a slider 11 a . The slider 11 a is provided with an inclined surface 15 provided for contact with the hinge lever 7 . The first fixing means 24 arranged on the slider 11 a include at least one guide groove 43 , extending in the longitudinal direction of the slider, for the second fixing means 23 arranged on the hinge cup 6 a , preferably for the fixing projection 14 arranged in the hinge cup 6 a (see FIG. 14 a ) for fixing the slider 11 a . In addition there is an introduction opening 41 , through which the fixing projection 14 can be arranged in the guide groove 43 . The slider 11 a can thus be moved relative to the fixing projection 14 in such a way that the fixing projection 14 can be passed through the introduction opening 41 and positioned in the guide groove 43 . In the damping stroke therefore the slider 11 a can be displaced relative to the fixing projection 14 mounted in the guide groove 43 . To remove the damping device 10 the fixing projection 14 is again threaded through the introduction opening so that the housing 10 can again be moved out of the hinge cup 6 a . In the illustrated embodiment the slider 11 a has on both longitudinal sides guide grooves 43 provided for receiving two fixing projections 14 disposed in mutually opposite relationship in the hinge cup 6 a.
The present invention is not limited to the illustrated embodiments but includes or extends to all variants and technical equivalents which can fall within the scope of the appended claims. The positional references adopted in the description such as for example up, down, lateral and so forth are also related to the directly described and illustrated Figure and are to be appropriately transferred to the new position upon a change in position.
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A furniture hinge, comprising a fitting part, a hinge cup that is articulated thereto for fastening to furniture parts, and a cushioning apparatus for cushioning a relative movement between the fitting part and the hinge cup, wherein the cushioning apparatus is disposed in or on the hinge cup, wherein the cushioning apparatus comprises a housing having first fastening means, and second fastening means are disposed on the hinge cup, wherein the housing of the cushioning apparatus can be inserted from above into the hinge cup and in the installed position is disposed substantially completely inside the hinge cup, wherein the housing of the cushioning apparatus and the hinge cup can be connected to each other in said installed position by the first and second fastening means.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Australian provisional patent application number 2013903774 filed on Sep. 30, 2013, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field
[0003] The present disclosure relates generally to overhead ‘garage’ doors, of the type used to close large openings in residential and commercial buildings. More particularly, the present disclosure relates to overhead doors of the sectional type, and to drive tracking arrangements and components for such doors.
[0004] 2. Description of Related Art
[0005] Sectional garage doors are well known in the art. Although the design of sectional garage doors can significantly differ, certain components are common to such door systems. Thus a typical sectional garage door has a door curtain made of a plurality—usually four or more—panel sections hinged together at their longitudinal edges about horizontal hinge axes.
[0006] A pair of generally inverted L-shaped guide tracks is mounted to the building, one at each side of the door opening, with the vertical leg of the L being at the side of the door opening and the horizontal leg being above the level of the opening and extending back into the building space. The junction of the horizontal and vertical legs of the track is defined by a radius.
[0007] The door includes a plurality of rollers mounted on the opposite sides of the door sections, which follow the guide tracks to guide movement of the door curtain between a closed (lowered) position in which the door is vertical and closes off the door opening and an open (raised) position where the door is stored overhead in a horizontal orientation.
[0008] Since a sectional door is relatively large and heavy, it is commonplace to provide a counter-balancing spring system which loads up one or more torsion or extension springs as the door is lowered, so that the spring tension assists raising of the door. Such systems are commonly used even where the door is power operated.
[0009] A traditional counter-balancing system includes one or more torsion springs on a horizontal torsion shaft which is secured to the building structure above the door opening. The shaft has a cable drum with a cable connected to the bottom section of the door. As the door is lowered, the withdrawal of the cable causes the shaft to turn, winding up the torsion spring. The number and size of the springs is selected so that spring tension is selected to counterbalance part of the weight of the door, so that the door is easier to raise.
[0010] One type of power operator drive mechanism comprises a motor drive and belt drive arrangement mounted on a horizontal track suspended from the building structure above and behind the centre of the door opening, parallel to but above the plane of the horizontal legs of the L-shaped tracks, with a linkage connecting to the centre top of the sectional door. This arrangement requires additional fixing and increases the headroom required for the installation, ultimately reducing the height of the door that can be installed in situations where headroom is limited.
[0011] WO 2007/051237 and WO 2011/003152 disclose garage door arrangements which the torsion spring, and optionally the motor, is mounted on the door curtain, providing advantages in manufacture and installation.
[0012] WO 2013/016777 describes a garage door drive arrangement suitable for new installation or for retrofitting to an existing sectional door. The arrangement comprises a drive guide track fitted to one of the side door guide tracks, guiding a drive belt, with a linkage to the door curtain.
[0013] The arrangement of WO 2013/016777 provides a convenient and reliable garage door drive arrangement, but there are aspects which could be improved to improve performance and installation.
SUMMARY
[0014] The present disclosure relates to a new and inventive drive apparatus for sectional garage doors, and aims to provide a drive apparatus which may be used either with the door arrangements of WO 2007/051237, WO 2011/003152 and WO 2013/016777, or with sectional garage doors of other types.
[0015] In one form, the present disclosure provides a carriage configuration for a garage door drive belt.
[0016] In a first aspect, there is disclosed a carriage member for a garage door drive belt, comprising first and second carriage elements, each carriage element comprising an inner member and an outer member adapted to retain an end of the drive belt therebetween, and an articulated connection between the first and second carriage elements.
[0017] In one example embodiment, each outer member has a bearing surface adapted to track along a drive belt guide track. Each carriage assembly may have a first end proximal the articulated connection and a second end distal from the articulated connection and through which the drive belt enters the carriage element, wherein the belt is captured between opposed belt-engaging surfaces of the inner and outer members.
[0018] The belt-retaining surface of the inner member may be notched to engage with a notched drive belt.
[0019] In a further example embodiment, the belt-retaining surfaces diverge from the bearing surface from the second end towards the first end of the carriage member. The bearing surface is preferably adapted to follow a convex bend in a guide track surface.
[0020] A further aspect of the disclosure provides a support arrangement for a garage door drive unit, comprising a drive unit hanger having means for attachment to a garage door structure, the hanger further having a weight-supporting connection to the drive unit, wherein the drive unit position is adjustable while the weight of the drive unit is supported.
[0021] The hanger may include a track providing weight-supporting connection while allowing positional adjustment of the drive unit.
[0022] Further aspects of the present disclosure will become apparent from the claims and from the illustrated embodiments and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Further preferred embodiments of the present disclosure will now be described with reference to the accompanying drawings.
[0024] FIG. 1 is an elevation of an example drive track assembly for garage door installation according to one example embodiment of the present disclosure.
[0025] FIG. 2 is a perspective view of a drive belt carriage assembly according to one example embodiment of the present disclosure.
[0026] FIG. 3 is a cross-section of the carriage assembly of FIG. 2 .
[0027] FIG. 4 shows the outer member of one carriage element of FIG. 2 being fitted over the inner member.
[0028] FIG. 5 shows an end assembly attached to one end of the drive guide track, in a further example embodiment, with the end assembly cover removed.
[0029] FIG. 6 is a perspective view of an adjustable tensioner assembly.
[0030] FIG. 7 shows the end assembly of FIG. 5 when fitted with the tensioner assembly of FIG. 6 .
[0031] FIG. 8 shows the assembly of FIG. 8 with the cover in place.
[0032] FIG. 9 is an elevation of a drive unit hanger arrangement according to a further exemplary embodiment of the present disclosure,
[0033] FIG. 10 is a perspective view of the drive unit hanger arrangement of FIG. 9 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] FIG. 1 is an elevation of a drive track assembly in accordance with one exemplary embodiment of the present disclosure.
[0035] The drive track 10 is of a general inverted L-shape, having a long vertical leg 12 , a shorter horizontal leg 14 and a curved track section 16 between them.
[0036] Each of the legs 12 , 14 and curved section 16 consist of an extruded track section having channels for guiding a notched drive belt 18 (see for example FIGS. 2 to 5 ), guided by rollers 20 .
[0037] The drive track 10 is adapted to be attached by brackets 22 to the door guide track (not shown) of the sectional garage door, to sit within the curve of the door guide track and generally in the plane of the guide track as described generally in WO 2013/016777.
[0038] The contents of WO 2007/051237, WO 2011/003152 and WO 2013/016777 are incorporated herein by reference.
[0039] At each end of the drive track is an end assembly 24 a, 24 b, more detail of which is described later in respect of FIGS. 5 to 8 .
[0040] The belt drive 18 is formed into an endless loop, joined by means of an articulated carriage assembly 26 which is described below in respect of FIGS. 2 to 4 .
[0041] FIGS. 2 to 4 show detail of the carriage assembly 26 , which forms both a belt joiner and a guide for travel of the belt 18 along the drive track 10 .
[0042] The carriage assembly 26 is made of two halves, 28 a and 28 b, each comprising an inner member 30 a, 30 b and an outer member 32 a, 32 b. The inner members 30 a, 30 b have overlapping portions 34 a, 34 b with aligned apertures, for receiving a connector pin 36 and retainer clip 38 for articulated connection of the two halves. The pin 36 may be extended to form a connection for a drive linkage to the sectional door curtain, to lift and lower the door curtain.
[0043] A lower surface 40 of the inner member is notched to match the profile of the drive belt 18 , and also angled relative to the lower bearing surface 42 of the outer member 32 , diverging in the direction approaching the articulated connection, for example by about 5 to 30 degrees, and more preferably about 8 to 20 degrees.
[0044] As shown in FIG. 4 , in use the end of the drive belt 18 is fitted against lower surface 40 of the inner member 30 and the outer member 32 is then slid over, to capture and retain the belt 18 between the inner and outer members.
[0045] A locking screw 46 is passed through aligned holes 44 a, 44 b in the inner and outer members to lock the inner and outer members together and to thus retain the belt 18 .
[0046] The same procedure is then repeated for the other half of the carriage, on the other end of the belt 18 , after the belt has been cut to the length required for that installation. The connector pin 36 and retainer clip 38 may then be inserted to connect the two halves of the carriage together, to form the belt into an endless loop.
[0047] The taper of the belt retention surfaces relative to the bearing surface 42 helps lock the belt in place. A further advantage of the arrangement is to help maintain the belt at a relatively stable belt tension as the carriage follows the bend 16 of the drive track 10 , thus helping reduce unnecessary strain on the drive motor.
[0048] FIG. 5 shows an end assembly for attachment to the guide track ends, including a body 44 formed of opposed halves, and a belt wheel 46 rotatably supported within the body which may be in the case of the bottom end assembly 24 a be freewheeling, or in the case of the upper leg end assembly 24 b, may be driven by a drive unit. The surface of belt wheel may be notched to match the notches of the drive belt 18 .
[0049] See FIGS. 9 and 10 and associated description below for more details of suspension of the drive unit.
[0050] FIG. 6 illustrates an adjustable tensioner assembly 48 , which is shown in FIGS. 7 and 8 fitted to the bottom end assembly 24 b. The tensioner consists of a clamping plate 50 which is adapted to clamp to the drive track 12 , and to provide an adjustable screw connection 52 bearing against end assembly 24 b. This assists in adjustable tensioning of the belt 18 , by adjusting separation of the end assembly from the track, against the tension of the drive belt 18 .
[0051] In practice, an adjustment of less than 20 mm, or even less than 10 mm, may be sufficient adjustment for most installations. If greater adjustment is required, adjustable tensioners may be fitted to both the top and bottom end assemblies 24 a, 24 b, though it is believed that this will not normally be necessary.
[0052] FIGS. 9 and 10 illustrate a support arrangement for a drive motor unit for the garage door, adapted for greater ease of installation.
[0053] The support arrangement includes a hanger bracket 54 with boltholes 56 adapted for attachment for connection of the hanger to the garage door support structure, for example to the garage door track. The hanger 54 also includes a re-entrant track portion 58 running parallel to the garage door track to which it is connected, for receiving enlarged head pins 60 mounted on top of the drive unit housing 62 .
[0054] In use, the support arrangement permits the hanger bracket to be connected to the door track and then attachment of the drive unit to the re-entrant track portion 58 . The hanger bracket track 58 supports the weight of the drive unit, while finer adjustments to the drive unit to align with the end assembly 24 b at the top end of the guide track may be made readily by the installer by sliding the drive unit along the support track 58 , avoiding the need for the installer to bear the weight of the drive unit while making those fine adjustments.
[0055] The concepts of FIGS. 9 and 10 may also find application in the installation of drive units for other garage door arrangements, not just those described herein and in WO 2013/016777.
[0056] In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise, comprised and comprises where they appear.
[0057] It will be understood that the present disclosure extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the present disclosure.
[0058] While particular embodiments of the present disclosure have been described, it will be evident to those skilled in the art that the present disclosure may be embodied in other specific forms without departing from the essential characteristics thereof The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the present disclosure being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. It will further be understood that any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the present disclosure relates.
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A carriage assembly is disclosed for a garage door drive belt. The assembly includes first and second carriage elements each having inner and outer members adapted to retain an end of the drive belt therebetween. An articulated connection extends between the first and second carriage elements. Also disclosed is a support arrangement for a garage door drive unit, comprising a drive unit hanger for attachment to a garage door structure, the hanger further having a weight-supporting connection to the drive unit, wherein the drive unit position is adjustable while the weight of the drive unit is supported.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates broadly to apparatus and methods for investigating subsurface earth formations. More particularly, this invention relates to borehole tools and methods for making hydraulic property measurements of an earth formation surrounding a borehole, and in particular apparatus and methods for generating appropriate pressure-pressure response functions in homogeneous and heterogeneous formations.
[0003] 2. State of the Art
[0004] The determination of permeability (fluid mobility) and other hydraulic properties of formations surrounding boreholes is very useful in gauging the producibility of formations, and in obtaining an overall understanding of the structure of the formations. For the reservoir engineer, permeability is generally considered a fundamental reservoir property, the determination of which is at least equal in importance with the determination of porosity, fluid saturations, and formation pressure. When obtainable, cores of the formation provide important data concerning permeability. However, cores are difficult and expensive to obtain, and core analysis is time consuming and provides information about very small sample volumes. In addition, cores, when brought to the surface, may not adequately represent downhole conditions. Thus, in situ determinations of permeability which can quickly provide horizontal and vertical determinations of permeabilities over larger portions of the formation are highly desirable.
[0005] Existing techniques for making permeability determinations can be classified into indirect and direct methods. In indirect methods, permeability is determined from empirical correlations which attempt to express permeability in terms of other measured formation parameters, such as porosity, saturation, or mineralogy. A direct measurement technique involves actual measurement of fluid flow, pressure, etc. and determination of permeability from these measurements.
[0006] Suggestions regarding a direct in situ determination of permeability via the injection or withdrawal of fluid into or from the formation and the measurement of pressures resulting therefrom date back at least to U.S. Pat. No. 2,747,401 to Doll (1956). In the Doll patent there is disclosed a method and apparatus for determining hydraulic characteristics, including permeability, fluid pressure, and hydraulic anisotropy, of formations surrounding a borehole. A pressure gradient is obtained in the formations by pressing or pushing a probe against the borehole wall. Pressure differences between different points are then used to obtain indications of hydraulic characteristics of the formations. In an embodiment disclosed in the patent, a pair of spaced probes are pressed against the formation, and a pressure gradient is generated by injecting a fluid into the formation at one of the probes (a source probe) at a constant flow rate. The other probe (a measurement probe) is coupled to a pressure responsive device. Pressure is measured at the measurement probe before and after injection of the fluid at the source probe. The permeability of the formation is then obtained using a formula in which permeability is proportional to viscosity times flow rate divided by the change in pressure. The patent points out that the pressure gradient can also be obtained by extracting fluid from the formation and that measurements can be made in more than one direction; e.g., vertical and horizontal, to obtain indications of both vertical and horizontal hydraulic characteristics.
[0007] Different devices have been used for making direct measurements of permeability. For example, devices whose primary use has been for sampling formation fluids, have also been used with some success in estimating formation permeability. Formation testing devices which can take repeated samples are disclosed, for example, in U.S. Pat. Nos. 3,780,575 to Urbanosky and 3,952,588 to Whitten, both of which are hereby incorporated by reference herein in their entireties. In these devices, a hydraulic pump provides pressure for the operation of various hydraulic systems in the device. Sample chambers are provided in the tool to take samples of formation fluid by withdrawing hydraulically operated pistons. Pressure transducers are provided to monitor pressure as the fluid is withdrawn, and pressure can be continuously recorded. So-called pre-test chambers are also typically provided and are operated to permit more reliable flow during the subsequent fluid withdrawal. Filters can also be provided to filter sand and other particulate matter, and pistons can be provided to clean the filters, such as when the tool is retracted.
[0008] One type of formation testing device includes an elongated body and a setting arm activated by setting pistons which are used to controllably urge the body of the device against a side of the borehole wall at a selected depth. The side of the device that is urged against the borehole wall includes a packer which surrounds a probe. As the setting arm extends, the probe is inserted against the formation, and the packer then sets the probe in position and forms a seal around the probe, whereupon the fluids can be withdrawn from the formation during pre-test and the actual test.
[0009] The primary technique presently used for in situ determination of permeability is the “drawdown” method where a probe of a formation testing tool is placed against the borehole wall, and the pressure inside the tool (e.g., at a chamber) is brought below the pressure of the formation, thereby inducing fluids to flow into the formation testing tool. By measuring pressures and/or fluid flow rates at and/or away from the probe, and processing those measurements, determinations regarding permeability are obtained. These determinations, however, have typically been subject to large errors. Among the reasons for error include the fact that if fluid is extracted at a fixed flow rate which is independent of permeability, as is typically done, in low permeability formations the pressure drop tends to be too large, and solution gas and/or water vapor forms and can make the results uninterpretable. Indeed, liberation of gas during drawdown provides anomalous pressure and fluid flow rate readings. Another source of error is the damage to the formation (i.e., pores can be clogged by migrating fines) which occurs when the fluid flow rate towards the probe is caused to be too large. See, e.g., T. S. Ramakrishnan et al., “A Laboratory Investigation of Permeability in Hemispherical Flow with Application to Formation Testers”, SPE Form. Eval. 10, pp. 99-108 (1995).
[0010] More recent patent disclosures of permeability testing tools include U.S. Pat. No. 4,742,459 to Lasseter, and U.S. Pat. No. 4,860,581 to Zimmerman et al. (both of which are hereby incorporated by reference herein in their entireties) which further develop the draw-down techniques. In the Lasseter patent, a logging device is provided having a source probe, a horizontal observation probe which is azimuthally displaced on the borehole wall with respect to the source probe position, and a vertical observation probe which is vertically displaced on the borehole wall with respect to the source probe position. The source probe is provided with means for withdrawing fluid at a substantially constant rate or pressure, while the vertical and horizontal probes, as well as the source probe, are provided with means for measuring formation pressure response as a function of time. According to the method for determining permeability, a transient pressure change is established in the formation by withdrawing fluid from the formation at the source probe location. The formation pressure response is then measured at the vertical and horizontal probes. By selecting a trial permeability value, theoretical formation pressure responses can be derived as a function of time at the probe locations. The theoretical formation pressure responses are then compared with the actually measured pressure responses in an iterative manner, with the difference being used as feedback to modify the trial value, until the difference is negligible.
[0011] The Zimmerman et al. patent mentions that in the drawdown method, it is essential to limit the pressure reduction so as to prevent gas liberation. In order to prevent gas liberation, Zimmerman et al. propose a flow controller which regulates the rate of fluid flow into the tool.
[0012] Additional progress in in situ permeability measurement is represented by U.S. Pat. No. 5,269,180 to Dave et al., U.S. Pat. No. 5,335,542 to Ramakrishnan et al., and U.S. Pat. No. 5,247,830 to Goode, all of which are hereby incorporated by reference herein in their entireties. In the Dave et al. patent, borehole tools, procedures, and interpretation methods are disclosed which rely on the injection of both water and oil into the formation whereby endpoint effective permeability determinations can be made. In the Ramakrishnan et al. patent, a tool which integrates hydraulic and electromagnetic measurements (images) is disclosed. In the Goode patent, methods are disclosed for making horizontal and vertical permeability measurements without the necessity for measuring flow rate into or out of the borehole tool. In particular, an interpretation scheme is presented in which the change in pressure at the vertical observation probe is related to the change in pressure at the horizontal probe through a convolutional integral. The kernel function G in this integral is independent of the flowrate at the sink probe. This scheme is called pressure-pressure deconvolution, and it eliminates the need for knowing the tool storage volume (i.e., the volume of fluid in the tool connected to the formation) and the formation damage at the sink probe. However, the problem of storage at the observation probes remains and can be a source of error in the interpretation because the local flow at each observation probe causes a pressure change that cannot be neglected. Thus, even with these inventions which have advanced the art significantly, the accuracy and scope of the information obtained is not to the level desired.
SUMMARY OF THE INVENTION
[0013] It is therefore an object of the invention to provide apparatus and methods for conducting accurate measurements of hydraulic properties of an earth formation.
[0014] It is another object of the invention to provide apparatus and methods for generating appropriate pressure-pressure response functions in homogeneous and heterogeneous formations.
[0015] It is a further object of the invention to provide methods and apparatus for eliminating storage effects in pressure-pressure deconvolutional analysis.
[0016] It is an additional object of the invention to provide a modified pressure-pressure deconvolution for improved stability.
[0017] Another object of the invention is to provide apparatus and methods eliminating storage effects without requiring additional testing of the formation.
[0018] In accord with the objects of the invention, the effects of storage on the interpretation of data obtained at the observation probes can be eliminated by controlling the storage volumes relative to the observation probes. For a homogeneous medium, the effect of storage on the interpretation of data from the observation probes may be eliminated by causing the flow line volumes connected to each observation probe to be equal to each other. For a heterogeneous medium, the effect of storage on the interpretation of data from the observation probes may be eliminated by causing the flow line volumes to vary in proportion to the permeabilities of the strata of the heterogeneous medium adjacent the probes. The borehole tool of the invention is therefore provided with means for conducting flow line volume adjustment. Thus, where the vertical observation probe is located in one stratum (layer) of the formation having a first permeability and the horizontal observation probe is located in another stratum having a second permeability, based on local drawdown permeabilities estimated in pretest procedures, the flow line volumes connected to the respective observation probes are adjusted in order to remove the effect of storage on the interpretation of data during testing.
[0019] Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a diagram, partially in schematic form, of an apparatus in accordance with an embodiment of the invention which can be used to practice an embodiment of the method of the invention;
[0021] [0021]FIG. 2 is a diagram, partially in schematic form, of portions of the logging device of FIG. 1;
[0022] [0022]FIG. 3 is a graph showing three plots of the pressure-pressure response function for a homogeneous medium at different storage ratios; and
[0023] [0023]FIG. 4 is a graph showing four plots of the pressure-pressure response function for a heterogeneous medium at different storage ratios.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] An apparatus 100 for investigating subsurface formations 31 traversed by a borehole 32 is seen in FIG. 1. Typically, the borehole 32 is filled with a drilling fluid or mud which contains finely divided solids in suspension. The investigating apparatus or logging device 100 is suspended in the borehole 32 on an armored multiconductor cable 33 , the length of which substantially determines the depth of the device 100 . A known depth gauge apparatus (not shown) is provided to measure cable displacement over a sheave wheel (not shown) and thus record the depth of the logging device 100 in the borehole 32 . The cable length is controlled by suitable means at the surface such as a drum and winch mechanism (not shown). Circuitry 51 , shown at the surface of the formation, although portions thereof may be downhole, represents control, communication and preprocessing circuitry for the logging apparatus. This circuitry may be of known type, and is not, per se a novel feature of the present invention.
[0025] The preferred logging device 100 has an elongated body 121 which encloses the downhole portion of the device controls, chambers, measurement means, etc. Arms 122 and 123 are mounted on pistons 125 which extend, under control from the surface, to set the tool. Mounted on the arm 122 are a source probe 160 , and spaced above and vertically therefrom, a vertical observation probe 170 . Mounted on the arm 123 is a horizontal observation probe 180 . The arm may also contain a further measuring device, such as an electrical microresistivity device at the position 190 . Conduits 61 , 71 , and 81 are provided and are slidably mounted in body 121 for communication between the probes 160 , 170 , and 180 , respectively, and the body 121 .
[0026] As is disclosed in previously incorporated U.S. Pat. No. 4,742,459, the source probe 160 preferably comprises either a fluid sink or a fluid source which includes a packer 161 with a fluid-carrying line that communicates with the formation when the packer is set. The present invention is not dependent on use of a particular type of mechanical means for withdrawing fluid from or injecting fluid into the formations, as any of numerous such device well known in the art may be utilized.
[0027] As seen in FIG. 2, a pretest chamber 169 is accessed via a valve 163 . A controlled flow system with chambers 164 is accessible via valve 165 . The control of sample dump to the borehole is via valve 167 . In addition, valve 166 a is provided along with sample chambers 166 b to permit storage of samples to be brought to the surface of the formation. A pressure measurement device 162 such as a strain gauge type of pressure meter is provided to monitor pressure at the probe. In accord with the preferred embodiment of the invention, and as described in previously incorporated U.S. Pat. No. 5,247,830 to Goode, no flow rate meter is required as flow rate is not used in making determinations of the hydraulic properties of the formation according to the preferred embodiment of the invention.
[0028] The vertical observation probe 170 comprises a packer 171 with an observation port or probe that engages the borehole, and communicates via fluid conduit (also called “flow line”) 177 with a pretest chamber 172 via a valve 173 . A high resolution high-accuracy pressure meter 175 , such as of the quartz piezoelectric type, is preferably provided to monitor the pressure at the probe. Extending from flow line 177 are a plurality of branch flow lines 177 a - 177 n . Each branch flow line is coupled to the main flow line 177 via valves 173 a - 173 n . In this manner, as will be discussed in greater detail hereinafter, the fluid storage volume associated with the probe 170 may be adjusted. Each branch flow line 177 a - 177 n may be a dead-end line, and if desired, each branch flow line 177 a - 177 n may be of equal size and hold an equal volume of fluid. Alternatively, the flow lines may hold different amounts of fluid, and/or one or more of the flow lines may be coupled to a fluid chamber (not shown) which can hold a substantial amount of fluid. As another alternative, a single branch flow line may be provided with multiple valves in series along the branch flow line. In this manner, valves may be opened in sequence to provide a desired storage volume for the probe. In any event, it is desirable that the storage volume fluidly coupled to the probe be adjustable by means of the branch flow line(s) so that the storage volume can be increased by a factor of ten or even one hundred relative to the storage volume when all branch flow lines are closed. Depending upon the arrangement of the branch flow line(s), (i.e., whether multiple branch flow lines are used and whether they are all equal in volume), the step may be larger or smaller. Thus, for example, using eleven branch flow lines ( 177 a - 177 k ) having storage volumes equal to {fraction (1/16)}, ⅛, ¼, ½, 1, 2, 4, 8, 16, 32, and 64 times the storage volume of flow line 177 , and by controlling the valves which couple and decouple the branch flow line to the main flow line, the total storage for the probe may be increased in steps of 6.25% to an amount over one hundred times (10,000%) the storage volume of the probe.
[0029] According to the preferred embodiment of the invention, the flow lines 177 a - 177 n (and preferably main flow line 177 ) are either filled (primed) with a liquid such as water or oil prior to placing the tool in the borehole, or the flow lines are provided with additional valves (not shown) which permit the lines to be flushed with reservoir fluid or with fluid carried downwhole (as described in the previously incorporated Dave et al. U.S. Pat. No. 5,269,180). Where the flow lines are filled with liquid prior to placement downhole, according to the preferred embodiment of the invention, it is preferred that the main flow line 177 still be provided with an additional valve to permit flushing of the main flow line.
[0030] The horizontal observation probe 180 is of similar construction to the vertical observation probe and includes a packer 181 with an observation port or probe that engages the borehole and communicates via a fluid conduit 187 with the pretest chamber 182 and valve 183 . A pressure measuring means 184 is also coupled to the fluid conduit 187 . Preferably, the fluid conduit 187 is of exactly the same storage capacity as the fluid conduit 177 associated with probe 170 . In addition, the fluid conduit 187 is also preferably provided with a plurality of branch flow lines 187 a - 187 n which are coupled thereto via valves 183 a - 183 n . In this manner, as will be discussed in greater detail hereinafter, the fluid storage volume associated with the probe 180 may be adjusted. Despite the preference of a quartz piezoelectric type pressure meter, the present invention is not dependent on use of a particular device for taking pressure measurements, as many such devices (e.g., a strain gauge or sapphire sensor) are well known in the art.
[0031] As with branch flow lines 177 a - 177 n , branch flow lines 187 a - 187 n (and preferably main flow line 187 ) are either filled with a liquid such as water or oil prior to placing the tool in the borehole, or the flow lines are provided with additional valves (not shown) which permit the lines to be flushed with reservoir fluid or with fluid carried downwhole. In this manner, the fluids contained in each of the probes 170 , 180 are matched.
[0032] The mechanical elements of the system are controlled from the surface of the earth hydraulically and electrically in a known fashion. Likewise, the pressure at the source probe and the observation probes are monitored and transmitted to the surface of the earth for recording in known manners.
[0033] The signal outputs of block 51 are illustrated as being available to processor 500 which, in the present embodiment, is implemented by a general purpose digital computer. It will be understood, however, that a suitable special purpose digital or analog computer could alternatively be employed. Also, it will be recognized that the processor may be at a remote location and receive inputs by transmission of previously recorded signals. The outputs of the computing module 500 are values or value-representative signals for formation hydraulic properties, developed in accordance with techniques described hereinbelow. These signals are recorded as a function of depth on recorder 90 , which generically represents graphic, electrical and other conventional storage techniques.
[0034] In operation, at a depth level at which measurements are to be taken, the pistons 125 are extended and the tool is set. Under control from the surface, a pretest is then performed at the source probe 160 and the observation probes 170 and 180 . The function of the pretest is to flush out mud or mud cake from between the source and observation probes and the formation so as to ensure good hydraulic seals and communication with the formation. During pretest, the fluid lines of the borehole tool are generally flushed to remove borehole fluid and mud. However, for purposes of the present invention, the pretest may also function in a manner well known in the art to obtain an estimate of permeabilities of the formation adjacent each of the probes. See, e.g., “RFT: Essentials of Pressure Test Interpretation”, Schlumberger, 1981.
[0035] Based on the rough estimates of the formation permeability adjacent the observation probes 170 , 180 , the relative fluid storage of flow lines 177 , 187 may be adjusted by opening appropriate valves chosen from valves 173 a - 173 n and 183 a - 183 n . In particular, if the estimates of formation permeability adjacent the observation probes 170 , 180 indicate that the tool is located in a homogeneous formation or a homogeneous portion of the formation (i.e., the estimates are equal), none of the valves 173 a - 173 n and 183 a - 183 n are opened as flow lines 177 and 187 are designed to have the same storage capacity. Thus, according to the invention, the storage effects on the pressure-pressure deconvolution will be effectively canceled as will be discussed in detail hereinafter. However, if the permeability estimates resulting from the pretest indicate that the tool is in a heterogeneous portion of the formation (i.e., the estimates are different), according to the invention, one or more of valves 173 a - 173 n and 183 a - 183 n are opened so that the ratio of the storage capacities of the flow lines 177 and 187 (including the branch flow lines in fluid communication therewith) is substantially equal to the ratio of the permeability estimates.
[0036] It should be appreciated that because the process of pretesting can cause different types of fluids to enter flow lines 177 and 187 , it may be desirable to flush flow lines 177 and 187 with formation fluids or fluids carried downhole before opening any of valves 173 a - 173 n or 183 a - 183 n and continuing.
[0037] The pretest (and any flushing) is followed by a withdrawal (“drawdown”) of the formation fluids into the sink probe line of the borehole tool. Drawdown is done at a constant flow rate if possible, and pressure measurements are typically taken at the source probe 160 and at observation probes 170 and 180 . Drawdown is accomplished by opening valve 165 and initiating the pressure controlled subsystem 164 to withdraw fluid from the formation. Fluid is withdrawn or injected at a substantially controlled pressure or rate. The valve is then closed at the time designated as the shut-in time. During this time, and for a predetermined time after shut-in time, the pressure at the source probe and at each observation probe is measured by the respective pressure gauges and sent to the surface of the earth where the measured pressures are recorded. Flow due to the compression of the fluid in the tool continues following shut-in. Typically, although not necessarily, pressure signals are sampled at a period of 0.1 seconds, converted to digital form, and sent to the surface for recording. Accordingly, there is available at the surface a record of the pressure as a function of time at the source probe and each of the observation probes. There are various available devices and techniques for withdrawing fluid from the formations at substantially constant pressure; examples being set forth in U.S. Pat. No. 4,507,957 or 4,513,612. In addition, there are various available techniques for interpreting the data resulting from the drawdown tests. According to the invention, the preferred methods for interpreting the data are set forth in previously incorporated U.S. Pat. No. 5,247,830 to Goode.
[0038] If, based on measurements obtained during drawdown, it is desired to take fluid samples, the source probe is activated by opening valve 166 a and fluid is withdrawn from the formation for a given time or until a particular amount of fluid has been withdrawn. No flow rate measurement is made. Pressure measurements at the source probe as well as at the observation probes are taken during sampling, and these measurements are sent uphole as hereinbefore indicated with respect to the measurements made during drawdown.
[0039] It should be noted that before sampling, if desired, a pumping module (not shown) may be used to pump fluids via the probe (sink) into the borehole, and at a desired time, divert the flow into a sampling chamber.
[0040] Having described the apparatus and procedure of the invention, an understanding of the underlying theoretical basis of the invention is in order. The convolution integral is widely used for solving time-dependent boundary value problems in variable rate well test analysis. For the pressure response p v (t) at the vertical observation probe 170 , the convolution integral can be written as:
p v ( t ) = ∫ 0 t q s ( τ ) G vs ( t - τ ) τ + ∫ 0 t q v ( τ ) G vv ( t - τ ) r + ∫ 0 t q h ( τ ) G vh ( t - τ ) τ , ( 1 )
[0041] where G represents the response functions with the first subscript denoting the observation point and the second subscript denoting the source, q represents actual flowrates, and the subscripts s, v, and h denoting the sink probe 160 , vertical probe 170 and horizontal probe 180 respectively. No specification of G is made other than requiring that the response be linear.
[0042] For a slightly compressible fluid of isothermal compressibility c, the law of mass conservation yields:
q v ( t ) = - c V v p v t ,
q h ( t ) = - c V h p h t , and
q s ( t ) - q ( t ) = - c V s p s t ( 2 )
[0043] where V is the tool volume and q(t) is the imposed drawdown rate at the sink. Substituting the equalities of equations (2) into equation (1) results in:
p v ( t ) = ∫ 0 t q s ( τ ) G vs ( t - τ ) τ - ∫ 0 t c V s p s τ G vs ( t - τ ) t - ∫ 0 t c V v p v τ G vv ( t - τ ) - ∫ 0 t c V h p h τ G vh ( t - τ ) t . ( 3 )
[0044] Similar expressions may be written for the pressure responses p h (t) and p s (t).
[0045] The following dimensionless variables may now be defined:
p vD = p v k l Q μ p hD = p h k d Q μ p sD = p v k r p Q μ t D = t k φμ c l 2 q D = q Q
[0046] with the following dimensionless response function being
G vsD = G vs μ k l φμ c l 2 k G hsD = G hs μ k d φμ c l 2 k G vhD = G vh μ k l φμ c l 2 k and G ssD , vvD , hhD = G ss , vv , hh μ k r p φμ c l 2 k
[0047] In the above expressions, Q is a characteristic rate, l is the distance between the sink and the vertical probe, d is an effective distance between the horizontal probe and the sink as defined in detail hereinafter, and r p is the probe radius. A characteristic permeability k has been chosen for the purpose of nondimensionalization.
[0048] Substituting the above dimensionless parameters into equation (3) and simplifying yields:
P vD ( t D ) = ∫ 0 t D q D ( τ ) G vsD ( t D - τ ) τ - [ V s φ l 2 r p ] ∫ 0 t D p sD τ G vsD ( t D - τ ) τ - [ V v φ l 2 r p ] ∫ 0 t D p vD τ G vvD ( t D - τ ) τ - [ V h φ l 2 d ] ∫ 0 t D p hD τ G vhD ( t D - τ ) τ . ( 4 )
[0049] If the nondimensional storage related constants are denoted by κ, then κ s =V s /φl 2 r p , κ h =V h /φl 2 r p , κ v =V v /φl 2 r p , δ=r p /d, and ε=r p /l. It is useful to note that r p /l and r p /d are much smaller than 1.
[0050] Laplace transformation of equation (4) with t D →s D gives
{overscore (p)} vD ( s D )= {overscore (G)} vsD ( s D ) {overscore (q)} D ( s D )− s D k s {overscore (G)} vsD ( s D ) {overscore (p)} sD ( s D )− s D k v {overscore (G)} vvD ( s D ) {overscore (p)} vD ( s D )−δs D κ h {overscore (G)} vhD ( s D ) {overscore (p)} hD ( s D ) (5)
[0051] where the transformed variables are denoted by the elevated bar ({overscore ( )}). Rearranging equation (5) yields
{overscore (p)} sD [s D k s G vsD ]+{overscore (p)} hD [δs D k h G vhD ]+{overscore (p)} vD [1+ s D k v G vvD ]={overscore (G)} vsD {overscore (q)} D (6)
[0052] Similar expressions for the horizontal and sink probes are:
p _ sD [ s D κ s G hsD ] + p _ hD [ 1 + s D κ h G _ hhD ] + p _ vD [ ɛ 2 δ s D κ v G _ hvD ] = G _ hsD q _ D ( 7 )
and {overscore (p)} sD [1+ s D κ s G ssD ]+{overscore (p)} hD [δ 2 s D kh {overscore (G)} shD ]+{overscore (p)} vD [ε 2 s D kv {overscore (G)} vsD ]={overscore (G)} ssD {overscore (q)} D (8)
[0053] By neglecting terms on the order of (δ), (ε), (δ 2 ), and (ε 2 ), in equations 6, 7, and 8 and explicitly solving for observation probe pressures, the following is obtained:
p _ vD = G _ vsD q _ D [ 1 + s D κ v G _ vvD ] [ 1 + s D κ s G _ ssD ] and ( 9 ) p _ hD = G _ hsD q _ D [ 1 + s D κ h G _ hhD ] [ 1 + s D κ s G _ ssD ] ( 10 )
[0054] Dividing equation (9) by equation (10) yields:
p _ vD p _ hD = G _ vsD G _ hsD [ 1 + s D κ h G _ hhD ] [ 1 + s D κ v G _ vvD ] ( 11 )
[0055] For testing of a formation with a multiprobe module such has been described herein, equation (11) suggests that the effect of storage volume connected to the vertical and the horizontal observation probes will cancel out if κ h =κ v and {overscore (G)} hhD ={overscore (G)} vvD . The condition {overscore (G)} hhD ={overscore (G)}vvD is satisfied if the vertical and the horizontal probes are geometrically similar and are set in a medium of similar properties (e.g., in a homogeneous medium). Even in a layered medium of alternating permeabilities the condition is met if both of the probes are set in similar streaks. If the layering is extremely fine, but the medium behaves as a homogeneous anisotropic medium in all the length scales of interest, the condition of {overscore (G)} hhD ={overscore (G)} vvD is met as well. The requirement that κ h =κ v or (V v =V h ) means that the flow line volume connected to the observation probes should be equal. Thus, according to the invention, flow lines 177 and 187 are preferably chosen to be of equal length and diameter so that the storage volume between the probe 171 and valve 173 is equal to the storage volume between probe 181 and valve 183 .
[0056] With κ h =κ v , equation (11) reduces to
p _ vD p _ hD = G _ vsD G _ hsD ( 12 )
[0057] With
G _ = G _ vsD G _ hsD ,
[0058] it follows that
p vD ( t D ) = ∫ 0 t D p hD ( τ ) G ( t D τ ) τ where ( 13 ) G = L - 1 ⌊ G _ vsD G _ hsD ⌋ ( 14 )
[0059] The function G(t) depends only on the geometry and the rock/fluid properties of the formation. It has diagnostic value for flow regime identification which is necessary to choose the correct inverse model for parameter estimation as set forth in previously incorporated U.S. Pat. No. 5,247,830 to Goode. The above analysis shows that a source of error in model identification and in the estimation of horizontal and vertical mobilities can be removed by equalizing the storage volumes at the monitor probes.
[0060] According to Goode, for system identification, one would normally deconvolve equation (13) to numerically calculate G and compare with known system behaviors. Inversion of equation (13) is numerically stable only if the vertical probe response “lags” that of the horizontal probe. When k v is larger than k h (e.g., in a formation with vertical microfractures) this is not necessarily the case and a modification of the G function to
G ^ = L - 1 [ G _ vsD G _ hsD + G _ vsD ] ( 15 )
[0061] would ensure that the numerator never leads the denominator signal.
[0062] In order to demonstrate the effectiveness of the modification, it is not necessary to model the details of the wellbore geometry and the formation. It is sufficient to consider response functions which are very similar to the proposed tool. This is achieved through the following approximations.
[0063] Regarding the self-response function such as Gss, Gvv, and Ghh, the presence of the wellbore is important since the radius of the probe r p is much smaller than the radius of the wellbore r w . Thus, the probe acts as though it is a source or sink in a flat plate. See, Wilkinson, D. and Hammond, P.: “A Perturbation Method for Mixed Boundary-Value Problems in Pressure Transient Testing”, Trans. Porous Media , (1990) 5, p. 609-636, and Ramakrishnan, T. S. et al.: “A Laboratory Investigation of Permeability in Hemispherical Flow with Application to Formation Testers”, SPE Form. Eval . (1995) 10, p. 99-108. However, this boundary value problem is of mixed-nature and cannot be exactly solved. For time scales larger than that required for pressure diffusion to propagate a few probe radii, the infinite time result may be used with the assumption of the transient being a point sink. This is equivalent to using an “effective probe radius”=(2/π)r p . Solving the diffusion equation with a point sink on a flat plate, and observing the pressure at (2/π)r p yields:
G _ ss , G _ vv , G _ hh = μ 4 kr p exp ⌊ - φμ cs k r p ⌋ ( 16 )
[0064] In contrast, since the vertical probe is far away form the sink, and l>>r w , as an observation probe, the presence of wellbore is secondary. Thus, for the response function {overscore (G)} vs an observation point may be considered in free space. Based on this, the following result is obtained:
G _ vs = μ 4 π kl exp ⌊ - φμ cs k l ⌋ ( 17 )
[0065] It may be seen from Goode, P. A. and Thambynayagam, R. K. M.: “Permeability Determination with a Multiprobe Formation Tester”, SPE Formation Eval. 7, pp. 297-303 (1992) that this is a good approximation because the wellbore shape factor approaches 1 for the vertical probe (i.e., the vertical probe is a point observation in free space).
[0066] In dimensionless form, the above equations reduce to:
G _ ssD , G _ vvD , G _ hhD = 1 4 exp ⌊ - r p l s D ⌋ and ( 18 ) G vsD = 1 4 π exp [ - s D ] ( 19 )
[0067] The approximation set forth above for the vertical probe is not as accurate when applied to the horizontal probe. If it is assumed that the probe is at a distance d in free space, then, instead of equation (17) for the vertical probe, the following is obtained for the horizontal probe:
G _ hs = μ 4 π kd exp ⌊ - φμ cs k d ⌋ ( 20 )
[0068] Here, the effective distance d may be approximated by the characteristic diffusion length πr w , and as a result, equation (20) reduces to
G _ hs = ≈ μ 4 π k ( π r w exp ⌊ - φμ cs k π r w ⌋ ( 21 )
[0069] This approximation differs from the true steady state value (s→0) by only about twenty percent. See, Goode, P. A. and Thambynayagam, R. K. M.; Permeability Determination with a Multiprobe Formation Tester,” SPE Formation Eval . (1992) 7, p. 297-303. Therefore, this approximation is expected to have the correct qualitative and nearly the same quantitative behavior as the correct response. In dimensionless form the following is obtained
G _ hsD = 1 4 π exp [ - ɛ δ s D ] ( 22 )
[0070] Application of equation (11) now yields
p _ vD p _ hD = exp [ - ( 1 - ɛ δ ) s D ] ( 1 + k h s D 4 exp [ - ɛ s D ] ) ( 1 + k v s D 4 exp [ - ɛ s D ] ) ( 23 )
[0071] Equation (23) allows an examination of the effect of having different storage volumes on the deconvolutional process utilized in the previously incorporated U.S. Pat. No. 5,247,830 to Goode. In particular, FIG. 3 shows the pressure-pressure response function (G vhD vs. time) for a homogeneous medium for observation probes having no storage (κ h =0 and κ v =0), for observation probes of the prior art where the horizontal probe storage volume is approximately 100 cc and the vertical probe storage volume is approximately 90 cc (corresponding to κ h =0.18 and κ v =0.17), and for observation probes having storage volumes such that κ h =0.18 and κ v =0.09. For purposes of generating the plots of FIG. 3, the formation permeability was assumed to be 10 mD, length l=70 cm, and r p =0.556 cm. As seen from FIG. 3, in a homogeneous formation, the deviation from the no-storage volume reference curve is minimal for the tool of the prior art. The deviation is somewhat larger where κ h =0.18 and κ v =0.09. In this case, because of the smaller storage volume in the vertical probe, there is a tendency for the vertical probe to lead the horizontal probe in comparison to the true response. Clearly, this can lead to a misinterpretation that the formation is anisotropic. Thus, according to the invention, it is desirable that the storage volumes at the observation probes be equal to each other (thereby reducing the right hand fraction term of equation (23) to one).
[0072] The impact of storage compensation in a heterogeneous medium is substantially larger than the impact in a homogeneous medium. This may be illustrated by first assuming a background homogeneous medium and by assuming that in the vicinity of the horizontal and vertical probes the formation permeabilities are k 1 and k 2 respectively. Thus, the self-response functions are determined by k 1 and k 2 . But G vs and G hs are based on the homogeneous permeability. As a result, equation (23) becomes
p _ vD p _ hD = exp [ - ( 1 - ɛ δ ) s D ] ( 1 + κ h s D k 4 k 1 exp [ - ɛ k s D k 1 ] ) ( 1 + κ v s D k 4 k 2 exp [ - ɛ k s D k 2 ] ) ( 24 )
[0073] It is evident that the right-hand fraction term of equation (24) cannot be reduced to one simply by choosing κ h =κ v . In fact, no universal solution is possible since it is impossible to adjust κ h and κ v to such that the storage effect is cancelled perfectly at all times. However, a practical solution is achieved by recognizing that the function G vv and G hh reach steady state much faster than G vh (due to the fact that r p /l<<1). As a result, a near-cancellation is achieved by choosing κ h and κ v to be proportional to k 1 and k 2 respectively. Mathematically, this is expressed by:
p _ vD p _ hD = exp [ - ( 1 - ɛ δ ) s D ] ( 1 + κ h s D k 4 k 1 exp [ - ɛ k s D k 1 ] ) ( 1 + κ v s D k 4 k 2 exp [ - ɛ k s D k 2 ] ) ≈ exp [ - ( 1 - ɛ δ ) s D ] ( 1 + κ h s D k 4 k 1 ) ( 1 + κ v s D k 4 k 2 ) ( 25 )
[0074] Equation (25) allows an examination of the effect of using different storage volumes on the deconvolution process with respect to heterogeneous formations. Using the same example used with respect to FIG. 3 (i.e., l=70 cm, and r p =0.556 cm), it is assumed that the background permeability is 10 mD and the permeability at the horizontal probe is 100 mD, while the permeability at the vertical probe is 1 mD. In particular, FIG. 4 shows the pressure-pressure response function (G vhD vs. time) for the heterogeneous medium. A reference response plot is set for observation probes having no storage (κ h =0 and κ v =0). A second plot for observation probes of the prior art where the horizontal probe storage volume is approximately 100 cc and the vertical probe storage volume is approximately 90 cc (corresponding to κ h =0.18 and κ v =0.17) is seen to be significantly displaced from the reference plot. However, adjusting the horizontal probe storage volume to one hundred times that of the vertical probe storage (based on the local permeability ratio) so that κ h =17.0 and κ v =0.17 is seen in FIG. 4 to essentially eliminate the displacement. Even partial compensation significantly improves the character of the response as can be seen from the plot where κ h =9.0.
[0075] There have been described and illustrated herein several embodiments of apparatus and methods for investigating properties of an earth formation traversed by a borehole. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while a downhole tool having three probes was described, it will be appreciated that other numbers of probes could be utilized. Also, while a tool which permits probe fluid storage volume to be increased by a factor of about one hundred was described, it will be appreciated that the increase in probe fluid storage volume could be significantly smaller or significantly larger depending upon the accuracy of measurements desired and the formations likely to be encountered. Further, while it is preferred that the horizontally and vertically displaced probes have identical flow line characteristics, it will be appreciated that such an arrangement is only preferred, as given the flexibility associated with the branch flow lines, it will typically be possible to arrange the probes so that the flow line storage volumes are equal for homogeneous formations or portions thereof. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
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The effects of storage on the interpretation of data obtained at observation probes of a borehole tool are eliminated by controlling the storage volumes relative to the observation probes. For a homogeneous medium, the effect of storage on the interpretation of data is eliminated by causing the flow line volumes connected to each observation probe to be equal to each other. For a heterogeneous medium, the effect of storage on the interpretation of data is eliminated by causing the flow line volumes to vary in proportion to the relative permeabilities of the strata of the heterogeneous medium adjacent the probes. The borehole tool is provided with mechanisms for conducting flow line volume adjustment.
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CROSS REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application is a continuation of U.S. patent application Ser. No. 14/588,203, titled “Internally Vented Toilet with Dedicated Exhaust System,” filed on Dec. 31, 2014. patent application Ser. No. 14/588,203 is herein incorporated by reference in its entirety.
STATEMENT OF GOVERNMENT RIGHTS
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not Applicable.
BACKGROUND
Technical Field
[0005] The present invention relates to an odor-eliminating apparatus. More specifically, an embodiment of the present invention involves a toilet ventilation exhaust system that employs a dedicated, internal, orificial, annular vent passage integral to the upper rim of the toilet bowl. When connected to an appropriate exhaust line and vent exhaust fan, this system effectively and efficiently eliminates toilet odors. This invention functions during normal operation and offers provisions for recovery from upset conditions of condensate buildup and overflow as well as for periodic maintenance if vent exhaust path clogging ever were to occur.
[0006] Current art toilets depend on a ceiling ventilation exhaust fan to remove bathroom odors which originate in the toilet. Many of the more noxious gases are considerably heavier than air so a prolonged ventilation period using the ceiling exhaust fan method is necessary to exhaust toilet odors. This process is inefficient and ineffective as the gases must exit the toilet and enter the room air space before being exhausted. This non-direct exhaust flow path makes the odorous gases susceptible to mixing with other air and to being carried into areas outside the toilet room, thus causing the exhaust fan to operate for an extended period of time to remove all odors and often ineffectively. Since current art ceiling exhaust fans generally operate at 1.42-3.12 cubic meters per minute (50-110 cubic feet minute), literally scores of cubic meters (hundreds or thousands of cubic feet) of air are removed by prolonged operation of the fan before the toilet odors are eliminated from the toilet and surrounding air space. This air generally is conditioned (i.e., heated or cooled) and continued exhaust flow will result in pulling more outside, unconditioned air into the home or building. Sustained exhaust fan operation and the need to condition excessive replacement air cause unnecessary operation of building exhaust and heating, ventilating, and air conditioning systems, thus demanding unnecessary energy consumption when compared to the proposed invention. Additionally, the current art exhaust fans often include a light which is energized when the exhaust fan is energized using the same on/off switch. Daytime use of the light may be an additional waste of energy.
[0007] Some have attempted to address the problem by employing the use of the existing rim jet ports for gaseous odor removal. Sharing of common vent/flow ports for both noxious air exhaust and flushing water would require cycling of the exhaust fan to reestablish the exhaust flow after flushing. Otherwise, the continuing ventilation exhaust flow will establish and maintain a small standing column of water in the vent/flow ports equal in height (in millimeters or inches) to the suction pressure of the exhaust fan and will prevent subsequent exhaust air flow. During this period there will be no further exhaust flow from the toilet, and noxious odors will escape from the toilet and into the surrounding area. This cycling of exhaust fan operation to eliminate this concern makes such arrangements in a single residence inconvenient. It is impractical or unworkable for such arrangements in a larger building with multiple toilets and a common exhaust ventilation system which cannot be cycled off then on after every individual flush. Additionally, using the same rim jet holes for both water and air flows will result in cyclical wetting and drying of the small diameter ports. This ultimately will clog these ports due to normal presence of soluble solids in the water. In such cases neither the flush water flow nor exhaust air flow will be maintained without frequent maintenance to keep the rim jet ports clear. This is not a workable approach to toilet operation or odor removal. Therefore, an aspect of the present invention which provides for a separate flow path for water introduction into the toilet bowl and a separate flow path for odor removal is necessary to maintain reliable and efficient toilet operation for both flushing and odor removal.
[0008] The toilet system of U.S. Pat. No. 5,727,263 discloses two separate flow paths with two separate exhaust fans, each servicing a separate exhaust path. In the event of toilet overflow or condensate buildup in the exhaust path, the fan motors, which are below toilet bowl level. would fail due to water intake and would require replacement. There is no design provision for drainage of condensate or overflow liquid on the upstream or downstream side of each exhaust fan. There is no provision for performing maintenance which may require unclogging or removing water in the vent exhaust path or performing other required cleaning of the vent exhaust path which may occur over time. There is no specified consideration for factors of vent exhaust orifice sizing. exhaust ventilation piping size, vent exhaust flow rate, or capillary action relating to fan performance capabilities.
[0009] The toilet system of U.S. Pat. No. 5,809,581 discloses a system without toilet overflow or condensate buildup remedies. There is no recovery of the system due to overflow or condensate buildup without excavating the floor to remove the liquid filled exhaust piping which slopes downward from the toilet rim and is buried into the floor below the toilet. This resulting water column would block vent exhaust air flow. deprive the exhaust fan of air flow, and cause exhaust fan failure and loss of vent exhaust flow. Consistent with the first deficiency, there is no element for draining any part of the vent exhaust path. There is no element for performing maintenance which may require unclogging of the vent exhaust path or performing other required cleaning of the exhaust pathway which may occur over time. There is no teaching of vent exhaust orifice sizing, exhaust ventilation piping size, vent exhaust flow rate, or capillary action relating to fan performance capabilities. There is no stated consideration for location of the exhaust fan with respect to concern for condensate buildup or toilet overflow condition. Drawings show the vent exhaust orifices smaller than the liquid rim jet flush orifices. While the drawings are not stated to be to scale, the air vent holes would be larger than the liquid rim, jet orifices to achieve adequate air flow and avoid capillary action concerns.
[0010] U.S. Pat. No. 7,331,066 discloses a toilet system with a non-collapsible, flexible, hollow tube running throughout the upper rim duct in contrast to the wholly integrated but separate casting of the annular exhaust passage described herein. The flexible, hollow tube running throughout the upper rim duct of U.S. Pat. No. 7,331,066 would reduce the otherwise available cross-sectional area of the liquid, upper rim duct, create turbulence, and impede liquid flow through the upper rim duct. The airflow means/air exhaust mechanism disclosed in U.S. Pat. No. 7,331,066 can be any selection of suction blower, vacuum pump, or exhaust fan. Also, a high pressure suction created by a vacuum pump or suction blower would exacerbate orifice clogging, jeopardize the function of the air exhaust mechanism due to the possibility of pulling water into these mechanisms with condensate buildup or toilet overflow, and would exacerbate efforts to perform effective back flushing of the vent exhaust passageways due to high suction pressures pulling in possible contaminants into the vent exhaust orifices. Some aspects of these concerns could be mitigated by the pressure switch which would turn off the exhaust mechanism when the user leaves the toilet, but upon subsequent usage of the toilet, failure of the system to function would be likely. There is no element for maintenance back flushing or cleaning. This connection between the vent exhaust orifices and the non-collapsible, flexible, hollow tube is a very restrictive flow path to the flexible, hollow tube and makes questionable the ability to provide adequate exhaust air flow. There is no provision to accommodate condensate buildup or toilet overflow. This could result in fan (or other exhaust mechanism) failure and cessation of function of the vent exhaust system. There is no consideration of capillary action. Capillary action could be significant due to the very restrictive flow paths shown between the vent exhaust orifices and the non-collapsible, flexible, hollow tube.
[0011] All of the aforementioned systems suffer from the same deficiency of permitting condensate or overflow conditions into the vent pathway whereby the water would block the evacuation of the fumes in the pathway.
[0012] The references do not address the upset conditions of condensate buildup or of toilet overflow which subsequently may render many of the other known systems to be non-functional. An embodiment of the present invention provides for features which would allow recovery without equipment damage from toilet overflow and condensate buildup. Embodiments of the present invention also permit maintenance back flushing to clear the annular vent passage, vent exhaust orifices, annular exhaust vent line, and parent exhaust line if clogging of the exhaust ventilation flow path were to occur for any reason over the lifetime of operation.
BRIEF SUMMARY
[0013] One embodiment of the present invention provides a toilet system comprising a toilet bowl having a rim jet annulus located circumferentially inside a portion of a rim disposed above and around the periphery of the toilet bowl wherein the rim jet annulus has a plurality of rim jet orifices for introducing water into the toilet bowl. An annular vent passage which is separate from the rim jet annulus is located circumferentially inside and concentric with the rim jet annulus of the toilet rim of the toilet bowl. The annular vent passage has a plurality of vent exhaust orifices located at the inner radius of the annular vent passage and positioned above the rim jet orifices to avoid communication of the water from the rim jet orifices into the annular vent passage via the vent exhaust orifices. According to another embodiment, the annular vent passage is predominantly located above the existing rim jet annulus. In either embodiment, the annular vent passage connects to an annular exhaust vent line at the back vertical plane of the toilet bowl to avoid interference with the rim jet annulus. The annular exhaust vent line slopes downward from the back vertical plane of the toilet bowl to a low point where there is located a low point drain line and a low point drain valve at the bottom of the low point drain line. The annular exhaust vent line continues with a constant slope upward for a distance to join with an enlarged parent exhaust line. The parent exhaust line is in communication with a bypass branch line upstream of a vent exhaust fan upstream isolation valve located upstream of a vent exhaust fan and the parent exhaust line. The annular exhaust vent line may exit the toilet bowl at a same elevation as the annular vent passage or may exit the toilet bowl below the toilet rim from inside the toilet bowl to avoid interference with the rim jet annulus flow path. For example, the vent exhaust orifices are sized in consideration for vent exhaust flow and capillary action consistent with the vent exhaust fan.
[0014] In a further embodiment, the bypass branch line tees off the parent exhaust line upstream of the vent exhaust fan upstream isolation valve and at a minimum elevation more than the sum elevations of the toilet rim plus the maximum suction pressure of the vent exhaust fan. Alternatively, the bypass branch line further comprises a branch line isolation/throttle valve which may be used for throttling of air flow or for throttling or isolating liquid flow for maintenance back flush operations. In yet another embodiment, the bypass branch line does not include a branch line isolation/throttle valve. The bypass branch line is sized to allow sufficient and continuous ventilation flow for the vent exhaust fan under normal and upset conditions to maintain exhaust flow through the vent exhaust orifices with the bypass flow and to serve as a maintenance access connection for back flushing the parent exhaust line, annular vent passage, and vent exhaust orifices.
[0015] In one embodiment, a single fan is used with a system as described herein to create a suction at the plurality of vent exhaust orifices of the annular vent passage of the toilet when one or more toilets are connected to the same parent exhaust line.
[0016] According to one embodiment, the upward slope of the annular exhaust vent line and parent exhaust line of a system as describe herein is at least 3 millimeters per 0.3 meters of piping from the low point drain line.
[0017] According to another embodiment, the low point drain line located at the low point of the annular exhaust vent line of the system described extends to a length which is greater than the height of the water column equivalent to the maximum suction pressure possible from the vent exhaust fan to ensure positive drainage under all use conditions, and the low point drain line and the low point drain valve at the end of the low point drain line have an internal diameter which is greater than the diameter of any vent exhaust orifice.
[0018] Another embodiment of a toilet system comprises a toilet bowl having a rim jet annulus located circumferentially inside a portion of a rim disposed above and around the periphery of the toilet bowl wherein the rim jet annulus has a plurality of rim jet orifices for introducing water into the toilet bowl. An annular vent passage is located through a portion of a circumference of the toilet bowl rim and is separate from the vent passage but circumferentially inside and concentric with the rim jet annulus such that the annular vent passage has a plurality of vent exhaust orifices located at the inner radius of the annular vent passage and above the outer, annular rim jet orifices to avoid communication of water from the plurality of rim jet orifices to the plurality-of vent exhaust orifices. The annular vent passage exits the toilet at the back vertical plane of the toilet bowl at an annular exhaust vent line to avoid interference with a water rim jet annulus flow path. The annular exhaust vent line slopes downward from the rear vertical plane of the toilet bowl, and deliberately creates a low point drain location, having a low point drain line tee from the low point drain location of the annular exhaust vent line which extends from the low point drain location to a length which is greater than a water column equivalent to the maximum suction pressure of a vent exhaust fan to ensure positive drainage under all conditions during normal operation, recovery from toilet overflow, and upon completion of back flushing activities. The annular exhaust vent line continues on an upward slope of at least 3 millimeters per 0.3 meters of piping to the rear vertical plane of the toilet where the vent exhaust line is enlarged to continue as a parent exhaust line which is in communication with a bypass branch line upstream of a vent exhaust fan upstream isolation valve located upstream of the vent exhaust fan and the parent exhaust line. The low point drain line and the low point drain valve at the end of the low point drain line have an internal diameter which is greater than the diameter of any vent exhaust orifice. For example, the vent exhaust fan of this embodiment is located in the remainder of the parent exhaust line at a minimum elevation greater than a sum elevation of the elevation of the toilet bowl rim plus the maximum suction pressure of the vent exhaust fan, and has a vent exhaust fan upstream isolation valve selected for minimum resistance to ventilation air flow and is located upstream of the vent exhaust fan and wherein the vent exhaust fan is capable of overcoming a capillary effect which may occur after water intrusion into the plurality of vent exhaust orifices, and is of sufficient suction pressure and flow capability to establish desired vent exhaust flow rate through the plurality of vent exhaust orifices even with air flow through the bypass branch line.
[0019] In one embodiment, the bypass branch line can be added at the elevation greater than the sum of the elevation of toilet rim plus the maximum suction pressure of the vent exhaust fan, and wherein the bypass branch line tees into the parent exhaust line upstream of the vent exhaust fan upstream isolation valve, and is sized to allow sufficient, continuous ventilation flow for the vent exhaust fan operation under both normal conditions and upset conditions of a toilet overflow or condensate condition blocking ventilation exhaust air flow through the annular vent passage, and is with or without an installed branch line isolation/throttle valve selected to ensure necessary air flow through the vent exhaust fan, and serves as a maintenance connection for back flushing the annular vent passage, vent exhaust orifices, annular exhaust vent line, or parent exhaust line in the event of vent path clogging.
[0020] In yet another embodiment, a method of venting an odor within a toilet system provided. An odor within a toilet bowl is vented through a plurality of exhaust orifices of an annular passage of the toilet bowl. The toilet bowl includes a rim jet annulus located circumferentially inside a portion of a rim disposed above and around the periphery of said toilet bowl wherein the rim jet annulus has a plurality of rim jet orifices for introducing water into the toilet bowl. An annular vent passage is located circumferentially inside the rim of the toilet bowl. The annular vent passage having the plurality of exhaust orifices and the annular vent passage is positioned concentric with the rim jet annulus to avoid communication of the water from the rim jet orifices into the annular vent passage via the vent exhaust orifices. The annular vent passage connects to an annular exhaust vent line at the back vertical plane of the toilet bowl to avoid interference with the rim jet annulus. The annular exhaust vent line slopes downward from the back vertical plane of the toilet bowl to a low point where there is located a low point drain line and a low point drain valve at the bottom of the low point drain line. From this point, the annular exhaust vent line continues with a constant slope upward for a distance to join with a parent exhaust line wherein the parent exhaust line is in communication with a bypass branch line and a vent exhaust fan upstream isolation valve located between a vent exhaust fan and the parent exhaust line wherein the annular exhaust vent line, the parent exhaust line, the exhaust fan upstream isolation valve, and vent exhaust fan are above ground. The odor is evacuated through the annular exhaust vent line with the aid of the vent exhaust fan when the fan is creating a suction at the plurality of exhaust orifices of the annular vent passage. In another embodiment, a single fan is used to create a suction at the plurality of vent exhaust orifices of the annular vent passage of the toilet when one or more toilets are connected to the same parent exhaust line.
[0021] The operation of an embodiment of the present invention under normal conditions of use will be transparent to the user, only requiring exhaust fan operation consistent with current exhaust fan control art. However, an embodiment also accommodates the condition of toilet overflow and condensate buildup anywhere in the vent exhaust, path while allowing recovery without equipment damage. Further, embodiments of the invention provide for as needed maintenance to back flush any portion of the exhaust system in the event of system clogging. The system and method may be applied to a single toilet and exhaust fan or to multiple connected toilets with interconnected vent lines to a common exhaust fan. It is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0022] The vent exhaust path may be considered the ventilation flow path comprising the annular vent passage, vent exhaust orifices, annular exhaust vent line, parent exhaust line, including in-line components, or any part of this path not otherwise specifically designated. The ventilation flow path communicates fumes from the toilet bowl to a location other than the room where the toilet bowl is located.
[0023] Embodiments of the present invention include a toilet having an inner annular vent passage which runs through a portion of the circumference of the toilet bowl rim. The annular vent passage is separate but concentric with the current art liquid flush rim jet annulus such that the vent exhaust orifices are located inside and above the outer, annular rim jet orifices to avoid communication between the vent exhaust orifices of the upper annular vent passage and the liquid rim jet orifices. The annular vent passage is formed integral to the toilet bowl rim and is not therefore flexible. The annular exhaust vent line serves as the annular vent passage exit flow path as the line exits the toilet, and it exits the toilet bowl to avoid interference with the water rim jet annulus flow path. The annular exhaust vent line slopes downward from the toilet bowl rim and deliberately creates a low point drain location. At the low point drain location of the annular exhaust vent line, there is located a low point drain line. The low point drain line extends from this low point to a length which is greater than the water column equivalent to the maximum suction pressure of the vent exhaust fan to ensure positive drainage under all conditions. A low point drain valve is located at the end of the low point drain line and, when open, permits drainage of liquid from condensate buildup during normal operation, upon recovery from a toilet overflow, and upon completion of back flushing operations of the vent exhaust flow path. The annular exhaust, vent line continues on an upward slope from the low point to the back vertical plane of the toilet where it would be enlarged to continue as the parent exhaust line.
[0024] Embodiments of the present invention include a dedicated vent, exhaust fan which is located at a minimum level above the sum elevations of toilet rim plus the maximum suction pressure of the exhaust fan. Upstream of the vent exhaust fan is located a vent exhaust fan upstream isolation valve which will be a gate or ball valve to minimize resistance to flow. If the vent exhaust fan is located at an elevation that will prevent water intrusion during a back flush maintenance activity, an upstream isolation valve may not be necessary. The vent exhaust fan must be capable of overcoming any effect from capillary action which may occur after water intrusion into the annular vent passage and be capable of sufficient flow capability to provide desired vent exhaust flow rate.
[0025] An embodiment of the present invention includes a bypass branch line which is upstream of the dedicated vent exhaust fan and upstream of the vent exhaust fan upstream isolation valve (if installed). The bypass branch line must be installed at an elevation greater than the sum of the toilet rim elevation and the maximum suction pressure of the vent exhaust fan. The bypass branch line is sized to allow sufficient, continuous ventilation flow for reliable vent exhaust fan operation even with toilet overflow or condensate condition blocking ventilation exhaust air flow. The bypass branch line may have installed a branch line isolation/throttle valve (globe valve or similar to allow effective throttling) to ensure vent exhaust fan flow under all conditions. The bypass branch line serves as a maintenance connection for back flushing the vent exhaust path if clogging ever were to occur.
BRIEF DESCRIPTION OF THE FIGURES
[0026] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention, The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings:
[0027] FIG. 1A and FIG. 1B illustrate cross-sectional views of he toilet rim according to embodiments of the present invention.
[0028] FIG. 2 is a top view of the toilet bowl rim according to one embodiment illustrating the relative numbers and locations of the current art rim jet orifices and the proposed vent exhaust orifices of the present invention.
[0029] FIG. 3A and FIG. 3B illustrate two different embodiments of the complete toilet/exhaust system present invention.
[0030] FIG. 4A and FIG. 4B illustrate two embodiments of the utility box configurations housing the bypass branch line and other components.
[0031] FIG. 5 is a view of the toilet exhaust system according to one embodiment of the present.
DETAILED DESCRIPTION
[0032] As used herein, “a” or “an” or “the” means one or more.
[0033] Referring now to FIGS. 1A and 1B , FIGS. 1A and 1B depict cross-section views of the toilet bowl rim 103 according to two embodiments of the present invention. In FIG. 1A , the vent exhaust orifices 105 of the ventilation exhaust path are located in the inner radius of the annular vent passage 111 which is circumferentially inside the rim jet annulus 113 , and the vent exhaust orifices 105 are located above the existing rim jet orifices 107 of the rim jet annulus 113 to avoid water intrusion during normal operation. In FIG. 1B , the vent exhaust orifices 105 of the ventilation exhaust path are located in the inner radius of the annular vent passage 111 which is concentric with but predominantly above the rim jet annulus 113 , and the vent exhaust orifices 105 are located above the existing rim jet orifices 107 of the rim jet annulus 113 to avoid water intrusion during normal operation. In the FIG. 1B embodiment, the outer, circumferential wall of the annular vent passage shares the toilet bowl wall with the rim jet annulus at the rim of the toilet howl. These vent exhaust orifices 105 are in communication with the balance of the ventilation exhaust path (i.e., annular vent passage, annular exhaust vent line, and parent exhaust line). Wall thickness for each toilet bowl wall of any embodiment of this invention would continue to he similar to the current art to ensure structural integrity during normal use, but is not limited thereto as the system could work with custom toilets having non-traditional toilet bowl wall thickness.
[0034] Referring now to FIG. 2 , a plan view embodiment of the toilet bowl rim 203 showing the relative number and location of the existing rim jet orifices 205 and the vent exhaust orifices 207 according to one embodiment of the present invention is illustrated. The size and number of the vent exhaust orifices may vary, depending on the suction pressure capability of the vent exhaust fan and desired vent exhaust flow rate. Cross-section 1 A of the toilet bowl rim is illustrated in FIG. 1A with an alternate embodiment illustrated in FIG. 1B .
[0035] Referring now to FIGS. 3A and 3B (associated with FIGS. 1A and 1B , respectively) show side view embodiments of the toilet 300 with the location of the annular exhaust vent line 315 leading from the annular vent passage 111 upon exiting at the back vertical plane 316 of the toilet bowl 301 and molded into the toilet body and connecting to the parent exhaust line 305 . The low point drain line 307 , low point drain valve 310 , and the constant slope upward of the annular exhaust vent line from the low point to the back vertical plane 317 of the toilet are illustrated. The exhaust path is illustrated by the dotted arrows. The vent exhaust fan 313 is positioned between the parent exhaust line outlet 309 and the vent exhaust fan upstream isolation valve 314 . The vent exhaust fan upstream isolation valve is a valve which offers little head loss (e.g., ball valve or gate valve). Further upstream of the vent exhaust fan upstream isolation valve is located a bypass branch line 311 which tees off the parent exhaust line 305 at a minimum elevation greater than the sum of the elevation of the toilet rim plus the maximum suction pressure of the vent exhaust fan. In the bypass branch line is a branch line isolation/throttle valve 312 (e.g., globe valve) which may be used for throttling of air flow or for throttling or isolating liquid flow for maintenance back flush operations. The branch line isolation/throttle valve may be present in either embodiment described in FIGS. 1A and 1B . The manner in which the annular exhaust vent line exits the toilet bowl rim in the system may vary in the two embodiments. In FIG. 3A , the embodiment of the annular exhaust vent line exits the toilet bowl rim below the toilet rim from inside the bowl at position 304 . In FIG. 3B , the embodiment of the annular exhaust vent line exits the upper part of the toilet rim outside of the toilet bowl 301 and at the same elevation as the annular vent passage at position 304 A.
[0036] Referring now to FIG. 4A , the installation of the vent exhaust fan 413 (with conventional on/off and/or proximity switch), the vent exhaust fan upstream isolation valve 414 , the bypass branch line 411 , and the branch line isolation/throttle valve 412 are illustrated according to one embodiment of the present invention. The bypass branch line and the branch line isolation/throttle valve exist to ensure continued vent exhaust fan flow even with toilet overflow or condensate buildup. This will prevent damage to the vent exhaust fan under upset conditions when there is no flow through the annular vent passage. FIG. 4B illustrates the installation of the vent exhaust fan at a significantly higher elevation (not to scale) than the other components, without a vent exhaust fan upstream isolation valve or a branch line isolation/throttle valve but with the bypass branch line according to another embodiment of the present invention. The utility box 403 is illustrated in FIGS. 4A and 4B . In FIG. 4A , the utility box includes the vent exhaust fan 413 , bypass branch line 411 with branch line isolation/throttle valve 412 , and the vent exhaust fan upstream isolation valve 414 . In FIG. 4B , the louvered utility box is in the same relative location, but with the vent exhaust fan at a higher elevation, no vent exhaust fan upstream isolation valve and the bypass branch line without a branch line isolation/throttle valve.
[0037] Any combination of the embodiments depicted in FIGS. 4A and 4B may be employed, depending on the intended approach to maintenance activities.
[0038] Referring now to FIG. 5 , the flow path of the ventilation exhaust from the toilet rim as it enters through the vent exhaust orifices 511 , travels through the ventilation exhaust annulus 504 , out the rear vertical plane 516 of the toilet bowl, as the annular exhaust vent line 515 to the low point drain line 507 , through the upwardly sloped portion of the annular exhaust vent line to the enlarged connection 509 at the rear vertical plane 517 of the toilet, and up through the parent exhaust line 508 , vent exhaust fan upstream isolation valve 514 , through the vent exhaust fan 513 , and to the outside according to one embodiment of the present invention. Some ventilation flow also will exist through the bypass branch line 505 during vent exhaust fan operation to protect the fan against no-flow conditions.
[0039] One embodiment of the present invention consists of a standard toilet configuration, but with an annular vent passage 111 and vent exhaust orifices 511 integral to the toilet bowl rim. The annular exhaust vent line 515 exits the toilet bowl so as not to interfere with the current art liquid flushing configuration. The vent exhaust orifices 511 would be located above and radially inside the current rim jet orifices 512 . This would prevent any water intrusion into the vent exhaust orifices during the normal flushing operation of the toilet. The annular exhaust line may exit the bowl through an opening at the rear vertical plane 516 of the toilet bowl. The continuing annular exhaust vent line will unavoidably slope downward from the toilet bowl rim and, therefore, create a low point where collection of liquid would occur due to toilet overflow or condensation. This location would serve as the low point drain for the vent exhaust system. At this low point location, there would be installed a tee-off low point drain line 507 from the annular exhaust vent line. To ensure positive drainage of the annular exhaust vent line and the parent exhaust line 508 under all conditions, this drain line length is greater than the height of the water column equivalent to the maximum suction pressure possible from the vent exhaust fan. The low point drain line 507 would have a petcock or other type of valve 310 installed at the bottom of the low point drain line. If exhaust ventilation flow is ever interrupted by toilet overflow or by collection of condensation, this low point drain valve may be opened to drain all liquid from the exhaust line even with continued vent exhaust fan operation. Alternatively, the low point drain valve could be left open for normal operation and closed only for vent line back flushing during maintenance as discussed further below. The low point drain valve would be closed for maintenance back flushing and open to drain the vent exhaust path upon completion of flushing operations.
[0040] From the low point drain line 507 in the annular exhaust vent line 515 , the annular exhaust vent line must continue on an upward slope to the connecting vertical portion of the parent exhaust line 508 in which will be located the vent exhaust fan upstream isolation valve 514 and the vent exhaust fan 513 . To avoid fragility and to add to the aesthetics of the toilet, it is preferred to mold the annular exhaust vent line integral with the existing body mold of the toilet for that portion of the annular exhaust vent line which is upstream the rear vertical plane 517 of the toilet. However, the annular exhaust vent line upstream the rear vertical plane 517 of the toilet may be created with materials and components that are not integral to the toilet mold. An upward slope of at least 3 millimeters per 0.3 meters of piping from the low point drain line must be maintained as the annular exhaust vent line and the parent exhaust line continue to the vent exhaust fan 513 . To ensure adequate vent exhaust flow, the size of the annular exhaust vent line 515 and the parent exhaust line 508 would need to be matched appropriately with the performance capability of the vent exhaust fan 513 . The annular exhaust vent line 515 would exit the rear vertical plane of the toilet 517 , connect with the enlarged connection 509 of the parent exhaust line 508 , and enter the wall. The enlarged connection may be made with an O-ring seal, threaded, glued fitting, hose clamp, or any other connecting type device and using either flexible or rigid piping from any of a number of material types. Enlarging the parent exhaust line would be advised to reduce the head loss in the exhaust line and increase the vent exhaust flow rate. The parent vent line would continue to the vent exhaust fan 513 and discharge to the outside or to a means to deodorize and return the air. The vent exhaust fan inlet must be located above a minimum height equal, to the sum of the level of the toilet rim plus the equivalent water column expected from the maximum suction pressure of the vent exhaust fan. That is, the vent exhaust fan is not located below the toilet bowl rim.
[0041] Operation of the vent exhaust fan would be controlled with a standard on/off wall switch or a proximity switch and power source as employed in current art. An optional embodiment is to appoint the vent exhaust fan with a rheostat controller to allow adjustment of the vent exhaust fan flow rate. The rheostat control of the vent exhaust fan is also current art.
[0042] A bypass branch line 505 would be installed at a minimum elevation greater than the sum elevation of the toilet rim plus the maximum suction pressure of the vent exhaust fan 513 and installed upstream of the vent exhaust fan upstream isolation valve 514 . The bypass branch line 505 is installed to provide a bypass flow capability such that a no-flow condition for the vent exhaust fan 513 would never occur, even with toilet overflow or condensate buildup blocking flow from the upstream portion of the vent exhaust path. This bypass branch line also would serve as the maintenance connection for back flushing of the exhaust system. To ensure the bypass flow is properly matched with the fan capabilities while maintaining adequate exhaust ventilation flow, the bypass branch line 505 may or may not include a branch line isolation/throttle valve 510 .
[0043] To accommodate back flush maintenance of the vent exhaust orifices 512 , the annular vent passage 504 , the annular exhaust vent line 515 , the parent exhaust line 508 , and a vent exhaust fan upstream isolation valve 514 (one such as a gate valve or ball valve to reduce head losses) may be installed upstream of the vent exhaust fan 513 . The vent exhaust fan upstream isolation valve 514 would be open during normal operation and shut only during maintenance back flushing. The vent exhaust fan upstream isolation valve 514 would serve to prevent water intrusion into the vent exhaust fan inlet during maintenance back flushing operations.
[0044] Another embodiment would be to raise the vent exhaust fan to a higher elevation to preclude the need for a vent exhaust fan upstream isolation valve. This embodiment would be appropriate so long as the pressure source of fluid for back flush operations would not exceed the equivalent water column height to the vent exhaust fan inlet. This arrangement also would avoid water intrusion into the vent exhaust fan inlet during maintenance back flushing operations.
[0045] To avoid a potentially damaging no-flow condition for the vent exhaust fan, the vent exhaust fan would he turned OFF during back flushing activities when a single vent exhaust fan exhausts a single toilet. Turning off the vent exhaust fan may not be necessary if the vent exhaust fan exhausts multiple toilets as sufficient flow may be available from the other vent exhaust paths even as flow is completely isolated from one toilet during the back flushing operation or resulting from toilet overflow or condensate buildup in the vent exhaust system of an individual toilet.
[0046] Any combination of the arrangements described in paragraphs [0042], [0043], and [0044] may be employed, depending on the intended approach to back flush maintenance capabilities.
[0047] For convenience and accessibility, the vent exhaust fan, the vent exhaust fan upstream isolation valve (if installed), the bypass branch line, and branch line isolation/throttle valve (if installed) may he installed in a louvered connection box integral to the back wall. This connection box must be louvered to permit flow through the bypass branch line.
[0048] The phenomenon of capillary action must be considered. Capillary action would occur if water were to be introduced into the vent exhaust orifices. Capillary action results in a residual water column in each orifice even after normal drainage, the water column level dictated by the individual radius of the vent exhaust orifices. The suction pressure of the vent exhaust fan must be adequate to overcome the resulting water column so vent exhaust flow can be reestablished and maintained after the vent exhaust orifices are flooded. Therefore, proper vent exhaust orifice sizing for adequate vent exhaust flow as well as for consideration of capillary action must be determined to be compatible with the vent exhaust fan performance specifications (i.e., its fan performance curve).
[0049] Use of a positive displacement exhaust driver instead of a common exhaust fan would negate the innate features of this invention which avoid equipment damage and ensure effective vent line drainage after a toilet overflow, condensate buildup, or post maintenance back flush condition. Also, a vent exhaust fan, contrary to a positive displacement or high pressure ventilation mechanism, would have a relatively low suction pressure so that the suction force would do little to cause any debris to clog the vent exhaust orifices, annular vent passage, annular exhaust vent line, or parent exhaust line. These design attributes of this invention make it easy for the maintenance back flush operation to clear any obstructions and restore toilet exhaust ventilation.
[0050] The internal vent exhaust path according to an embodiment of the proposed invention will more effectively and more efficiently contain and remove toilet gases with less required energy and in less time than the current art. The use of a dedicated vent exhaust fan would reduce energy consumption without sacrifice to efficiency or effectiveness. A dedicated vent exhaust fan or a vent exhaust fan of shared use may be placed on a rheostat so that vent exhaust fan flow rate could be adjusted according to need. However, at all times the suction pressure of the vent exhaust fan must be adequate to meet the vent exhaust flow requirements and overcome any concerns associated with capillary action.
[0051] In a preferred embodiment of the present invention, a toilet comprises a toilet bowl with an upper rim which includes a separate, integrally-molded inner circumferential, annular vent passage with multiple vent exhaust orifices in number and size to be compatible with vent exhaust flow needs and the vent exhaust fan performance specifications. The annular vent passage connects to the annular exhaust vent line at the rear vertical plane of the toilet bowl and would be molded into the body of the toilet and would slope downward to the low point drain line as it exits the toilet bowl and then slope continuously upward from the low point drain line toward the back of the toilet. At the bottom of the low point drain line, a low point drain isolation valve is located. The low point drain line would be of adequate length to drain the parent exhaust line even during exhaust fan operation. Therefore, the length of the drain line must be greater than the maximum suction pressure capability of the vent exhaust fan. The properly sized annular exhaust vent line follows the contour of the toilet mold as it slopes upward to the rear of the toilet. At this point the annular exhaust vent line connects to the enlarged parent exhaust line. This connection would be made using any of the various means discussed previously. The parent exhaust line will continue to the vent exhaust fan which will be preceded by the vent exhaust fan inlet isolation valve (gate valve or equivalent for minimizing head loss). The vent exhaust fan upstream isolation valve for the vent exhaust fan could be excluded if the vent exhaust fan is installed at an elevation that would exceed the equivalent elevation of the head pressure from any back flushing source of fluid. Upstream of the vent exhaust fan upstream isolation valve would be connected a bypass branch line properly sized with or without an in-line branch line isolation/throttle valve to ensure reliable vent exhaust fan operation under all conditions without damaging the vent exhaust fan. The bypass branch line would be installed at a minimum elevation greater than the sum elevation of the toilet rim plus the maximum suction pressure of the vent exhaust fan and installed upstream of the vent exhaust fan upstream isolation valve (if installed). The vent exhaust fan outlet will be connected to the continuing parent exhaust line and vent to the outside.
[0052] Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art, and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference.
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This invention pertains to an internally exhausted toilet bowl which employs basic principles of fluid flow to provide reliable, more efficient, and more effective removal of noxious toilet odors while reducing energy consumption when compared to current art. This is accomplished during all conditions of normal operation. In case of toilet overflow or condensate buildup, the impact on the vent exhaust path from these upset conditions can be resolved easily, and normal operation can be restored without damage to any components. Additionally, this invention includes maintenance features that would provide means for back flushing the annulus vent line and orifices if clogging ever were to occur.
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CROSS-REFERENCE
This application is a continuation-in-part of U.S. patent application Ser. No. 13/712,910 Dec. 12, 2012 which is incorporated by reference herein for all purposes.
FIELD OF THE INVENTION
The embodiments of the present invention relate to a construction zone safety system using radio frequency identification (“RFID”) devices or other signal-based devices.
BACKGROUND
Construction zone safety is critically important to all parties involved including, but not limited to, construction companies, construction workers, insurance companies, land developers and municipalities. The seriousness of construction zone safety is evidenced by the creation of the Occupational Safety and Health Administration (“OSHA”) which is tasked with monitoring construction zones as well as other areas. In one respect, OSHA is concerned with injuries or death of construction workers.
It would be advantageous to develop a signal-based safety system to reduce or eliminate injuries and accidents at construction zones.
SUMMARY
The embodiments of the present invention involve the use of one or more readers on heavy construction equipment (e.g., loaders) which detect signals emanating from signal transmitters on clothing or equipment of construction workers. In one embodiment, responsive to the detection of one or more signals emanating from behind a heavy piece of equipment, or in another position relative to the piece of heavy equipment, a controller integrated on the piece of heavy equipment causes the parking/emergency brake to be applied and/or transmission to be disengaged automatically without operator involvement.
In one embodiment, one or more readers are attached to the rear of the piece of heavy equipment and detect signals from RFID devices attached to the clothing or equipment of construction workers in the construction zone. The readers are positioned to capture signals from behind and/or along sides of the piece of heavy equipment. Hardware installed on the piece of heavy equipment serves to apply the parking brake of the piece of heavy equipment and/or disengage the transmission responsive to a controller signal.
In another embodiment, a wet brake system (also known as a hydraulic brake system) is triggered automatically responsive to the detection of one or more signals emanating from behind a heavy piece of equipment, or in another position relative to the piece of heavy equipment. This embodiment works well with fully loaded equipment which requires additional distance to slow down and ultimately stop. For example, a fully loaded loader can be stopped in 12 feet when traveling at 10 mph in reverse.
In other embodiments, additional technology such as infrared sensors, acoustic sensors, thermal imaging sensors, cameras with human recognition software, radar, lidar and/or custom RF equipment (subject to FCC license and FCC Part 15) may be used to locate workers near the piece of heavy equipment namely a danger zone.
Other variations, embodiments and features of the present invention will become evident from the following detailed description, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a and 1 b illustrate an overhead view of a construction zone and danger zone utilizing a system/method according to the embodiments of the present invention;
FIG. 2 illustrates a rear view of a heavy piece of equipment with readers attached according to the embodiments of the present invention;
FIG. 3 illustrates a view of the parking brake lever and related mechanisms without the system detailed herein installed;
FIGS. 4 a - 4 c illustrate views of a piece of heavy equipment with parking brake control mechanism installed according to the embodiments of the present invention;
FIG. 5 illustrates a view of portions of the parking brake control mechanism uninstalled according to the embodiments of the present invention;
FIG. 6 illustrates a block diagram of certain electrical components of the system according to the embodiments of the present invention;
FIG. 7 illustrates a block diagram of a system according to the embodiments of the present invention;
FIG. 8 illustrates a flow chart detailing a methodology of using the system according to the embodiments of the present invention;
FIG. 9 illustrates a block diagram of a system according to the embodiments of the present invention;
FIGS. 10 a - 10 e illustrate an automatically controlled de-clutch brake pedal adapted to control a wet brake system according to the embodiments of the present invention;
FIGS. 11 a - 11 b illustrate a hydraulic control which forms part of the automatic wet brake system according to the embodiments of the present invention;
FIG. 12 illustrates a block diagram of an automatic brake system according to the embodiments of the present invention;
FIG. 13 illustrates a flow chart detailing one methodology associated with the automatic brake system according to the embodiments of the present invention;
FIG. 14 a illustrates a side view of a heavy piece of equipment with a single antenna in place according to the embodiments of the present invention; and
FIG. 14 b illustrates an overhead view of a construction zone and danger zone utilizing a system/method according to a single antenna embodiment of the present invention.
DETAILED DESCRIPTION
For the purposes of promoting an understanding of the principles in accordance with the embodiments of the present invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive feature illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed.
The embodiments of the present invention are directed to a system and method for protecting workers in construction zone by detecting the location of the workers in the construction zone and automatically, under certain conditions, controlling pieces of heavy equipment, such as loaders, bulldozers, excavators and the like, accordingly.
FIGS. 1 a and 1 b show overhead views of a construction zone 100 utilizing a system/method according to the embodiments of the present invention. A danger zone 110 is identified generally behind a piece of heavy equipment 120 . While the danger zone 110 is shown generally behind the piece of heavy equipment 120 , those skilled in the art will recognize that the danger zone 110 may be on either side or in front of the piece of heavy equipment 120 as well. As shown in FIG. 2 , one or more interrogators or readers (also known as two-way radio transmitter-receivers (transceivers)) 130 - 1 through 130 - 3 are attached to a rear portion of the piece of heavy equipment 120 . The readers 130 - 1 through 130 - 3 are configured to transmit signals to one or more RFID tags 140 - 1 through 140 -N and read a response from the RFID tags 140 - 1 through 140 -N. The RFID tags 140 - 1 through 140 -N are adhered to or contained within the clothing (e.g., vest) or equipment (e.g., hard hat) worn by construction workers in the construction zone. In one embodiment, as detailed below, the readers 130 - 1 through 130 - 3 transmit received signals to a controller 150 which is configured to control certain facets of the piece of heavy equipment 120 responsive thereto.
In one embodiment, the controller 150 is a processor on a circuit board driven by pre-programmed software or firmware linking the readers 130 - 1 through 130 - 3 with the controller 150 and hardware configured to automatically control the piece of the heavy equipment 120 .
As shown in FIGS. 1 a and 1 b , the danger zone 110 takes on a semi-circular zone dictated by the range of the RFID tags 140 - 1 through 140 -N and strength and position of the readers 130 - 1 through 130 - 3 . In one embodiment, the danger zone 110 is defined by a space ten feet laterally in both directions from the rear of the piece of heavy equipment 120 , eighteen feet diagonally from the rear of the piece of heavy equipment 120 and twenty-four feet directly rear of the piece of heavy equipment 120 . Construction zones include many obstacles such that the objective is to create a workable environment whereby the piece of heavy equipment is not being needlessly stopped. Thus, different construction zones may require danger zones of different dimensions and sizes. The contractor or other entity may determine the appropriate size of the danger zone for a given job.
In one embodiment, responsive to the piece of heavy equipment 120 being in a reverse gear, the readers 130 - 1 through 130 - 3 are activated such that the readers 130 - 1 through 130 - 3 begin to transmit signals receivable by RFID tags 140 - 1 through 140 -N which then transmit identification information (e.g., serial number associated with the RFID tag and worker identification information), to the readers 130 - 1 through 130 - 3 . The received information from the RFID tags 140 - 1 through 140 -N is, in one embodiment, transmitted to the controller 150 integrated into the piece of heavy equipment 120 . The controller 150 , using stored software, firmware and/or other pre-programmed code, evaluates the information signals received from the RFID tags 140 - 1 through 140 -N to determine a location of the RFID tags 140 - 1 through 140 -N relative to the piece of heavy equipment 120 . Responsive to the controller 150 determining that one or more of the RFID tags 140 - 1 through 140 -N are located in the danger zone 110 , the controller 150 causes application of the parking brake of the piece of heavy equipment 120 and/or disengagement of the transmission of the piece of heavy equipment 120 into a neutral position thereby stopping the piece of heavy equipment 120 from continuing in motion. Application of the parking brake may automatically move the transmission of the heavy piece of equipment 120 into a neutral position.
FIG. 3 shows standard parking brake lever 185 and linkage 186 which engages and disengages the parking brake via the parking brake lever 185 . The linkage 186 is driven by a rod and button apparatus or other parking brake control apparatus in the cab of the heavy piece of equipment 120 . Depression of the button causes the parking brake to be released while pulling of the button engages the parking brake. FIGS. 4 a - 4 c show views of a parking brake mechanism installed on the heavy piece of equipment 120 to facilitate automatic application of the parking brake responsive to receipt of a signal corresponding to a construction in a danger zone. FIG. 5 shows views of the parking brake mechanism of the embodiments of the present invention uninstalled. The mechanism includes a controller 150 (shown in FIG. 6 ), a pair of relays 151 , 152 , a pull/hold coil 170 , solenoid 175 , and linkage 176 attached to parking brake lever 185 . A first relay 151 of 24V arms the system responsive to the piece of heavy equipment 120 being in a reverse gear. Responsive to a signal corresponding to a worker in the danger zone being received, the second relay 152 of 12V triggers the solenoid 175 forcing the linkage 176 to apply the parking brake.
FIG. 7 shows a block diagram 200 of a system according to the embodiments of the present invention. As detailed above, the system includes one or more readers 130 - 1 through 130 -N, RFID tags 140 - 1 through 140 -N, controller 150 and power source 160 for system components installed on piece of heavy equipment 120 . In one embodiment, an AC inverter converts DC power from the piece of heavy equipment 120 to drive the readers 130 - 1 through 130 -N and other electronic devices. The controller 150 communicates with a mechanical parking brake pull/hold coil 170 configured to physically apply the parking brake 195 of the piece of heavy equipment 120 which in turn automatically disengages the transmission and places the transmission into a neutral position. A solenoid 175 , when activated by the controller 150 , drives the pull/hold coil 170 which is attached to a parking brake lever 185 beneath the piece of heavy equipment 120 thereby moving the parking brake lever 185 causing the parking brake to be applied and the transmission to shift into the neutral position. Normally, a parking brake lever 185 requires 4-5 pounds of force to be applied and therefore the pull-hold coil 170 and solenoid 175 are configured to apply at least 5 pounds of force but ideally 7.5 to 10 pounds of force are applied. The parking brake pull/hold coil 170 may be installed to run parallel to the manual parking brake coil 190 which is installed at the factory during manufacture of the piece of heavy equipment 120 and is driven by manual actuation of the parking brake button 191 in the cab. A factory cab alarm 195 alerts the operator to the application of the parking brake lever 185 . Obviously, application of the parking brake lever 185 is immediately known to the operator given the sudden stop of the piece of heavy equipment 120 but the factory cab alarm 195 provides the operator with the reason for the sudden stop (i.e., not a mechanical failure).
Exemplary operation of the system is detailed in flow chart 300 of FIG. 8 . At 305 , readers are positioned on a piece of heavy equipment and configured to define a desired danger zone. At 310 , RFID tags are placed on worker clothing and/or equipment and configured to transmit desired information carrying signals. At 315 , it is determined if the transmission of the piece of heavy equipment is in a reverse gear. If not, the flow chart 300 loops back to 315 . If so, at 320 , the readers are activated. At 325 , signals transmitted by said RFID tags are read by readers on a piece of heavy equipment. At 330 , signals received by said readers are transmitted to a controller. At 335 , the controller determines if the RFID tags are in the defined danger zone. If not, the flow chart 300 loops back to 325 . If so, at 330 , the controller triggers a solenoid to drive a pull/hold coil causing a parking brake lever to be engaged and parking brake to be applied and transmission shifted into neutral. At 335 , an operator of the piece of heavy equipment must manually disengage the parking brake from the cab once the danger zone is clear.
In one embodiment, as shown in block diagram 400 of FIG. 9 , the system includes the components of block diagram 200 plus a transmitter 405 configured to send a signal to the pager, smart phone, personal digital assistant or other mobile device 410 of a construction site manager or other supervisory personnel. The signal may also be transmitted to a personal computer. The signal alerts the manager that the heavy piece of equipment 120 was forcibly stopped to prevent injury to one or more construction workers. This allows the manager to investigate and memorialize the incident.
FIG. 6 illustrates a block diagram 500 of exemplary electrical components of the system according to the embodiments of the present invention. As shown, a series of readers/antennas 505 - 1 through 505 - 3 communicate with switch 510 and uses a transmitter 515 to transmit a 928 MHz signal (or any other RF signal frequency) to the RFID tags and a receiver 520 to receive feedback signals from the RFID tags. A controller 525 communicates with the readers/antennas 505 - 1 through 505 - 3 and an optional user interface 530 . The controller 525 also communicates with (i.e., triggers) the parking brake mechanism.
FIGS. 10 a - 10 e illustrate an automatically controlled de-clutch brake pedal adapted to control a wet brake system according to the embodiments of the present invention. The de-clutch brake pedal 600 is secured by a de-clutch pedal bracket 605 attached to the heavy piece of equipment and is controlled (i.e., depressed and released) automatically by a hydraulic cylinder 610 in physical contact with the brake pedal 600 . FIG. 10 d shows the de-clutch brake pedal 600 , bracket 605 and hydraulic cylinder 610 when not installed while FIG. 10 e shows the de-clutch brake pedal 600 when not installed. The hydraulic cylinder 610 receives hydraulic fluid via an input tube 615 and discharges hydraulic fluid via an output tube 620 .
In one embodiment, the physical contact between the hydraulic cylinder 610 and de-clutch brake pedal 600 involves a rotatable arm assembly 625 attached at a first end 626 to the hydraulic cylinder 610 and attached at a second end 627 to the de-clutch pedal bracket 605 .
As set forth above, responsive to the piece of heavy equipment 120 being in a reverse gear, the readers 130 - 1 through 130 - 3 are activated such that the readers 130 - 1 through 130 - 3 begin to transmit signals receivable by RFID tags 140 - 1 through 140 -N which then transmit identification information (e.g., serial number associated with the RFID tag and worker identification information), to the readers 130 - 1 through 130 - 3 . The received information from the RFID tags 140 - 1 through 140 -N is, in one embodiment, transmitted to the controller 150 integrated into the piece of heavy equipment 120 . The controller 150 , using stored software, firmware and/or other pre-programmed code, evaluates the information signals received from the RFID tags 140 - 1 through 140 -N to determine a location of the RFID tags 140 - 1 through 140 -N relative to the piece of heavy equipment 120 . Responsive to the controller 150 determining that one or more of the RFID tags 140 - 1 through 140 -N are located in the danger zone 110 , the controller 150 causes the de-clutch brake pedal 600 to depress by directing hydraulic fluid to the hydraulic cylinder 610 which forces application of the de-clutch brake pedal 600 causing the automatic application of the hydraulic disc or wet brakes of the heavy piece of equipment 120 . In one embodiment, the hydraulic fluid directed to the de-clutch brake pedal 600 is transferred to the hydraulic cylinder 610 by means of hydraulic control 630 integrated into the stock or factory hydraulic system of the heavy piece of equipment 120 . Those skilled in the art will understand that a separate hydraulic system (in addition to the factory hydraulic system) may be installed to control the automatic de-clutch pedal 600 . In one embodiment, the application of the de-clutch pedal 600 also disengages the transmission of the piece of heavy equipment 120 into a neutral position.
FIGS. 11 a - 11 b illustrate the hydraulic control 630 which: (i) transfers hydraulic fluid to the hydraulic cylinder 610 responsive to the de-clutch brake pedal 600 being depressed; and (ii) transfers hydraulic fluid to the disc brakes responsive to the de-clutch brake pedal 600 being depressed.
FIG. 12 illustrates a block diagram of an automatic brake system 700 according to one embodiment of the present invention. The system 700 comprises the de-clutch brake pedal 705 , de-clutch brake pedal bracket 710 , hydraulic cylinder 715 , hydraulic controller 720 and disc brakes 725 - 1 through 725 - 4 . This automatic wet brake system may operate independently or in combination with the parking brake system described above.
FIG. 13 shows a flow chart 800 detailing one methodology associated with the automatic brake system 700 . At 805 , it is determined by the readers if the heavy equipment is in reverse gear. If not, the chart 800 loops back to 805 . If so, at 810 , it is determined by the readers if a person is in the danger zone. If not, the chart 800 loops back to 805 . If, at 815 , it is determined that a person is in the danger zone, at 820 , the hydraulic control causes the hydraulic cylinder to be depressed thereby depressing the de-clutch brake pedal. At 825 , responsive to the de-clutch brake pedal being depressed, hydraulic fluid is moved to the disc brakes of the heavy piece of equipment causing the disc brakes to be applied thereby stopping the heavy piece of equipment. At 830 , responsive to the person being outside of the danger zone, the hydraulic control releases the hydraulic cylinder and de-clutch brake pedal by removing some or all of the hydraulic fluid acting on the hydraulic cylinder. In another embodiment, the driver of the heavy piece of equipment may manually release the hydraulic cylinder and de-clutch brake pedal.
While previously detailed embodiments show multiple readers/antennas, FIGS. 14 a and 14 b show a single centrally-positioned antenna 900 configured to read RFID tags 905 - 1 through 905 -N in a defined danger zone 910 . Responsive to the antenna 900 receiving a signal from one of the RFID tags 905 - 1 through 905 -N readers the hydraulic control causes the hydraulic cylinder to be depressed thereby depressing the de-clutch brake pedal.
Although the invention has been described in detail with reference to several embodiments, additional variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.
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A system incorporating one or more interrogators or readers on heavy construction equipment (e.g., loaders) detect signals emanating from signal transmitters on clothing or equipment of construction workers. Responsive to the detection of a signal emanating from behind the heavy equipment, or in another position relative to the heavy equipment, the driver is notified audibly of the danger such that the driver may stop the movement of the heavy equipment or causes the brakes to be applied and transmission to be disengaged automatically without operator involvement. In another version, a wet brake system (also known as a hydraulic brake system) is triggered automatically responsive to the detection of one or more signals emanating from behind a heavy piece of equipment, or in another position relative to the piece of heavy equipment. A hydraulic cylinder is configured to depresses a de-clutch brake pedal when personnel are identified in a danger zone.
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RELATED APPLICATIONS
This application relates to and claims priority from U.S. Application Ser. No. 60/317,442 filed Sep. 7, 2001 entitled POWER SWIVEL, AIR DELIVERY SYSTEM AND ROTATING HEAD, the disclosure of which is hereby incorporated in its entirety by reference.
FIELD OF THE INVENTION
The present invention relates to machinery and methods for exploring beneath the earth's surface and, more particularly, to stratigraphic exploration.
BACKGROUND OF THE INVENTION
One conventional technology useful for exploring the subsurface characteristics at a geological location includes the use of a cone penetrometer. This apparatus has a cone with an electronic stress sensor that is forced downward through the various subsurface layers. As the cone penetrates different strata, the data sensed by the cone is either collected in the cone or transmitted back to the surface. This data indicates characteristics and thickness of the different strata below the surface.
Recently, other technologies that fall into the general class known as “direct push” equipment have been developed to provide other data about subsurface conditions. One common technology of this nature is known as GeoProbe® and another is HydroPunch.
In practice, these direct push technologies, including the cone penetrometer, are delivered to a field site on some type of mobile platform such as a truck or track-mounted vehicle. The platform is relatively large and heavy in order to handle the forces applied, and support the equipment, involved in direct push techniques. A sensor, such as a cone, is attached to a section of pipe which is, itself, coupled using any of a variety of known means to a mounting system. Included in any of these different platforms are hydraulic rams that attach to this mounting system and produce the downward force needed to push a sensor (and attached piping) down through the ground.
The rams force the mounting system downward which forces the piping and sensor downward as well. As more piping is needed, the mounting system is detached from the top piping section, a new pipe segment is added, and pushing continues. For example, in cone penetrometry, each pipe segment is typically one meter long.
Even though direct push systems can generate up to 40,000 lbs of force, these systems are unable to penetrate or push sensors through consolidated or cemented layers below the surface. In the past, when a consolidated layer was reached, either the site data collection stopped or a conventional drilling rig was brought in to penetrate the consolidated layer.
However, the logistical difficulty in utilizing a conventional drilling rig makes this solution very problematic. An available rig has to first be found and then be delivered to the site. In preparation for the arrival of the drilling rig, the direct push equipment must be cleared from the site and the site prepared for the rig. Water collection ponds and other infrastructure is needed for the conventional drilling rig. Once the drilling operation is completed, the site must be cleaned-up and restored for the return of the direct push equipment.
Accordingly, there is an unmet need for methods and machinery useful with direct push equipment that allows drilling through consolidated surfaces that can be accomplished quickly, efficiently, economically and with as little disruption as possible at a field site.
SUMMARY OF THE INVENTION
The present invention addresses these and other needs by providing an air drilling swivel that works with any direct push equipment so as to provide drilling capabilities in the field without the presence of a conventional drilling rig. As a result, the use of direct push equipment is not significantly hampered when consolidated or cemented layers are encountered during subsurface exploration. Within the present application, the term “direct push” is used for convenience and is intended to encompass both conventional direct push equipment as well as driven, hammer driven, or driven-vibrating equipment.
One aspect of the present invention relates to a method for drilling. According to this aspect direct push equipment is used to push a first set of pipe sections and sensor down a bore hole. Then, the first set of pipe sections and sensor are removed from the bore hole and the direct push equipment. Next a power swivel is attached to the direct push equipment, along with a second set of pipe sections and drill bit; and then drilling is performed further down the bore hole with the power swivel.
Another aspect of the present invention relates to a power swivel for drilling down a bore hole. According to this aspect, the power swivel includes a stationary housing configured to be mounted to direct push equipment; a hollow rotating drive shaft configured to rotate within the stationary housing; and a set of hollow pipe sections. A far end of the pipe sections has a drill bit and a near end of the pipe sections is coupled with the rotating drive shaft such that the hollow region of each pipe section aligns with the hollow region of the rotating drive shaft. Within this arrangement, the stationary housing includes one or more air inlet apertures, and the rotating drive shaft includes one or more air openings and arranged within the housing. These different air openings are arranged so that, while the drive shaft is rotating, the one or more air openings periodically align with the one or more air inlet passages to provide a passage way for air into the hollow drive shaft.
Still other objects and advantages of the present invention will become readily apparent from the following detailed description, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modifications in various obvious 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
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
FIG. 1A illustrates an exemplary direct push operation.
FIG. 1B illustrates an exemplary drilling operation according to an embodiment of the present invention.
FIG. 2 illustrates a more detailed view of the operation of FIG. 1 B.
FIG. 3 illustrates a flowchart of using embodiments of the present invention to drill with direct push equipment.
FIG. 4 illustrates a schematic view of an exemplary swivel according to embodiments of the present invention.
FIGS. 5A and 5B illustrate a detailed view of the swivel of FIG. 4 .
FIG. 6 illustrates a detailed view of an exemplary drive shaft useful in embodiments of the present invention.
FIG. 7 illustrates an exploded view of a drilling nipple and packoff according to embodiments of the present invention.
FIG. 8 illustrates an exemplary air delivery system according to embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
To aid with the explanation of the present invention, concrete examples have been given of borehole size, drill rod size, equipment names and drilling environments. The present invention is not limited to these and other specific cases provided herein which, instead, are give only by way of example to aid in the understanding of the present invention.
FIG. 1A depicts a schematic view of direct push equipment being used in the field. The specific details of the equipment platform 101 (e.g., truck, track-mounted vehicle, etc.) are not shown as the platform involves conventional direct push equipment and which is known in the art.
Within the equipment platform 101 , there is a mounting plate 102 that is coupled with one or more pipe sections 104 . These multiple pipe sections 104 descend below the surface of the ground 106 and end with a tip section 108 that includes a sensor or other electronic/sampling equipment. The hydraulic ram or rams 110 is coupled with the mounting plate 102 to provide the downward force needed to push the tip or sampling device 108 through the ground 106 .
Although depicted as a simple block diagram in FIG. 1A, the hydraulic ram 110 is typically plural hydraulic rams that are evenly located around the mounting plate so as to provide sufficient and evenly distributed downward pressure. The hydraulic ram 110 also provides the upward force needed to raise the plate 102 in order to add new pipe sections 104 and to raise the pipe sections 104 when the tip 108 needs to be removed from the ground.
The arrangement of FIG. 1A will result in the tip sampling equipment 108 being pushed through the ground 106 until a layer is reached that is consolidated, or cemented, and proves too hard to penetrate with direct push technology.
FIG. 1B depicts a schematic view of the power swivel 120 attached to the mounting plate 102 and hydraulic rams in accordance with embodiments of the present invention. The power swivel 120 is attached in this manner so that a consolidated layer 122 can be drilled through. Within the field of drilling, in general, a swivel is a mechanical device that simultaneously suspends the weight of a drill string and provides for the rotation of the drill string beneath it. A swivel includes a stationary part, that is coupled with a power source (e.g., a hydraulic motor) and a mounting platform, and a rotating part that is coupled with a drill string. Conventionally, a swivel also permits a high-volume flow of drilling mud or air from the stationary part through to the rotating part without leaking.
The specific type of hydraulic motor is not critical to the present invention; however, one exemplary motor having sufficient capacity to be effective is the DANFOSS OMS 80 151F500 3.
Instead of the sensor tip 108 used in the direct push configuration of FIG. 1A, the drilling arrangement of FIG. 1B includes a drill bit 126 fixedly attached at the end of the drill string comprised of multiple drill pipe sections 124 . A hydraulic source provides input to a hydraulic motor 130 that powers the swivel 120 . As the hydraulic motor 130 causes a drive shaft of the power swivel 120 to rotate, the drill string 124 rotates causing the drill bit 126 to rotate and cut through the consolidated layer 122 . Typical size bore holes would range from 1.25 inches in diameter to 6.25 inches in diameter; although larger scale equipment could be used to produce larger holes.
In the arrangement of FIG. 1B, the power swivel 120 is rigidly and securely attached to the mounting plate 102 and hydraulic rams. Similarly, sections of drill pipe 124 are connected to the power swivel 120 . In this manner, the hydraulic ram's action to force the plate 102 downwards (or upwards) is transferred through the power swivel to the drill pipe sections 124 . As a result, the drill bit 126 rotates and is pushed through the layer 122 to effect drilling of that layer. By utilizing the direct push platform, that includes hydraulic rams, hydraulic fluid, mounting plates, etc., drilling through consolidated layers is performed without the need to bring in a conventional drilling rig with all the accompanying difficulty.
As shown in FIG. 1B, the power swivel 120 also includes an air inlet 132 that receives an air flow from a source 134 . The details and utilization of this air inlet 132 is depicted more clearly in FIG. 2 .
FIG. 2 shows a more detailed view of the power swivel 120 but, so as not to obscure these details, omits some of the equipment depicted in FIGS. 1A and 1B. In particular, there is a circuitous flow path (illustrated by the arrows) in the drilling arrangement of FIG. 1B that allows air, or other fluids, to be introduced at the power swivel 120 , flow through the power swivel 120 , enter the pipe string 124 , flow through the pipe string 124 , exit through the drill bit 126 , enter the bore hole, and then exit above ground thereby removing drill cuttings from the borehole.
An air source 202 is connected to the power swivel 120 , typically through some type of nipple 204 , to produce sufficient air flow to permit drilling. An exemplary air source could be the SULAIR 185H Air Compressor. Additives (e.g., water, surfactants, foam, etc.) 206 can be added to the air flow into the power swivel 120 . The proper use of additives according to different drilling conditions encountered in the field is known to a skilled artisan and can be used to improve drilling efficiencies and rates.
The air flow enters the power swivel 120 and is directed downwards toward the pipe string 124 . The pipe sections of the pipe string are hollow and permit the air flow to proceed towards the drill bit 126 . The drill bit 126 has exit holes, similar in size to the inside diameter of the pipes in the pipe string 124 . The air exiting the drill bit 126 enters the borehole 208 and lifts the cutting towards the surface. For example, the drill bit 126 can be approximately 2.5 inches in diameter while the pipes have an outside diameter of nearly two inches. This difference in sizes creates an annular region that permits the air to flow upwards unrestricted but that is not so large as to result in a large loss of velocity. Upon nearing the surface, the air flow is redirected by an air nipple 210 .
The air nipple 210 includes a portion 214 that is ideally the diameter of the borehole 208 , or at times even larger, and is inserted into the top of the borehole 208 to a depth of approximately 2 to 3 feet or more, for example. The air nipple includes a flange 216 and an annular elastomeric packoff 212 . The annular packoff 212 forms a seal around the drill pipe 124 that is inserted through the opening of the air nipple 210 . The air nipple 210 also includes an exit aperture 218 , known as a blewie line, that allows air flow and cuttings to exit the borehole 208 and acts to direct the exit flow in a desired direction. The air nipple 210 is located at a depth such that the exit aperture 218 is approximately 6 to 18 inches from the surface of the ground 106 . A collection apparatus (not shown) can be connected with the aperture 218 to collect cuttings for further analysis and to filter the exiting air flow to prevent detrimental air quality near the drilling site.
In operation, the air flow in the borehole 208 rises until it reaches the air nipple 210 . The air flow then enters the annular region formed between the section 214 and the drill pipes 124 . The air flow then exits out the exit aperture 218 .
FIG. 3 depicts a flowchart of an exemplary method of utilizing the power swivel 120 . According to the flowchart, subsurface exploration begins, in step 302 , with operating the direct push equipment in a normal fashion. This operation continues until step 304 when a consolidated or cemented layer is encountered. At this point direct push operations cannot continue.
Accordingly, the pipes that have been attached to the direct push sensors or sampling device are removed, in step 306 , one-by-one from the hole in preparation for drilling. Once the direct push sensors or sampling devices and pipes are removed, the power swivel can be attached, in step 308 , to the mounting plates and hydraulic rams of the direct push platform. As the power swivel weighs about 100 lbs, it can be maneuvered into place by personnel at the drill site either manually or with mechanical assistance. Attachment of the power swivel also includes connecting the power swivel (and hydraulic motor) to a hydraulic source and an air source.
Next, in step 310 , the drill bit and sufficient piping to reach the bottom of the borehole are coupled together and lowered into the borehole. However, before this step is started, an air nipple and pack-off are inserted into the borehole so that the air flow properly exits from the borehole during drilling.
In step 312 , the drill string and the power swivel are connected together so that the drilling operation, in step 314 , can take place. The drilling operation continues until the consolidated layer is penetrated.
After drilling is completed, the drill bit, piping and power swivel are removed from the direct push platform in step 316 . Afterwards, the direct push sensor, drill pipes and equipment are re-installed, in step 318 , so that the direct push operation can continue if desired.
Preferably, the same piping can be used in either direct push operation or in drilling operation. One requirement being that the drilling piping needs to have a hollow core to allow air flow of a sufficient volume to permit removal of the cuttings from the bottom of the borehole.
In an alternative scenario, all the strata of interest may be below a known consolidated layer. In this scenario, it is not necessary to start with a direct push operation until reaching that consolidated layer. Instead, drilling can commence from the surface, using the power swivel, and only after the desired stratum has been reached will the direct push equipment be lowered into the borehole.
A high-level illustration of the power swivel according to one embodiment is depicted in FIG. 4 . According to this embodiment, the power swivel includes a number of features that improve its reliability, ease of use and maintenance. Furthermore, one of the critical elements when air drilling is maintaining a sufficient air flow through the flow path. The power swivel of FIG. 4 is designed so that air flow is not restricted into the drill string which results in a large volume of air flowing through the drilling system without the build-up of high pressures. In practice, the present power swivel design enjoys internal pressures typically less than 125 psi.
The hydraulic motor 402 is not specifically a part of the power swivel but is depicted in FIG. 4 to show its relation to the other parts. The swivel 400 includes a number of major sub-assemblies as shown in FIG. 4 . Near the motor 402 , is the planetary gear assembly 404 , this gear assembly reduces the RPMs of the motor 402 to spin the drive shaft 406 . Typically, the drive shaft rotates between 0 and 60 RPMs. The drive shaft 406 engages a splined shaft 414 so that when the shaft 406 rotates so does the splined shaft 414 . The other end of the splined shaft 414 is operatively coupled with a connecting piece 418 to which a drill string (not shown) is connected. The spinning spline shaft 414 causes the connecting piece 418 to spin which, in turn, rotates a drill bit at the end of a drill string (not shown).
Part of the planetary gear 404 , the drive shaft 406 and a portion of the spline shaft 414 are surrounded by a housing 408 . During drilling operations, these assemblies rotate within the housing 408 while the housing 408 remains stationary. Although not drawn to scale in FIG. 4, the housing 408 includes mounting flanges 416 which are attached to the direct push platform. Through these flanges 416 , the hydraulic rams of the direct push platform are able to exert downward pressure on the housing 408 and a drill string connected thereto. The drill string is forced downwards in the borehole, typically at a range of 0 to 5,000 lbs, while the drill string is rotating. The hydraulic rams also exert an upward force when the drill string needs to be raised.
The external splines on the splined shaft 414 mate with internal splines on the drive shaft 406 in such a way as to permit the spline shaft 414 to move upwards within the opening of the drive shaft 406 to facilitate adding or removing pipe sections to the connecting piece 418 . Also, an O-ring or other means (not shown) is included near the top of the spline shaft 414 so that a tight seal is maintained with the drive shaft 406 .
The airflow through the power swivel is unrestricted because of the alignment and size of holes 410 and 412 as well as the hollow nature of the rotating components. Holes 410 in the housing 408 are used (typically with a nipple) to introduce air from an external air source into the swivel 400 . The holes 412 in the drive shaft 406 allow the air to enter the inside of the rotating portion of the swivel 400 . As the drive shaft 406 rotates, one of the holes 412 regularly aligns with the housing hole 410 to create an unrestricted path for air to flow. Conventional drill pipes have an internal diameter of approximately one square inch, although larger (or smaller) sizes are also useful. Thus, the airflow through the holes 410 and 412 of the power swivel 400 should also provide for a full square inch of air to match the inner diameter of the pipe string. By providing this unrestricted airflow, the swivel 400 will allow faster drilling as the large air volume will be able to quickly complete its circuit and remove any cuttings from the borehole.
The embodiment of FIG. 4 depicts four holes 412 spaced at 90 degrees around the drive shaft 406 and two holes 410 opposite each other on the housing 408 . Preferably, the holes 412 are roughly one inch square while the holes 410 are slightly larger at approximately 1.3 to 1.4 square inches. Other sizes, numbers, and placements of these holes are also contemplated which provide the equivalent unrestricted air flow throughout the swivel 400 .
Both holes 410 do not need to be used simultaneously; doing so only increases the volume of air available for drilling. If one hole 410 is not being used, then it can be plugged.
FIGS. 5A and 5B illustrate a side view and a cutaway view, respectively, of a particular embodiment of a power swivel. There are elements of the power swivel 500 that are conventional items such a O-rings, bearings, bolts, etc. that are used in a conventional manner and, although shown in the figures, are not discussed in great detail.
Starting at the top of the swivel 500 shown in FIG. 5A, there is a flange 502 which is useful for attaching the planetary gears, the hydraulic motor and the swivel 500 together. The flange 502 is merely the bottom portion of the planetary gear while the remaining portion of the gear above the flange is not shown in this figure. An air inlet nipple 504 is shown on both sides of the housing 506 which is also known as a case weldment assembly. This housing 506 remains stationary during operation of the swivel 500 while other sub-assemblies housed inside rotate.
Below a middle flange of the housing 506 , is a retractable cover 508 that permits access within the housing 506 without requiring disassembly. In reference to FIG. 5B, flexible packing 534 is depicted near the top of the swivel 500 . This packing can be, for example, Thermabraid™ packing which is flexible graphite, and will eventually wear down over the lifetime of the swivel 500 . Adjustment screws are accessible though the opening behind the cover 508 that enable tightening of the surfaces around the flexible packing 534 . By tightening the pressure on the packing 534 , its useful lifetime can be extended as compared to packing which needs replacing when it beings showing signs of wear.
Returning to FIG. 5A, attached to the housing 506 , using bolts 512 , is a flange mounting assembly 510 . This assembly 510 is the part of the swivel 500 which is mounted on the direct push equipment during drilling.
The spline shaft 514 exits from the bottom of the housing 506 and couples with a transition, or extension, piece 516 connected to the end piece 518 . The tip of the end piece 518 is threaded to mate with conventional drilling piping.
The top of FIG. 5B is similar to that of FIG. 5A in that a portion 530 of the planetary gear is depicted. Within FIG. 5B, there are also a number of O-rings (e.g., 528 , 542 , and 554 ) that provide for fluid tight seals between adjacent surfaces. These seals help ensure that the air flow through the power swivel 500 is not diminished by leaks.
Similarly, there are screws (e.g., 520 ) and bolts (e.g. 522 ) that are used in their conventional manner to fixedly attach two adjoining surfaces such as the lock plate 526 to its mating surface. There are also a number of elements that are arranged in the annular region between the stationary swivel housing 506 and the rotating drive shaft 548 ; these elements support the smooth operation of the power swivel but other, functionally equivalent substitutes are contemplated and considered to be within the scope of the present invention. Some of these support elements include the union cylinder 536 , the disc spring 538 , a washer 540 , the union bearing 546 and the casing bearing 552 .
The planetary gear 530 has a rotating shaft that is splined on its external face. The drive shaft 548 has a region near its top that has splines on its internal face. While it is possible that these two splines can be arranged so that they mate and engage each other during operation, the preferred embodiment of FIG. 5B includes a spline bushing 532 . This bushing 532 has splines on both its internal and external faces. The splines on the inside of the bushing engage the shaft of the planetary gear and the splines on the outside of the bushing 532 engage the inside of the drive shaft 548 . FIG. 6 shows a more detailed view of the drive shaft 548 . The splines 602 near the top are what mate with the spline bushing 532 . The center section 606 is preferably smooth on the inside as this portion does not need to mate with any other surfaces. The bottom section 604 (although not visible from this perspective) includes internal splines that engage the spline shaft 514 . A plug 544 fits within the drive shaft 548 below the splined section to prevent air from exiting from the top of the swivel 500 .
In operation, the drive shaft 548 rotates at approximately 0 to 60 RPM while the drilling bit is being driven down the borehole. Just as importantly, though, the holes 608 of the drive shaft 548 regularly rotate in front of the air inlets in the housing 506 so that air enters the swivel 500 in an unrestricted manner.
Two important elements of the swivel 500 are thrust bearing 524 and tapered roller bearing 550 . The thrust bearings 524 keep the thrust from being transferred in an upward motion to the gear train and prevent downward thrust from being transferred to the housing. As a result, wear and tear on the machinery will be significantly reduced which saves maintenance time and costs. The tapered bearing 550 acts as both a thrust bearing (similar to 524 ) and as an axial thrust bearing. In other words, this bearing 550 also helps eliminate lateral wear on the packing and housing of the swivel thereby eliminating vibration and lateral movement.
Drilling Nipple and Packoff
FIG. 7 depicts a detailed view 700 of the drilling nipple and packoff whose operation was explained in relation to FIG. 2 . In a preferred embodiment, this device 700 is composed of a steel tube 702 approximately 2.5′ in length having an internal diameter of approximately 3 inches and an outside diameter of about 3.5 inches. The tube 702 can be constructed from cold rolled steel or other equivalent materials. The lateral opening 704 forms approximately a 90 degree bend with the tube 702 and is around 8 inches from a flange 705 . The flange 705 is part of the tube 702 and has a center hole with a 3 inch diameter and a larger outside diameter such as, for example, 6 inches. There are multiple holes through the flange 705 to permit the pipe wiper 706 and top flange 708 to be secured to the flange 705 . The pipe wiper 706 can be similar to a one inch pipe wiper manufactured by A. W. Rubber, Inc. that acts as a sealing element between a drilling borehole and push/drill rods or pipes. The top flange 708 also has a three inch inner diameter and a larger outer diameter, such as 8 inches.
Air Delivery System
As mentioned earlier, the power swivel preferably provides air drilling adapted to a variety of push equipment. One embodiment of an air delivery system for the power swivel is depicted in FIG. 8 . The air delivered to the power swivel flows through the drilling system in an unrestricted manner such that a full inch of air flow is supported during drilling operations. The embodiment of FIG. 8 is described within the specific environment of providing a full square inch of air flow through the power swivel. If different air volumes are desired, different dimensioned equipment can be readily substituted.
An air compressor 802 is used to provide an external source of air into the air delivery system 800 . The compressor 802 is connected to a fitting 804 , such as a 1.00″ NPT×1.25″ Chicago fitting, that is connected to a section of pipe 806 , such as 1″ extra-heavy steel piping. A Sensor 808 can be included to sense and indicate pressure conditions before the valve 810 . Valve 810 is a 1.25″ NPT, normally closed, remotely operated valve and is connected by the pipe section 811 with a 1.25″ NPT, normally open, valve 814 .
The valves 810 and 814 can be solenoid valves or pneumatic valves or even other equivalent valve mechanisms. The valve 810 is used to control and shut off the air supply to the swivel. In the case of a power failure or an emergency, the valve will automatically close to shut off the air supply. In the event of an emergency, valve 814 will open to discharge unrestricted to the atmosphere. This is to release pressure from the piping system. In normal operating mode, the valve 814 can be controlled to release to the atmosphere so as to relieve pressure in order to permit addition or removal of additional rods from the drill string. Both valves 810 and 814 are controllable from a control panel 812 in the drill equipment operator's station.
The precise placement of sensors 808 and 816 on their respective piping segments is not critical as long as sensor 808 is placed before the valve 810 and sensor 816 is placed after the valve 814 . These sensors are used to sense pressure within the air delivery system and provide this data to the drill operator.
The end of the air delivery system 818 connects (preferably using some type of quick connect coupling) to a flexible high-pressure delivery line (not shown). The delivery line is connected with the swivel thereby providing air for the drilling operation.
The various embodiments of the swivel described herein have usually been described in the environment of air drilling because air drilling has a number of advantages over fluid drilling. However, the present invention can utilize water, or mud, drilling techniques as well. Similarly, mist drilling, foam drilling and other drilling techniques are contemplated for use with the present invention. The use of air flow, however, eliminates contaminated drilling fluvias being raised to the surface, significantly reduces the potential for contamination of underground aquifers through filtration of free water in the mud system, and enables drilling in freezing weather.
Although the present invention has been described and illustrated in detail, it is understood that the same is by way of illustration and example only, and is not to be taken as a limitation, in scope or spirit, of the present invention which is limited only by the terms of the appended claims.
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A power swivel provides the rotational force to drill consolidated subsurface strata while an unrestricted airflow through the swivel and down a drill string remove cuttings from the borehole. The power swivel is configured to mount on direct push/driven-vibrating equipment, such as a cone penetrometer, to eliminate the need for a conventional drilling rig when a consolidated layer is encountered during direct push/driven-vibrating operations. A drilling nipple and pack-off are provided near the surface to maintain the air flow during drilling and to direct the cuttings to a desired location. Also, a dual-valved air delivery system provides safe, remote-controlled air flow to the swivel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 61/176,402 titled Adjustable Locking Spacer, filed May 7, 2009.
[0002] The present invention relates generally to an adjustable leveling pedestal to support raised access flooring, and more particularly, but not by way of limitation, to an adjustable leveling pedestal that allows for infinite height adjustment of the floor by moving stopping members along a shaft.
BACKGROUND OF THE INVENTION
[0003] Adjustable pedestals for flooring are well known in the art, but suffer from significant drawbacks. For example, prior art adjustable spacers have limited vertical positioning, limited ability to adjust the vertical positioning during loading, and are cumbersome to work with and install. Typical adjustable pedestals are provided with a base, a slotted or notched shaft and a top plate. The shaft is received within, and moves in and out of, the base and locks into position with a clip, rod, cotter pin, or similar mechanism. The spacer is only positionable at heights which correspond to the slots or notches on the shaft.
[0004] Also, typical adjustable pedestals are not adjustable while a load is applied. The downward force of the load precludes vertical adjustment of the adjustable pedestal unless something is provided to support or lift the applied load. Prior art pedestals are also difficult to install and cumbersome to work with.
[0005] Therefore, a need exists for an adjustable leveling pedestal that is selectively adjustable when a load is applied. Simple installation and minimal types of part are also desirable. It is to such an adjustable leveling pedestal that the present invention is directed.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention provides a pedestal to support access flooring. The pedestal includes a base, a head, first and second support members, a threaded support shaft, and first and second threaded nuts. The first support member is inserted into the base and the second support member is inserted into the head. The threaded support shaft is removably inserted into the first and second support members. The first and second threaded nuts are rotatably attached to the support shaft. The first threaded nut abuts the second support member and the second threaded nut abuts the first threaded nut. The first threaded nut can be rotated to move the second support member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1A is a front elevational view of a portion of an adjustable leveling pedestal in accordance with a preferred embodiment of the present invention.
[0008] FIG. 1B is a front elevational view of the adjustable leveling pedestal of FIG. 1A in accordance with a preferred embodiment of the present invention.
[0009] FIG. 2 is a top plan view of a plurality of floor panels having the adjustable leveling pedestals of FIG. 1B disposed at each corner thereof.
[0010] FIG. 3 is a top plan view of a plurality of floor panels having the adjustable leveling pedestal of FIG. 1B disposed at the adjoining corners.
[0011] FIG. 4A is a side elevational view of aligned pair adjustable leveling pedestals of FIG. 1B .
[0012] FIG. 4B is a side elevational view of the misaligned pair of adjustable leveling pedestals of FIG. 4A before alignment.
[0013] FIG. 5 is a front elevational view of another presently preferred embodiment of an adjustable leveling pedestal.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring now to the drawings, and more particularly to FIGS. 1A and 1B , shown therein is an adjustable leveling pedestal 10 for raising and leveling access flooring panels (see FIGS. 4A and 4B ) away from a surface 18 . The adjustable leveling pedestal 10 is provided with a top engaging member 22 , a bottom engaging member 24 , a first adjustable stop 26 , a second adjustable stop 30 and a support shaft 34 .
[0015] In a presently preferred embodiment, the top engaging member 22 is fabricated to interface with a head 14 . The top engaging member 22 preferably has a generally square cross sectional area, although it may have many different geometries that would be apparent to one of ordinary skill in the art. It will be understood that the geometry of the top engaging member 22 should cooperate with the head 14 to provide a substantially secure interface, which can preferably be assembled without tools by inserting the top engaging member 22 into the head 14 . The top engaging member 22 is preferably constructed of a plastic or fiberglass material, but can be fabricated out of any suitable material, such as a resin, other plastic polymer, natural material(s) such as a wood or fiber based material, metal (such as steel, titanium, aluminum or blends thereof) and combinations thereof. The top engaging member 22 is provided with an interface 42 which is fabricated to connect the top engaging member 22 with the support shaft 34 . In a presently preferred embodiment, the interface 42 is a bore fabricated such that the support shaft 34 fits snugly within the interface 42 , preferably without using tools.
[0016] The bottom engaging member 24 is preferably similar in construction and function to the top engaging member 22 with a generally square cross sectional area, but can also have any number of differing geometries that would be apparent to one of ordinary skill in the art. It will be understood that the geometry of the bottom engaging member 24 should cooperate with, for example, the geometry of a base 46 to provide a substantially secure interface, preferably without using tools. The bottom engaging member 24 is preferably constructed of a plastic or fiberglass material, but can be fabricated out of any suitable material, such as a resin, other plastic polymer, natural material(s) such as a wood or fiber based material, metal (such as steel, titanium, aluminum or blends thereof) and combinations thereof. The bottom engaging member 24 is provided with an interface 50 which is also made to connect the bottom engaging member 24 with the support shaft 34 . In a presently preferred embodiment, the interface 50 is also a bore fabricated such that the support shaft 34 fits snugly within the interface 50 , preferably without using tools. The lengths of both the top engaging member 22 and the bottom engaging member 24 should be of sufficient size and the length of their respective bores should be of sufficient depth to receive portions of the support shaft 34 .
[0017] The support shaft 34 of the adjustable leveling pedestal 10 is provided with a first end 58 and a second end 62 . The support shaft 34 is preferably made of fiberglass and threaded along its entire length (all threading not shown in FIGS. 1A and 1B ). The support shaft 34 should be of a size that can be snugly fit into interfaces 42 and 50 of the top engaging member 22 and the bottom engaging member 24 , respectively, but can be removed with minimal force, preferably without using tools. The support shaft 34 is constructed so as to cooperate with both the first adjustable stop 26 and the second adjustable stop 30 to provide height adjustability for the adjustable leveling pedestal 10 . The support shift 34 includes threads 66 that are operable to engage the first adjustable stop 26 and the second adjustable stop 30 . Other shaft configurations (such as partially threaded) that allow the support shaft 34 to engage the first adjustable stop 26 and the second adjustable stop 30 may likewise be utilized.
[0018] The first adjustable stop 26 is preferably a plastic flanged nut (flange not shown) for receiving an end of the support shaft 34 . The flange of the first adjustable stop 26 is preferably oriented such that the flange abuts the top engaging member 22 . The first adjustable stop 26 may be fabricated out of any suitable material, for example, a resin or plastic polymer, natural material(s) such as a wood or fiber based material, metal (such as steel, titanium, aluminum or blends thereof), fiber or glass based materials and combinations thereof. As mentioned above, the flange of first adjustable stop 26 is constructed so as to engage with at least a portion of the top engaging member 22 in order to hold the top engaging member 22 in a fixed configuration relative to the bottom engaging member 24 . In operation, the first adjustable stop 26 is secured against a bottom surface 78 of the top engaging member 22 by turning the first adjustable stop 26 until it abuts the bottom surface 78 of the top engaging member 22 .
[0019] The second adjustable stop 30 is preferably a standard nut similar in construction and operation to the first adjustable stop 26 . The second adjustable stop 30 is positioned below the first adjustable stop 26 and operates to substantially preclude downward movement of the first adjustable stop 26 along the support shaft 34 after the second adjustable stop 30 has been tightened against the first adjustable stop 26 .
[0020] In operation, the first adjustable stop 26 and the second adjustable stop 30 are threaded onto the support shaft 34 . The first end 58 of the support shaft 34 is inserted into the interface 42 of the top engaging member 22 and the second end 62 of the support shaft 34 is inserted into the interface 50 of the bottom engaging member 24 , preferably without using tools. To secure the top engaging member 22 , the first adjustable stop 26 is turned until the flange contacts the bottom surface 78 of the top engaging member 22 . To lock the first adjustable stop 26 and therefore top engaging member 22 , the second adjustable stop 30 is turned until it contacts the bottom of the first adjustable stop 26 . The cooperative use of the first adjustable stop 26 and the second adjustable stop 30 allow for infinite adjustability and fine adjustments to the overall length of the adjustable leveling pedestal 10 .
[0021] To selectively increase the height of the top engaging member 22 , the top engaging member 22 is moved upwardly along the support shaft 34 by turning the first adjustable stop 26 to raise the top engaging member 22 . To lock the first adjustable stop 26 and therefore top engaging member 22 , the second adjustable stop 30 is turned until it contacts the bottom of the first adjustable stop 26 . To selectively lower the height of the top engaging member 22 the second adjustable stop 30 is turned in the opposite direction, moving the second adjustable stop 30 downwardly along the support shaft 34 . Next, the first adjustable stop 26 is turned in the opposite direction moving the first adjustable stop 26 downwardly along the support shaft 34 . The top engagement member 22 is then moved downwardly along the support shaft 34 until the bottom of the top engagement member contacts the first adjustable stop 26 . The first adjustable stop 26 and the second adjustable stop 30 can be turned by hand or using a wrench or other suitable tool.
[0022] The adjustable leveling pedestal 10 is constructed so as to be used for spacing floor panels 14 a distance away from a surface 18 . When utilized for spacing floor panels 14 a distance away from the surface 18 , the adjustable leveling pedestal 10 is preferably provided with a channel (not shown) that is bolted to the head 44 . Preferably, the channel can be slid onto the bolts connecting it to the head (or heads) without the use of tools. This can be accomplished by proper spacing of the bolt and a nut so that during installation of the flooring system the channel can be simply slid onto the nut. The channel is preferably long enough to be bolted to as many adjustable leveling pedestals 10 as are needed to support the floor panels 14 and thereby occupy the area desired for the raised access flooring. In another preferred embodiment, the channel includes a soft material such as foam rubber attached to the top side. The soft material provides an interface between the channel and the floor panels 14 that prevents the floor panels 14 from moving and prevents unwanted noise when loads are applied to the floor panels 14 . In another preferred embodiment, the base 46 is secured to the surface 18 with an adhesive, as will be readily apparent to one skilled in the art. As stated previously, the base 46 is configured to mate with the bottom engaging member 24 . In one embodiment, the base 46 is constructed having a vertical support 108 having a recess 112 for receiving the bottom engaging member 24 , and a base flange 114 for connecting the base 46 to the surface 18 . The base flange 114 is preferably of a square cross section that includes four holes. The adhesive, in addition to securing the base flange 114 (and thereby the base 46 ), extrudes through the holes to additionally secure the base 46 . The base 46 is constructed from any suitable rigid and durable material, for example, a resin or plastic polymer, natural material(s) such as a wood or fiber based material, metal (such as steel, titanium, aluminum or blends thereof), fiber or glass based materials and combinations thereof. The base flange 114 of the base 46 may also be secured to the surface 18 via a fastener such as, for example, threaded fasteners, screws, nails, rivets, in addition to the adhesive.
[0023] The head 44 is substantially identical in construction to the base 46 , though only the head 44 is typically bolted, such as to the channel (not shown). In one preferred embodiment, the head 44 is constructed having a vertical support 110 having a recess 120 for receiving the top engaging member 22 , and a head flange 128 for connecting the head 44 to the channel. The head flange 128 of the head 44 is preferably of a square cross section that includes four holes (not shown) and is preferably bolted to the channel. In a preferred embodiment, the channel runs along the interface of adjacent floor panels 14 and supports the weight of the floor panels 14 . The floor panels 14 are preferably made from fiberglass, and if constructed from such material the floor panels 14 remain securely on the channel.
[0024] Referring now to FIG. 3 , shown therein is a plurality of floor panels 14 , each of which is provided with four adjustable leveling pedestals 10 , one adjustable locking spacer 10 positioned on each corner 116 . Although a raised floor can be assembled in this fashion, the added benefit of using the channel and a fewer number of adjustable leveling pedestals cannot be realized.
[0025] Referring now to FIG. 4B , shown therein is a misaligned pair of floor panels 14 (channel is not shown). When installing floor panels 14 , if the surface 124 is not level, the floor panels 14 will not be level.
[0026] When floor panels 14 are uneven, the height of one or more of the floor panels 14 may be either raised or lowered to align the floor panels 14 via the adjustable leveling pedestal 10 . By way of non-limiting example, a floor panel 14 having an adjustable leveling pedestals 118 A and 118 B and abuts another floor panel 14 having an adjustable leveling pedestal 122 A and 122 B. The floor panel 14 having the adjustable leveling pedestal 122 B is positioned at a height lower than the floor panel 14 having the adjustable leveling pedestal 118 A and 118 B due to, for example, variations of the surface 124 . To adjust the height of the floor panel 14 having the adjustable leveling pedestal 122 B, the first adjustable stop 138 of the adjustable leveling pedestal 122 B is moved upwardly along the support shaft 130 , therefore moving the top engaging member 134 upwardly and in-turn, increasing the height of the floor panel 14 . When the desired height of the floor panel 14 is achieved, the second adjustable stop 126 is moved upwardly along the support shaft 130 until it abuts the bottom of the first adjustable stop 138 . This process may be repeated, extending and retracting the adjustable locking spacer 122 B until the correct floor panel 14 height is achieved (see FIG. 4A ).
[0027] Referring now to FIG. 5 , shown therein is another presently preferred embodiment of the adjustable leveling pedestal 200 with channel 202 . A head 204 is preferably bolted to the channel 202 . Similar to FIGS. 1A and 1B , the adjustable leveling pedestal 200 includes a first adjustable stop 208 and a second adjustable stop 216 , secured to a threaded support shaft 212 .
[0028] From the above description, it is clear that the present invention is well adapted to carry out the objects and to attain the advantages mentioned herein as well as those inherent in the invention. While presently preferred embodiments of the invention have been described for purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the invention disclosed.
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The present invention provides a pedestal for use in raised access flooring, such as for magnetic resonance imaging rooms and computer rooms. The pedestal includes a base, a head, first and second support members, a threaded support shaft, and first and second threaded nuts. The invention is easy to install and can be made of all non-metalic parts. The base and the head can be constructed identically to minimize the type of parts needed for manufacturing and inventory. The first and second support members can also be constructed identically, further minimizing the parts needed.
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STATUS OF RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No. 10/379,174 filed on Mar. 4, 2003, now pending, the contents of which are incorporated by reference as if set forth in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to methods and apparatus for packaging, and more particularly to packaging for products used to disinfect, deodorize, add color and/or add fragrance to toilet bowls.
BACKGROUND OF THE INVENTION
[0003] Both commercial and residential toilets often use treated water for several purposes. The water is treated to provide disinfectant, anti-bacterial, anti-odor and other useful properties that make the toilet “self-cleaning” to the extent that situations such as the proliferation of mold, slime, calcium or lime deposits and iron oxide stains are diminished, and so that the bowl is as clean as possible after each use from the turbulent action of the flush cycle alone. Additionally, the water is often treated to add color and fragrance, both of which improve the aesthetics of the toilet and the room. A fragrance is any molecule that diffuses via vaporization into the atmosphere (under local conditions of temperature and pressure) and subsequently activates a specific receptor in the nasal cavity. The fragrance may either mask an unpleasant odor or may simply be an environmental improvement.
[0004] Toilet water treatment systems fall into two broad categories, i.e., those that treat the water in the tank, and those that treat the water in the bowl. Systems operating within the tank range from solid “drop in” tablets to more elaborate systems such as that shown in U.S. Pat. No. 6,192,524—Black, which discloses a system that is affixed to the overflow drain tube found in toilet tanks. However, commercial toilets and many newer residential toilets are either tankless or have a significantly reduced tank volume. Therefore, a system that is attached to the toilet bowl itself is ultimately of wider applicability.
[0005] Systems attaching a simple fragrance-containing solid to the bowl rim are well known in the art, as are more elaborate systems that dispense liquids into the water. For example, both U.S. Design Pat. No. D466,583—Heijdenrijk and U.S. Pat. No. 6,434,758—Camp, et al. disclose rim mounted systems. Both these patents are assigned to Sara Lee Household and Body Care, a company that manufactures and sells the Ambi-Pur™ line of devices to treat the water in toilet bowls. The systems disclosed in the Sara Lee patents have a holder with a flexible section for suspending the unit from the toilet bowl rim and a reservoir that holds an active substance such as cleansing and air freshening liquids. These liquids are introduced to a porous section that lies in the path of the flushing water, i.e., underneath the rim and along the interior bowl surface. The porous mass is in constant communication with the active substance such that when the unit in place, a discharge opening discharges active substance on to the porous mass. The active substance is later washed into the water when the toilet flushes. The problem with such systems, however, is that as with a solid “cake” hanging under the bowl rim, the active substance is constantly being eroded and dissipated. Moreover, upon flushing, the initial volume of flush water carries the highest concentration of active substance out of the bowl entirely, leading to waste and ineffective results.
[0006] Thus, none of these prior art systems addresses the problems outlined above. There remains therefore a long-felt yet unmet need for providing a simple device mounted to the toilet bowl rim that will effectively and reliably introduce an active substance at a later point in the flush cycle so that the highest concentration of active substance is not carried away with the initial volume of flush water. It would further be desirable to provide such improvements in a manner applicable across a wide variety of packaging designs, and combinations of active substances and the forms of the active substances (solid, liquid, gel, etc.) in a cost-effective manner.
SUMMARY OF THE INVENTION
[0007] These shortcomings of the prior art are remedied, however by an apparatus for introducing material into a toilet bowl that has a rim holder positioned within the toilet bowl and a material container filled with a material along with a material dispenser connecting the rim holder and a vessel section of the material container, such that the vessel section comprises walls and a lower aperture open to the toilet bowl. In operation, upon initiation of a flush cycle, this apparatus fills the vessel section to a predetermined level causing the material to be dispensed into the vessel section. There is a wick, valve or other structure that permits material to be admitted to the vessel section when a predetermined volume of flush water is collected. In certain preferred embodiments, the rim holder and vessel section are integral, and in certain embodiments, the rim holder further comprises a hanger. The apparatus is preferably molded from a plastic material and the material preferably comprises at least one liquid component. The material is at least one material selected from the group comprising a fragrance, a disinfectant, a coloring agent, and a cleaner. In preferred embodiments, a float is provided that controls a valve so that the rising level of liquid in the vessel section causes the material from the material container to be released. The float can be connected to a valve, or alternatively to a resilient member that is deformed to create an opening. In still another embodiment, the float itself acts as a valve or stopper and admits material into the vessel section when the liquid level rises to a predetermined level.
[0008] The present invention also discloses methods of adding a material to a toilet bowl by positioning a rim holder within the toilet bowl, positioning a material container in fluid communication with the rim holder, and then diverting a portion of flush water entering the toilet bowl into a vessel section. Material is mixed with the water in the vessel section and a mixture including the material flows into the toilet bowl via a lower aperture in the vessel section after an initial volume of flush water has exited the toilet bowl. Preferably, the mixing takes place when a predetermined level within the vessel section is reached, and the flow through the lower aperture is metered so that substantially all the liquid within the vessel section is dispensed into the bowl after a flush cycle is substantially competed. In preferred embodiments, the material added is at least one material selected from the group comprising a fragrance, a disinfectant, a coloring agent, and a cleaner.
[0009] The present invention therefore discloses, in preferred embodiments, apparatus for dispensing a material into a toilet bowl that has a rim holder with a hanger portion that engages the toilet bowl, a vessel section that holds a volume of flush water, a lower aperture that drains the vessel section; and a material container received by the vessel section, whereby material is admitted to the vessel section after a predetermined level of flush water fills the vessel section. Most preferably, the rim holder and the material container are molded from plastic and the material is at least one material selected from the group comprising a fragrance, a disinfectant, a coloring agent, and a cleaner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a preferred embodiment 100 of the present invention;
[0011] FIG. 2 is an exploded perspective view of the assembly illustrated in FIG. 1 ;
[0012] FIG. 3 is a cross-sectional view of an apparatus made in accordance with the present invention taken along line 3 - 3 of FIG. 1 and shown affixed to a toilet bowl;
[0013] FIG. 4 , is a view similar to that of FIG. 3 , showing the invention in use at a later stage in the flush cycle;
[0014] FIGS. 5-7 are a sequence of front elevation views illustrating the operation of one preferred embodiment of the present invention;
[0015] FIGS. 8-10 are a sequence of front elevation views illustrating the operation of another preferred embodiment of the present invention;
[0016] FIGS. 11-13 are a sequence of front elevation views illustrating the operation of still another preferred embodiment of the present invention; and
[0017] FIG. 14 is a side elevation, in cross-section, of a broken away, enlarged view of the seal component shown in FIGS. 11-13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present invention is implemented in several preferred embodiments, which are discussed below as illustrative examples. This description is provided for purposes of understanding of the invention and is not meant to be limiting.
[0019] Referring now to FIG. 1 , there is shown a perspective view of a preferred embodiment 100 of the present invention in which a material container 110 is inserted into a rim holder 120 . Further details of this embodiment can be seen with reference to FIG. 2 , which is an exploded perspective view of the assembly illustrated in FIG. 1 . As will be appreciated by those of skill in the art, in certain embodiments the entire assembly 100 will be sold as a disposable assembly, while in other embodiments, the material container 110 will be sold independently for replacement in an existing rim holder 120 . As will be further understood by those of skill in the art, the rim holder 120 may be made of any of a number of materials, primarily molded polymers, however, alternative materials include metals, fiber composite materials and ceramics. Similarly, the material container 110 may be formed from a molded polymer, glass or ceramic or other material. The choice will take into consideration the nature of the liquid being held inside and chosen so as to minimize degradation of the nature of the liquid, e.g., the preservation of fragrance strength, cleansing and disinfectant power, and color stability.
[0020] The material container 110 provides a housing for at least one material (“M”) that is to be admitted to the water that is to remain in a toilet bowl. The material may be a cleaner, a disinfectant, a fragrance or a colorant, or any combination of such materials, all of which are well known, either alone or in various combinations. Additionally, the material may be provided in solid, gel, particle, liquid or any combination of forms so long as the material in the material housing 110 is water-soluble. It should be noted that although the discussions herein relate to toilets that use water, it should be understood that the concepts of the present invention have equal applicability to “chemical” toilets that use a medium other than water. When flushed, such embodiments will provide the same mechanism of action as described below, except that the toilet bowl is not filled with water, and the material “M” will be soluble in whatever chemical flushing agent the toilet uses
[0021] An elevation cross-sectional view of an apparatus made in accordance with the present invention affixed to a toilet bowl is shown in FIG. 3 . As illustrated, a hanger portion 122 of the rim holder 120 extends over and engages the rim of the toilet bowl 50 in a manner known in the art. As mentioned above, the material chosen for the hanger portion will provide sufficient strength, flexibility and resilience to accommodate this function. The geometry of the hanger 122 is chosen so that the assembly 100 is disposed below the top of the rim 52 , and partially underneath the lower edge of the rim 54 , as illustrated. Also shown in FIG. 3 is an approximation of the water flow in a flushed toilet, shown by the arrows. Upon flushing, water flows from the lower edge of the rim 54 , and due to the construction of the rim holder 120 , a portion of this flow is captured in the vessel section 124 of the rim holder 120 .
[0022] Referring how to FIG. 4 , there is illustrated a view similar to that of FIG. 3 , the primary difference being that the water flow from the flushing action of the toilet has substantially filled the vessel section 124 . In other words, the view of FIG. 4 is at a later time in the flushing cycle than the view shown in FIG. 3 . At this point, the water level “L” has risen so that material “M” held in the material container 110 is now mixed with the water in the vessel section 124 , and this mixture is released into the toilet bowl from a lower aperture 126 , as shown by the arrow in FIG. 4 . In a preferred embodiment, the size and structure of the vessel section will be designed to create a mixture of material and fresh water that is sufficient for the intended purpose, whether cleansing, fragrance, deodorizing, disinfecting, color, or any combination of these functions.
[0023] Also shown in FIG. 4 is the material dispenser 128 , which causes the material “M” to be mixed with the water in the vessel section 124 . The material dispenser 128 can be a simple wick or tube, a section of permeable material, such as a sponge or foam, in such embodiments, when the water captured in the vessel section 124 rises to a predetermined level, the material “M” is in contact with the water and fills the vessel section with a solution of water and the material. Alternatively, in certain preferred embodiments the material dispenser 128 is a somewhat more complex mechanism, e.g., a valve with a float actuation such that the valve opens when the level within the vessel section 124 rises to a sufficient level. The material dispenser 128 may be part of the material container 110 , part of the rim holder 120 , or a separate component that cooperates with of the main components. In any embodiment, the function required is that the material M is admitted into and mixed with the water only upon a sufficient level “L” in the vessel section 124 , that in turn correlates to a predetermined time into the flush cycle. As a result, as explained above, since the aperture 126 is designed to permit liquid to escape at a slower rate than it is admitted, the filled vessel section 124 will continue to be drained after the flush cycle is complete, and as a result, the solution of water and material M will be introduced into the bowl at a higher concentration with substantially less waste and greater effectiveness than found in prior art designs.
[0024] Referring now to FIGS. 5-7 , there is illustrated a front elevation view of a preferred embodiment of the present invention. In this embodiment, as discussed above, a hanger portion 122 extends from a rim bolder 120 , which also have a vessel section 124 . Disposed above the vessel section 124 is a material container 110 and connecting the two is a material dispenser 128 . As discussed above, in certain preferred embodiments, the material dispenser 128 is a valve, and as illustrated in FIGS. 5-7 , the valve used to selectively admit the material “M” from the material container 110 to the vessel section 124 is a simple flap valve 228 that opens and closes as the level of liquid in the vessel section 124 rises and falls. As seen in FIG. 5 , the material dispenser 128 includes a valve 228 that is comprised of an arm 226 that opens and closes a dose container 227 . At the opposite end of the arm 226 is a float 230 . In FIG. 5 , the flush cycle has not yet been initiated and the vessel section 124 is empty. The material dispenser 128 is filled with a pre-determined amount of material “M” that has been admitted to the dose container 227 via gravity flow through an aperture connecting the two vessels. Referring now to FIG. 6 and as described above with reference to FIGS. 1-4 , upon initiation of a flush cycle the vessel section 124 fills with flush water and this rising fluid level causes the float 230 to move upwardly and pivot the arm 226 , which has the effect of opening the dose container 227 . As illustrated in FIG. 6 , this condition permits the contents of does container to be admitted into the volume of flush water that has been collected in the vessel section 124 . As described above, the mixture of flush water and material “M” is now admitted to the fresh water in the toilet bowl, and as a result the level of liquid within the vessel section 124 begins to drop, as illustrated in FIG. 7 . The dropping of the liquid level causes the float 230 to drop and thereby re-seal the dose container 227 . As seen in FIG. 7 , the device begins to re-set itself by material “M” beginning to drip into the dose container 227 , which will fill and reach equilibrium, awaiting another discharge. As will be readily understood by those of skill in the art, the structural members illustrated in FIGS. 5-7 can be replaced by other structures that carry out a similar function, for example, the pivoting structure can be replaced by a float 230 that moves vertically and removed or releases a cover over the dose container 227 .
[0025] Another embodiment of the present invention is illustrated in FIGS. 8-10 . Using a similar numbering system to describe this embodiment, a float 230 is again employed, but instead of moving or displacing a valve, the float 230 is used to physically open the dose container 227 . In this embodiment, the dose container 227 is comprised of a hollow structure that is made of a flexible material and most preferably slit longitudinally, as seen in the detailed view of FIG. 8 . The float 230 is attached to the dose container 227 , preferably near the distal end, i.e., the end farthest displaced from the material container 110 . As explained above, the dose container is filled with material “M” by a gravity drip from the material container 110 . In certain preferred embodiments, the dose container 110 will be made from a flexible tube made from silicone or a similar flexible and resilient material, while in other embodiments, the dose container 227 will be made from a foam material, such as an open celled foam, that will become saturated with the material “M.” In operation, flush water will fill the vessel section 124 and, as seen in FIG. 9 , the liquid level in the vessel section rises, displacing the float 230 , which in turn causes the dose container 227 to be deformed so that it becomes deformed and releases the material it contains. As illustrated, if the dose container 227 has a slit the slit deforms into an opening. Alternatively, the if the dose container is made of foam, in certain embodiments a slit will not be necessary and the urging of the float against the material container 227 , which is fixed relative to the vessel section, will compress the foam and squeeze the material “M” from the pores or cells of the foam. Preferably, the material container 227 is made of foam and slit, as illustrated, and thus takes advantage of both the deformation and the squeezing action caused by the upward motion of the float 227 . In a manner similar to the embodiments discussed above, once the material “M” is released, it mixes with the flush water in the vessel section 124 and is discharged into the toilet bowl. As the liquid level drops, illustrated in FIG. 10 , the dose container 227 returns to its original position and in the embodiment illustrated, the slit re-seals itself so that the dose container may again receive a quantity of material “M” so it is ready for another cycle.
[0026] FIGS. 11-14 illustrate another embodiment of the present invention. In this embodiment, the float 230 and the valve 226 described above are preferably a single seal component 330 that provides a sealing and releasing function and thus selectively admit material into the vessel section. As seen in FIG. 11 the seal component 330 is disposed in an aperture that connects the material container 110 and the vessel section 124 . As explained in further detail below, the seal component 330 has a flange that seals the material container so that no material “M” flows or is introduced into the vessel section 124 . As illustrated in FIG. 11 , the forces of gravity and the weight of the material “M” together provide a downward pressure between flush cycles. Upon initiation of a flush cycle, the liquid level within the vessel section 124 begins to rise and, as seen by comparing FIGS. 12 and 13 , when the level in the vessel section 124 reaches a pre-determined point, the float function of the seal component 330 will be initiated and it will be displaced upwardly, breaking the seal and permitting a flow of material “M” into the vessel section 124 . Unlike the other embodiments illustrated in FIGS. 5-10 , in this embodiment, the volume of material “M” is not a pre-determined “dose.” Instead, by selecting the diameter of the seal component 330 and the rate of discharge from the vessel section 124 , an efficient use of the material “M” is obtained. As the mixture or solution of the material “M” and the flush water is discharged, the seal component drops back into its original position, again sealing the material container 110 and effectively halting the discharge of the material “M.”
[0027] Further detail of the seal component 330 are illustrated in FIG. 14 , which is a cross-sectional elevation view of the seal component 330 in the sealed position, as seen in FIGS. 11-12 . The seal component 330 has an upper flange 331 that rests within a corresponding sealing groove 332 that is formed in the bottom surface of the material container 110 . The seal component 330 also has a main body 333 that is of a smaller diameter than the aperture “A” in the material container, so that when the seal component 330 rises, the material “M” can flow between the edges of the aperture “A” and the main body 333 as seen in FIG. 13 . Preferably, but not necessarily, the seal component 330 also has a lower flange 334 that serves to both enhance the float function of the device and as a “stop” so that if the vessel section 124 is over-filled, the seal component 330 will not be pushed up into the material container 110 .
[0028] In accordance with the present invention, the device 100 described above enables a material, for one example a fragrance liquid, to be dispensed into a toilet bowl 50 both during and after the flushing cycle. In this aspect the present invention provides a significant improvement over the prior art in that previously treated liquid was flushed away since it was created either before or during the flush cycle, in some instances resulting in the majority of the liquid being flushed out of the bowl. On the other hand, a device made in accordance with the present invention will provide a system wherein the material, whether a cleaner, disinfectant, colorant, fragrance, etc. remains substantially in the water remaining in the toilet bowl after the flush cycle has ended.
[0029] Upon review of the foregoing, numerous adaptations, modifications, and alterations will occur to the reviewer. These will all be, however, within the spirit of the present invention. Accordingly, reference should be made to the appended claims in order to ascertain the true scope of the present invention.
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Methods and apparatus for dispensing a material such as a fragrance, a disinfectant, a coloring agent, or a cleaner into a toilet bowl are disclosed. In accordance with certain preferred embodiments of the present invention, a rim holder and material container are provided. The rim holder includes a vessel section that collects flush water after initiation of a flush cycle. After the volume within the vessel section reaches a a predetermined level, the material is mixed with the water and permitted to flow into the toilet bowl from a lower aperture. The present invention permits the material to be added alter in the flush cycle so that the material is no carried way with the initial flow, but instead remains in the bowl after the flush cycle is complete.
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CROSS-REFERENCES TO RELATED APPLICATIONS
None
BACKGROUND
This invention relates to an apparatus for detecting the relevant properties of subterranean formations while drilling wells for oil, natural gas, and geothermal energy. More specifically, the invention relates to the measurement of the linear rebound position, velocity, and acceleration of a down-hole fluid-driven percussive piston which impacts a drill bit, thus penetrating the subterranean formations. Such pistons are referred to in the industry as “down-hole hammers,” examples of which are disclosed in U.S. Pat. Nos. 5,396,965, 5,488,998, and 5,497,839. U.S. Pat. No. 5,396,965 discusses in detail the principles involved in the operation of a down-hole hammer actuated by drilling mud. These patents are incorporated herein. Drilling mud is only one of a number of different fluids used to drive down-hole hammers; any gas or liquid such as air, water, brine, or a foam combination could drive the mechanism upon which this invention is based.
The materials to be penetrated by such a drill vary by the type, depth, and location of the well. Knowledge of the lithology being drilled assists the drilling crew in the selection of drilling parameters and indicates when a “pay zone” is near. Thus, it would be very useful to obtain information about the physical characteristics of the formations being drilled. Specifically, it is helpful to know the hardness of the formations, their approximate composition, and whether or not they are part of a subterranean fracture. This would allow the surface team to steer the bit towards places where the type of energy being sought can be efficiently acquired. In the drilling process, it is also advantageous to optimize the drilling rate to minimize labor and tool replacement costs. The optimum set of conditions such as frequency of hammer impact, force of impact, presence of pulsed jet action, and rotational speed of the drill bit, varies by the hardness, depth, and composition of the formations being drilled. For example, impact-resistant diamond cutters that have a long life in medium hardness rock will tend to decompose and wear away under the high temperatures generated by drilling through hard, abrasive formations. If real-time data on the characteristics of the subterranean formations being penetrated could be acquired, a control system could be implemented to adapt the drilling conditions to the type of rock encountered.
When two objects collide, the energy with which they rebound depends upon the elasticity and hardness of both. Thus, an analysis of the rebound characteristics (position, velocity, and acceleration over time) of the hammer will also reveal the hardness and general makeup of the formations in contact with the bit. The harsh environment in which the hammer operates makes conventional measurement methods impractical; potentiometers, interferometers, and other instruments that measure displacement will not function well in the presence of high-pressure abrasive fluids, vibrations, and impact forces. There is a need for some novel method of discovering the hammer's position, velocity, and acceleration during the short period of time after it strikes the drill bit.
Additional utility would attend such a method if it could measure the position, velocity, or acceleration of the hammer at other points in its reciprocating motion as well. For example, simple knowledge of the impact velocity or frequency of the hammer may be used to help detect wear or malfunction of the hammer. As a second example, knowledge of the position of the hammer may enable the use of more flexible electromechanical valves to control hammer motion. In typical hammer mechanisms, such as those described in the patents above, the only variables that can be altered during drilling are the pressure or flow rate of fluid entering the drill string. This allows the drilling team to control only the frequency and force of impact, both of which must simultaneously increase or decrease. Optimization of the drilling process requires more control over the motion of the hammer, some of which can be attained through the use of computer-controlled valves. These would allow the drilling crew to dynamically modify the stroke of the hammer, thus, for example, increasing the hammer frequency while decreasing the force of imp act, etc. This type of control system would need data describing the hammer's displacement over its full range of motion.
Several different types of transducers exist; they are based upon principles such as variable resistance, optical interference, acoustic rebound, piezoelectric excitation, and magnetic flux variance. The following are examples of some that could be configured to measure the motion of the piston.
One means of optical measurement is the interferometer. It functions by focusing a beam of coherent light through a beam splitter. One part of the beam bounces off of a stationary mirror while the other bounces off of a moveable mirror; when the two returning beams are simultaneously visible, differences in the observed wavelengths indicate the displacement of the moveable mirror. In hammer machines that run on transparent fluids such as air, this can be used to determine the location of the piston over time.
Acoustic rebound transducers utilize sonic or ultrasonic waves and measure the speed of a passing object by utilizing such phenomena as the “Doppler effect.”
Variable resistance transducers include potentiometers, which measure the displacement of an electrical contact along a coil of wire. The wire of the coils is of a known resistivity; when the contact closes the circuit with a known voltage source by touching one of the coils, the resulting output voltage is proportional to the length of wire the current must travel through. Thus, the voltage is a measure of the relative displacement of the contact and the coil.
Piezoelectric transducers function based on the unique tendency of some materials, such as single crystal quartz, to develop a charge when subjected to a mechanical strain. The charge generated is proportional to the force on the crystal; thus, the piezoelectric load cell can be used to measure force. This, in turn, yields a measurement of the acceleration when the load cell is attached to a moving object such as the piston; the weight of the cell will press on the crystal to produce a measurable charge in proportion to the magnitude of the acceleration. Since they measure changes in force, piezoelectric crystals can also readily be configured to measure pressure changes in fluids. Such a pressure transducer mounted in the fluid cavity above the piston or likewise on the drill string closer to the point of impact would yield data that generally describes the motion of the hammer, as derived from the cyclical fluid pressure variations.
There are also other types of transducers that operate based on measurement of changes in magnetic flux. Linear variable displacement transducers, or LVDT's, have one coil wrapped around a magnetically permeable core. When the core moves between two other concentric coils, the ac voltage through the first coil will excite a voltage output in the other two in proportion to the core's proximity to them. Thus, the LVDT measures the location, or displacement, of the core.
When the piston strikes the impact mass, there are two components to its motion: the transient response and the steady response. The transient response is the portion of the waveform induced as a direct result of the impact; its amplitude upon impact is significant but drops to zero before the end of the cycle. The steady response is the normal, near-sinusoidal waveform of the piston's motion resulting from the fluid pressures that actuate it. The transient response yields information regarding the impact and consequently the physical makeup of the formations being impacted. The steady response describes the piston's general motion and therefore provides data that can be used to deduce the piston's frequency, stroke length, and impact force.
For the analysis of subterranean features as well as diagnostic testing of the hammer's operation, the displacement, velocity, and acceleration of the piston are all useful quantities. If one is known, the other two can be determined from it by integration or differentiation. However, since the piston does not always strike the impact mass or reach the same point at the top of its stroke, there may be a need for a position datum if displacement is not the variable being directly measured. In other words, it might be necessary to know at which point in time the piston reaches a certain position once each cycle because inaccuracies in the integration over time may build up and yield an inexact measurement of the position of the piston. The sensor could be a simplified version of any of the displacement transducers discussed above, as it only needs to provide a simple signal to indicate that the piston has reached the predetermined position.
For the invention, the magnetic flux-based transducer was chosen as the most viable for down-hole applications. Lateral vibrations in the piston's movement, abrasive down-hole conditions, and high velocities make it difficult to use any transducer in which the moving and stationary parts must be in contact with each other, such as the potentiometer. It is similarly impractical to extend any wires from the piston to a stationary part of the drill string because the piston's motion will tend to break the wires in fatigue while the abrasive effects of the drilling fluid will rapidly wear away exposed electrical conductors. For these reasons, it is desirable to use a transducer in which the only communication between moving and stationary parts does not require contact between the piston and the drill string. A magnetic coupling accomplishes this criterion and provides a particular advantage for down-hole applications, since such a coupling may operate in typically opaque drilling mud. Although either permanent or electrically activated magnets can be used, permanent magnets are preferable for mounting in a hammer piston because they reduce the number of electrical contacts required.
Yet further functionality of the above-mentioned measurement method is apparent when one considers that an electrical signal generated by this method may be useable as an electrical power source. Data acquisition, data transmission, and control systems, as described above, require a steady source of power down-hole. Due to the time and expense required to retrieve the drill from the borehole, it is critical to find a power system that will operate for as long as possible without the need for maintenance or replacement. A down-hole power system should be designed to operate for at least 100 hours.
Several methods of providing electricity down-hole have been tested with limited success. New lithium technology currently being implemented in batteries cannot provide a long enough life to be useful for powering complex systems down-hole. The abrasive environment makes turbines and other bladed rotary generators particularly short lived. The motion of the down-hole hammer, however, may be used to provide the needed means of down-hole electricity generation.
The present invention is a method of measuring the motion characteristics of the hammer through the use of a transducer mounted on the piston, drill bit, or drill string. A transducer is a device that converts one form of energy to another. Thus, in this invention, a portion of the energy resident in the hammer is converted into electrical energy. The present invention thus becomes not only a motion sensor, but also an electrical generator.
The preferred embodiment of the transducer consists of a series of coils and magnetic flanges mounted inside the hammer. In this embodiment, the transducer will provide valuable information on the transient and steady motion of the hammer in the form of an electric signal strong enough to constitute a power source.
SUMMARY
The present invention constitutes a method for satisfying three functional needs in implementing down-hole control, measurement, and telemetry systems. This device provides a means of measuring the hammer's impact characteristics, a means of determining its general displacement profile over time, and a means of generating electrical power for use in down-hole systems.
Combining existing technologies solves these problems. First of all, fluid-driven hammers, as shown in U.S. Pat. Nos. 5,396,965, 5,488,998, and 5,497,839 are used to convert hydraulic pressure to linear kinetic energy. Linear alternators, such as those described in U.S. Pat. Nos. 4,454,426, 4,602,174, 5,180,939, and 5,389,844 convert linear kinetic energy to electrical energy. These patents are incorporated herein. The amplitude of the electric waveform produced is in proportion to the velocity of the linear reciprocator.
The basic principles are as follows. When a magnetic field passing through a coil changes in strength or orientation, a voltage is induced in proportion to the change in the field divided by the time required for the change to occur. This principle is commonly used to convert between mechanical and electrical forms of energy. The relative motions of the magnets and the coils can be rotational or linear. Linear reciprocating elements have been used as components for linear motors and alternators, such as those disclosed in U.S. Pat. Nos. 4,454,426 and 4,602,174, as well as measurement devices such as linear variable displacement transducers (LVDT's). A coil and magnet system is used to measure the location of a compressor piston with respect to the cylinder head in U.S. Pat. No. 5,342,176, incorporated herein by this reference.
The preferred embodiment of this invention utilizes permanent magnets mounted on a stationary member in the hammer housing. Coils are also mounted on a stationary member and the motion of the hammer (a mass of magnetic material) past the permanent magnets causes a changing flux field. This changing flux field induces a current in the coils, which can be measured and used to feed electrical devices. In a second embodiment of this invention, the magnets may be mounted on the hammer, which reciprocate with respect to coils mounted on a stationary member in the hammer housing. Similarly, the measurement device can be mounted on the drill bit, which will display a similar rebound characteristic. The hammer's position and acceleration can also be obtained by integration and differentiation, respectively. This yields the desired information concerning the rebound and general motion of the hammer.
The voltage induced by such a configuration produces an alternating current waveform. If the magnetic field is strong and there are a large number of coils, the amplitude of the waveform will be large enough to constitute a signal useful as a power source. See U.S. Pat. No. 4,491,738, incorporated herein, for an example of a machine that generates small amounts of electricity down-hole independent of a hammer.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a sectioned view of the cylindrical hammer subassembly that shows the transducer (mounted in the hammer housing), signal-conveying wires, and signal analysis and rectification modules.
FIG. 2 is a sectioned view of the same hammer subassembly with the transducer mounted on the drill bit.
FIG. 3 is a sectioned view of the preferred embodiment of the transducer/generator mounted in the hammer housing.
FIG. 4 is a sectioned view of the portion of the hammer containing the transducer, in a region towards the bottom of the transducer (section A—A in FIG. 3 ); it shows the layout of the magnetic rings and flanges.
FIG. 5 is a sectioned view of a region towards the top of the hammer transducer (section B—B in FIG. 3 ).
FIG. 6 is the view shown in FIG. 3; the hammer is near the bottom of its stroke.
FIG. 7 is a blowup of the portion of FIG. 6 contained by the dotted lines. The arrows represent the path of the magnetic flux.
FIG. 8 is the sectioned view of FIG. 3 depicting the hammer near the top of its stroke.
FIG. 9 is a blowup of FIG. 8 . The arrows represent the path of the magnetic flux.
FIG. 10 is a graph that shows the motion of the hammer over time, as simulated by a testing apparatus that incorporates the preferred embodiment transducer.
FIG. 11 is a graph that shows the signal generated by the preferred embodiment transducer over time.
FIG. 12 is a graph of the scaled numerical integral of the testing data shown in FIG. 11, as obtained through the trapezoidal method.
DETAILED DESCRIPTION
FIG. 1 depicts the invention in generalized form. The hammer 21 is shaped like a large tube surrounding the throat 24 and, in turn, surrounded by the wall of the drill string 25 . The hammer is actuated by one or more valves (not shown—see U.S. Pat. No. 5,396,965 for details on the operation of one particular hammer design). The hammer 21 reciprocates in axial fashion and at the bottom of its stroke, strikes the top of the drill bit 23 . The drill bit 23 is designed to transmit the impact of hammer 21 to the rock below.
The transducer 22 is one of several types that measure position, velocity, or acceleration. It can be one of the optical, acoustic, variable resistance, piezoelectric, or, most preferably, magnetic flux-based type. The transducer 22 is preferably mounted to the throat 24 and generates an electric current as the hammer 21 moves. The electric current travels through the wires 26 to reach the signal processor 27 . The signal processor 27 reads the electric current from the hammer transducer 22 and interprets it to provide an output signal which describes the position, velocity, or acceleration of the piston 21 ; this signal can be analyzed by the surface crew or a down-hole computer. Other transducers similar to that of FIG. 1 may be placed on the throat 24 or the drill string 25 to provide additional information regarding the position, velocity, or acceleration of the piston 21 .
The substantially sinusoidal signal generated by the transducer 22 continues on to the power supply circuitry 28 which adjusts its waveform to a direct current form (or conditioned alternating current) of the proper voltage required by down-hole devices. The output from the power supply circuitry may be used as the power source for electric down-hole components.
FIG. 2 shows a similar system with the transducer 22 located inside the drill bit 23 . When the hammer 21 strikes the bit, the rebound characteristics of the bit will be similar to that of the hammer 21 . The current once again passes through the wire 26 to reach the signal processor 27 . A power supply may be added in this case as well, although the power output of this particular design will be much lower than that shown in FIG. 1, due to the small relative motion of the hammer bit 23 .
FIG. 3 is a sectioned view of the preferred embodiment of the transducer 22 , attached to the throat 24 as in FIG. 1 . The inner wall of the hammer 21 has been bored out to accommodate the transducer 22 . Both hammer 21 and throat 24 are constructed from ferritic or otherwise magnetic materials, such as mild or high strength steels. A lower flange 31 , also constructed from magnetic material, is securely positioned on throat 24 by retainer rings 38 and 39 . Between the bore of the lower flange 31 and the throat 24 are located a plurality of permanent magnets 33 . The lower flange is constructed so as to reside, at least in part, in close proximity to the inner wall of hammer 21 . Just uphole of the lower flange 31 , is located a continuously wound coil of insulated electrical wire 34 , which is wrapped around the throat 24 . A non-magnetic retainer ring 37 rests against the top of the coil 34 and maintains the axial position of the coil 34 . A non-magnetic sleeve 35 encloses the coil 34 and separates it from the fluid space 36 . The upper flange 32 encircles the coil 34 in close proximity. The upper flange is constructed of magnetic material, and is fixedly attached to the inner wall of the hammer 21 .
The magnets 33 are of radial polarity: each magnet has its north pole on the outer face and its south pole on the inner face. The magnets 33 are constructed of a magnetic material such as Alnico, neodymium, samarium cobalt, or a magnetic ceramic. The retainer rings 37 , 38 , and 39 are constructed of some material with low magnetic permeability, such as 300 series stainless steel.
The signal-conveying wire 26 is an extension of the wire coils 34 and is wrapped around the throat 24 in a spiral configuration so that it carries the current to the signal processor 27 (shown in FIG. 1 ).
The wire coils 34 , composed a material of low electrical resistivity, are insulated from each other and enclosed by a nonmagnetic sleeve 35 which protects them from the abrasives in the drilling fluid. The sleeve 35 can be composed of an austenitic (a nonmagnetic molecular phase) stainless steel, chrome, ceramic or some similar hard substance which is nonmagnetic, abrasion-resistant, and applicable at low temperatures. Similarly, the sleeve 35 might also consist of a soft polymer or elastomer that will resist wear by abrasive elements in the drilling fluid.
The fluid space 36 extends through the bore of hammer 21 and provides fluid communication between a cavity above the hammer 21 and a cavity below it. The magnetic flanges 31 and 32 , the sleeve 35 , and the retainer rings 37 , 38 , and 39 are dimensioned such that they allow mud to flow past them without significant pressure drop.
FIG. 4 is a cross section of the preferred embodiment of the transducer 22 , as seen from along the axis of the drill string. This figure shows the radial orientation of the throat 24 , the magnets 33 , the lower flange 31 , and the piston 21 . As shown, fingers 40 protrude outward from the body of the lower flange 31 , so as to obtain dose proximity with piston 21 , while still providing space for mud to flow past the flange (see fluid space 36 ). The flange 31 is constructed of steel, iron, or some similar material with a high magnetic permeability.
FIG. 5 is a second cross section of the preferred embodiment of the transducer 22 as seen from along the axis of the drill string. This figure shows the radial orientation of the throat 24 , coils 34 , sleeve 35 , upper flange 32 , and piston 21 . As shown, fingers 41 protrude inward from the body of the upper flange 32 , so as to obtain close proximity with coils 34 , while still providing space for conducting flow past the flange (see fluid space 36 ). The flange 32 is constructed of steel, iron, or some similar material with a high magnetic permeability.
FIG. 6 is the same cross-sectional view as that shown in FIG. 3, except the hammer 21 is shown near the bottom of its stroke. FIG. 7 is a magnified view of part of the transducer 22 in FIG. 6. A high-permeability path through the coils 34 exists, due to the close proximity of flanges 31 and 32 with the hammer 21 and coil 34 respectively. This path is shown by the bold arrows in the figure. The magnetic flux will travel through this path to complete the circuit between the north and south poles.
FIG. 8 is similar to FIG. 6, except that it shows the hammer 21 near the top of its stroke; FIG. 9 depicts the resulting flux paths. The flux will now travel through a longer path around the coils because the upper flange 32 has moved to the top of the coils, thereby increasing the length of the high-permeability flux path.
Operation of the transducer 22 proceeds as follows. As the hammer 21 oscillates, the magnetic flux path will vary from that shown in FIG. 7 to that shown in FIG. 9 . As per Faraday's law of induction, any change in magnetic flux through the coils 34 will generate a voltage, and therefore, induce an electric current in the coils 34 . This electric signal is proportional to the rate of change of the magnetic flux, which is proportional to the velocity with which the hammer 21 moves. Thus, this signal is a measure of the speed and direction of the motion of the hammer 21 . The principles involved in generating electricity by manipulating magnetic flux are described in detail in U.S. Pat. Nos. 4,454,426 and 5,342,176. Although the drawings depict a single coil and a single array of magnets, several coil/magnet couples may be used to increase the magnitude or quality of the output signal.
FIG. 10 shows the position of the hammer 21 , as measured by a position sensor mounted on a testing apparatus designed to simulate its motion. FIG. 11 is a sample of testing data that shows the voltage induced by the motion in FIG. 10 . This voltage is proportional to the velocity of the hammer, which can be obtained by taking the time derivative of the hammer position shown in FIG. 10 .
In practice, the transducer will yield a signal lie that of FIG. 11 which must be integrated and scaled to give the position of the hammer. The signal processor 27 can perform this function in a number of different ways including numerical integration and curve-fitting in conjunction with mathematical integration.
There are several well-known algorithms the signal processor 27 can use to numerically integrate the voltage signal of FIG. 11 . Two of these are the trapezoidal method and Simpson's rule. The integral of a function is simply the area between the function and the axis that represents zero. The trapezoidal method and Simpson's rule both separate the function into a series of narrow strips; the end of the strip can be approximated as a straight line, as in the trapezoidal method, or a polynomial curve, as in Simpson's Rule. The areas of the strips can be easily computed and added to form a fairly accurate estimate of the area between the function and the zero axis. The signal processor 27 would form a new strip after it takes each voltage measurement; by adding the area of this strip to the sum of the areas previously calculated, the signal processor 27 would keep a running integral of the voltage. FIG. 12 is the scaled numerical integral of the testing data shown in FIG. 11, as obtained through the trapezoidal method. With some small deviations, its shape is very similar to that of the output of the position sensor, which is shown in FIG. 10 .
There are also several well-known methods that could be used to approximate the voltage output of the transducer as a function that can be mathematically integrated. The voltage output can be fit to sinusoidal, polynomial, or exponential waveforms; combinations of mathematical functions can also be used. As a further alternative to the digital numerical methods described above, an analog integrator and amplifier may be constructed to give position information.
Power supplies are readily available to convert one electric signal to another as required by the load, or the device that requires power. Since most down-hole devices require DC power, the power supply of FIG. 1 would convert the signal from the AC output of the transducer to a DC waveform. The power supply could also incorporate a battery, capacitor, or both to store up voltage for times when the power required exceeds the transducer output.
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A method of creating an electric signal that describes the motion of a down-hole, fluid-driven percussive tool is disclosed. The signal is obtained by attaching an electromagnetic transducer to the percussive tool, the member impacted by it, or the drill string. The rebound characteristics of the tool yield a measurement of the physical characteristics of the subterranean formation being penetrated. The tool's position over time is useful for diagnosing and regulating the operation of the tool. The transducer can also be configured to generate a signal large enough to be used as a power source.
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This application claims the benefit of Provisional Application No. 60/351,577, filed Jan. 25, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to wall covering borders and layer sheets of wall covering that are attached to a wall without wallpaper paste or other type of adhesive, and more particularly to wall covering borders and wall covering in general that are attached to a wall by placing them into a channel or clip.
2. Description of Prior Art
Wall coverings are used to provide a decoration for walls. These coverings offer an alternative from painting by providing more decorative and design options. Wall coverings can also be used as borders or trim on walls, providing a touch of color or design on an otherwise plain wall surface. However, wall coverings, either full or borders, must be pasted or adhered to walls making them a permanent decoration. The result is that, when a wall covering is removed, the wall itself is often damaged, requiring it to be patched and repainted or recovered. Changing wallpaper, either as a trim or for a larger portion of a wall, is difficult since the old paper must be removed which is a time consuming and tedious process, and is generally frowned upon by the owners of residences, rental units, stores, offices or cottages where such changes are more likely to occur (or at least be more desirable) due to the change in tenants. Thus, owners of rental homes, apartments, offices and stores usually will not permit the renters or temporary dwellers to apply new wall coverings or change existing ones. There is a desire of building owners in particular, and of others who are responsible for changes in wall design, to have a pasteless wall paper system for changing wall paper without having to scrape off or otherwise remove old wallpaper before installing new wall paper. In addition, there is a desire for those decorating walls to have a fast and inexpensive way to change wall paper. Further, it is difficult to apply traditional wall coverings or wall borders to textured or non-smooth walls.
SUMMARY OF THE INVENTION
The present invention provides a solution to the problems of the prior art with a pasteless wall covering system in which wall covering becomes easily installable, removable, changeable and reusable without damaging walls. This invention will allow apartment and other rental property owners, such as store and office owners, to encourage tenants to change wall decorations to suit individual tenant's tastes, and will also enable tenants to easily install and change wall decorations on non-smooth or textured wall surfaces. The invention has particular advantages for wall covering borders but it can be used for larger sections of wall coverings as well. Further, it could be used with non-paper wall coverings such as fabric, carpeting, etc.
In accordance with a preferred embodiment of the present invention, a conventional wall covering border is attached to a semi-rigid paper type stock, or a decoration is printed onto a semi-rigid paper type stock, creating a semi-rigid wall covering border. Likewise, the semi-rigid paper stock can itself carry the decoration and form the border. A holder for the semi-rigid wall covering border is created by scoring and folding a channel that is stapled or otherwise attached to the wall surface at the desired wall covering border location.
An object of this invention is to provide an article that serves as a wall covering border or wall covering and is easy to install and change.
A further object of this invention is to provide an article that serves as a wall covering border or wall covering and is interchangeable.
A further object of this invention is to provide an article that serves as a wall covering border or wall covering and does not damage the wall surfaces when removed.
Yet another object of this invention is to provide an article that serves as a wall covering border or wall covering and can go over smooth or textured surfaces.
Yet another object of this invention is to provide an article that serves as a wall covering border or wall covering and is reusable.
Yet another object of this invention is to provide an article that serves as a wall covering border or wall covering and is inexpensive.
Yet another object of this invention is to provide an article that serves as a wall covering border or wall covering and has no pattern matching required.
Yet another object of this invention is to provide an article that serves as a wall covering border or wall covering and is supplied in a continuous roll.
Still another object is to provide a wall paper system for providing a pasteless or adhesiveless wall paper that can be easily and quickly changed.
These and other objects will become apparent from the following description of a preferred embodiment taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
FIG. 1 is an end perspective view of a wall covering border in a holder;
FIG. 2 is an end view of the wall covering border in the holder of FIG. 1 ;
FIG. 2 a is a top view of the holder prior to folding the channels;
FIG. 3 is a side view of a two layer or two member wall covering border;
FIG. 3 a is a side view of a one piece wall covering border;
FIG. 4 is a side view of the two piece wall covering border in a holder;
FIG. 5 is a perspective view of the wall covering border in a holder,
FIG. 6 is a perspective view of the wall covering border in a holder,
FIG. 7 is a front perspective view of an interior or exterior corner;
FIG. 8 is a top view of the wall covering border corner piece; and
FIG. 9 is a front perspective view of a wall covering border in a holder on a wall.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein the showings are for the purpose of illustrating the preferred embodiment of the invention only, and not for the purpose of limiting same, FIG. 1 and FIG. 2 show a wall covering border 2 in a holder 4 . The holder 4 can be can preferably be made of PVC or other materials, can be flexible or made of flexible materials, and can preferably have a matte finish that does not reflect light. The length of the holder can be as short as about three feet. A preferred length can be between six and thirty feet. The holder 4 has a top longitudinal side 6 , a bottom longitudinal side 8 , and a support 9 including a front surface 10 and a back surface 12 . The longitudinal sides 6 , 8 of the holder 4 are folded over twice to form channels, top channel 16 and bottom channel 18 , each having a base 20 a , 20 b , and a channel or fold lip 22 a , 22 b with a fold or channel edge 24 a , 24 b , extending along the length of the holder 4 . The channels 16 , 18 hold the wall covering border 2 when it is installed on the wall. As shown in FIG. 2 a , the holder can be scored with score lines 26 in the front surface 10 so that it can be stored and distributed without channels and folded to create the channels 16 , 18 at the installation site.
Numerous attachments means can be used to attach the back surface 12 of the holder 4 to a wall. Such means include hook and latch systems such as Velcro®, adhesives, double faced tape, staples, or glue. In a preferred embodiment, the top channel lip 22 a is larger than the bottom channel lip 22 b. In a preferred embodiment, the channel lips 22 a, 22 b, are biased in an inward direction, that is, the channel lips have “memory”, so that they press against the wall paper border, holding the border firmly in place.
FIG. 3 shows the wall covering border 2 which is comprised of a top member 28 and a bottom member 30 . The top member 28 can preferably be made of wall covering material, which can be from 2″ to 30″ wide, and, in one preferred embodiment, from 6¼″ to 6¾″ wide. The bottom member 30 can be made of a semi-rigid paper stock. The paper stock, or alternative material, should be flexible enough so that wall covering border 2 can be changed from a flat position to a roll for storing and transporting. The bias of the roll could help keep it in place in the holder. For the bottom member 30 , a material having one side covered with pressure sensitive adhesive can be used to so that the bottom member 30 can be inexpensively and simply attached to the top member 28 . In the alternative, as shown in FIG. 3 a, the decoration can be placed directly on a semi-rigid paper stock 32 .
FIG. 4 shows a second embodiment, wherein the holder 40 is separated into two pieces, each “J” shaped and having a back 42 , an upper wall 44 and a front or top 46 . A channel 48 is formed between the top 46 and the back 42 of the holder 40 , there being two channels 48 for each assembly. FIG. 5 shows another embodiment, wherein the holder 50 can preferably be made of molded foam, channeled wood or other moldable, semi-rigid material. In the alternative, the holder 50 can be made of rigid or semi-rigid PVC with clear edges, similar to the material found in vertical blinds. The front 52 of the holder 50 can be rounded or angled. A pair of opposing channels 54 are formed between the front 52 and the back 56 of the holder 50 .
Another embodiment of the invention is shown in FIG. 6 in which the holder 60 , attached to a wall 62 , is the hook-type material of a hook and latch connecting system, such as Velcro, and the latch material 64 is attached to the back of the wall covering border 2 . In the alternative, the holder 60 could be made of double faced adhesive tape.
FIG. 7 shows a corner piece 70 , which can be used at the junction of walls, typical inside corners as well as outside corners. These corner pieces can be made of rigid PVC vinyl, wood, foam, plastic or other materials. The holder 4 and wall covering border 2 can be applied to each wall forming the juncture and the corner piece 70 can be inserted into the corner, abutting holder. In the embodiment shown in FIG. 7 , the corner piece can contain slots 72 into which the wall covering border 2 can be inserted. In the alternative, the wall covering border may abut the corner piece. In a preferred embodiment, the wall covering border 2 and holder 4 may be bent to wrap the corner; no special corner piece would be necessary.
FIG. 8 shows a corner piece 80 which can be used in a non-square corner, that is, a corner that is not 90°. This corner piece 80 has a center score-line 82 along which it can be bent or folded, creating the desired corner angle. In addition, a channel 84 is formed between the top 86 , the side 88 and the back 90 of the corner piece 80 , there being two channels 84 for each corner piece 80 . The top 86 and the side 88 of the channel 84 do not extend the entire length of the wall covering border holder; instead, each terminates before reaching the score-line 82 , enabling the corner piece to bend and form the corner angle. There are vertical score-lines 92 along which the corner piece can be folded to create the top and the side of the channel.
Installation of the current invention is easy. In the embodiment shown in FIGS. 1 and 2 , channels 16 , 18 are created by folding the holder 4 along the scored lines 26 . In all of the embodiments, the holder 4 , 40 , 50 , 60 is attached to the wall using fasteners such as clips, staples, or adhesives such as pressure sensitive adhesives and double faced tape. Key shaped holes can be made in the backs of the holder having an enlarged bottom portion and a narrow top portion. A screw or other fastener can be inserted in a wall with its top end extending outwardly from the wall, and the back of the holder can be placed so that the head of the fastener extends through the enlarged bottom portion hole. The holder can then be released so that the fastener supports the holder through the upper edge of the narrow portion of the hole. Once the holder is secured on the wall, the wall covering border 2 is unrolled and inserted into the holder 4 , preferably by sliding it into the channel 16 , 18 , 48 , 54 along the wall. Corner pieces, which can be made of rigid PVC vinyl, wood, foam or plastic, can be used at the junction of walls. These corner pieces can contain slots into which the wall covering border can be inserted. Corner pieces can be used in typical inside corners as well as outside corners; in both cases, the channel 16 , 18 , 48 , 54 and wall covering border 2 can be applied to each wall forming the juncture. The wall covering border 2 may wrap the corner, if it is pliable enough.
Changing the wall paper is very easy. The user simply grasps the end portion of the wall paper and withdraws it from the holder, and inserts a replacement wall paper by forcing it between the front and back of the holder.
The invention has been described with particular emphasis on the preferred embodiments. It should be appreciated that these embodiments are described for purposes of illustration only, and that numerous alterations and modifications may be practiced by those skilled the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention or the equivalents thereof.
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The present invention provides a pasteless wall covering system in which wall covering becomes easily installable, removable, changeable and reusable without damaging walls. A wall covering border is attached to, or made from, a semi-rigid paper stock and is held on the wall by a holder with channels. The holder can be created by scoring and folding a top and bottom channel. The holder can be attached to the wall by stapling, adhesives or other attachment means.
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RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S. Provisional Application No. 60/594,660 filed Apr. 27, 2005, the entire contents of which are incorporated herein and made a part hereof.
FIELD OF THE INVENTION
[0002] This application relates to piling repairs and, more specifically, to a unitary pile jacking sleeve adapted for installing and compressively loading new piling without overhead access and without disrupting a deck structure/super-structure.
BACKGROUND
[0003] Pilings of concrete, timber, steel or composite materials are an integral structural part of marine structures, such as bridges, docks, piers and wharves. Pilings, which are driven or jetted into the ground to some determined depth, support a structure above the water's surface. For convenience of reference, the term “ground” is used herein to broadly denote any terrain suitable for supporting a piling, whether it is above water or below water, whether it is natural or man-made, and whether it is comprised sand, rocks, soil, other materials and combinations thereof.
[0004] Unfortunately, the exposure of piling makes them susceptible to degradation. Wood pilings are particularly prone to deterioration from biological infestation as well as structural damage due to overloading, impact, and abrasion. Steel pilings are prone to damage by corrosion and structural overloading and impact. Concrete pilings deteriorate chemically with time and experience structural degradation due to overloading, impact, abrasion and freeze-thaw cycling. A damaged piling typically includes a deteriorated section above or below the soil line that compromises the ability of the piling to support its intended design load.
[0005] While various encasement, wrapping and replacement techniques have emerged to repair such inevitable damage, these techniques have shortcomings. Encasement and wrapping are suitable if the damage has not seriously compromised the structural integrity of the piling. To repair more serious damage, a section of a piling may have to be replaced or the piling may have to be replaced in its entirety. However, conventional replacement techniques (e.g., techniques requiring a crane and pile driving leads) typically require dismantling a portion of the deck structure/super-structure and replacing and loading a damaged section of piling or installing and loading a new piling. Other techniques require complex arrangements of separate couplings to splice in a new pile section. No known techniques provide means for compressively loading a replacement section of pile or installing a new two-piece pile to design specifications.
[0006] As a consequence of the foregoing, there exists a longstanding need for a new and improved system and method for efficiently replacing and loading a damaged section of piling and/or installing and loading new piling. The system and method should enable replacement without dismantling the supported deck structure/super-structure. Additionally, the system should be relatively easy to use and have relatively few separate components (i.e., preferably a unitary component) to facilitate above water, splash zone and underwater application. Furthermore, the system should enable compressively loading a replacement pile to proper design specifications. Moreover, the system should work with various types of pilings of various cross-sectional shapes.
[0007] The invention is directed to overcoming one or more of the problems and fulfilling one or more of the needs as set forth above.
SUMMARY OF THE INVENTION
[0008] To overcome one or more of the problems and fulfill one or more of the needs as set forth above, in one aspect of an exemplary embodiment of the invention, a unitary pile jacking sleeve is provided. The sleeve has a bottom sleeve section, an intermediate sleeve section and a top sleeve section. The bottom sleeve section, intermediate sleeve section and top sleeve section are adapted to structurally support a design load. The bottom sleeve section has an open bottom end and a top end attached to the intermediate section, and the bottom section is adapted to receive through the open bottom end of the bottom section the top end of a bottom pile that has a bottom end secured in the ground. The top sleeve section has an open top end and a bottom end attached to the intermediate section. The top section is adapted to receive the bottom end of a top pile that extends from the open top end to a supported structure. The design load is greater than the weight of the top pile. The intermediate sleeve section being disposed between and adjoining the top sleeve section and the bottom sleeve section.
[0009] In another aspect of an exemplary implementation of the invention, the top sleeve section includes means for enabling lateral (i.e., horizontal) access to the top sleeve section by the top pile. As one example, such means may include a hinged door adapted for enabling lateral (i.e., horizontal) access to the top sleeve section by the top pile.
[0010] In another aspect of an exemplary implementation of the invention, a stationary plate partitions the bottom sleeve section from the intermediate sleeve section, and a floating plate separates the intermediate section from the top section,
[0011] In another aspect of an exemplary implementation of the invention, an aperture provided in the intermediate sleeve section is adapted for allowing insertion and removal of at least one jack into the intermediate sleeve section.
[0012] In another aspect of an exemplary implementation of the invention, a plurality of fastener apertures are provided in the pile jacking sleeve. The fastener apertures are adapted to allow mechanical fasteners to pass therethrough.
[0013] In another aspect of an exemplary implementation of the invention, a plurality of filler apertures are provided in the pile jacking sleeve. The filler apertures are adapted to allow filler material to pass therethrough.
[0014] In another aspect of another exemplary implementation of the invention, a bottom sleeve section, an intermediate sleeve section and a top sleeve section are provided. The bottom sleeve section, intermediate sleeve section and top sleeve section are adapted to structurally support a design load. The bottom sleeve section has an open bottom end and a top end attached to the intermediate section. The bottom section is adapted to receive through the open bottom end of the bottom section the top end of a bottom pile that has a bottom end secured in the ground. The top sleeve section has an open top end and a bottom end attached to the intermediate section. The top section is adapted to receive the bottom end of a top pile that extends from the open top end to a supported structure. The design load is greater than the weight of the top pile. The top sleeve section further includes means for enabling lateral (i.e., horizontal) access to the top sleeve section by the top pile.
[0015] In another aspect of another exemplary implementation of the invention, the means for enabling lateral (i.e., horizontal) access to the top sleeve section by the top pile is comprised of a hinged door adapted for enabling lateral (i.e., horizontal) access to the top sleeve section by the top pile.
[0016] In another aspect of another exemplary implementation of the invention, a stationary plate partitions the bottom sleeve section from the intermediate sleeve section, and a floating plate separates the intermediate section from the top section.
[0017] In another aspect of another exemplary implementation of the invention, an aperture in the intermediate sleeve section allows insertion and removal of at least one jack into the intermediate sleeve section.
[0018] In another aspect of another exemplary implementation of the invention, a plurality of fastener apertures are provided in the pile jacking sleeve. The fastener apertures are adapted to allow mechanical fasteners to pass therethrough.
[0019] In another aspect of another exemplary implementation of the invention, a plurality of filler apertures are provided in the pile jacking sleeve. The filler apertures are adapted to allow filler material to pass therethrough.
[0020] In another aspect of another exemplary implementation of the invention, at least one jack is disposed between the stationary plate and the floating plate, and configured to enable urging the floating plate away from the stationary plate.
[0021] In another aspect of another exemplary implementation of the invention, a jacket surrounds the intermediate sleeve section, top sleeve section, and bottom sleeve section.
[0022] In another aspect of another exemplary implementation of the invention, a solidifying filler is provided between the jacket and the intermediate sleeve section, top sleeve section, and bottom sleeve section.
[0023] In another aspect of yet another exemplary implementation of the invention, a method of repairing a pile using a pile jacking sleeve according to principles of the invention is provided. The method includes sliding the bottom sleeve section down along the bottom pile until the stationary plate rests securely on top of the bottom pile; opening the means for enabling lateral access to the top sleeve section by the top pile; maneuvering the bottom end of the top pile laterally into place through the opened means for enabling lateral access until the bottom end of the top pile rests upon the floating plate; exerting a compressive force against the floating plate to urge the floating plate away from the stationary plate until a determined compressive force is exerted onto the entire pile; and securing the top pile to the top section of the pile jacking sleeve after the determined compressive force is reached. The method may further include encasing the pile jacking sleeve in an encasement and solidifying filler.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The foregoing and other aspects, objects, features and advantages of the invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
[0025] FIG. 1 is a perspective view of an exemplary cylindrical pile jacking sleeve according to principles of the invention;
[0026] FIG. 2 is a profile view of an exemplary installed cylindrical pile jacking sleeve according to principles of the invention;
[0027] FIG. 3 is a top sectional view of an exemplary encased cylindrical pile jacking sleeve according to principles of the invention;
[0028] FIG. 4 is a perspective view of an exemplary pile jacking sleeve with a square/rectangular cross section according to principles of the invention;
[0029] FIG. 5 is a profile view of an exemplary installed pile jacking sleeve with a square/rectangular cross section according to principles of the invention; and
[0030] FIG. 6 is a top sectional view of an exemplary encased cylindrical pile jacking sleeve according to principles of the invention.
[0031] Those skilled in the art will appreciate that the figures are not intended to be drawn to any particular scale. The invention is not limited to the exemplary embodiments depicted in the figures or the shapes, relative sizes, proportions or materials shown in the figures.
DETAILED DESCRIPTION
[0032] One exemplary methodology according to principles of the invention entails removing a damaged upper elevation of a piling by cutting. The damaged section up to the pile cap may be removed. As piling are typically designed to hold several times the weight of a supported pier and structures thereon, damaged sections may typically be removed one at a time, without endangering the stability of the pier or supported structures. Nevertheless, temporary supports (e.g., a crane/false work) may be utilized throughout the repair, out of an abundance of caution, to ensure structural integrity.
[0033] Next an exemplary pile jacking sleeve according to principles of the invention is installed. Referring to FIG. 1 , a perspective view of an exemplary cylindrical pile jacking sleeve 100 is shown. The sleeve 100 includes a bottom section 105 , an intermediate section 110 and a top section 115 .
[0034] As a structural member, the sleeve 100 is designed to be at least as strong as the piling. The sleeve can support the weight of the top section of the piling plus the load that the piling was intended to carry. By way of illustration, without limitation, cylindrical sleeves comprised of steel and having a consistent wall thickness of ¼ to 1 inch (or more) is considered adequate for most applications. Of course, the composition and wall thickness may vary while still providing the requisite structural support and without departing from the scope of the invention.
[0035] The sleeve 100 is sized to engage the piling sections. The cylindrical sleeve 100 has an inner diameter that is about slightly larger than the outer diameter of the piling sections.
[0036] The sleeve includes a plurality of apertures. A plurality of bolt holes 125 are provided to receive bolts or other mechanical fasteners for securing the sleeve to the remaining sections of the piling or new piling. A plurality of optional grout windows 130 are also provided to allow grout to fill the gap between the sections of the piling, between the piling and the sleeve and between the sleeve and an optional jacket. While the windows are displayed as rectangular openings, apertures having other shapes, sizes and proportions may be used. Additionally, at least one window 150 (or a hinged or bolted door) in the intermediate section 110 sized to allow one or more hydraulic jacks to be inserted and removed from the intermediate section 110 of the sleeve is also provided.
[0037] A hinged 145 door 120 with a closure 310 (as shown in FIG. 3 ) is provided in the top section 115 , as a means for enabling lateral (i.e., horizontal) access by a new pile section. When the door 120 is open, the cut end of the new section of piling may be received laterally into the top section 115 of the sleeve. Thus, the bottom section 105 of the sleeve 100 may receive an existing or new bottom section of piling, while the top section 115 of the sleeve 100 may laterally receive a new top section of piling through the open door. Those skilled in the art will appreciate that the hinged door enables the sleeve to couple sections of piling, without dismantling or damaging the supported deck structure/super-structure. Those skilled in the art will further appreciate that one or more hinged doors (e.g., a pair of hinged doors) may be utilized without departing from the scope of the invention. Additionally, the hinged door 120 may pivot along a vertical hinged axis 145 in a conventional door-like manner or along a horizontal hinged axis in a drawbridge-like manner (not shown). Furthermore, other means for enabling lateral (i.e., horizontal) access such as removable panels may be utilized without departing from the scope of the invention.
[0038] A pair of plates 135 and 140 are also provided as pile support structures. A stationary plate 1 35 provides a stable base upon which the sleeve rests on a lower pile section and a jack may be placed. It also provides a surface for evenly distributing forces. The stationary plate, which may be welded or otherwise joined to the sleeve 100 , partitions the bottom 105 from intermediate (i.e., jacking) 110 sections. When extended, the jack is supported by the stationary plate 135 and exerts compressive force against a floating plate 140 , which provides a uniform, hard stable surface to exert and distribute upward forces against the bottom end of the top section of piling. Placing a jack surface directly against the bottom end of the top section of piling would risk damaging the piling. The floating plate 140 may move longitudinally in the sleeve and distributes concentrated jacking forces over the engaged section of the new upper pile. One or more stoppers (e.g., protrusions) may be provided to define a range of motion for the floating plate 140 .
[0039] Referring now to FIG. 2 , a side sectional view of an exemplary installed cylindrical pile jacking sleeve 100 according to principles of the invention is shown. An existing or new pile stub (i.e., bottom section of piling) 200 is received in the bottom section 105 of the sleeve. A plurality of lag bolts or thru bolts 210 secure the bottom section of the piling 200 to the sleeve 100 . The stationary plate 135 rests atop the bottom section of the piling 200 .
[0040] One or more jacks 215 are provided in the intermediate section 110 of the sleeve 100 . Actuation of the jacks 215 forces the floating plate 140 upwardly, away from the stationary plate 135 . The jacks 215 should be positioned and utilize a head that is conducive to even stress distribution and minimizes eccentricity between the jacks 215 and floating plate 140 . One or more force or pressure measuring devices, such as calibrated hydraulic pressure gauges, may be operatively coupled to the jacks 215 to monitor the load. The jacks may be inserted (and optionally removed) through a window 150 (or a hinged door) in the intermediate section 110 . As the sleeve 100 is structurally adequate to support the required load, including the new pile 205 , the jacks 215 may be removed after the new pile 205 is secured to the sleeve. Alternatively, the jacks 215 , which are typically considered expendable, may be left in place.
[0041] A new pile (i.e., top section of piling) 205 is received in the top section 115 of the sleeve 100 . A plurality of lag bolts or thru bolts secure the top section of piling 205 to the sleeve 100 , after the piling 205 has been loaded to a determined design load (i.e., a compressive load) by jacking. The top section of piling 205 rests atop the floating plate 140 .
[0042] During installation, the pile jacking sleeve is first fitted onto the upper end of a bottom pile stub 200 and slid down along the bottom pile until the stationary plate 135 rests securely on top of the bottom pile stub 200 . Next, the one or more jacks 215 are placed between the floating plate 140 and the stationary plate 135 . Alternatively, the jacks 215 are placed between the floating plate 140 and the stationary plate 135 before the pile jacking sleeve is fitted onto the upper end of a bottom pile stub 200 . Next, the hinged pile access door 120 is opened to receive the bottom end of the top (i.e., new) pile 205 . The top pile 205 can then be maneuvered laterally into place through the opened hinged pile access door 120 . When in place, the top pile 205 will extend approximately from the bottom of the supported deck structure/super-structure down to the floating plate 140 . Laterally maneuvering the top pile 205 into place allows the new piling fit into any tight location, beneath a supported deck structure/super-structure, without having to dismantle or damage the supported deck structure/super-structure.
[0043] After the top and bottom piling 200 , 205 , jacks 215 and jack sleeve 100 are in place, the jacks 215 are actuated. Actuation may entail directly or indirectly applying hydraulic pressure or mechanical force to cause the jacks 215 to exert compressive force against the floating plate 140 and the top pile 205 supported thereon. Pile jacking force at any instant may be read from a load indicator operably coupled to the jacks 215 , floating plate 140 and/or top pile 205 . The jacks 215 are actuated until the exerted compressive force levels the supported deck structure/super-structure and/or the compressive force exerted reaches a design load for the supported deck structure/super-structure.
[0044] Once the desired compressive force is achieved, the top pile 205 may be locked into place. For example, a plurality of lag bolts or thru bolts may be used to secure the top section of piling 205 to the sleeve 100 , after the piling 205 has been loaded to the determined design load (i.e., a compressive load) by jacking. As discussed above, the sleeve 100 is structurally adequate to support the required load, including the new pile 205 . Therefore, the jacks 215 may either be removed after the new pile 205 is secured to the sleeve 100 or left in place as expendable support structures.
[0045] Referring now to FIG. 3 , after the piling sections 200 and 205 are secured to the sleeve 100 , the sleeve may optionally be encased in a conventional encasing manner for piling repairs. The encasement may be structural or non-structural. By way of example and not limitation, a rebar lattice comprised of vertical reinforcing bars 315 coupled by horizontal reinforcements 300 (collectively rebar) may be wrapped concentrically around the sleeve 100 . Then a jacket 320 may be wrapped concentrically around the rebar 300 and 315 . The ends of the jacket 320 may be secured together using a form flange 305 or other attachment (e.g., mechanical attachment, weld, or thermal or chemical bond). Spaces between the jacket 320 , rebar 300 and 315 and piling 200 and 205 (e.g., annular space 325 ) may then be filled with an appropriate filler such as concrete, epoxy, cement and/or grout.
[0046] The filler may be introduced in a conventional manner for underwater construction. By way of example and not limitation, pressurized fluid filler may be pumped into the spaces between the jacket 320 , rebar 300 and 315 , jacketed portions of piling 200 , 205 , and other jacketed components using a suitable pump and conduit (e.g., a hose). Upon solidification, the jacket components are securely embedded in the resultantly formed strong, durable, protective filler material.
[0047] Referring now to FIG. 4 , a perspective view of an exemplary rectangular (e.g., square) pile jacking sleeve 400 is shown. The sleeve 400 includes a bottom section 440 , an intermediate section 445 and a top section 450 .
[0048] As a structural member, the sleeve 400 is designed to be at least as strong as the piling. In the exemplary embodiment illustrated in FIG. 4 , the sleeve can support the weight of the top section of the piling plus the load that the piling was intended to carry. By way of illustration, without limitation, rectangular sleeves comprised of steel and having a consistent wall thickness of ¼ to 1 inch (or more) is considered adequate for most applications. Of course, the composition, shape and wall thickness may vary while still providing the requisite structural support and without departing from the scope of the invention.
[0049] The sleeve 400 is sized to engage rectangular or square piling sections. The sleeve 400 is sized slightly larger than the outer dimensions of the piling sections.
[0050] The sleeve includes a plurality of apertures. A plurality of bolt holes 430 are provided to receive bolts or other mechanical fasteners for securing the sleeve to the remaining sections of the piling or new installed piling. A plurality of grout windows 410 is also provided to allow grout (or other filler material) to fill the gap between the sections of the piling, between the piling and the sleeve and between the sleeve and an optional jacket. While the windows are displayed as rectangular openings, apertures having other shapes, sizes and proportions may be used. Additionally, at least one window 455 (or a hinged door) in the intermediate section 445 sized to allow one or more hydraulic jacks to be inserted and removed from the intermediate section 445 of the sleeve is also provided.
[0051] A hinged 435 door 425 is provided in the top section 450 to facilitate new pile installation. When the door 425 is open, the cut end of the new upper piling may be received laterally into the top section 400 of the sleeve. Thus, the bottom section 440 of the sleeve 400 may receive the cut end of the bottom section of the piling or new piling, while the top section 450 of the sleeve 400 may laterally receive the new upper piling through the open door. Those skilled in the art will appreciate that the hinged door enables the sleeve to couple pre-existing and/or new top and bottom pilings or sections of piling, without dismantling or damaging the supported deck structure/super-structure.
[0052] A pair of plates 415 and 420 are also provided. A stationary plate 415 provides a stable base upon which the sleeve rests on a lower pile section and a jack may be placed. It also provides a surface for evenly distributing forces. The stationary plate, which may be welded or otherwise joined to the sleeve 400 , partitions the bottom 440 from intermediate (i.e., jacking) 445 sections. When extended, the jack is supported by the stationary plate 415 and exerts compressive force against a floating plate 420 , which provides a uniform, hard stable surface to exert and distribute upward compressive force against the bottom end of the top section of piling. Placing a jack surface directly against the bottom end of the top section of piling would risk damaging the piling. The floating plate 420 may move longitudinally in the sleeve and distributes concentrated jacking forces over the cross-section of the new upper pile. One or more stoppers (e.g., protrusions) may be provided to define a range of motion for the floating plate 420 .
[0053] Referring now to FIG. 5 , a side sectional view of an exemplary installed square/rectangular pile jacking sleeve 400 according to principles of the invention is shown. A portion 510 of an existing or new pile stub (i.e., bottom section of piling) 500 is received in the bottom section 440 of the sleeve. A plurality of lag bolts or thru bolts (e.g., bolts 600 as shown in FIG. 6 ) secure the bottom section of the piling 500 to the bottom section 440 of the sleeve. The stationary plate 415 rests atop the bottom section of the piling 510 .
[0054] One or more jacks 515 are provided in the intermediate section 445 of the sleeve 400 . Actuation of the jacks 515 forces the floating plate 420 upwardly. One or more force or pressure measuring devices, such as calibrated hydraulic pressure gauges, may be operatively coupled to the jacks 515 to monitor the load. The jacks may be inserted (and optionally removed) through a window (or a hinged door) in the intermediate section 445 . As the sleeve 400 is structurally adequate to support the required load, including the new pile 520 , the jacks 515 may be removed after the new pile 520 is secured to the sleeve. Alternatively, the jacks 515 , which are typically considered expendable, may be left in place.
[0055] A new pile (i.e., top section of piling) 520 is received in the top section 450 of the sleeve 400 . A plurality of lag bolts or thru bolts (e.g., bolts 600 as shown in FIG. 6 ) secure the top section of piling 520 to the top section 450 of the sleeve 400 , after the piling 520 has been loaded to a determined design load by jacking. The top section of piling 520 rests atop the floating plate 420 .
[0056] Referring now to FIG. 6 , after the piling sections 510 and 520 are secured to the sleeve 400 , the sleeve may be encased in a conventional encasing manner for piling repairs. Encasements may be structural or non-structural. By way of example and not limitation, a rebar lattice comprised of vertical reinforcing bars 605 coupled by horizontal reinforcements 620 (collectively rebar) may be wrapped concentrically around the sleeve 400 . Then a jacket 615 may be wrapped concentrically around the rebar 620 and 605 . The ends of the jacket 615 may be secured together using a form flange 610 or other attachment (e.g., mechanical attachment, weld, or thermal or chemical bond). Spaces between the jacket 615 , rebar 620 and 605 and piling 500 and 520 may then be filled with an appropriate filler such as concrete, epoxy, cement and/or grout.
[0057] A pile jacking sleeve according to principles of the invention is not limited to any specific materials. Any materials suitable for marine construction, including, but not limited to, steel, galvanized steel, stainless steel, aluminum, other metals, alloys thereof, and composites may be utilized within the scope of the invention.
[0058] While the invention has been described in terms of various embodiments, implementations and examples, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims including equivalents thereof. The foregoing is considered as illustrative only of the principles of the invention. Variations and modifications may be affected within the scope and spirit of the invention.
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A pile jacking sleeve includes a structural sleeve having a bottom section, an intermediate section and a top section. A stationary plate partitions the bottom section from the top section. A floating plate separates the intermediate section from the top section. A hinged door at the top section allows lateral entry of a piling into the top section when the door is open. An aperture allows insertion and removal of at least one jack into the intermediate section. Actuation of the jack urges the floating plate away from the stationary plate, controllably imparting a load to installed piling. A plurality of bolt holes are also provided in the sleeve to secure piling thereto. The sleeve may be jacketed for additional protection. A plurality of grout windows are also provided in the sleeve to enable filling the structure with a solidifying filler.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a differential pressure-activated valve in a sub to be placed in a tubular of a well before the tubular is placed in the well. More particularly, a barrier valve in a sub is provided to seal pressure in both directions, to open in response to a pressure applied uphole, to provide a full opening diameter of the tubular and to be locked in the open position.
[0003] 2. Description of Related Art
[0004] Valves are used in diverse applications in the tubulars of wells. (“Tubulars” includes casing, liners and tubing.) For example, safety valves are placed in tubing that are designed to close if flow upward through the tubing is otherwise uncontrolled. Sliding sleeves to form valves are placed in casing to be opened or shut by devices placed inside the casing, and valves are placed in casing or tubing of complex (or “smart”) wells to control flow rate from different laterals of the well. Examples of valves for wells are in U.S. Pat No. 8,622,336 and in U.S. Pat No. 8,757,268. Further examples of valves to be inserted in tubulars are provided in U.S. Pub. No. 2009/0272539, disclosing a valve in a tubular that may be mechanically closed, and U.S. Pub. No. 2009/0229829, disclosing a valve having a valve element on trunnions that move along a track.
[0005] One type of valve used in casing is a “float valve,” which is used at the shoe (bottom) or distal end of every casing that is cemented in a wellbore to prevent flowback (or U-tubing) of more dense cement slurry when pressure is released at the surface after displacing the cement slurry with water. A float valve is normally a simple ball check valve. The float valve may also be used in the process of “floating” casing into a well. “Floating” casing is used to allow casing to be placed in horizontal wells with less weight of the casing and less frictional resistance as the casing is placed in a horizontal segment of a well. Floating casing is accomplished by placing nitrogen or air inside the casing to decrease the weight of the casing. This facilitates inserting the casing over longer horizontal sections. One operator's experience with “floating” a tubular into a well is described in the paper “Statoil uses flotation of 10¾-in, liner to reach beyond 10 km in Gullfaks Field,” Drilling Contractor , May/June 2007, pp. 66-74.
[0006] There are risks associated with the process of floating casing or a liner into a well. Leaks in the tubular may occur that allow liquid to enter the tubular and result in the casing or liner becoming stuck in the well before it is properly placed. For this and other operations in drilling and running tubulars into wells, a valve that can be placed at selected locations along a tubular string and opened to the full diameter of the tubular by a pressure increase at the surface of the tubular is needed. A series of valves, each of which may be called a “cascade barrier valve,” may be preferred. This valve, when open, should allow movement of downhole tools through the tubular without restriction. When closed, cascade barrier valves at selected locations along the casing may be used to prevent fluid leaking in and filling a long interval of the casing while it is being floated into a horizontal well.
[0007] In drilling or working on vertical, directional or horizontal wells, a plurality of pressure barriers is needed to decrease the risk of uncontrolled flow from a well. Valves in tubulars in wells that form a pressure barrier until opened by a surface operation and then are locked open to provide full inside diameter also offer wide opportunities for increasing well safety.
[0008] What is needed is a valve in a sub that will seal pressure in both directions, open in response to a selected pressure applied uphole, provide a full opening diameter of the tubular when open and be locked in the open position.
BRIEF SUMMARY OF THE INVENTION
[0009] A full-opening valve in a sub for placement in a string of casing, liner or tubing that is opened by a selected pressure applied from the surface is provided. A shear ring or pin is selected to shear at a selected differential pressure in response to a pressure increase at the surface and allows a lower flow tube having the inside diameter of the tubular to move axially. This allows an upper flow tube having the same inside diameter to move axially, pushing open a flapper having dual sealing surfaces, which seal on the adjacent ends of the upper and lower flow tubes. Movement of the upper flow tube may push a pin supporting the flapper to move through a groove to a position where the flapper can move to the open position, where it conforms to the shape of the inside of the tubular. The flapper is locked in the open position for the life of the valve by operation of the upper flow tube and a snap ring, which locks the upper flow tube in position over the open flapper. The valve may be used to provide a pressure barrier in the casing during floating of the casing into a horizontal well or after the casing is in place or it may be used in tubing to prevent flow in the tubing in either direction until a selected pressure is applied at the surface. Valves may be adapted to open at a differential pressure across the valve which varies over a broad range of differential pressures within the operating pressure of the valve.
[0010] The valve may be closed during deployment and once activated is locked in the open position.
[0011] The isolation valve may be used by itself to provide a barrier in either the casing or the tubing, or may be used in conjunction with additional valves to form chambers in the tubular string.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0012] FIG. 1 is a cross-section view of valve sub 10 in the closed or run-in condition.
[0013] FIG. 2 is a cross-section view of valve sub 10 after shearing of a disk or pin and before opening of the flapper.
[0014] FIG. 3 is a cross-section view of valve sub 10 in the open position.
[0015] FIG. 4 is a cross-sectional view of the valve sub 10 at cross-section “ 4 ” in FIG. 1 .
[0016] FIG. 5 is an isometric view of the flapper in closed position with outer parts removed from the drawing.
[0017] FIG. 6 is an isometric view of the flapper in the partially-open position with outer parts removed from the drawing, identifying upper and lower sealing surfaces on the flapper.
[0018] FIG. 7 is an isometric view of the flapper in open position with outer parts removed from the drawing.
[0019] FIG. 8 is a perspective view of the flapper.
[0020] FIG. 9 is a side view of the flapper positioned between the upper and lower flow tube.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIG. 1 , isolation valve 10 has lock housing 12 , which is adapted to be joined in a tubular string, normally by pipe treads (not shown) and which preferably has the same inside diameter as the tubular string. Preferably, the outside diameter of the isolating valve is not more than the outside diameter of couplings in the tubular string. Seal 13 provides a barrier between lock housing 12 and upper spring housing 15 . Upper flow tube 18 preferably has the same inside diameter as the minimum inside diameter of lock housing 12 and is adapted to slide within upper spring housing 15 . Upper flow tube 18 may have internal shifting profile 11 . Shifting profile 11 may be used for optional manual shifting to open flapper 24 and allow intervention from uphole by jarring or other mechanical force if isolation valve 10 is not operating properly. Shifting profile 11 a may be the well-known “B-style” shifting profile, for example. Bearing 14 contacts upper coil spring 16 and allows low-resistance rotation of the end of the spring as it is compressed or expands. Snap ring 17 is compressed in the radial direction in the position shown in FIG. 1 and is adapted to slide within upper spring housing 15 and once it finds the spring housing 15 lock ring profile 17 a , the snap ring 17 will lock the upper flow tube 18 open. Seal 21 perfects a seal between housing adapter 20 and lower spring housing 25 .
[0022] Flapper 24 is supported by flapper pin 22 locked between the upper and lower flow tubes and flapper 24 is free to move along the axis of lower flow tube 29 as pressure is applied uphole (from the left side of FIG. 1 ) to apply a known force to shear ring or pin 30 . Only a small displacement is required for shearing the ring or pin, so the ring or pin can be sheared even if a normal volume of liquid is on the low-pressure side of flapper 24 .
[0023] Flapper 24 is supported within a flapper housing 35 best shown in FIG. 5 . Key 34 maintains upper flow tube 19 and flapper housing 35 in axial alignment and key 44 maintains lower flow tube 29 in axial alignment with the flapper housing 33 . A shock absorbing element 33 is secured to flapper housing 35 by screws 42 .
[0024] Referring to FIG. 2 , shear ring or pin 30 is shown after shearing in the axial direction, with separation into two parts, the two parts being axially displaced, allowing flapper pin 22 and flapper 24 to move into position for opening before it has opened. The axial force of compressed shifting spring 26 , through bearing 28 (which reduces resistance to rotation of the shifting spring) then quickly moves lower flow tube 29 downhole to make a space for opening of flapper 24 . Flapper 24 , supported by pin 22 , is opened by the force of spring 16 acting on upper flow tube 18 . Lower flow tube 29 must move rapidly enough to allow flapper 24 to fully open without interference from lower flow tube 29 . The force of spring 26 is selected to be great enough to meet this requirement. After flapper 24 is open it is then covered in the open position by upper flow tube 18 as shown in FIG. 3 .
[0025] FIG. 3 shows flapper 24 in the open position. Note that flapper 24 has the same center of the radius of curvature in the radial plane when open as the upper flow tube 18 and lower spring housing 25 . This allows open flapper 24 to be located between upper flow tube 18 and lower spring housing 25 . Lower spring 26 has expanded in the axial direction, moving lower flow tube 29 . Snap ring 17 has moved in the axial direction such that radial compression of the snap ring has caused it to move radially outward into snap ring receptor 17 a . This causes upper flow tube 18 to be permanently locked in position, covering flapper 24 . Torque stop plug 31 may be located at the distal end of lower spring housing 25 to prevent radial movement between lower sub 32 and lower spring housing 25 . Lower spring housing 25 is joined to lower sub 32 , which may be adapted to be joined to a tubular (not shown).
[0026] FIG. 4 shows cross-section 4 identified in FIG. 1 . Lock housing 12 is shown behind the cross-section. Lower spring housing 25 concentrically encloses closed flapper 24 and lower spring 26 . Flapper pin 22 supports flapper 24 , which is shown in the open position in FIG. 7 .
[0027] FIG. 5 is an isometric view of flapper 24 in a closed position with parts not shown that block the view of the flapper. FIG. 6 is an isometric view of the flapper in a partially open position. This view also identifies sealing surfaces 240 and 241 on the flapper shown in FIG. 8 . When the flapper is closed, these surfaces mate with surfaces on upper flow tube 18 and lower flow tube 29 to form a hydraulic seal. Normally the sealing surfaces are covered with an elastomer or other type of sealing material. FIG. 7 is an isometric view of flapper 24 in the open position with parts not shown that block the view of the flapper.
[0028] FIG. 8 is a perspective view of the flapper 24 . Sealing surface 240 engages an end of upper flow tube 18 and sealing surface 241 engages an end of lower flow tube 29 as shown in FIG. 9 .
MODE OF OPERATION
[0029] The mode of operation is as follows. With the flapper closed, the formation is isolated and the flapper is sandwiched between the upper and lower flow tubes, effecting a bi-directional seal above and below the flapper.
[0030] When hydrostatic pressure is applied from above, the flapper shears a shear ring or pin or any other destructible retention mechanism via the lower flow tube which then moves axially downward. When the destructible element 30 releases, the lower flow tube 29 moves axially downwardly by virtue of biased spring 26 , thereby allowing the flapper to freely rotate to the open position.
[0031] The upper flow tube 18 , biased by a second spring 16 which is weaker than spring 26 , pushes the flapper to the fully open position shown in FIG. 3 .
[0032] Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims.
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A valve to act as a barrier to fluid movement in a tubular is provided. A flapper in the valve may be opened by application of a selected pressure differential across the flapper. The flapper opens to allow a cylinder to shift and cover the open flapper. A method of placing a tubular string within a well using the valve as an isolation valve to form gas filled chambers for floating the tubular string into the well is also disclosed.
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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 AND DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to curved railing systems and particularly to curved railing systems that use segmented infill panels.
2. Description of the Prior Art
Many buildings have decks, porches and balconies (note the works “deck” herein shall include to decks, porches, and balconies) added to them. They provide useful outdoor space and add value to the building from both a utility perspective as well as an aesthetic perspective. One of the more aesthetically pleasing balcony configurations are those that contain one or more radiused or curved sides. While aesthetically pleasing, however, balconies with curved sides can present difficult challenges for those designing and installing the associated railing system.
Railing systems are used to provide safety on an elevated deck, as well as providing an aesthetically pleasing element of the overall design. The problem with curved railings is obtaining infill panels (such as glass) that match the curve. Curved glass is expensive. Moreover, fitting the segmented top rail to the construction adds labor cost because the top rail must be custom fitted in the field by making precise miter cuts to join the top rail segments together. It requires considerable skill on the part of the installer to make multiple precision miter cuts. Otherwise, the entire appearance of the railing will be negatively impacted. Because curved railing involve considerably higher costs and require a higher level of skilled labor to install, they are generally limited to high budget projects. Moreover, the use of curved decks is also limited for the same reason.
BRIEF DESCRIPTION OF THE INVENTION
The instant invention overcomes these difficulties. It is a railing system that accommodates balcony applications with one or more curved sides, yet does not use curved infill panels while utilizing a continuous curved top rail that eliminates the need for miter cuts in the installation. It uses a series of vertical posts that follow the line of a desired curve. The posts have a bottom rail and space to hold infill panels that may be glass, solid panels of metals or plastics, perforated metal or plastic panels, vertical pickets, or cables. All of these infill panels are straight panels that are not curved. A special post cap is installed on the vertical posts. The post cap has pivoting articulating brackets that are used to support and align glass channels. The top rail is a continuous length of railing that matches the desired curve. The top rail is placed over the vertical posts and glass channels. In this way, the entire assembly produces a curved rail design at a lower cost and with less labor than a conventional curved rail.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of a section of curved rail according to the disclosed invention.
FIG. 2 is a top detail view of the curved rail system, showing the outline of the curved top rail and the position of the posts and infill panels beneath it.
FIG. 3 is a partially exploded view of a section of the curved rail.
FIG. 4 is a partially exploded view of a section of the rail showing the post cap assembly.
FIG. 5 is a detail view of an assembled in-line post.
FIG. 6 is a detail of an assembled end post.
FIG. 7 is a detail view of an assembled corner post.
FIG. 8 is a top view of a post cap.
FIG. 9 is a side view of a post cap.
FIG. 10 is a bottom view of a post cap.
FIG. 11 is a bottom perspective view of a post cap.
FIG. 12 is a top perspective view of a post cap.
FIG. 13 is a cross-sectional view of the top rail.
FIG. 14 is a cross sectional view of a top rail showing full potential range of glass channel positions.
FIG. 15 is a cross-sectional view of a glass channel.
FIG. 16 is a bottom view of an articulating bracket.
FIG. 17 is a side view of an articulating bracket.
FIG. 18 is a bottom perspective view of an articulating bracket.
FIG. 19 is a top perspective view of an articulating bracket.
FIG. 20 is a detail of an infill panel made of perforated metal panels.
FIG. 21 is a detail of an infill panel made of vertical pickets.
FIG. 22 is a detail of an infill panel made of cables.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , a perspective view of a section of curved rail according to the disclosed invention is shown. The main components of the railing system 10 are a series of vertical post assemblies 11 , a length of bottom rail 12 that runs between the vertical post assemblies 11 , a number of infill panels 13 that fit between the vertical post assemblies 11 and rest on the bottom rail sections 12 , and a top rail 14 that sit atop the vertical post assemblies and the infill panels. At the end of the top rail 14 is an end cover 14 a as shown. The infill panels may be glass, solid panels of metal, perforated metal panels, vertical pickets, or cables. See FIGS. 20-22 . shows a curved rail at a nominal ten-foot radius. The vertical post assemblies 11 are placed 42 inches on center. Note that infill panels 13 are straight and run diagonally under the rail. Of course, for other radii or curved rail, the dimensions will change accordingly. For example, placement of the vertical post assemblies must be done to keep the infill panels straight under the curved rail. This can be done easily, by first laying out the desired radius for the curve (shown in the dashed lines) and then placing the posts at the spacing needed to keep the infill panels straight and under the rail. Of course, there maybe radii of curves that are too sharp to enable the infill panels and vertical post assemblies to fit under the rail. However, for most general applications, such problems can be eliminated by taking care in the initial design to ensure a useable radius for the rail.
This figure also shows two articulating bracket assemblies 20 and an end assembly 21 . The two articulating bracket assemblies are the heart of the system and are discussed in detail below.
FIG. 3 is a partially exploded view of a section of the curved rail. At the top of the railing, is the curved top rail 14 . This is normally made of aluminum, although other materials can be incorporated as well. It has a large flat area to allow the diagonal positioning of the glass channel 15 . The glass channel 15 is a length of straight aluminum channel that is attached to the top rail 14 with screws 15 a . Note that, although this element is designated as a “glass channel” its use is not limited to glass infill panels, as is discussed above. A length of vinyl insert 16 is placed within the glass although this element is designated as a “glass channel” its use is not limited to glass infill panels, as is discussed above. A length of vinyl insert 16 is placed within the glass channel 15 to secure and protect the infill panels 13 , which may be glass, metal or plastic. At the bottom of the infill panels 13 is another length of vinyl insert 17 to secure and protect the infill panels. Finally, the bottom rail 12 is attached to the posts, as discussed above. Note that the bottom rail is normally mitered at the posts to ensure a clean fit for the rails.
FIG. 3 also shows the some details of the assembly of the post cap. The post cap 20 is secured to the vertical post with screws 20 a . Articulating mounting brackets 25 help to secure the glass channels to the post cap. For a center run, two articulating mounting brackets 25 are normally used. The articulating mounting brackets 25 are pivotably secured to the post caps, as discussed below. This allows the articulating mounting brackets 25 to be positioned properly to align the glass channels 15 with the curve of the top rail (see FIG. 2 ). Once the base railing sections are all in place and secure, the articulating mounting brackets 25 strengthen the glass channels. Moreover, the adjustability of the articulating mounting brackets 25 aids in the overall installation as the alignment of the components is greatly simplified.
FIG. 4 is a partially exploded detail view of a section of the rail showing details of the post cap 20 . As in FIG. 3 , the top rail 14 is shown positioned above the other railing components. A vertical post 11 is positioned as discussed above. Two lengths of glass channel 15 are shown on either side of the vertical post 11 . Note the screws 15 a that secure the glass channels 15 to the top rail 14 . As mentioned above, the post cap 20 is secured to the vertical post by screws 20 a . Note that the particular shape of the post cap is discussed in detail below. Note also that the post cap is secured to the top rail by screws 20 f as discussed below.
Here, the articulating mounting brackets 25 are shown clearly. They are secured to the top rail by screws 25 a . The articulating mounting brackets 25 have a generally triangular shape with a hole 25 b at the apex of the triangle and two mounting block 25 c at the base corners. The hole 25 b is positioned on a pivot point on the post cap 20 as discussed below.
The mounting blocks 25 c have a dual purpose. First, they secure the top rail with the screws 25 a . Second, they form a channel in which the glass channel rests. In this way, the glass channels are positioned and strengthened. Moreover, because the articulating mounting brackets 25 can pivot around the mounting hole 25 b , the glass channels can be easily adjusted in the proper position without having to make intricate and precise miter cuts.
FIG. 5 is a detail view of an assembled in-line post. In this figure, the vertical post 11 is shown at the bottom of the assembly. The post cap 20 is shown secured to the vertical post with the screws 20 a . The articulating mounting brackets 25 are shown positioned on the post cap 20 and the glass channels 15 are shown positioned between the mounting blocks 25 c.
FIG. 6 is a detail of an assembled end post. Here, the railing reaches an end. There is only one length of glass rail 15 extending out from the vertical post 11 . The post cap 20 is attached to the vertical post with screws 20 a as before. Note, however, that the post cap 20 has been modified. As discussed below, the post caps have two flanges 20 b . These flanges can be cut off as needed. Thus, in FIG. 6 , one of the flanges has been removed to present a 90-degree corner for the end of the railing. As before, an articulating mounting bracket 25 is shown positioned on the post cap 20 and the glass channel 15 is shown positioned between the mounting blocks 25 c . Of course, for an end installation, only one articulating mounting bracket 25 is needed.
FIG. 7 is a detail view of an assembled corner post. In this figure, the post cap 20 is again shown with one flange 20 b removed. Note that the articulating mounting brackets 25 are shown positioned on the post cap 20 at right angles, to make the corner. As before, the glass channels 15 are shown positioned between the mounting blocks 25 c of the articulating mounting brackets 25 .
FIGS. 5 , 6 and 7 show the versatility of this system. Using only a few components, any configuration and angular setup (within reasonable design parameters) can be achieved easily and quickly with a minimum of field installation labor.
FIGS. 8-12 show details of the post cap 20 . FIG. 8 is a top view of a post cap 20 . The post cap has a formed shape as shown. On three sides, there are mounting flanges 20 b . On two of the side, cast-in cutting guides 20 c are shown. As discussed above, these cutting guides are used to make end and corner post caps in the field. On each of the mounting flanges, are mounting holes 20 d . These holes are used to secure the post cap to the top rail with screws 20 f . See e.g., FIG. 4 .
The post caps 20 have four countersunk mounting holes 20 e that are used to secure the post cap to the vertical posts 11 .
FIG. 9 is a side view of a post cap. Note that the top of the post cap is flat. The countersunk mounting holes 20 e are shown extending downward from the bottom of the post cap to form spacers 20 g . Note also, the pivot point 20 h that also extends below the bottom surface of the post cap. The pivot points are used to hold the articulating mounting bracket 25 at hole 25 b.
FIG. 10 is a bottom view of a post cap. Once again, the spacers 20 g are shown as well as the countersunk holes 20 d , and the pivot points 20 h.
FIG. 11 is a bottom perspective view of a post cap. The mounting holes 20 d and the spacers 20 g are shown as well as the countersunk holes 20 d , and the pivot points 20 h.
FIG. 12 is a top perspective view of a post cap. Here again, the mounting holes 20 d and mounting holes 20 e are shown as well as the cut lines 20 c.
FIG. 13 is a cross-sectional view of the top rail. In this figure, the top rail 14 is shown. Within the top rail is a mounting plate 14 b that is used to attach the glass channels 15 .
FIG. 14 is a cross sectional view of a top rail showing glass channels installed. In this view, the glass channels 15 are shown secured to the top rail using the screws 15 a . Note that two glass channels are shown. In actuality, only one glass channel is used. This figures illustrates the widest range of positions that the glass channel takes as the lower unit is built to support the curved top rail. See FIG. 2 , which also shows the ranges of positions of the glass channel under the top rail as the curve progresses. In the preferred embodiment, the widest spacing of the glass channels is 3.070 inches on center.
FIG. 15 is a cross sectional view of a glass channel 15
FIG. 16 is a bottom view of an articulating bracket. Here, the mounting hole 25 b and mounting blocks 25 c are shown.
FIG. 17 is a side view of an articulating bracket. Here, the mounting blocks 25 c are shown extending above and below the man body of the triangular articulating bracket. This not only provides additional support for the mounting screws, it also adds substance to better support the glass channels that fit between them.
FIG. 18 is a bottom perspective view of an articulating bracket. Note that in this view, the mounting holes are counter sunk.
FIG. 19 is a top perspective view of an articulating bracket.
FIG. 20 is a detail of an infill panel made of perforated panels. In this figure, the infill panels 13 are shown as perforated panels. These can be either metal or plastic, as desired.
FIG. 21 is a detail of an infill panel made of vertical pickets. Here, a number of vertical pickets 30 are shown. The pickets 30 are used in place of a solid infill panel. Although the pickets shown are simple vertical pickets, any other style of pickets may be used.
Finally, FIG. 22 shows cables 34 run between the posts in lieu of a panel.
It is possible to use many different materials and styles for the infill panels and the figures shown are not meant to be exclusive or limiting.
The present disclosure should not be construed in any limited sense other than that limited by the scope of the claims having regard to the teachings herein and the prior art being apparent with the preferred form of the invention disclosed herein and which reveals details of structure of a preferred form necessary for a better understanding of the invention and may be subject to change by skilled persons within the scope of the invention without departing from the concept thereof.
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A curved railing system that does not use curved infill panels and has a continuous curved top rail. It uses a series of posts that follow the desired curve. The posts have a bottom rail and space to hold infill panels that may be glass, solid panels, perforated panels, vertical pickets, or cables. All of these infill panels are straight panels that are not curved. A special post cap is installed on the posts. The post cap has pivoting articulating brackets that are used to support and align glass channels. The top rail is a continuous length of railing that matches the desired curve. The top rail is placed over the posts and glass channels. In this way, the entire assembly produces a curved rail design at a lower cost and with less labor than a conventional curved rail.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon provisional application Serial No. 60/065,617, filed Nov. 18, 1997.
BACKGROUND OF THE INVENTION
Casement windows include a sash hinged to a frame or jamb so that by rotation of the handle the window could be moved to an open position or a closed position. Various structures have been suggested to attempt to provide a firm locking of the sash to the frame. Problems exist, however, regarding the window sagging while in the locked as well as the open condition.
SUMMARY OF THE INVENTION
An object of this invention is to provide a sag prevention and correcting system for windows, particularly casement windows.
A further object of this invention is to provide such a sag prevention system which operates in connection with the locking arrangement.
In accordance with this invention the sag prevention system is used with a locking arrangement wherein the sash includes at least one and preferably a pair of spaced keepers of a multi-point locking system. The frame has a tie bar arrangement with a roller for each keeper. When the window is rotated to its closed condition the handle for the tie bar arrangement is moved to slide the rollers upwardly for engagement with the keepers. In accordance with the invention a lifting block is located adjacent one of the keepers to be disposed directly above its roller when the window is in the locked condition. The lifting block may be integral with the keeper or may be a separate member. Any sagging is prevented by the lifting block contacting the roller.
THE DRAWINGS
FIG. 1 is a front elevational view of a casement window in the locked condition in accordance with this invention;
FIG. 2 is a fragmental front elevational view of the casement window in the unlocked condition;
FIG. 3 is a fragmental side elevational view of the window shown in FIG. 2;
FIG. 4 is a fragmental front elevational view of a casement window in the locked condition;
FIG. 5 is a fragmental side elevational view of the window shown in FIG. 4;
FIG. 6 is a fragmental side elevational view of a modified form of keeper/lifting block arrangement in accordance with this invention;
FIG. 7 is a fragmental end elevational view of a tie bar having a cylindrical roller;
FIG. 8 is a fragmental and elevational view of a tie bar having a shouldered roller and a keeper with a flange;
FIG. 9 is a fragmental front elevational view showing a casement window in its unlocked condition having a modified form of link structure;
FIG. 10 is a fragmental side elevational view of the arrangement shown in FIG. 9;
FIG. 11 is a fragmental side elevational view showing yet another form of vertical adjustment mechanism in accordance with this invention;
FIG. 12 is a fragmental end elevational view of the arrangement shown in FIG. 11;
FIG. 13 is a fragmental side elevational view showing still yet another form of vertical adjustment mechanism in accordance with this invention;
FIG. 14 is a fragmental end elevational view of the arrangement shown in FIG. 13;
FIG. 15 is a fragmental side elevational view of yet another form of vertical adjustment mechanism in accordance with this invention;
FIG. 16 is an enlarged fragmental end view showing a vertical adjustment mechanism for the link in accordance with this invention; and
FIG. 17 is a front elevational view of a gauge used for locating the lifting block in the window of FIGS. 1 - 5 .
DETAILED DESCRIPTION
FIG. 1 illustrates a casement window 10 which includes a frame or jamb 12 and a sash 14 which extends around the window pane itself. Sash 14 is hinged to frame 12 by hinge arms at the bottom area 16 of the window assembly so that the window can be moved to an open position or a closed position. The rotation is controlled by handle 18 in a known manner and its details are not critical to an understanding of this invention.
FIGS. 2-5 illustrate the details of the invention wherein a sag prevention system is incorporated with locking members of a known multi-point locking system on the sash and frame. Reference is made to U.S. Pat. Nos. 5,074,075, 5,118,145 and 5,448,857, the details of which are incorporated herein by reference thereto with regard to the known multi-point locking system with which the invention may be adapted. The invention thus has the advantage of requiring only minor structural additions to the known locking system.
As shown in FIGS. 2-3 the various components are in their unlocked condition. FIG. 2 illustrates a tie bar 20 having a pair of spaced rollers or abutment members 22 which may be frusto-conically shaped, as shown in FIG. 2 or may have other types of shapes such as shown in FIGS. 7 and 8. It is to be understood that while the members 22 are referred to as rollers, it is not necessary in the broad practice of the invention that the members 22 actually rotate. What is important is that the members 22 present an abutment surface as later described. Members 22 may be considered first abutment members. The tie bar 20 is mounted to the frame 12 . A pair of second abutment members keepers 24 , 26 is mounted to the sash, as shown in FIG. 3 . Keeper 24 has an inclined cam edge 28 and a vertical guide surface or straight guide edge 30 . Keeper 26 has an inclined cam edge 32 and a straight guide edge 34 . In accordance with this invention a lifting block 36 is disposed outwardly from the upper end of straight edge 34 . Although only one lifting block 36 is illustrated in FIG. 3, it is to be understood that the invention may be practiced with a lifting block for each roller as illustrated in phantom in FIG. 5 by the reference numeral 36 A. Similarly, while a pair of rollers and keepers are illustrated, the invention may be broadly practiced with only a single roller and keeper.
Tie bar 20 is mounted to a link 38 which in turn is mounted to a pivotable handle 40 . When handle 40 is in the up position the tie bar is in its unlocked condition where the rollers 22 are spaced from the keepers 24 , 26 . When handle 40 is rotated downwardly the tie bar is shifted upwardly and the rollers contact the keepers, as shown in FIGS. 4-5.
The sequential contacting of the keepers takes place by the lower roller 22 first contacting and rolling against inclined cam edge 32 of lower keeper 26 . When the lower roller reaches the junction with straight guide edge 34 upper roller 22 begins to contact inclined cam edge 28 of upper keeper 24 . Similarly, where abutment member 22 is a roller, the roller may but need not rotate. In continued upper movement of the rollers, the lower roller 22 rides against straight guide edge 34 while upper roller 22 rides against inclined edge 28 and ultimately straight guide edge 30 . When the rollers are both located at the straight edges the window sash is pulled tightly against the weather seals of the frame.
Thus, as described above, each keeper is in the path of movement of the vertically moving roller 22 so that when the rollers 22 contact the inclined and straight edges of each keeper, a locking results.
In accordance with this invention lifting block 36 is mounted outwardly of straight edge 34 generally in line with or more accurately across the path of movement of lower roller 22 . Lifting block 36 is illustrated in FIGS. 3 and 5 as being integral with keeper 26 and extending outwardly from guide edge 34 . It is to be understood, however, that the invention may be practiced where the lifting block is a separate element mounted adjacent to and upwardly from keeper 26 .
FIGS. 4-5 show the condition of the components in the fully locked position. As shown therein, lower roller 22 is located directly below lifting block 36 when upper roller 22 is along straight guide edge 30 of upper keeper 24 . In the fully locked condition roller 22 would be at the lower edge 44 of block 36 . If there should be any tendency for the sash to sag, such tendency is prevented by lower roller 22 acting as an abutment against edge 44 for lifting block 36 thereby preventing downward movement or sagging of the sash, or lifting the sash if it has sagged while in the open position.
Preferably, lifting block 36 is located at lower keeper 26 . The invention, however, may also be practiced by having the lifting block at the upper keeper 24 located directly above the upper roller 22 when the handle 40 is moved to its down position as shown in FIGS. 4-5. The invention may also be practiced by having a lifting block for each keeper, particularly when used with a heavy sash. The preferred practice of the invention is illustrated where there is a single lifting block located at the lower keeper 26 and where the sash is not particularly heavy.
As noted, the lifting block 36 may be integral with keeper 26 or may be a separate member located directly above the lower roller 22 . Not only does lifting block 36 prevent sagging and support the sash in its locked position, but also the lifting block corrects minor sag while the sash is in its open position.
The invention may be practiced by having one or both keepers or lifting block 36 vertically adjustable in its location on sash 14 . FIG. 3, for example, illustrates a pair of slots 27 to be formed in keeper 26 so that the keeper 26 could be slidably moved up or down and then locked in position by the illustrated screws or fasteners.
Any other suitable structure may be used to permit the vertical adjustability of the keepers and/or lifting block. FIG. 6, for example, illustrates the lifting block 36 to include the same type of slot/fastener arrangement so as to be independently movable with respect to keeper 26 . FIG. 6, further illustrates a variation of the invention where the contact surface 35 of lifting block 36 is arcuate to receive cylindrical roller 22 A. The cylindrical roller is also shown in FIG. 7 .
FIG. 8 shows a variation of the invention where one of the keepers such as keeper 24 has a flange 25 for contacting roller 22 B which is in the form of a cylinder having an outwardly extending shoulder 23 which rides against flange 25 .
Where lifting block 36 is not integral with keeper 26 the two pieces could have mating teeth or cams engaged with each other to effect vertical movement of one piece with respect to the other. Where vertical adjusting structure is used care should be taken to take into account the weight of the window as it might affect the efficiency of performance of the vertical adjusting structure.
FIGS. 9-10 show a variation of the invention wherein the link 38 A associated with handle 40 is connected to tie bar 20 by a fork structure 100 wherein the fork arms or prongs 101 are disposed on each side of a pin 102 fixed on tie bar 20 .
FIGS. 11-12 illustrate a further vertical adjustment mechanism which may be used in accordance with this invention. As shown therein, the pin 102 A is eccentrically mounted or may be of elliptical form so that upon rotation of the pin the forked end of link 38 A is moved up or down. For example, as shown in FIG. 12, the eccentrically mounted pin 103 is secured to tie bar 20 with a cam disk 105 disposed between link 38 A and tie bar 20 . Rotation of eccentric pin 103 affects the precise location of link 38 at its area of mounting to tie bar 20 . A known mechanism commonly referred to as TORX would provide this type of adjustment.
FIGS. 13-14 illustrate yet another form of vertical adjustment mechanism wherein a hexagonal cam disk 105 A is mounted to pin 103 so that rotation of pin 103 causes pin 102 disposed between the fork arms of link 38 A to move the arms upwardly or downwardly. Such adjustment may be easily achieved by using a conventional adjustment wrench W.
FIG. 15 illustrates yet another manner of adjustment wherein the link 38 B is made of two parts 39 A and 39 B which are connected together by a suitable fastener 41 extending through elongated slot 43 thereby controlling the degree of overlap of link parts 39 A and 39 B.
FIG. 16 illustrates yet another form of adjustment where link 20 A is provided with teeth 31 for engagement with complementary teeth 33 on link 38 C. A suitable threaded fastener 29 and nut 29 B may be manipulated to move the mating teeth 31 , 33 into and out of engagement with each other.
FIG. 17 illustrates a gauge 42 which may be used for properly positioning the lifting block and more particularly its lower edge 44 on the sash. As shown therein gauge 42 is of two piece construction for locating the bottom keeper lifter on casement windows with multi-point locking systems. A pair of sliding members 46 , 48 comprise gauge 42 . Each member includes a slot 50 into which pins 52 , 52 of the other member are slidably mounted. The members 46 , 48 can be locked together in any suitable manner once the proper height adjustment can be achieved.
Lower member 48 includes a lower surface 54 which would be placed on the bottom hinge track of frame 12 . A side wall 56 is dimensioned to correspond to the stack height of the hinge and spacers, if used. Such height might, for example, be {fraction (7/16)} inches. Surface 58 would be set in the bottom sash arm mounting surface. A cutout 60 avoids contact with weld flash. For example, the cut out 60 includes a relief notch 59 with a recess 61 to accommodate any weld flash at the corner of the window frame F, shown in phantom. Surface 62 of upper member 46 would correspond to the top tangent surface of the bottom roller in the locked position. This would also correspond to the lower edge 44 or 35 of lifting block 36 . A similar surface 64 in line with surface 62 is provided also to correspond to the tangible surface of the bottom roller. Either of the surfaces 62 , 64 could be used for determining where the lifting block 36 should be located with regard to its lower surface.
Thus, in use the surface 54 would be placed on the bottom hinge track. Members 46 , 48 would be slidably adjusted so that surface 62 or 64 would be tangent to the bottom roller 22 in the locked position. Members 46 , 48 would then be locked to fix this distance. Surface 58 would be set in the bottom hinge sash arm mounting surfaces. By the proper placement and selection of the various surfaces in gauge 42 , accurate placement of the lifting block 36 can be assured.
The above procedure allows for the proper placement and location of the lifting block 36 with respect to roller 22 . If it is more desirable to adjust the location of the roller in order to obtain the proper alignment and positioning with respect to the lifting block 36 the following procedure can be used. Surface 58 of gauge 42 would be set in the bottom hinge sash arm surface. Slide members 46 , 48 would be selectively adjusted so that surface 62 or 64 would correspond to the location of surface 44 or 35 of lifting block 36 . Members 46 , 48 would then be locked to fix this distance. Surface 54 would be placed on the bottom hinge track surface. Roller 22 would then be adjusted so that roller 22 would be tangent to surface 62 or 64 . This adjustment of the location of roller 22 could be made by using the various techniques shown in FIGS. 11-14 and/or 17 .
Gauge 42 is useful not only in retrofitting existing windows to add a separate lifting block, but could also be used in original manufactured windows to be sure of proper location of the roller and the lifting block whether the lifting block is integral with the lower keeper or is a separate member.
It is to be understood that the invention may be practiced in manners other than specifically shown and described. For example, the tie bar may be mounted to either the sash or the frame with the fixed abutment member mounted on the other of the sash or the frame. The tie bar may have the roller as its movable abutment member, as described, or the keeper may be mounted on the tie bar and be an abutment member with the roller or abutment member on the other of the sash or the frame. Where the keeper is mounted on the tie bar, the keeper may be considered as a second abutment member and the roller would be a first abutment member. In these variations the lifting block would be disposed across the path of movement of the movable or second abutment member so as to be contacted by the second abutment member when the window assembly is in its locked position to minimize sag and to correct for sag.
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A casement window utilizes a multi-locking system having a pair of spaced keepers and a tie bar with a corresponding pair of rollers. In the locking action the rollers ride against the inclined and straight vertical surfaces of the keepers. A lifting block is located immediately above the lower roller when the locking system is in its locked condition. The lifting block prevents sagging and supports the sash in the locked condition. The provision of a lifting block in combination with the known multi-point locking system takes advantage of the locking system components to prevent sagging.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates generally to flashing devices used to prevent moisture from penetrating seams existing in structures, and more particularly to the use of a system of flashing components to render seams found in interior walls impervious to moisture.
[0003] 2. Description of Prior Art
[0004] Flashing devices used to prevent moisture from penetrating seams, are well known in the industry. Most such devices are designed to preyent environmental moisture, such as rain or melted snow, from penetrating the seams found in the exterior walls of structures. An example of such a flashing device is U.S. Pat. No. 6,035,582, dated Mar. 14, 2000, issued to William L. Pacific. The '582 patent discloses flashing employing multilayered construction.
[0005] Other flashing devices are designed to prevent interior moisture, such as water from a shower or bathtub, from penetrating seams found in interior walls or floors of rooms such as bathrooms. Examples of such flashing devices are U.S. Pat. No. Des. 404,806, dated Jan. 26, 1999 and issued to Joseph M. Callahan, U.S. Pat. No. 5,159,723, dated Nov. 3, 1992 and issued to Ray B. Benedict, U.S. Pat. No. 5,103,602, dated Apr. 14, 1992 and issued to Richard A. Stevens, et al., and U.S. Pat. No. Des. 299,963, dated Feb. 21, 1989 and issued to Joseph M. Callahan. The '806 patent discloses flashing containing two parallel flanges forming a u-shaped channel adapted to receive wall board; tiling is placed against the outer flange while the inner flange is interposed between the wallboard and the wall-substrate. The entire assembly is installed along the edge of a bathtub. The '723 patent incorporates a downward-oriented horizontal channel into the outer surface of a bathtub, with the channel adapted to receive the upturned edge of flooring. Water flowing down the side of the bathtub would be directed along the flooring away from the joint of the bathtub and floor. The '602 patent discloses a flashing device to be interposed between a bathtub and flooring, with a resilient member adapted to be inserted into a seam between the bathtub and floor. The '963 patent is similar to the '806 patent, with the addition of a third flange depending downward from the forward flange. Each of these flashing devices are specially adapted to bathtub installation, and cannot be used for more general purpose rooms.
[0006] U.S. Pat. No. 6,282,855, dated Sep. 4, 2001 and issued to Stephen Shipton is a general purpose wall trim system offering waterproofing between wall coverings and base members. The device is adapted to be placed against a wall substrate, having an upper flange interposed between wall substrate and a wall covering. However, the device incorporates the base trim member, thereby eliminating the use of general purpose base members, such as base tile. The incorporation of the base member into the device also increase the cost of manufacture, rendering it less practical.
[0007] None of the prior art devices are specifically adapted for use in so-called “wet rooms.” In many industrial and commercial settings, such rooms are designed to be cleaned by applying water to the walls and floor with a high pressure hose. Such rooms may include kitchens, dish rooms, mop rooms, lavatories, cart rooms, and the like. The water, once sprayed about the room, drains through a floor drain. Cleansing solvents are often used in such circumstances to improve the cleaning of the room. A typical configuration of the walls of such rooms comprises a wall substrate, which may be wall board, dry wall, concrete, cinder block, cement board, gypsum board, sheet rock, or the like; base tile, typically manufactured of ceramic tile, located along the lower portion of the wall substrate and adjacent to the floor; and a wall covering, which may be stainless steel sheeting, plastic, tile, or other moisture resistant material, and which is placed over the wall substrate directly above and adjacent to the base tile. A seam is formed at the junction of the wall covering and the base tile. Typically, some form of grout or silicone-based sealant is applied to the seam to prevent moisture penetration. While preventing moisture penetration into the sub-wall is always important to prevent rot or other damage, it is especially necessary in these types of rooms, because the generally waterproof nature of the wall covering and base tile prevents the evaporation of any moisture which may penetrate the seams, such that even a tiny amount of moisture penetration can result in great damage.
[0008] Existing methods of sealing the seams between the wall covering and base tile are ineffective in keeping all moisture out of the seams. This is because during cleaning water is directed at the walls, including the seams, with great force exerted by the high pressure hose, causing the water stream to quickly break down grout or silicone-based sealants applied to the seams. When chemical solvents are used, this breakdown occurs even more rapidly. Moisture then penetrates the seams, migrates throughout the sub-wall and floor, and causes expensive damage.
[0009] None of the prior art devices discovered adequately address the problem of moisture penetration through the seams located between the wall covering and base tile in a simple yet effective manner, while still permitting standard building techniques using standard construction materials. The present invention, however, solves this problem. By using a solid barrier constructed of a waterproof and durable material suitably adapted to withstand the force of high pressure hoses, placed within the seams and shaped to direct moisture outward and downward, the invention represents an effective, inexpensive, and long-term solution to the problem. It is addresses the problem of sealing corners, both inside and outside corners, which often are the weak point in wet-room waterproofing systems. Moreover, the method of installation claimed herein further allows quick and easy implementation of the invention using existing construction techniques and without the need for retrofitting the wall components or otherwise substituting preferred construction materials.
SUMMARY
[0010] In one aspect, the invention is directed to a flashing system adapted to render wall seams impervious to moisture, for use in the interior of a structure, said interior formed of one or more walls, each said wall being comprised of a wall substrate, a wall covering adapted to be positioned over the wall substrate, and base tile adapted to be positioned over the wall substrate and located along the lower portion of the wall directly below and adjacent to the wall covering, with the wall covering and base tile forming said seams. The flashing system is comprised of one or more of a wall sealing component, an inside corner sealing component, and an outside corner sealing component, each component adapted to be positioned within and over the seams such that moisture contacting the wall is directed downward and away from the seams.
[0011] This aspect may include one or more of the following features: flashing strips having flanges adapted to be positioned along a wall and to fit between the wall covering and wall substrate and over the base tile such that moisture contacting the flashing strip will be directed downward and away from the seam; inside corner flashing members having flanges adapted to fit within an inside corner and between the wall covering and wall substrate and over the base tile such that moisture contacting the inside corner will be directed downward and away from the seams; outside corner flashing members having flanges adapted to fit over an outside corner and between the wall covering and wall substrate and over the base tile such that moisture contacting the outside corner will be directed downward and away from the seams; components resistant to chemical corrosion; components constructed of aluminum, steel, stainless steel, fiberglass, rigid plastic, rubberized plastic, composite materials such as polymer matrix composites, metal matrix composites, ceramic matrix composites, and laminate matrix composites, and synthetic materials such as polycarbonate and polystyrene; components with rearwardly angled lower flanges; flashing strips with tapered lower flanges; attachment components employing fasteners and apertures, or adhesive strips, or adhesive compounds, to fixedly secure flashing strips, inside corner flashing members, and outside corner flashing members to the wall substrate; and a waterproofing compound adapted to be applied between the components and the wall.
[0012] In another aspect, the invention is directed to a method of rendering seams in a structure impervious to moisture, for structures as described above. This method includes preparing the room by removing the wall covering from the walls, if necessary, and having the wall substrate and base tile in place; for each wall of the room, providing one or more flashing strips, positioning a first flashing strip horizontally against the wall such that the first end of the flashing strip is adjacent to one corner of the room, placing the upper flange of the flashing strip against the wall substrate such that the lower flange is positioned over base tile, and fixedly attaching the upper flange of the flashing strip to the wall substrate, positioning each subsequent flashing strip horizontally against the wall such that the first end of the flashing strip overlaps the second end of the previously installed flashing strip, placing the upper flange of the flashing strip against the wall substrate such that the lower flange is positioned over base tile, and fixedly attaching the upper flange of the flashing strip to the wall substrate, and positioning a final flashing strip horizontally against the wall such that the first end of the final flashing strip overlaps the second end of the previously installed flashing strip and the second end of the final flashing strip is adjacent to the corner of the room, cutting the final flashing strip, if necessary, in order to fit the remaining length of the wall, placing the upper flange of the flashing strip against the wall substrate such that the lower flange is positioned over base tile, and fixedly attaching the upper flange of the flashing strip to the wall substrate; for each interior corner of the room, providing an inside corner flashing member, positioning the inside corner flashing member against the interior corner, such that the upper flanges of the inside corner flashing member are placed against the wall substrate, the lower flanges of the inside corner flashing member are positioned over base tile, with the lower flanges positioned to partially overlap the ends of adjacent flashing strips, and fixedly attaching the upper flanges of the inside corner flashing members to the wall substrate; for each outside corner of the room, providing an outside corner flashing member, positioning the outside corner flashing member over the outside corner, such that the upper flanges of the outside corner flashing member are placed against the wall substrate, the lower flanges of the outside corner flashing member are positioned over base tile, with the lower flanges positioned to partially overlap the ends of adjacent flashing strips, and fixedly attaching the upper flanges of the outside corner flashing members to the wall substrate; and positioning the wall covering onto the wall substrate. This aspect may include applying a waterproofing compound prior to positioning the components against the wall, to create an additional waterproof seal within the seams.
[0013] It is an object of this invention to provide a new and improved flashing system for use in rooms designed to be cleaned by the application of water to the walls and floor with a high pressure hose. The invention allows builders and renovators to waterproof seams in such rooms quickly, easily, and inexpensively, with highly effective and long-lasting results. Because of the simplicity of the invention, it may also be used in any wall having horizontal seams where moisture penetration is an issue, even if high pressure hoses are not used for cleaning.
[0014] Other features and advantages of the invention are described below.
DESCRIPTION OF DRAWINGS
[0015] [0015]FIG. 1 is a perspective front view of a flashing strip, with the center portion cut away, thereby depicting both the first and second ends of the flashing strip and depicting the exterior surface and the upper and lower flanges and the shaped transition area of the flashing strip.
[0016] [0016]FIG. 1 a is a cross sectional view of the flashing strip having a downwardly curved shaped transition area.
[0017] [0017]FIG. 1 b is a cross sectional view of the flashing strip having a substantially horizontally oriented shaped transition area.
[0018] [0018]FIG. 2 is a perspective view of a flashing strip properly installed in a wall and the relationship of the flashing strip to the wall substrate, wall covering, and base tile.
[0019] [0019]FIG. 3 is a perspective front view of an inside corner flashing member.
[0020] [0020]FIG. 4 is a perspective front view of an outside corner flashing member.
DETAILED DESCRIPTION OF THE INVENTION
[0021] [0021]FIG. 1 shows a perspective front view of a flashing strip 20 , which is a single instantiation of the wall sealing component. FIG. 3 shows a perspective front view of an inside corner flashing member 60 , which is a single instantiation of the inside corner sealing component. FIG. 4 shows a perspective front view of an outside corner flashing member 110 , which is a single instantiation of the outside corner sealing component. The flashing system invention claimed herein is comprised of one or more of these three components, which may be used singly or in conjunction with each other to provide waterproofing to the seams 10 found between wall coverings 6 and base tile 8 , thereby preventing moisture penetration through to the wall substrate 4 , studs, joists, and other internal wall components which are subject to damage from moisture. Such a flashing system is intended for use in commercial or industrial structures which are subjected to the presence of moisture, particularly water applied to interior walls by high pressure hoses, such as in kitchens, dish rooms, mop rooms, lavatories, cart rooms, and the like. The flashing system is specifically engineered to be effective, simple to manufacture and install, and less expensive than other such devices.
[0022] The wall sealing component is constructed of a material impervious to moisture. Optionally, the wall sealing component may be constructed of a material also resistant to chemical corrosion. This optional feature is useful where the rooms in which the wall sealing component is installed are exposed to a combination of water and chemical solvents, such as may be found in cleaning agents. The materials from which the wall sealing component may be constructed may be rigid, semi-rigid or malleable, or flexible, though such materials must exhibit a sufficient durability to withstand direct exposure to high pressure water. Preferred materials from which the wall sealing component may be constructed include aluminum, steel, stainless steel, fiberglass, rigid plastic, rubberized plastic, composite materials such as polymer matrix composites, metal matrix composites, ceramic matrix composites, and laminate matrix composites, and synthetic materials such as polycarbonate and polystyrene. Other materials exhibiting the required characteristic of imperviousness to moisture and the optional characteristic of resistance to chemical corrosion may also be used.
[0023] The wall sealing component is comprised of one or more flashing strips 20 . Each flashing strip 20 of the wall sealing component is adapted to be placed along seams 10 running the width of walls. One or more flashing strips 20 may be used along each wall, as required by the width of the wall. The last flashing strip 20 installed on a wall may be cut as necessary to custom fit the width of the wall. Each flashing strip 20 had the same size and shape as each other flashing strip 20 , except along their lengths, which may vary as needed. Therefore, the description of a single flashing strip 20 , provided below, applies to each flashing strip 20 comprising the wall sealing component, excepting any requirement for a uniformity of length. The flashing strip 20 has an upper flange 36 , a lower flange 38 , and a shaped transition area 42 interposed between and connecting the upper flange 36 and the lower flange 38 . Each of these subcomponents of the flashing strip 20 run the entire length of the flashing strip 20 . The flashing strip 20 is of seamless once piece construction, whereby the subcomponents of the flashing strip 20 integrate into each other. The absence of seams 10 in the construction of the flashing strip 20 allows it to be an effective moisture barrier.
[0024] The flashing strip 20 has an exterior surface and an interior surface. The exterior surface of the flashing strip 20 is that surface facing the interior of the room and which may be exposed to direct application of moisture. The interior surface of the flashing strip 20 is that surface facing away from the interior of the room and which is placed against the wall substrate 4 and base tile 8 . The surfaces of the upper and lower flanges 36 , 38 and the shaped transition area 42 that correspond to the exterior surface of the flashing strip 20 as a whole are defined as exterior surfaces, and the surfaces of the upper and lower flanges 36 , 38 and the shaped transition area 42 that correspond to the interior surface of the flashing strip 20 as a whole are defined as interior surfaces. The flashing strip 20 has a substantially uniform thickness, as measured from the exterior surface to the interior surface. The flashing strip 20 has a first end 32 and a second end 34 , the two ends located laterally and opposite each other.
[0025] The upper flange 36 of the flashing strip 20 is substantially planar and oriented substantially vertically. The lower flange 38 of the flashing strip 20 is also substantially planar and oriented substantially vertically, in a plane substantially parallel and exterior to the plane of the upper flange 36 . The lower flange 38 has a lower edge 40 opposite the junction of the lower flange 38 with the shaped transition area 42 . The shaped transition area 42 connecting the upper and lower flanges 36 , 38 may have any suitable shape appropriate for shedding moisture in a substantially downward and exterior direction. The substantially vertical orientations of the upper and lower flanges 36 , 38 and their substantially planar shapes permit the flanges of the flashing strip 20 to be placed flush against the wall substrate 4 and base tile 8 , while the shaped transition area 42 of the flashing strip 20 is positioned over and placed in contact with the top edge 58 of base tile 8 .
[0026] In one embodiment of the invention, the shaped transition area 42 is oriented substantially perpendicular to the upper flange 36 and extends outward and downward from the upper flange 36 in a smoothly curving manner until it achieves a substantially vertical orientation at its juncture with the lower flange 38 . This embodiment is appropriate for use with cove base tile 8 . FIG. 1 a shows a cross sectional view of a flashing strip 20 having a shaped transition area 42 as described in this embodiment. In another embodiment, the shaped transition area 42 is oriented substantially perpendicular to the upper flange 36 and substantially perpendicular to the lower flange 38 , thus being substantially planar and oriented substantially horizontally. This embodiment is appropriate for use with base tile 8 having a squared off top edge 58 . Figure 1 b shows a cross sectional view of a flashing strip 20 having a shaped transition area 42 as described in this embodiment.
[0027] When multiple flashing strips 20 are used along a single wall, each flashing strip 20 other than the flashing strips 20 on the ends is intended to overlap a portion of one adjacent flashing strip 20 and to be overlapped in part by a portion of the other adjacent flashing strip 20 . Specifically, the first end 32 of each flashing strip 20 is suitably adapted to partially overlap the second end 34 of an adjacent flashing strip 20 .
[0028] In one embodiment the lower flange 38 of each flashing strip 20 has a varying width, the width being defined as the dimension of the lower flange 38 from the junction of the lower flange 38 and the shaped transition area 42 to the lower edge 40 of the lower flange 38 . The variance of the width of the lower flange 38 is substantially constant, with the width of the lower flange 38 at the first end 32 of the flashing strip 20 greater than the width of the lower flange 38 at the second end 34 of the flashing strip 20 , this difference in width being substantially equal to the thickness of the flashing strip 20 . As a result of this variance in the width of the lower flange 38 , the lower flange 38 exhibits a slight upward taper along its lower edge 40 in the direction from the first end 32 of the flashing strip 20 to the second end 34 . That is, the second end 34 of the flashing strip 20 is narrower than the first end 32 of the flashing strip 20 by an amount substantially equal to the thickness of the flashing strip 20 . The purpose of this upward taper is to accommodate the overlap of the first end 32 of a flashing strip 20 over the second end 34 of an adjacent flashing strip 20 . The relatively wider first end 32 of the flashing strip 20 will substantially cover the relatively narrower second end 34 of the overlapped, adjacent flashing strip 20 , forming a substantially even line along the lower edges 40 of the two flashing strips 20 at their point of overlap, thereby improving the aesthetics of the finished installation.
[0029] In another embodiment, the lower edge 40 of the lower flange 38 of each flashing strip 20 is angled rearward. The angle is slight, preferably between 10° and 30° from vertical. This angling of the lower edge 40 of the lower flange 38 rearward causes the lower flange 38 to fit tighter against the base tile 8 , further reducing the incidence of moisture penetration between the lower flange 38 of the flashing strip 20 and the base tile 8 . FIGS. 1 a and 1 b depict the rearward angling of the lower edge 40 of the lower flange 38 of the flashing strip 20 .
[0030] [0030]FIG. 2 depicts a flashing strip 20 as it is intended to be installed within a wall. Each flashing strip 20 is positioned along a wall in the following manner: the upper flange 36 is placed between the wall substrate 4 and the wall covering 6 , and above the base tile 8 , with the exterior surface of the upper flange 36 positioned against the wall covering 6 and the interior surface of the upper flange 36 positioned against the wall substrate 4 . The lower flange 38 is placed over base tile 8 with the interior surface of the lower flange 38 positioned against base tile 8 . The shaped transition area 42 is placed along the top edge 58 of the base tile 8 , such that the interior surface of the shaped transition area 42 is in contact with the top edge 58 of the base tile 8 . With the wall covering 6 in place, the upper flange 36 is not visible, the shaped transition area 42 is partially visible, and the lower flange 38 is completely visible. The flashing strip 20 thus extends through the seam 10 formed at the juncture of the wall covering 6 and the base tile 8 . Moisture contacting the wall in the area of the flashing strip 20 is prevented from penetrating the seam 10 , and is directed downward and away from the seam 10 .
[0031] In one embodiment, a waterproofing compound 56 may be used with the flashing strip 20 . The waterproofing compound 56 is placed along the top edge 58 of the base tile 8 such that the waterproofing compound 56 contacts both the base tile 8 and the interior surface of the shaped transition area 42 of the flashing strip 20 , forming an unbroken seal between the flashing strip 20 and base tile 8 for the length of the flashing strip 20 . The waterproofing compound 56 is also placed upon the exterior surface of the second end 34 of the flashing strip 20 such that the waterproofing compound 56 contacts both the second end 34 of the flashing strip 20 and the interior surface of the first end 32 of the adjacent flashing-strip 20 which overlaps the second end 34 of the flashing strip 20 , forming an unbroken seal between the two flashing strips 20 . This additional waterproof seal prevents moisture directed upward against the lower flange 38 , for example, through back splashing, which may seep between the lower flange 38 and the base tile 8 , from passing between the flashing strip 20 and base tile 8 or between adjacent flashing strips 20 through to the wall substrate 4 . Any suitable waterproofing compound 56 may be used, for example, silicone.
[0032] The flashing strip 20 has an attachment component 44 suitably adapted for attaching the flashing strip 20 to a wall. In one embodiment, the attachment component 44 comprises a plurality of apertures formed into the upper flange 36 of the flashing strip 20 , and a plurality of fasteners 90 suitably adapted to pass through the apertures. For example, the fasteners 90 may be screws or nails. The flashing strip 20 is secured to the wall by passing the fasteners 90 through the apertures and into the wall substrate 4 .
[0033] In another embodiment, the attachment component 44 comprises an adhesive strip. The adhesive strip has a first side and a second side, with both sides being adhesive. The first side of the adhesive strip is fixedly attached to the interior surface of the upper flange 36 of the flashing strip 20 , thereby affixing the adhesive strip to the flashing strip 20 . The flashing strip 20 is then pressed against the wall substrate 4 so that the second side of the adhesive strip is placed in contact with the wall substrate 4 , adhering thereto, thereby fixedly attaching the flashing strip 20 to the wall substrate 4 . Any suitable adhesive strip having the aforementioned characteristics may be used, for example double-sided mounting tape. The adhesive strip may be pre-mounted on the flashing strip 20 or secured thereto during installation.
[0034] In yet another embodiment, the attachment component 44 comprises an adhesive compound. The adhesive compound is applied along the interior surface of the upper flange 36 of the flashing strip 20 , then the upper flange 36 of the flashing strip 20 is pressed against the wall substrate 4 such that the adhesive compound is in contact with and interposed between the upper flange 36 of the flashing strip 20 and the wall substrate 4 , thereby fixedly attaching the flashing strip 20 to the wall substrate 4 . Any suitable adhesive compound having the characteristics of easy application and quick drying may be used.
[0035] The flashing strips 20 may be of any suitable length, the length defined as the linear dimension from the first end 32 to the second end 34 . In one embodiment the length of the flashing strip 20 is between five feet and eight feet. In the preferred embodiment, the length is seven feet. The width of the upper flange 36 , defined as the linear dimension from the junction of the upper flange 36 and the shaped transition area 42 to the top edge of the upper flange 36 , and the width of the lower flange 38 of the flashing strip 20 , previously defined, may be of any suitable widths. In one embodiment the widths of the upper and lower flanges 36 , 38 are between one and four inches. In the preferred embodiment, the widths are two inches each. Other lengths and widths may also be used without deviating from the spirit of the invention.
[0036] The inside corner sealing component is constructed of a material impervious to moisture. Optionally, the inside corner sealing component may be constructed of a material also resistant to chemical corrosion. This optional feature is useful where the rooms in which the inside corner sealing component is installed are exposed to a combination of water and chemical solvents, such as may be found in cleaning agents. The materials from which the inside corner sealing component may be constructed may be rigid, semi-rigid or malleable, or flexible, though such materials must exhibit a sufficient durability to withstand direct exposure to high pressure water. Preferred materials from which the inside corner sealing component may be constructed include aluminum, stainless steel, steel, fiberglass, rigid plastic, rubberized plastic, composite materials such as polymer matrix composites, metal matrix composites, ceramic matrix composites, and laminate matrix composites, and synthetic materials such as polycarbonate and polystyrene. Other materials exhibiting the required characteristic of imperviousness to moisture and the optional characteristic of resistance to chemical corrosion may also be used.
[0037] The inside corner sealing component is comprised of one or more inside corner flashing members 60 . FIG. 3 shows a perspective view of an inside corner flashing member 60 . Each inside corner flashing member 60 of the inside corner sealing component is adapted to be positioned against an inside corner formed by a first wall and an adjacent second wall, whereby the first and second walls form an angle of less than 180°. Typically, the inside corner will be formed by the first and second walls forming an angle of 90°. The inside corner flashing member 60 is adapted to be positioned at the junction of the two seams 10 meeting at an inside corner.
[0038] The inside corner flashing member 60 has a first upper flange 68 and a second upper flange 70 , a first lower flange 72 and a second lower flange 78 , a first shaped transition area 84 interposed between and connecting the first upper flange 68 and the first lower flange 72 , and a second shaped transition area 86 interposed between and connecting the second upper flange 70 and the second lower flange 78 . The first and second upper flanges 68 , 70 are adjacent to each other along a common edge oriented substantially vertically. While the first and second upper flanges 68 , 70 typically are oriented substantially perpendicular to each other, the angle between said flanges 68 , 70 may vary, provided it does not exceed 180°. The first and second lower flanges 72 , 78 are adjacent to each other along a common edge oriented substantially vertically. While the first and second lower flanges 72 , 78 typically are oriented substantially perpendicular to each other, the angle between said flanges 72 , 78 may vary, provided it does not exceed 180°. The inside corner flashing member 60 is of seamless once piece construction, whereby the subcomponents of the inside corner flashing member 60 integrate into each other. The absence of seams 10 in the construction of the inside corner flashing member 60 allows it to be an effective moisture barrier.
[0039] The inside corner flashing member 60 has an exterior surface 62 and an interior surface 64 . The exterior surface 62 of the inside corner flashing member 60 is that surface facing the interior of the room and which may be exposed to direct application of moisture. The interior surface 64 of the inside corner flashing member 60 is that surface facing away from the interior of the room and which is placed against the inside corner of the wall against the wall substrate 4 and base tile 8 . The exterior surface 62 of the inside corner flashing member 60 is substantially concave. The surfaces of the first and second upper flanges 68 , 70 , the first and second lower flanges 72 , 78 , and the first and second shaped transition areas 84 , 86 that correspond to the exterior surface 62 of the inside corner flashing member 60 as a whole are defined as exterior surfaces, and the surfaces of the first and second upper flanges 68 , 70 , the first and second lower flanges 72 , 78 , and the first and second shaped transition areas 84 , 86 that correspond to the interior surface 64 of the inside corner flashing member 60 as a whole are defined as interior surfaces. The inside corner flashing member 60 has a substantially uniform thickness, as measured from the exterior surface 62 to the interior surface 64 .
[0040] The first upper flange 68 of the inside corner flashing member 60 is substantially planar and oriented substantially vertically. The second upper flange 70 of the inside corner flashing member 60 is also substantially planar and oriented substantially vertically. The first lower flange 72 of the inside corner flashing member 60 is substantially planar and oriented substantially vertically, in a plane substantially parallel and exterior to the plane of the first upper flange 68 of the inside corner flashing member 60 . The first lower flange 72 has a first lower edge 74 opposite the junction of the first lower flange 72 with the first shaped transition area 84 . The second lower flange 78 of the inside corner flashing member 60 is also substantially planar and oriented substantially vertically, in a plane substantially parallel and exterior to the plane of the second upper flange 70 of the inside corner flashing member 60 . The second lower flange 78 has a second lower edge 80 opposite the junction of the second lower flange 78 with the second shaped transition area 86 .
[0041] The first shaped transition area 84 connecting the first upper and lower flanges 68 , 72 and the second shaped transition area 86 connecting the second upper and lower flanges 70 , 78 may have any suitable shape appropriate for shedding moisture in a substantially downward and exterior direction. The second shaped transition area 86 is adjacent to and integrated with the first shaped transition area 84 . The substantially vertical orientations of the first and second upper and lower flanges 68 , 70 , 72 , 78 and their substantially planar shapes permit the flanges of the inside corner flashing member 60 to be placed flush into an inside corner and against the wall substrate 4 and base tile 8 , while the first and second shaped transition areas 84 , 86 of the inside corner flashing member 60 are positioned over and placed in contact with the top edges 58 of base tile 8 .
[0042] In one embodiment of the invention, the first shaped transition area 84 of the inside corner flashing member 60 is oriented substantially perpendicular to the first upper flange 68 of the inside corner flashing member 60 and extends outward and downward from the first upper flange 68 in a smoothly curving manner until it achieves a substantially vertical orientation at its juncture with the first lower flange 72 . The second shaped transition area 86 has an equivalent shape and orientation relative to the second upper and lower flanges 70 , 78 . This embodiment is appropriate for use with cove base tile 8 . In another embodiment, the first shaped transition area 84 is oriented substantially perpendicular to the first upper flange 68 and substantially perpendicular to the first lower flange 72 , thus being substantially planar and oriented substantially horizontally. The second shaped transition area 86 has an equivalent shape and orientation relative to the second upper and lower flanges 70 , 78 . This embodiment is appropriate for use with base tile 8 having a squared off top edge 58 .
[0043] The inside corner flashing member 60 is intended to overlap a portion of the adjacent flashing strips 20 . Specifically, the first upper and lower flanges 68 , 72 of the inside corner flashing member 60 are suitably adapted to partially overlap the second end 34 of an adjacent flashing strip 20 , and the second upper and lower flanges 70 , 78 of the inside corner flashing member 60 are suitably adapted to partially overlap the first end 32 of an adjacent flashing strip 20 .
[0044] In one embodiment the first lower flange 72 of the inside corner flashing member 60 has a width greater than the width of the lower flange 38 of the flashing strip 20 at the second end 34 of the flashing strip 20 , the width of the first lower flange 72 being defined as the dimension of the first lower flange 72 from the junction of the first lower flange 72 and the first shaped transition area 84 to the first lower edge 74 of the first lower flange 72 . The difference of the width of the first lower flange 72 of the inside corner flashing member 60 relative to the width of the lower flange 38 of the flashing strip 20 at the second end 34 of the flashing strip 20 is substantially equal to the thickness of the flashing strip 20 . Similarly, the second lower flange 78 of the inside corner flashing member 60 has a width greater than the width of the lower flange 38 of the flashing strip 20 at the first end 32 of the flashing strip 20 , the width of the second lower flange 78 being defined as the dimension of the second lower flange 78 from the junction of the second lower flange 78 and the second shaped transition area 86 to the second lower edge 80 of the second lower flange 78 . The difference of the width of the second lower flange 78 of the inside corner flashing member 60 relative to the width of the lower flange 38 of the flashing strip 20 at the first end 32 of the flashing strip 20 is substantially equal to the thickness of the flashing strip 20 . As a result of these variances in the widths of the first and second lower flanges 72 , 78 , as the inside corner flashing member 60 overlaps the adjacent flashing strips 20 , the relatively wider first and second lower flanges 72 , 78 of the inside corner flashing member 60 will substantially cover the relatively narrower lower flanges of the adjacent flashing strips 20 , forming a substantially even line along the lower edges 40 of the adjacent flashing strips 20 and the inside corner flashing member 60 at their points of overlap, thereby improving the aesthetics of the finished installation.
[0045] In another embodiment, the first and second lower edges 74 , 80 of the first and second lower flanges 72 , 78 of each inside corner flashing member 60 are angled rearward. The angle is slight, preferably between 10° and 30° from vertical. This angling of the first and second lower edges 74 , 80 of the first and second lower flanges 72 , 78 rearward causes the first and second lower flanges 72 , 78 to fit tighter against the base tile 8 , further reducing the incidence of moisture penetration between the first and second lower flanges 72 , 78 of the inside corner flashing member 60 and the base tile 8 .
[0046] Each inside corner flashing member 60 is suitably adapted to be positioned against an inside corner of a room, formed by the junction of a first wall and a second wall, in the following manner: the first upper flange 68 of the inside corner flashing member 60 is placed between the wall substrate 4 and the wall covering 6 of the first wall, and above the base tile 8 , with the exterior surface 62 of the first upper flange 68 of the inside corner flashing member 60 positioned against the wall covering 6 of the first wall, and with the interior surface 64 of the first upper flange 68 of the inside corner flashing member 60 positioned against the wall substrate 4 of the first wall. The second upper flange 70 of the inside corner flashing member 60 is positioned along the second wall in the same manner. The first lower flange 72 of the inside corner flashing member 60 is placed over base tile 8 , with the interior surface 64 of the first lower flange 72 of the inside corner flashing member 60 positioned against base tile 8 . The second lower flange 78 of the inside corner flashing member 60 is positioned along the second wall in the same manner. The first and second shaped transition areas 84 , 86 are placed along the top edge 58 of base tile 8 , such that the interior surfaces 64 of the first and second shaped transition areas 84 , 86 are in contact with the top edge 58 of base tile 8 . With the wall coverings 6 in place, the first and second upper flanges 68 , 70 are not visible, the first and second shaped transition areas 84 , 86 are partially visible, and the first and second lower flanges 72 , 78 are completely visible. So positioned, the inside corner flashing member 60 extends through the seams 10 formed at the junctions of the wall coverings 6 and base tile 8 of the first wall and the second wall. Moisture contacting the first wall or the second wall in the area of the inside corner flashing member 60 is prevented from penetrating the seams 10 , and is directed downward and away from the seams 10 .
[0047] In one embodiment, a waterproofing compound 56 may be used with the inside corner flashing member 60 . The waterproofing compound 56 is placed upon a portion of the exterior surface of the shaped transition area 42 of each adjacent flashing strip 20 which will be overlapped by the inside corner flashing member 60 , such that the waterproofing compound 56 contacts both the flashing strips 20 and the interior surfaces 64 of the first and second shaped transition areas 84 , 86 of the inside corner flashing member 60 , forming an unbroken seal between the inside corner flashing member 60 and the flashing strips 20 . The waterproofing compound 56 is also placed upon the exterior surface of the second end 34 of the flashing strip 20 adjacent to and overlapped by the first flanges 68 , 70 of the inside corner flashing member 60 and upon the exterior surface of the first end 32 of the flashing strip 20 adjacent to and overlapped by the second flanges 72 , 78 of the inside corner flashing member 60 such that the waterproofing compound 56 in contact with the components 20 , 60 forms an unbroken seal between the components 20 , 60 . This additional waterproof seal prevents moisture directed upward against the first and second lower flanges 72 , 78 of the inside corner flashing member 60 , for example, through back splashing, which may seep between the inside corner flashing member 60 and the flashing strips 20 , from passing between the inside corner flashing member 60 and the flashing strips 20 . Any suitable waterproofing compound 56 may be used, for example, silicone.
[0048] The inside corner flashing member 60 has an attachment component 88 suitably adapted for attaching the inside corner flashing member 60 to a wall. In one embodiment, the attachment component 88 comprises a plurality of apertures formed into the first and second upper flanges 68 , 70 of the inside corner flashing member 60 , and a plurality of fasteners 90 suitably adapted to pass through the apertures. For example, the fasteners 90 may be screws or nails. The inside corner flashing member 60 is secured to the wall by passing the fasteners 90 through the apertures and into the wall substrate 4 .
[0049] In another embodiment, the attachment component 88 of the inside corner flashing member 60 comprises a first adhesive strip 96 and second adhesive strip 102 . The first adhesive strip 96 has a first side and a second side, with both sides being adhesive. Likewise, the second adhesive strip 102 has a first side and a second side, with both sides being adhesive. The first side of the first adhesive strip 96 is fixedly attached to the interior surface 64 of the first upper flange 68 of the inside corner flashing member 60 , thereby affixing the first adhesive strip 96 to the inside corner flashing member 60 . In the same manner the second adhesive strip 102 is affixed to the interior surface 64 of the second upper flange 70 of the inside corner flashing member 60 . The inside corner flashing member 60 is then pressed into a corner against the wall substrate 4 so that the second sides of the first and second adhesive strips 96 , 102 are placed in contact with the wall substrate 4 , adhering thereto, thereby fixedly attaching the inside corner flashing member 60 to the wall substrate 4 . Any suitable adhesive strip having the aforementioned characteristics may be used, for example double-sided mounting tape. The first and second adhesive strips 96 , 102 may be pre-mounted on the inside corner flashing member 60 or secured thereto during installation.
[0050] In yet another embodiment, the attachment component 88 of the inside corner flashing member 60 comprises an adhesive compound. The adhesive compound is applied along the interior surfaces 64 of the first and second upper flanges 68 , 70 of the inside corner flashing member 60 , then the first and second upper flanges 68 , 70 of the inside corner flashing member 60 are pressed against the wall substrate 4 such that the adhesive compound is in contact with and interposed between the inside corner flashing member 60 and the wall substrate 4 , thereby fixedly attaching the inside corner flashing member 60 to the wall substrate 4 . Any suitable adhesive compound having the characteristics of easy application and quick drying may be used.
[0051] The first and second upper flanges 68 , 70 and the first and second lower flanges 72 , 78 of the inside corner flashing members 60 may be of any suitable length and width, the length defined as the linear dimension along the flanges 68 , 70 , 72 , 78 from the junction of the first 68 , 72 and second flanges 70 , 78 to the respective outer edges of those flanges 68 , 70 , 72 , 78 , and the width defined as the linear dimension along the flanges 68 , 70 , 72 , 78 from the junction of the upper 68 , 70 and lower flanges 72 , 78 with the first and second shaped transition areas 84 , 86 to the respective top and bottom edges of those flanges 68 , 70 , 72 , 78 . In one embodiment the lengths of the flanges 68 , 70 , 72 , 78 are between two inches and six inches. In the preferred embodiment, the lengths are three inches. In another embodiment the widths of the flanges 68 , 70 , 72 , 78 are between one and four inches. In the preferred embodiment, the widths are two inches each. Other lengths and widths may also be used without deviating from the spirit of the invention.
[0052] The outside corner sealing component is comprised of one or more outside corner flashing members 110 . FIG. 4 shows a perspective view of an outside corner flashing member 110 . Like the inside corner flashing member 60 , each outside corner flashing member 110 has a first upper flange 118 and a second upper flange 120 , a first lower flange 122 and a second lower flange 128 , a first shaped transition area 134 interposed between and connecting the first upper flange 118 and the first lower flange 122 , and a second shaped transition area 136 interposed between and connecting the second upper flange 120 and the second lower flange 128 . However, each outside corner flashing member 110 of the outside corner sealing component is adapted to be positioned over an outside corner formed by a first wall and an adjacent second wall, whereby the first and second walls form an angle of more than 180°. Typically, the outside corner will be fonned by the first and second walls forming an angle of 270°. The exterior surface 112 of the outside corner flashing member 110 is substantially convex. Thus, while an inside corner flashing member 60 is angled such that its flanges extend forward from an interior corner, an outside corner flashing member 110 is angled such that its flanges extend rearward from an outside corner. In all remaining aspects, the outside corner sealing component is substantially identical to the inside corner sealing component.
[0053] The invention also comprises a method of rendering seams 10 in a structure impervious to moisture. The structure comprising an interior room having walls, each wall having a wall substrate 4 , a wall covering 6 , and base tile 8 located along the lower portion of the wall directly below and adjacent to the wall covering 6 , and the seams 10 to be rendered impervious to moisture are formed at the junctions of the wall covering 6 and base tile 8 . The method comprises the following steps:
[0054] (1) The room is prepared by removing the wall covering 6 from the walls, if necessary, and having the wall substrate 4 and base tile 8 in place.
[0055] (2) For each wall of the room, one or more flashing strips 20 are provided, as necessary to extend the entire length of the wall, the flashing strips 20 having the characteristics as described above.
[0056] (3) For each wall of the room, a first flashing strip 20 is positioned horizontally against the wall such that the first end 32 of the flashing strip 20 is adjacent to one corner of the room.
[0057] (4) The upper flange 36 of the flashing strip 20 is then placed against the wall substrate 4 with the interior surface of the upper flange 36 positioned against the wall substrate 4 , in such a manner that the lower flange 38 is positioned over base tile 8 with the interior surface of the lower flange 38 positioned against base tile 8 , and the shaped transition area 42 is positioned over the top edge 58 of base tile 8 .
[0058] (5) The upper flange 36 of the flashing strip 20 is fixedly attached to the wall substrate 4 by the attachment component 44 of the flashing strip 20 , thereby securing the flashing strip 20 in place.
[0059] (6) For each subsequent flashing strip 20 used along the same wall, the flashing strip 20 is positioned horizontally against the wall such that the first end 32 of the flashing strip 20 overlaps the second end 34 of the previously installed flashing strip 20 . Steps (4) and (5) are then repeated for each flashing strip 20 .
[0060] (7) The final flashing strip 20 needed to extend the entire length of the wall is positioned horizontally against the wall such that the first end 32 of the final flashing strip 20 overlaps the second end 34 of the previously installed flashing strip 20 and the second end 34 of the final flashing strip 20 is adjacent to the corner of the room. If necessary in order to achieve the proper fit, the final flashing strip 20 may be cut by making a vertical cut through the upper flange 36 , shaped transition area 42 , and lower flange 38 . Steps (4) and (5) are then repeated for the final flashing strip 20 .
[0061] (8) For each interior corner of the room, formed by the junction of a first wall and a second wall, an inside corner flashing member 60 is provided, the inside corner flashing members 60 having the characteristics as described above.
[0062] (9) For each interior corner of the room, an inside corner flashing member 60 is positioned against the interior corner, such that the first upper flange 68 of the inside corner flashing member 60 is placed against the wall substrate 4 of the first wall with the interior surface 64 of the first upper flange 68 positioned against the wall substrate 4 , and the second upper flange 70 of the inside corner flashing member 60 is placed against the wall substrate 4 of the second wall with the interior surface 64 of the second upper flange 70 positioned against the wall substrate 4 . Positioned as such, the first lower flange 72 of the inside corner flashing member 60 is positioned over base tile 8 with the interior surface 64 of the first lower flange 72 positioned against base tile 8 , and positioned partially overlapping the second end 34 of an adjacent flashing strip 20 . Similarly, the second lower flange 78 of the inside corner flashing member 60 is positioned over base tile 8 with the interior surface 64 of the second lower flange 78 positioned against base tile 8 , and positioned partially overlapping the first end 32 of an adjacent flashing strip 20 . Once properly positioned, the inside corner flashing member 60 is fixedly attached to the wall substrate 4 by its attachment component 88 .
[0063] (10) For each outside corner of the room, formed by the junction of a first wall and a second wall, an outside corner flashing member 110 is provided, the outside corner flashing members 110 having the characteristics as described above.
[0064] (11) For each outside corner of the room, an outside corner flashing member 110 is positioned over the outside corner, such that the first upper flange 118 of the outside corner flashing member 110 is placed against the wall substrate 4 of the first wall with the interior surface of the first upper flange 118 positioned against the wall substrate 4 , and the second upper flange 120 of the outside corner flashing member 110 is placed against the wall substrate 4 of the second wall with the interior surface of the second upper flange 120 positioned against the wall substrate 4 . Positioned as such, the first lower flange 72 of the outside corner flashing member 110 is positioned over base tile 8 with the interior surface of the first lower flange 72 positioned against base tile 8 , and positioned partially overlapping the second end 34 of an adjacent flashing strip 20 . Similarly, the second lower flange 78 of the outside corner flashing member 110 is positioned over base tile 8 with the interior surface of the second lower flange 78 positioned against base tile 8 , and positioned partially overlapping the first end 32 of an adjacent flashing strip 20 . Once properly positioned, the outside corner flashing member 110 is fixedly attached to the wall substrate 4 by its attachment component.
[0065] (12) The method is completed by positioning all wall coverings 6 onto the wall substrate 4 , such that the wall coverings 6 overlap all upper flanges 36 , 68 , 70 , 118 , 120 of the flashing strips 20 , inside corner flashing members 60 , and outside corner flashing members 110 , and are adjacent to all shaped transition areas 42 , 84 , 86 , 134 , 136 of the flashing strips 20 , inside corner flashing members 60 , and outside corner flashing members 110 .
[0066] In one embodiment of the method, an additional step is performed between steps (1) and (2) to provide for additional waterproofing between the flashing strip 20 and base tile 8 . A waterproofing compound 56 is placed along the top edge 58 of base tile 8 , such that the waterproofing compound 56 contacts base tile 8 and the interior surface of the flashing strips 20 after same are positioned as described in step (4). The waterproofing compound 56 is also placed between the overlapping ends 32 , 34 of adjacent flashing strips 20 . This forms an unbroken seal impervious to moisture between base tile 8 and the flashing system.
[0067] In another embodiment of the method, an additional step is performed between steps (8) and (9) to provide for additional waterproofing between the flashing strips 20 and the inside corner flashing member 60 . For each interior corner of the room, the waterproofing compound 56 is placed upon the portions of the exterior surfaces of the shaped transition areas 42 of the adjacent flashing strips 20 which are to be overlapped by the inside corner flashing member 60 . The waterproofing compound 56 is also placed between the overlapping flanges 68 , 70 , 72 , 78 of the inside corner flashing member 60 and the ends 32 , 34 of the adjacent flashing strips 20 . So applied, the waterproofing compound 56 contacts the exterior surfaces of the adjacent flashing strips 20 and the interior surface 64 of the inside corner flashing member 60 after same is positioned as described in step (9), thereby forming an unbroken seal impervious to moisture between the flashing strips 20 and the inside corner flashing member 60 .
[0068] In yet another embodiment of the method, an additional step is performed between steps (10) and (11) to provide for additional waterproofing between the flashing strips 20 and the outside corner flashing member 110 . For each outside corner of the room, the waterproofing compound 56 is placed upon the portions of the exterior surfaces of the shaped transition areas 42 of the adjacent flashing strips 20 which are to be overlapped by the outside corner flashing member 110 . The waterproofing compound 56 is also placed between the overlapping flanges 118 , 120 , 122 , 128 of the outside corner flashing member 110 and the ends 32 , 34 of the adjacent flashing strips 20 . So applied, the waterproofing compound 56 contacts the exterior surfaces of the adjacent flashing strips 20 and the interior surface of the outside corner flashing member 110 after same is positioned as described in step (11), thereby forming an unbroken seal impervious to moisture between the flashing strips 20 and the outside corner flashing member 110 .
[0069] Installing the flashing system pursuant to the method described hereinabove renders the seams 10 in a room impervious to moisture, even when that moisture is directed at the seams 10 by high pressure hoses. When the components of the flashing system are constructed of materials resistant to chemical corrosion, cleaning solvents can be safely used in such rooms without risk of penetration through the seams 10 into the sub-wall with the resultant damage that would otherwise occur.
[0070] The invention is not limited to what is described in the foregoing embodiments. Other embodiments not specifically set forth herein are also within the scope of the following claims.
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A flashing device comprised of one or more components adapted to render seams found in interior walls impervious to moisture. The flashing system utilizes a combination of a waterproof, durable construction with a fluid-shedding shape to prevent moisture from penetrating wall seams and causing damage to the sub-wall and floor. The components include flashing strips adapted for use along walls, and corner pieces adapted for use with inside and outside corners. A method for installing the flashing system, allowing for quick, easy, and effective waterproofing of so-called “wet rooms,” which include commercial kitchens, dish rooms, mop rooms, lavatories, and the like which are cleaned by directing water and/or cleaning fluids at the floor and walls.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/545,998, filed Oct. 11, 2011, which is hereby incorporated by reference.
FIELD
[0002] The present disclosure concerns embodiments of a construction technique that can be used for modifying existing walls.
BACKGROUND
[0003] There are many structures in need of structural reinforcement or retrofitting to provide better insulation, waterproofing, a vapor barrier, and/or aesthetic properties. In some cases these are older structures whose designs or methods of construction are inadequate in light of present engineering standards and construction methods. In other cases these are new structures under construction that could benefit from the development of new methods of reinforcing and otherwise modifying existing designs.
[0004] Accordingly, it would be desirable to provide methods of modifying these walls in ways that provide greater strength, insulation, waterproofing, vapor-proofing, or aesthetics. One method of reinforcing such walls is disclosed in U.S. Pat. No. 6,662,516 B2, which describes a method of filling a double wall structure and methods of reinforcing a single wall structure with a foamable, adhesive material. Some of the methods described therein require the use of studs and in some cases the use of mechanical fasteners to secure the reinforcing materials to the existing wall. The use of studs in such methods can create thermal pathways which lead to energy losses through the wall and represent an additional cost. Similarly, the use of mechanical fasteners represents an additional cost and may create perforations in the reinforcing material, decreasing its insulation and waterproofing qualities. Thus, methods of modifying existing walls to provide a traditional wall surface without the use of studs or mechanical fasteners would be desirable.
SUMMARY
[0005] Disclosed herein are embodiments of an invention allowing the modification of existing walls. The disclosed methods can be applied to a wall of an old house or building or to a recently constructed existing wall of a house or building under construction. In some embodiments, a form assembly is provided with a form member facing an existing wall, to which sheathing panels are attached. The cavity created between the sheathing panels and the existing wall can be filled with a foamable, adhesive material which adheres to the sheathing panels and the existing wall and creates an adhesive connection between them. In some embodiments, the form assembly is vertically adjustable to facilitate the installation of multiple rows of sheathing panels. In some embodiments, the foamable, adhesive material is introduced in successive layers.
[0006] In one embodiment, a temporary form member can be positioned such that its inner surface is separated from and faces an existing wall. A sheathing panel can be temporarily secured to the form member and the cavity between the sheathing panel and the existing wall can be filled with a foamable, adhesive material which is allowed to cure. Thereafter, the temporary form member can be removed from the sheathing panel.
[0007] In another embodiment, a plurality of vertical posts can be positioned in a row along an existing wall. A vertically adjustable form member can be coupled to the vertical posts such that an inner surface of the form member is separated from and faces the existing wall. A sheathing panel can be temporarily secured to the inner surface of the form member and the cavity between the sheathing panel and the existing wall can be filled with a foamable, adhesive material which is allowed to cure. Thereafter, the temporary form member can be removed from the sheathing panel.
[0008] In yet another embodiment, a plurality of vertical posts can be spaced apart from each other in a row along the length of an existing wall. Vertical sliding members can be adjustably coupled to the vertical posts and upper and lower adjustable frame arms can be connected to the top and bottom, respectively, of the vertical sliding members. Thereafter, a form member can be connected to the upper and lower adjustable frame arms such that it is separated from and faces the existing wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1 and 2 illustrate a method for securing a sheathing layer to an existing wall, according to one embodiment.
[0010] FIGS. 3 and 4 are front elevation and top plan views, respectively, of a completed wall structure comprising a sheathing layer mounted to the interior surface of an existing wall.
[0011] FIG. 5 illustrates from a top plan view a system for modifying an existing wall.
[0012] FIG. 5A illustrates from a side view a system for modifying an existing wall.
[0013] FIGS. 6 and 7 illustrate a method of securing a sheathing layer to an existing wall, according to one embodiment.
DETAILED DESCRIPTION
[0014] FIGS. 1-2 and 5 - 5 A illustrate a method for securing a sheathing layer 8 to an existing wall 10 . In particular embodiments, the sheathing layer 8 is secured to the wall 10 without any studs positioned in the cavity C between the sheathing layer and the wall. The method involves the use of a foamable, adhesive material to secure the sheathing layer to the wall. The foamable, adhesive material also serves as a vapor barrier and a waterproofing layer for the wall structure, and insulates the structure. The sheathing layer also provides a suitable wall surface to which various finishes can be applied (e.g., paint, texturing materials). The method has particular applicability for waterproofing a concrete wall or a masonry wall constructed from courses of masonry units (e.g., bricks, stones, concrete blocks, concrete masonry units, etc.), but can be used to modify a wall of any material. The existing wall can be a wall of an old structure (e.g., house or building) being renovated, or a recently built wall of a new structure being built. As such, the disclosed methods can be used for constructing new wall structures or for retrofitting existing wall structures.
[0015] The sheathing layer 8 can be formed from any of various known materials, such as plywood, gypsum board (drywall), composition board, OSB, hardy board, metal siding, or other forms of boarding known in the art. In particular embodiments, the sheathing layer is formed from standard sections, or panels 14 of gypsum board, which typically are manufactured and sold in 4 foot×8 foot panels, 4 foot×9 foot panels, 4 foot×10 foot panels, or 4×12 foot panels. Gypsum board is desirable because it provides a fire-resistant layer over the adhesive material that is used to secure the sheathing layer to the wall 10 and because gypsum board provides a suitable wall surface that can be finished with any of various decorative materials, such as paint, wall paper, etc. In the illustrated embodiment, the sheathing layer is installed on the interior surface of the existing wall 10 . In other embodiments, a sheathing layer can be installed on the exterior surface and/or the interior surface of the existing wall.
[0016] Referring again to FIGS. 1-2 and 5 - 5 A, the individual panels 14 of the sheathing layer 8 can be installed using a slip form assembly 12 , which is configured to retain individual panels 14 in a vertical position spaced from the wall 10 such that a cavity C is formed between the sheathing panels 14 and the interior surface of the wall 10 . In various embodiments, the width of this cavity is at about 2 inches, but can vary depending upon the particular application. In use, the slip form assembly 12 contacts the outer surface of a sheathing panel 14 being installed and provides resistance against the force exerted on the inner surface of the panel by the foamable material injected into the cavity C.
[0017] As illustrated in FIG. 5 , the slip form assembly 12 can comprise a plurality of vertical posts 16 that are spaced horizontally from each other along a straight line spaced apart from the interior of the wall 10 . Each post 16 can extend the height of the room and can be secured at its lower end to the floor 18 and at its upper end to the ceiling 20 . Any of various suitable fasteners (e.g., nails, screws, etc.) can be used to temporarily secure the posts in place relative to the floor and the ceiling. For relatively tall walls (e.g., walls that are about 30 feet or greater in height between the floor and the ceiling), the posts can be reinforced with temporary wire ties or struts that secure the posts to the existing wall 10 .
[0018] As illustrated in FIG. 5 , a pair of support posts 16 can be provided for every sheathing panel 14 . Mounted to each pair of vertical posts 16 is a movable slip form frame 22 , which includes a respective vertical sliding member 17 on each post 16 , a vertically disposed form member 24 , a form frame 21 , a pair of upper frame arms 13 and a pair of lower frame arms 15 . Each vertical sliding member 17 is configured to slide vertically along a vertical post 16 , and is connected at its upper end to an upper frame arm 13 , and at its lower end to a lower frame arm 15 . The upper and lower frame arms are connected to a respective form frame 21 , which is connected to a vertically disposed form member 24 . In this configuration, the form member 24 is rigidly supported by and vertically movable with the vertical sliding members 17 , which are in turn supported on a pair of vertical posts 16 . FIG. 1 shows the slip form frame 22 in its lowermost position and configured for the installation of the lowermost row 9 a of panels 14 . The slip form frame 22 can be raised vertically relative to the support posts 16 as the rows of panels 14 are installed one on top of another, as illustrated in FIG. 2 , and as further described below.
[0019] Each sheathing panel 14 can be a conventional 4 foot×12 foot piece of drywall, and each form member 24 can have an overall size (length and height) that is about the same as the size of the panels 14 . For example, when installing 4 foot×12 foot panels, the form member 24 can have a height of about 4 feet and a length of about 12 feet. In the embodiment illustrated in FIG. 5 , each sheathing panel 14 and corresponding form member 24 is 12 feet wide, and each form frame 21 is 11 feet 10 inches wide, leaving two inches of clearance between neighboring form frames 21 . As illustrated, for a 12-foot sheathing panel 14 , the paired support posts 16 can be spaced 6 feet 8 inches apart, leaving 5 feet 4 inches separating posts of adjacent pairs.
[0020] In FIGS. 1-2 , the form member 24 is connected directly to the pair of upper frame arms 13 and the pair of lower frame arms 15 . Alternatively, the form member 24 can be supported on a form frame 21 , which is in turn supported by the pair of upper frame arms 13 and the pair of lower frame arms 15 , as illustrated in FIGS. 5-5A . The form frame 21 can comprise an upper, horizontally disposed elongate tubular member 60 extending between a pair of upper frame arms 13 , and a lower, horizontally disposed elongate tubular member 62 extending between a pair of lower frame arms 15 , each extending horizontally along the length of the wall 10 . The form frame can further comprise a plurality of vertically disposed tubular members 64 extending between the upper tubular member 60 and the lower tubular member 62 , and spaced apart from each other at regular intervals. In this configuration, the form frame resembles a ladder extending along and facing the wall, with the vertical tubular members 64 representing rungs of the ladder. Use of the intermediate form frame 21 can be advantageous to increase the rigidity of the form member 24 in cases where the form member 24 comprises a relatively flexible material, e.g., plywood.
[0021] In some embodiments, the upper and lower frame arms are configured to permit adjustment of the position of the form member 24 relative to the wall 10 and therefore the size of the cavity. For example, as illustrated in FIG. 5A , the upper frame arm 13 can comprise a first plate 70 connected to the upper end of the vertical sliding member 17 and a second plate 78 connected to the upper end of the form frame 21 . A first angle iron, or bracket, 72 can be bolted or otherwise secured to the first plate 70 and a second angle iron, or bracket, 76 can be bolted or otherwise secured to the second plate 78 . A threaded rod 74 can be welded to the first and second angle irons, thereby completing the upper arm 13 . In some embodiments the upper frame arm may also be provided with a turnbuckle 80 connecting two sections of the threaded rod 74 for adjusting the length of the upper frame arm 13 , in which case the two sections of threaded rod can be threaded into brackets 72 and 76 . In some embodiments, the lower frame arm 15 comprises a first slotted tube 82 having an outside diameter slightly smaller than the inside diameter of a second slotted tube 84 so that the first slotted tube 82 can be inserted into the second tube in a telescoping manner. By inserting the first slotted tube into the second so that their slots align and sliding one slotted tube with respect to the other, the length of the lower frame arm 15 may be adjusted. By providing a bolt 86 through the slots in both tubes and tightening it with a wingnut 88 , the lower frame arm 15 may be secured and may be provided with strength sufficient to be walked on. The first slotted tube 82 may be connected to the form frame 21 and the second slotted tube may be connected to the vertical sliding member 17 by any suitable techniques or mechanisms, such as bolts, welding, etc. In this configuration, the adjustable nature of the upper and lower frame arms allows rapid changes in the width of the cavity and provides a simple method for achieving proper orientation of the sheathing panels during construction.
[0022] Because the foil member 24 comes in direct contact with the sheathing layer, the form member 24 desirably has a surface that minimizes sliding friction with the outer surface of the sheathing layer when the form member is raised to a higher elevation for installing the next row of panels 14 . For example, the form member 24 can comprise a metal or metal clad form, or a base layer (e.g., metal) having a low friction polymeric layer or coating made of PTFE (polytetrafluoroethylene) or HDPE (high-density polyethylene). The low friction surface allows the form member 24 to slide upwardly relative to a panel 14 of the sheathing layer after it has been installed.
[0023] The form assembly 12 can be provided with releasable securement devices that secure the frame 22 at selected positions along the height of the support posts 16 for installing each row of panels 14 . The securement devices can be, for example, removable pins that extend into openings in the support posts 16 and corresponding openings in the sliding frame 22 .
[0024] A plurality of slip form assemblies 12 can be provided, on which plural form members 24 can be mounted end-to-end such that a form extends along the entire length of the wall 10 . In this configuration, a row of panels 14 extending the entire length of the wall 10 can be positioned adjacent the wall 10 at the same time and secured in place with continuous layers of adhesive material extending the length of the wall in the cavity C. After each row of panels is formed, the frames 22 and respective form members 24 are raised to install the next row of panels 14 above the previously formed row of panels.
[0025] In certain applications, such as when installing a sheathing layer on a relatively long wall, the frames 22 and form members 24 need not extend the entire length of the wall. In such cases, a complete row of panels 14 extending the length of the wall can be installed in sections that extend less than the length of the wall. When forming a partial row of panels, the exposed end of the cavity C can be covered with a layer of material to retain the adhesive material in the cavity.
[0026] Prior to placing the lowermost row of panels 14 on the slip form assembly 12 , a starter clip 26 can be secured to the floor at the location where the lowermost row of panels 14 is to be installed. The clip 26 can be an L-shaped bracket or angle bracket that extends the entire length of the wall or at least partially along the length of the wall at the intersection of the floor and the lower edges of the panels 14 . The clip 26 helps prevent the panels from sliding inwardly toward the wall. As shown in FIG. 1 , the upper edge of the panel 14 can be temporarily secured to the upper edge of the form 24 , such as with one or more spring clips or clamps 28 spaced along the upper edge of the form 24 . As shown in FIG. 3 , one or more conventional ply clips 38 can be used to help align the adjacent vertical edges of adjacent panels 14 in the same row. A layer of tape 50 can be applied to the adjacent vertical edge portions of the panels 14 on their inner surface (inside the cavity) to help seal the abutting edges of the panels and prevent or at least minimize foam leaks. A roller device 52 can be used to apply the tape to the inner surface of the panels (inside the cavity). Alternatively, the tape 50 can be applied to the outer surface of the sheathing layer. At the corner of the sheathing layer, the vertical edges of the panels 14 can be secured to a vertical angle bracket 54 .
[0027] After the lowermost row 9 a of panels 14 is in place to form the cavity C, the cavity can be filled with the foamable, adhesive material 30 to bond the panels 14 to the existing wall 10 . In particular embodiments, the cavity is filled with a plurality of layers 32 of the foamable, adhesive material 30 . Desirably, the adhesive material 30 has the following characteristics: high adhesion to provide a strong bond between the walls; high compressive, tensile, and shear strength; and low expansion. The adhesive material 30 desirably is sufficiently elastic to adsorb energy transmitted to the wall structure caused by seismic activity, has a minimal set up or cure time, and produces minimal off gases harmful to those handling the adhesive material. The adhesive material 30 also may be selected to provide waterproofing for the wall structure to which the adhesive material is applied. Some examples of adhesive material that can be used include, without limitation, open or closed cell polyurethane foam, or other suitable materials. Closed cell foams are most desirable in that they are substantially impervious to water. A suitable polyurethane foam is SR Foam, a closed cell polyurethane foam available from SR Contractors (Portland, Oreg.). The adhesive material 30 desirably has a density from about 1 lb./ft. 3 to 10 lbs./ft. 3 , and even more desirably from about 2 lbs./ft. 3 to 10 lbs./ft. 3
[0028] The adhesive material can be formed by mixing a resin base material stored in a first container with a conventional activating agent stored in a second container. In one example, the base material and activating agent are mixed in a one-to-one ratio. To form polyurethane foam, such as described above, the base material would be a polyurethane resin. The base material may contain surfactants, fire retardants, a blowing agent and other additives. The density of the adhesive material 30 introduced into the cavity can be varied by starting with a base material of a different formulation, typically by varying the amount of activating agent in the formulation.
[0029] Pumps (not shown) in the first and second containers pump the resin base material and activating agent, respectively, through respective hoses (not shown) into a proportioning unit (not shown). The proportioning unit pumps the base material and the activating agent at about 1000 psi through respective hoses 34 to a spray gun, or nozzle, 36 wherein the base material is mixed with the activating agent. The proportioning unit and the hoses desirably have heating coils to preheat the base material and activating agent to about 120 degrees F. When the materials mix in the spray gun 36 , the activating agent triggers an exothermic chemical reaction, the product of which is the adhesive foam material 30 typically having an initial temperature of about 140 degrees F. During this early exothermic stage, the foam is in a viscous seam-like state and can be poured into the cavity. Once in the cavity the foam flows and expands to fill the cavity. The slip form assembly 12 holds the panels 14 in place against the force exerted by the expanding foam.
[0030] The nozzle 36 is moved longitudinally along the bottom of the cavity to form an even layer 32 of material of a height H. After the adhesive material is sprayed into the cavity to form the bottommost layer 32 , the end of the nozzle 36 is raised a sufficient distance so as to avoid contact with the expanding adhesive material, which is allowed to cure before another layer of adhesive material is formed on the bottommost layer 32 . Preferably, the adhesive material is cured until it expands at only a minimal rate (e.g., the adhesive material has expanded to about 99 percent of its expanded state), or more even preferably, to a point where the adhesive material no longer expands. The cure time is a function of the foam density. For example, the cure time for a foam density of 2 lbs./ft. 3 is about 4 minutes while the cure time for a foam density of 10 lbs./ft. 3 may be longer. Once the adhesive material has substantially cured, the end of the nozzle 36 is positioned at a point just above the previously formed, bottommost layer 32 and adhesive material is sprayed on top of the bottommost layer as the nozzle is moved longitudinally along the cavity so as to form an additional layer of adhesive material. The layering process is then repeated until the cavity is filled with layers having substantially the same height H (as illustrated in FIG. 1 ). In particular embodiments, the height H of each layer 32 is about 6 inches to about 48 inches, with about 12 inches being a specific example. Additional details regarding the foamable material 30 and the technique for forming successive layers in the cavity are provided in U.S. Pat. No. 6,662,516, which is incorporated herein by reference.
[0031] After filling the cavity and allowing the adhesive material to cure, another row 9 b of panels 14 can be installed above the previously installed row 9 a of panels. To install the next row of panels, the clips 28 are removed from the form 24 , and the frame 22 and the form member 24 are raised to a new position above the previously installed row 9 a , as depicted in FIG. 2 . The panels 14 of row 9 b are positioned such that their lower longitudinal edges abut the upper edges of the panels below. As best shown in FIG. 3 , one or more conventional ply clips 38 can be placed along the upper edges of the lower panels and the lower edges of the upper panels to assist in aligning the panels of the adjacent rows. The abutting longitudinal edge portions of the panels can be covered with a layer of tape 50 (which can be placed on either the inner or the outer surface of the panels). After a cavity is formed between the row 9 b of the panels and the wall 10 , the cavity can be filled with the adhesive material 30 , in the manner described above. The process of raising the frame 22 and the form 24 , installing a new row of panels, and filling the cavity with the adhesive material 30 can be repeated as needed until the uppermost panel is installed.
[0032] When installing the uppermost row of panels adjacent the ceiling 20 , an upper angle bracket 40 can be secured to the ceiling to assist in supporting the upper edges of the panels 14 in the uppermost row (see FIG. 2 ). In order to inject the foamable material 30 into the cavity, a series of small holes 42 , large enough to receive the distal end portion 44 of the nozzle, can be formed along the upper edge portion of the panel 14 . The distal end portion 44 of the nozzle 36 can be inserted into the various holes 42 for forming layers 32 of adhesive material 30 filling up the cavity C between the wall 10 and the uppermost row of panels 14 .
[0033] Advantageously, the adhesive material 30 secures the panels of the sheathing layer to the wall 10 without any studs or mechanical fasteners, such as nails or screws. The layers of material 30 also function as a water and air barrier for the wall structure such that traditional wall waterproofing is not required. The adhesive material 30 also insulates the wall structure and further reduces energy losses by eliminating the thermal transfer pathways of furring studs. After the sheathing layer is installed, the slip form assembly 12 can be converted into a movable platform 19 for use in finishing the outer surface of the sheathing layer (e.g., painting the sheathing layer). For example, the frame 22 and the form 24 can be placed in a horizontal position to allow a worker to sit or stand on the form 24 when applying a finish to the sheathing layer. Further, in some embodiments, the seams where sheathing panels 14 meet may be sealed with a sealant 11 , such as an epoxy or a polyurethane foam, with one specific example being the Hilti CF 812 Window and Door Low-Pressure Filler Foam. The sealant 11 between panels 14 may be applied to vertical seams within rows of sheathing panels 14 , as well as horizontal seams between rows. Thereafter, the slip form assembly 12 can be removed.
[0034] FIGS. 3 and 4 are front elevation and top plan views, respectively, of a completed wall structure comprising a sheathing layer 8 mounted to the interior surface of the wall 10 . As shown in FIG. 3 , the sheathing layer 8 comprises a plurality of rows 9 a , 9 b , etc. of panels 14 extending the length of the wall 10 . Of course, the number of rows of panels will depend on the height of the wall 10 and the dimensions of the sheathing panels 14 .
[0035] FIGS. 6 and 7 illustrate a method for securing a sheathing layer 8 to an existing wall 10 , using a frame assembly 12 ′ of a different construction. As illustrated, the frame assembly 12 ′ comprises a slip form frame 100 having a vertical sliding member 102 , three connecting members 104 , and a form member 24 . The vertical sliding member 102 is mounted to one or more vertical posts 16 for vertical movement (upwardly and downwardly) relative to support posts 16 . The three connecting members 104 are each attached to the sliding member 102 at one end and to the form member 24 at the other. This arrangement rigidly connects the form member 24 to the sliding member 102 and allows the form member 24 to be adjusted up and down as the sliding member 102 moves along the support posts 16 . FIG. 6 shows the slip form frame 100 in its lowermost position, for installation of the lowermost row 9 a of sheathing panels 14 . The slip form frame 100 can be raised vertically relative to the support posts 16 to install another row 9 b of sheathing panels 14 , as shown in FIG. 7 .
[0036] In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. I therefore claim as my invention all that comes within the scope and spirit of these claims.
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Systems and methods for modifying existing walls are disclosed. In some embodiments, a form assembly is provided with a form member facing an existing wall, to which sheathing panels are attached. The cavity created between the sheathing panels and the existing wall can be filled with a foamable, adhesive material which adheres to the sheathing panels and the existing wall and creates an adhesive connection between them. In some embodiments, the form assembly is vertically adjustable to facilitate the installation of multiple rows of sheathing panels. In some embodiments, the foamable, adhesive material is introduced in successive layers.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to a network of piping. More particularly, it relates to an expansible-type piping network insertible into an underground well or cavity and to a method of using the piping network. Specific embodiments of the invention are directed to the expansion, extension, enlargement, or development of the lower section of a borehole or drilled well. The invention can be utilized in those areas of petroleum technology related to unconsolidated or loosely consolidated hydrocarbon-bearing formations, such as heavy oil deposits or tar sands formations. The invention can also be utilized in the solution mining of soluble material. In another aspect, the invention can also be used to install a radial pipe system in a mined-out or hydraulic cut-out slot or cavern. Primarily, the invention is useful when the hydrocarbon of the hydrocarbon-bearing formation has a high viscosity at normal reservoir conditions. These conditions are related to a minimum or low effective reservoir permeability. In a further aspect, the invention has usage to extend the effective well bore radius for more efficient drainage or injection, regardless of the hydrocarbon viscosity or formation permeability whenever there is excessive resistance to flow from any type blockage at the well bore.
The invention can be used to extend the effective drilled well bore radius through a method of inserting, perpendicularly from the well bore, a radial network of pipes into a relatively unconsolidated formation. After the pipes have been inserted into the formation, the pipe network can be used to carry fluids into the formation, for stimulation of production or development of channels of communication for injection and flow.
The invention has several objects, such as:
installation of a horizontal network of pipes in a formation through a single vertical bore hole.
changing the generally vertical orientation of tubing in a bore hole to a generally horizontal orientation of the tubing in the formation outside the bore hole.
extending or enlarging the effective area or size of a drilled well or bore hole.
establishment of inter-well fluid communication.
processing of single cell production wells, in a "huff and puff" manner.
placing a tubing-diverting tube guide in a vertical bore hole.
a release arrangement whereby a tubing-diverting tube guide can operate to change the direction of tubing, from generally vertical in a bore hole to generally horizontal outside the bore hole.
These objects, together with other objects and advantages which will become subsequently apparent, reside in the details of construction and operation as more fully described and claimed hereinafter.
SUMMARY OF THE INVENTION
My invention for the apparatus involved in the radial pipe network for underground use and the method of using this network fulfills the above-mentioned objects of the invention.
The apparatus itself is typically suspended from and connected to a tube or conduit, such as a drill string or drill pipe. An adapter manifold is used to connect the drill pipe with the remainder of the radial pipe network, and this manifold, or housing, is generally cylindrical in nature. On the upper horizontal surface of the manifold, there is an outlet for connecting the manifold with the drill string or drill pipe. The lower horizontal surface of the manifold has a plurality of outlets. The internal structure of the manifold has passageways allowing the flow of fluid from the drill pipe to the outlets of the manifold.
Attached to and suspending from the lower horizontal surface of the manifold is a plurality of flexible tubes, these tubes being individually fastened to the outlets and generally extending downwardly from the manifold.
At some distance from the lower horizontal surface of the manifold, these tubes enter and are surrounded by a tube guide head. This guide head is generally circular in nature, is horizontally oriented, and has a plurality of openings to accomodate individually the tubes. On the lower surface of the cylindrical tube guide head are attached tube guides. These tube guides extend downwardly from the lower surface of the tube guide head and receive, divert, and direct the tubes leaving the tube guide head. The tube guides, in a released position, are arcuately shaped, thus projecting outwardly from the normal size of the manifold-tube bundle-tube guide head apparatus. In an assembled position, under tension, the tube guides are positioned to have their individual longitudinal axes parallel to the previously described axis of the apparatus. The tube guides and tube guide head, although receiving and guiding the ultimate direction of the flexible tubes, are not rigidly attached to the tubes but surround or enclose the individual tubes, with the tube guides and tube guide head allowing movement of the tubes into and through the head and guides.
At the distal end of the flexible tubes, which extend past the distal ends of the tube guides, is an end cap. This cap, generally in the form of a hollow hemisphere, has the spherical portion of the cap extending downwardly relative to the distal ends of the flexible tubes. A keeper plate, generally circular in nature, is mounted on and covers the open portion of the hemisphere. This keeper plate has individual openings to receive the distal ends of the individual tubes extending from the tube guides. The end cap has an outlet in its spherical portion, opposite the keeper plate.
The above-described pipe network receives fluid from the drill pipe and divides and directs the fluid flow into and through the individual flexible tubes. When the tube guides are in the released position, the fluid flow through the flexible tubes is directed radially outward from the long axis of the tube network. When the tube guides are in the closed, or compressed, position, the fluid flow through the individual flexible tubes is directed into and through the outlet in the lower portion of the end cap.
The method of utilizing this pipe network comprises the steps of:
(a) moving a fluid stream from a conduit, such as a drill pipe, into a pipe manifold attached to the lower end of the conduit (drill pipe),
(b) allowing the fluid to flow from the manifold into individual flexible tubes attached to the manifold, in which the longitudinal axes of the flexible tubes are generally parallel,
(c) enclosing, guiding, and directing the flexible pipes through a tube guide head and associated tube guides, wherein the arcuate tube guides are connected to the lower surface of the tube guide head, such that the ultimate direction of the fluid flow is governed by the ultimate disposition of the tube guides.
(d) arranging the tube guides, and associated flexible tubes enclosed therein, in a closed position, wherein the tube guides are in a compressed orientation in a tube bundle, with the distal ends of the flexible tubes extending through and beyond the distal ends of the tube guides.
(e) allowing the fluid flow into, through, and out of an end cap, generally hemispherical in nature, that surrounds and encloses the distal ends of the tubes of the tube bundle, with an outlet in the lower portion of the end cap offering an outlet for the fluid flow, and
(f) allowing a different direction of flow from the flexible tubes when the end cap is removed, thus placing the tube bundle in the released, or open, position, wherein the flexible tubes, oriented by the arcuately-shaped tube guides, direct the fluid flow in a radial pattern and direction that is generally normal to the longitudinal axis of the tube network, thus allowing a generally vertically-directed fluid flow to be diverted into a generally horizontally-directed flow.
The above-described apparatus, and method of operation, offer a pipe network that ultimately can direct fluid flow in a generally horizontal direction, with the network being introduced into a subterranean formation through a single vertical bore hole. The generally vertical orientation of the tubing in the tube bundle can be directed to a generally horizontal orientation of the tubing when the assembled network is moved through and out of the vertical bore hole. By using the above-described apparatus and method in a plurality of locations, several wells with associated bore holes can be formed, and inter-well communication can be established. If only a single bore hole and single tube network is used, a single well can be processed, in a "huff and puff" manner, using the alternate inflow and outflow of processing fluid through the drill string and pipe network. The apparatus and method of operation also involve a release arrangement whereby the tubing network can be held in one orientation by an end cap and then can assume a different orientation when the end cap is removed. This release arrangement allows a change of orientation of the flexible tubes from generally vertical to generally horizontal, thus allowing the fluid flow to spread horizontally throughout a greater expanse of underground formation than would be allowable when using only a normally vertical tubing orientation.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of the lower portion of the pipe network, with the tube guides in a closed, or compressed, position.
FIG. 2 shows a side view of the lower portion of the pipe network, with the end cap released and the arcuately-shaped tube guides in a released, or open, position.
FIG. 3 shows a side view of one application of the pipe network, showing the drill string, the portions of the pipe network, the formation, and the tube guides in a released portion, with the flexible tubes entering the unconsolidated formation.
FIGS. 4, 5, and 6 show top, bottom, and side views, respectively, of the adapter manifold.
FIGS. 7 and 8 show top and side views of the tube guide head and tube guides in a released, or open, position.
FIGS. 9, 10 and 11 show top, bottom, and side views of the end cap.
DETAILED DESCRIPTION OF THE INVENTION
Since, in one embodiment of the invention, this underground radial pipe network is to be inserted into an underground formation via a well shaft or borehole, the overall diameter of the bundle is such that the assembled bundle can freely travel up and down the bore hole, moved by the drill string or drill pipe. Depending on the depth of the underground formation to be investigated, the overall diameter of the assembled tube bundle can vary from about 4 to about 12 inches. An exemplary tube bundle will have an outside or overall diameter of about 61/2 inches.
For examples of bundle sizes at various formation depths, these values are given:
______________________________________Formation Depth Bundle Size (OD)______________________________________About 500' 83/4"About 1500' 7"About 3000' 7"______________________________________
These measurements are adapted from known petroleum drilling practices.
FIGS. 1 and 2 illustrate the guide mandrel in assembled and released positions.
The number of flexible tubes 12, fixed to and depending from the adapter manifold and movable into, through, and out of the tube guide head and tube guides, varies, broadly, in number from about 2 to about 8, depending on the size of the bore hole and the usable size of each flexible tube. Although FIGS. 1-11 illustrate the use of 4 flexible tubes, these figures merely illustrate one embodiment of the invention. The overall length of the flexible tubes, from the adapter manifold to the distal ends, equals the desired radius of operation of the pipe network when it is extended for operation in the subterranean formation. Broadly, this length can vary from about 50 feet to about 150 feet. In FIGS. 7 and 8, the tube guides 51 can have an inner diameter of about 1-11/2, based on a "bundle" having 4 tubes. In FIG. 3, flexible tubes 32, preferably made of medium tensile steel, have a range of 3/4-11/4" OD, so that they are movable through the tube guides 31, which are made of spring steel. The adapter manifold 34 (FIGS. 3 and 4), the tube guide head (FIGS. 7 and 8), and the end cap (FIGS. 9, 10, and 11) are made of weldable mild steel. The drill string and borehole casing are well-known in the drilling art and need not be discussed here.
As noted in FIGS. 1, 2, and 3, the distal ends of flexible tubes 32 can be cut at a 45° angle ("mule-shoed") to act as a sled in initiating the horizontal travel after receiving the bending moment from tube guides 31. As noted in the figures, the flexible tubes, depending from the adapter manifold 34, are inserted in a spring-loaded guide mandrel made up of a tube guide head 13, and attached larger tubes or flat spring leaves, which act as tube guides 11. As noted in FIGS. 1 and 2, the relaxed, or open, position of the tube guides or spring leaves are in the general shape of about 90° arcs. The proximal end of each leaf or guide tube is fixed in a solid metal mandrel or tube guide head 53 (FIGS. 7 and 8). The distal ends of the leaves or tube guides, when in open position, open outwardly from the general longitudinal axis of the assembly, like an upside-down umbrella. In an assembled, or closed, position the spring leaves or tube guides are compressed, and flexible tubes 12 pass into, through, and out of the tube guides 11 and into the openings in the plate covering the upper portion of the end cap (FIG. 1). In FIG. 9, these tube inlets 63 are honed and provided with seals to give a pressure seal with the flexible tubes. A port, or outlet, 64 is found in the hemispherical portion of the end cap most distant from the plate.
In the operation of this radial pipe network, the flexible tubes, fixed to the lower portion of the adapter manifold 34, are passed through openings 53 (FIGS. 7 and 8), through tube guides 51, and into the end cap (FIG. 9). This means that the tube guides 11 and the flexible tubes 12 are compressed into the configuration shown in FIG. 1, with the distal ends of the flexible tubes projecting through the distal ends of the tube guides into the end cap 15. This end cap acts as a retainer for the ends of the flexible tubes, keeping the tube bundle in the assembled, or closed, position (FIG. 1).
The assembled tube bundle, with end cap in place, is attached to the distal end of the drill pipe and lowered through the well bore to the desired place in the underground formation. If necessary or desirable, fluid can be pumped down the drill pipe, through the tube bundle, and out the port in the end cap, to provide a form of jet action to assist in lowering the assembled tube bundle through the material in the formation,, either in the loose, unconsolidated stage or in a slurry stage.
At the desired depth, a steel ball is dropped into the drill pipe and travels through the tubing network downwardly until it is located in the end cap, where it seals the outlet port. Additional pump pressure applied at this time will force fluid through the tube assembly and into the end cap and will overcome the spring resistance holding the tubes in the end cap, removing the end cap and allowing the spring leaves or guide tubes to flare outwardly, assuming a position such as shown in FIG. 2.
The tube guides, having lengths of approximately 4-6 feet, have a relaxed arcuate shape of approximately a 90° arc. When the spring tension held by the end cap is released, these tube guides, with enclosed flexible tubes, assume the released position. By lowering the principal tubing string, with continued circulation for jetting at the ends of the flexible tubes, the flexible tubes can be pushed and washed out into the unconsolidated formation (or slurry). The limit of the tubing travel and the extent of the flexible tube penetration occurs when the adapter manifold 34 reaches the tube guide head 33 of the guide mandrel. Drill collars and bumper jars can also be used to help drive the tubes into place, if necessary. Sonic vibrations can also be applied to the tubing string to help effect final tube placement.
After placement, treating fluids can then be pumped through the drill pipe and radial flexible tube network to perform the desired results. In well casing of sufficient size, a second string of tubing can be run to recover production from a different level in the well bore.
The treating fluid pumped through the radial tube network is distributed throughout the horizontally-placed flexible tubes. For example, orifice plugs limiting the flow through the distal end of each flexible tube can be used in conjunction with predrilled holes in the horizontally exposed portions of the flexible tubes. These predrilled holes can be filled with temporary metal plugs, such as magnesium plugs. To make the holes available for the distribution of the processing fluid, a preliminary flow of a plug-removing liquid, such as dilute acid, can be pumped through the radial tube network, thus making distribution of the ultimate processing fluid more efficient through the exposed portions of the flexible tubes.
In one embodiment of the operation of this radial tube network, preliminary work can be done in the underground formation to form a cavity around the axis of the well bore. Other devices, not shown, can be used to cut away the unconsolidated formation by jet action of fluids, such as water, to form a slurry. When the cavity, formed by the jetting action, is filled with slurry, the drill string connected to the jetting apparatus can be withdrawn, and the radial tube network can be connected to the drill pipe and lowered, as described above. When the processing stage is completed, the flexible tubes can be withdrawn by pulling with the drill pipe. The released guide mandrel will be left in place at the bottom of the bore hole. If the flexible tubes are stuck there, various cutting devices, known in the petroleum drilling industry, can be used to separate the radial pipe network at the adapter manifold, leaving those portions below in the underground formation.
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The network, useful in conducting fluids to underground sites, is an assembly of flexible pipes or tubes, suspended from and connected to a drill pipe. The flexible pipes, assembled in a bundle, are spring biased to flare outwardly in an arcuate manner when a releasable cap on the distal end of the bundle is removed. The assembled bundle is inserted into and lowered down a bore hole. When the cap is released, the pipes flare radially and outwardly. Fluid, pumped into and through the assembly, can be directed into the underground formation for various purposes.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] This disclosure relates to improvements in leakage detection.
[0002] General usage leak detectors are known and used to detect leakage of relatively low temperature fluids in a system, such as water. A typical leak detection system utilizes an electric capacitor on the exterior of a pipe within the system. Water that leaks from the pipe contacts the capacitor, changing the capacitance and indicating a leak.
SUMMARY
[0003] A leak detector according to an exemplary aspect of the present disclosure includes a fabric including a conductor, the fabric having an electric property between the conductor and a reference, the electric property having a first value in response to the fabric being in a non-wetted state with regard to a working fluid and the electrical property having a second value different than the first value in response to the fabric being in a wetted state with regard to the working fluid.
[0004] In a further non-limiting embodiment of the foregoing example, the working fluid is a high temperature working fluid.
[0005] In a further non-limiting embodiment of any of the foregoing examples, the fabric is selected based on the high temperature working fluid.
[0006] In a further non-limiting embodiment of any of the foregoing examples, the working fluid is molten salt.
[0007] In a further non-limiting embodiment of any of the foregoing examples, the fabric is adjacent a conduit.
[0008] In a further non-limiting embodiment of any of the foregoing examples, the conduit contains the working fluid.
[0009] In a further non-limiting embodiment of any of the foregoing examples, the reference is a second conductor of the fabric.
[0010] In a further non-limiting embodiment of any of the foregoing examples, the reference is ground.
[0011] In a further non-limiting embodiment of any of the foregoing examples, the reference is a conduit.
[0012] A leak detection system according to an exemplary aspect of the present disclosure includes a conduit for carrying a working fluid, and a detector on the outside of the conduit, the detector including a fabric with a conductor having an electrical property that changes responsive to contact with the working fluid.
[0013] In a further non-limiting embodiment of the foregoing example, the fabric is a sleeve configured to fit on the outside of the conduit, the sleeve extending around a central axis and between axial ends and an inner surface and an outer surface relative to the central axis. The conductor has a portion that is embedded within the fabric between the inner surface and the outer surface.
[0014] In a further non-limiting embodiment of any of the foregoing examples, the sleeve includes at least one groove on at least one of the outer surface or the inner surface.
[0015] In a further non-limiting embodiment of any of the foregoing examples, the at least one groove is elongated and extends along a longitudinal axis that is perpendicular to a longitudinal axis defined by the sleeve.
[0016] A leak detector according to an exemplary aspect of the present disclosure includes a porous sleeve configured to fit on the outside of a conduit, the porous sleeve extending around a central axis and between axial ends and an inner surface and an outer surface relative to the central axis, and an electrical circuit having at least a portion that is carried by the porous sleeve, the electrical circuit having an electrical property that changes responsive to contact with a leaked fluid.
[0017] In a further non-limiting embodiment of the foregoing example, the electrical circuit includes a controller configured to activate an indicator in response to change in the electrical property.
[0018] In a further non-limiting embodiment of any of the foregoing examples, the porous sleeve is a fabric.
[0019] In a further non-limiting embodiment of any of the foregoing examples, the electrical circuit includes a portion that is dissolvable in the leaked fluid.
[0020] In a further non-limiting embodiment of any of the foregoing examples, the electrical circuit is open when free of any contact with the leaked fluid.
[0021] In a further non-limiting embodiment of any of the foregoing examples, the electrical circuit is closed when free of any contact with the leaked fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
[0023] FIG. 1 shows an example leak detection system.
[0024] FIG. 2 shows a modified leak detection system having an electrical circuit that is normally closed.
[0025] FIG. 3 shows a cross-section through a conduit and portion of a leak detector.
[0026] FIG. 4 shows an example of a sleeve of a leak detector having a groove on an outer surface.
[0027] FIG. 5 shows another example sleeve of a leak detector having a groove on an inner surface.
[0028] FIG. 6 shows another example of a sleeve of a leak detector having multiple grooves that run parallel to electrical leads.
[0029] FIG. 7 shows an example of a porous sleeve of a leak detector.
[0030] FIG. 8 shows another example of a leak detector in which a conduit serves an electrical lead.
DETAILED DESCRIPTION
[0031] FIG. 1 illustrates an example leak detection system 20 including a leak detector 22 . In this example, the leak detection system 20 is adapted for a system that carries a relatively high temperature fluid, such as molten salt in a concentrated solar power plant. It is to be understood, however, that some or all of the embodiments disclosed herein can be also used in other systems or systems that utilize lower or higher temperature fluids. Other examples are the use of the leak detection system 20 for in-situ medical devices to detect leaking body fluids after surgery.
[0032] In the illustrated example, the leak detection system 20 includes a conduit 24 that carries a working fluid. The working fluid can be a molten salt, such as potassium nitrite salt, sodium nitrite salt, fluoride salt or a mixture of salts. The leak detector 22 is mounted on the outside of the conduit 24 and has an electrical property that changes in response to contact with the working fluid. Thus, the change in the electrical property indicates a leak of the working fluid from the conduit 24 . In this regard, the leak detector 22 can be located on a portion of the conduit 24 where leaked working fluid is likely to flow to. For instance, the leak detector 22 can be located at a vertically low portion on the conduit 24 such that any leaked working fluid gravitationally flows downward and over the leak detector 22 .
[0033] In the illustrated example, the leak detector 22 includes an electrical circuit 26 that has a conductor, first electrical lead 26 a, and a reference conductor, second electrical lead 26 b. The electrical leads 26 a / 26 b are connected to a controller 28 . For example, the controller 28 can include an indicator 30 , such as a visual indicator, audible indicator, etc., control logic, a power source or other additional features for controlling the operation of the leak detector 22 .
[0034] The electrical leads 26 a / 26 b are carried on a fabric 32 that is configured in this example as a sleeve to fit on the outside of the conduit 24 . As an example, the fabric 32 includes fibers 32 a that are arranged in a fiber network and pores 32 b extending between the fibers 32 b . The fibers 32 a can be natural, organic fibers, synthetic polymer fibers or other fibers suitable for the intended use. That is, the fabric 32 is selected based on the type and temperature of the working fluid. The fiber network is a woven structure, for example. The fabric 32 sleeve has an inner diameter corresponding to the diameter of the conduit 24 to enable the fabric 32 to be slid over the conduit 24 .
[0035] In this example, the fabric 32 sleeve is cylindrical and extends around a central axis A between axial ends 34 a / 34 b and an outer surface 36 a and an inner surface 36 b. As can be appreciated, the electrical leads 26 a / 26 b can be attached on the outer surface 36 a of the fabric 32 , attached on the inner surface 36 b of the fabric 32 or embedded within the fabric 32 between the outer surface 36 a and the inner surface 36 b.
[0036] In this example, the electrical circuit 26 is open when free of any contact with the working fluid. Leaked working fluid from the conduit 24 flows into the fabric 32 and bridges the electrical leads 26 a / 26 b to complete the circuit. In the completed circuit, electrical current can flow between the electrical leads 26 a / 26 b and change the state of an electrical property of the leaked detector 22 , to indicate a leak.
[0037] Alternatively, as shown in FIG. 2 , a modified electrical circuit 26 ′ is closed when free of any contact with the working fluid. In this example, the electrical circuit 26 ′ includes a portion 26 c that changes electrical properties when in contact with the working fluid. Thus, when there is no leak, current flows between the electrical leads 26 a / 26 b through the portion 26 c. However, upon leakage of the working fluid from the conduit 24 , the leaked working fluid dissolves or changes the electrical properties of the portion 26 c to change the state of the electrical circuit 26 ′. The change from one state to the other state indicates a leak.
[0038] FIG. 3 illustrates a cross-section showing a further example in which there is a layer of thermal insulation 40 between the conduit 24 and the leak detector 22 . In this example, the fabric 32 is mounted on the outside of the layer of thermal insulation 40 . Specifically, in systems such as concentrated solar power plants that carry working fluid at temperatures typically in excess of 500° F./260° C., the conduit 24 includes the layer of thermal insulation 40 to reduce thermal losses.
[0039] FIG. 4 illustrates another example fabric 132 that can be used in the leak detector 22 . In this disclosure, like reference numerals designate like elements where appropriate and reference numerals with the addition of one-hundred or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding elements. In this example, the fabric 132 includes at least one groove 150 on the outer surface 36 a thereof. The groove 150 is generally larger than the pores between the fabric fibers. The groove 150 facilitates directing any leaked working fluid into contact with the electrical leads 26 a / 26 b. For example, any leaked working fluid flowing over the sleeve 132 is caught within the groove 150 and thereby directed into contact with the electrical leads 26 a / 26 b. The groove 150 thus enhances leak detection where the fluid or molten salt might not otherwise contact the leads 26 a / 26 b.
[0040] FIG. 5 shows another example sleeve 232 having a groove 250 on the inner surface 36 b thereof. The groove 250 operates similar to the groove 150 described above.
[0041] FIG. 6 illustrates a further example of a fabric 332 that includes multiple grooves 350 on the outer surface 36 a. It is to be understood, however, that the grooves 350 may alternatively may be on the inner surface 36 b. Although only two grooves 350 are shown, additional grooves may be used. In this example, the grooves 350 are elongated in a direction that is generally parallel to the central axis A of the fabric 332 sleeve. The electrical leads 26 a / 26 b generally extend in a direction parallel to axis A′, which is perpendicular to the central axis A. Orienting the grooves 350 to be perpendicular to the electrical leads 26 a / 26 b facilitates directing any of the leaked working fluid into contact with the electrical leads 26 a / 26 b.
[0042] FIG. 7 illustrates another example fabric 432 , or porous sleeve in this example, that can be used in the leak detector 22 . In this example, the electrical leads 26 a / 26 b (only electrical lead 26 a shown) are embedded within the fabric 432 between the inner surface 34 b and the outer surface 34 a. The fabric 432 includes pores 460 through which any leaked working fluid can flow to contact and bridge the electrical leads 26 a / 26 b. The size of the pores 460 in the fabric 432 can be tailored to the viscosity of the working fluid, to provide a wicking action that facilitates leakage detection. Further, the fabric 432 protects the electrical leads 26 a / 26 b from outside damage.
[0043] FIG. 8 illustrates another example in which the conduit 24 serves as an electrical lead in place of the electrical lead 26 b. The conduit 24 is grounded at G such that any leaked working fluid from the conduit 24 bridges the fabric 532 to complete the circuit between the electrical lead 26 a ′ and the conduit 24 , which thus serves as the reference.
[0044] Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
[0045] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
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A leak detector includes a fabric having a conductor. The fabric has an electric property between the conductor and a reference. The electric property has a first value in response to the fabric being in a non-wetted state with regard to a working fluid and the electrical property has a second value different than the first value in response to the fabric being in a wetted state with regard to the working fluid.
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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 portable apparatus for forming reinforced concrete, hollow core units of a modular building structure, and more particularly to conical spacers used for supporting and spacing supplemental forms in parallel relationship to primary forms of a core unit and for providing locating holes when removed for vertical alignment of the core unit for casting multi-storied structures.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. Nos. 3,993,720 and 4,029,287 disclose apparatus for forming modular building structure with both patents disclosing nonremovable conical spacers adapted to support and space vertical steel plates of supplemental forms in parallel relationship the required distance from the vertical steel plates of the primary form. Since these nonremovable conical spacers can only serve a single given function, a need exists for removable conical spacers that not only can be used again but the hole from which they have been removed can also serve as a means for later form alignment purposes.
SUMMARY OF THE INVENTION
In accordance with the invention claimed, an improved spacer is provided for use in forming hollow core modular building structures of single or multi-story construction.
It is, therefore, one object of this invention to provide an improved conical shaped spacer for use in forming modular building structures.
Another object of this invention is to provide an improved conical spacer for spacing form components and when cast in concrete decks may be removed to provide alignment holes for sequential multi-storied form use.
A further object of this invention is to provide an improved apparatus for forming modular building structures which employs removable conical spacers used for spacing and alignment purposes.
Further objects and advantages of the invention will become apparent as the following description proceeds and the features of novelty which characterize this invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more readily described by reference to the accompanying drawing in which:
FIG. 1 is a front end elevational view of an assembled inner form or cell structure showing the side wall, ceiling and corner filler components of the device in fully expanded relationship with removable side panels of a supplemental form shown in combination with the novel conical spacers disclosed and claimed herein;
FIG. 2 is a partial sectional view of a conical tapered hole in a precast deck formed by use of the claimed spacer used as a location means for a plunger of a cell structure for alignment purposes;
FIG. 2A is a sectional view showing how the conical spacer is held in place in the form prior to casting the deck shown in FIGS. 1 and 2;
FIG. 3 is a view similar to FIG. 2 showing the plunger of the form assembly penetrating the hole formed by the spacer previously removed;
FIG. 4 is a view similar to FIG. 3 with the plunger fully in place in the taper hole previously formed by the spacer disclosed herein;
FIG. 5 is a cross sectional view of plunger and one of its guiding frames;
FIG. 6 is a perspective view of a spacer and guide frame supporting a rebar;
FIG. 7 is a view partially in section of a spacer support frame and rebar in cast concrete; and
FIG. 8 is a view showing the spacer being removed from its position shown in FIG. 7 to provide an alignment hole.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings by characters of reference, FIG. 1 discloses an assembled inner form or cell structure 10 for use in precasting hollow core construction comprising right and left side wall assemblies or frames 11 and 12, respectively, and a top or ceiling assembly 13.
It should be noted that the inner form of cell structure 10 is capable of being utilized to produce a plurality of single story interconnected hollow core concrete units in side by side relationship or a plurality of similar units in high rise relationship of two or more storied structures. Therefore, when the cell structure is being set up to produce the first story of a multiple unit structure, the side walls 11 and 12 of the forms are allowed to rest on the level inner top surfaces of the previously prepared concrete footings or on a floor or ground surface as indicated in FIG. 1 of the drawings. When being set up to produce a second and subsequent stories of the structure, the side walls 11 and 12 are supported a slight distance above the level surfaces of the floor/ceiling portion of the finished hollow core unit directly below as described in U.S. Pat. No. 4,029,287 which is incorporated herein by reference.
Each cell structure 10 includes two or more bridge like heavily constructed steel inner frame members 18, the quantity depending on the overall length of the cell structure and each inner frame consists of a horizontal tie beam 19 and a pair of depending side members 20 and 21. The frame member is preferably fabricated of standard I-Beam steel stock which is welded to form a perfectly squared contiguous form which is installed in the interior of cell structure 10 in spaced parallel relationship to the side wall assemblies 11 and 12 and the top or ceiling assembly 13. This frame member is arranged to move or reciprocate vertically with assemblies 11, 12 and 13 to which it is rigidly secured by longitudinally disposed parallel I-beams 22. These I-beams 22 extend between the inner surface of the ceiling assembly over and beyond the horizontal top surfaces of the bridge like inner frame members 18. The depending vertical side members 20 and 21 are movably associated with the side wall assemblies 11 and 12 by pairs of hydraulic cylinders 23, pairs of outwardly extending angle brackets 24 having removable pins, and pairs of pivoting link and bracket assemblies 25.
The side wall assemblies 11 and 12 and the top or ceiling assemblies 13 are preferably fabricated of heavy gauge steel plates that are perfectly flat and smooth on their outer surfaces having welded thereto on their inner surfaces a plurality of equally spaced, parallel vertical or horizontally disposed reinforcing ribs 26. The ceiling plate is just wide enough to extend beyond the ends of the horizontal ribs 27 to provide an equal right angle opening or vacated space 28 which extends the full length of the inner form or cell 10 when the same is in either its fully expanded or contracted position to allow for the manual insertion or removal of the longitudinal segments of suitable split, flexible, corner filler pieces 29 into or out of the right angle openings 28. The filler pieces are provided to square off and close the corner openings in preparation for the forming of a hollow core concrete unit and to allow for removal of the inner form or cell from the formed unit when the concrete is set.
Reference is made to the description in U.S. Pat. No. 4,029,287 for a more detailed description of cell structure 10 and its function.
When the building project calls for the construction of single or multiple width side by side hollow core concrete units of either one or several stories high, the inner form or cell structure 10 is set up or installed so that the opposed smooth outer surfaces of the side plates of the side wall assemblies 11 and 12 are spaced apart the required distance. In order to form the outside vertical side walls of the cell, it is necessary to utilize supplement frame members or forms of any suitable type having smooth surfaced vertically mounted steel plates 30 (indicated in FIG. 11). These plates are temporarily attached to side wall plates 11 and 12 by means of removable bolts or studs which are threaded through the respective vertical plates from both sides thereof into the threaded bores of a plurality of removable conical spacers 31 embodying the invention. These spacers are adapted to support and space the vertical steel plates 30 of the supplemental forms in parallel relationship the required distance from the vertical steel plates 11 and 12.
When the particular hollow core concrete units of the building structure are cured, these forms can quickly be removed from their described attachment to side plates 11 and 12 of the side wall assemblies of the cell structure by simply removing the bolts or studs from the plates and conical spacers 31. Spacer 31 are then removed from the finished concrete walls for reuse.
The inner form or cell structure 10 may be utilized to form the hollow core units of a high rise or several storied building structure and the difficult task of setting up or installing the cell structures on the top surface of the finished floor/ceiling portion 15 of the concrete units in proper aligned and spaced relationship for forming the next story of the building structure has been simplified by the utilization of spacers 31.
The conical spacer 31, as shown in FIGS. 2A and 6, comprises an elongated plastic or metallic conical housing 32 having a smooth outer surface and a threaded aperture 33 extending axially therethrough or at least a part thereof for receiving a threaded bolt 34 at either or both ends thereof.
This spacer is then used, as shown in FIG. 1, for spacing and supporting the vertical steel plates 30 of the supplemental forms to the wall assemblies of the cell structure by bolts 34 extending through apertures in the supplemental form and the steel plates and into the spacers for holding them in a predetermined position between the supplemental form and the cell structure.
To aid in holding rebars in place between the supplemental forms and the steel plates 11 and 12 an apertured circular shaped clamp 35 may be secured to rebars 36 and the conical spacer. As shown in FIGS. 5-7, housing 32 of spacer 31 is longitudinally moved through the aperture in the clamp until a snug fit occurs at a given point along its length, thereby holding the rebar in the center of the gap between the supplemental form and members 11 and 12 during a concrete pouring operation. Depending on the size of the aperture of clamp 35, the rebar may be placed at various places in the poured concrete.
After concrete 37 is poured and set the spacer is removed, as shown in FIG. 8, since it is no longer needed to hold in position the rebar.
If the building structure is to be two or more stories high, spacer 31 is used to provide form alignment holes 38 in the ceiling of the first and/or any story of the multi-story building. To accomplish this function the conical spacers are positioned in a ceiling of the module of the building in the same manner as disclosed above with the spacer tapering downwardly, as shown in FIGS. 2 and 2A.
Then after removal of the spacer by the removal of the spacer bolt 34, the housing is withdrawn upwardly leaving a tapering hole 38 in the ceiling of the building.
In order to receive and position the inner form or cell structure 10 in parallel alignment, above the top floor/ceiling 15 of the finished lower structure, the above described tapered holes 38 are used by parts of the cell form mounted above the ceiling of the lower structure for alignment purposes.
As shown in FIGS. 2-4, an alignment plunger 40 of the form forming a part of cell structure 10 is mounted above holes 38 and is reciprocally moved into holes 38 by its handle 41 for form aligning purposes and is sequentially moved out of these holes later when the concrete of the newly poured upper story has set.
Although but one embodiment of the invention has been shown and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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A conical spacer assembly for supporting and spacing one member relative to another member comprising a conical housing having a smooth outer surface and hole extending axially therethrough for receiving at one or both ends thereof a bolt in threaded arrangement therewith. A flat circular shaped clamp having an aperture extending laterally therethrough is provided for receiving through its aperture the housing of the spacer which clamp snugly engages the housing at a point along its length laterally thereof and engages and supports a rebar at one or more point around its periphery.
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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 a continuation-in-part of and claims priority in U.S. patent application Ser. No. 14/085,524, filed Nov. 20, 2013, which is incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related generally to an automobile display canopy with a specialized anchoring system, and more particularly to a canopy which is anchored by plates secured by the wheels of an automobile while providing optimal viewing display of the vehicle in a car-show setting.
2. Background and Description of the Related Art
Car shows and other automobile-related events typically feature a large outdoor space where a number of vehicles are on display for the viewing public and other automobile enthusiasts. Ideal weather for such events is a sunny, warm, clear day. This can result in the sun beating down on the expensive custom paint job of a prized automobile for hours at a time. Additionally, rain or other inclement weather can appear at any time. Vehicle owners desire to protect their vehicles from the sun and other weather effects, but often this is impossible during auto-show settings.
Currently, if a person wants to protect their vehicle from the elements, they would have to put their vehicle into a garage or shed, cover their vehicle with a tarp or soft cover, or use a common patio tent. However, these means of vehicle protection do not facilitate the display of vehicles at auto-shows. Permanent garages and sheds cannot be transported to show sites, and would make it difficult for viewers to see the vehicle stored within. Similarly, tarps and soft covers conceal the car completely, and therefore are not suitable for protecting a vehicle at a car show or event.
While some auto enthusiasts use collapsible patio tents more commonly seen at sporting tailgate events, there are several problems with these tents. First, they are not typically intended for setup on pavement or concrete, where automobiles would typically be parked. Because of this, a tent set up at a car show has a high likelihood of being blown over in the wind. The long metal legs of such tents pose serious danger to the paint and finish of these highly cared-for vehicles at car shows. If such a tent were to blow over, several vehicles could be damaged. Typical means of anchoring these tents have not solved this issue. For this very reason, such tents are banned at most, if not all, car show events. Even still, existing collapsible tents are typically not large enough to accommodate vehicles for these purposes.
What is desired is a canopy that may be anchored by the automobile itself, is customizable for automobiles of any size, and which is highly portable. Heretofore there has not been available an automobile display canopy with the advantages and features of the present invention.
SUMMARY OF THE INVENTION
The present invention is an automobile canopy with an anchor system for securing the canopy to the ground using the automobile itself. The general components of the present invention are a collapsible canopy including at least four canopy legs, and four anchor platforms which hold the canopy in place and allow a vehicle to drive onto the plates, thereby securing the entire system to the ground.
The anchors may include a single tire stop, signaling to the driver when the wheel reaches a stopping point. An alternative embodiment may include both a front stop and a rear stop. The legs of the canopy must be collapsible. They may telescope or be disassembled temporarily.
An alternative embodiment anchor would include several mounting slots for mounting the base of the canopy legs to accommodate larger and smaller vehicles.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
FIG. 1 is an isometric view of a preferred embodiment of the present invention incorporated into a typical environment.
FIG. 1A is a detailed isometric view taken about the circle 1 A of FIG. 1 .
FIG. 1B is a detailed isometric view taken about the circle 1 B of FIG. 1 .
FIG. 2 is a top plan elevation of an anchor plate embodying an element of a preferred embodiment of the present invention.
FIG. 3 is a side elevational view thereof.
FIG. 4 is a front elevational view thereof.
FIG. 5 is a side elevational view detailing the connection at the end of a pole element comprising one of the canopy legs, which is an element of a preferred embodiment of the present invention.
FIG. 6 is a side elevational view detailing an alternative embodiment thereof.
FIG. 7 is a top plan view of an alternative embodiment anchor plate embodying an element of an alternative embodiment of the present invention.
FIG. 8 is a top plan view of another alternative embodiment anchor plate embodying an element of an alternative embodiment of the present invention.
FIG. 9 is a side elevational view thereof.
FIG. 10 is a rear elevational view thereof.
FIG. 11 is a diagrammatic side elevational view of the alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
I. Introduction and Environment
As required, detailed aspects of the disclosed subject matter are disclosed herein; however, it is to be understood that the disclosed aspects 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 how to variously employ the present invention in virtually any appropriately detailed structure.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.
A preferred embodiment of the present invention provides an automobile display canopy 2 featuring four anchors 4 which allow the canopy to be deployed around the vehicle 6 while being anchored to the ground by the vehicle 6 such that the canopy will not blow over causing damage to the vehicle 6 or other vehicles in the vicinity.
II. Embodiment or Aspect of the Vehicle Display Canopy 2 Having Anchors 4
As shown in FIG. 1 , the canopy 2 includes a number of collapsible legs 9 , four anchor plates 4 , a canopy covering 8 and connections 22 between the covering 8 and the legs 9 . In a preferred embodiment, each of the legs 9 is separated into at least two portions, shown in FIG. 1 as a top portion 10 and a bottom portion 11 . The two portions are connected by a pin 19 . Alternatively, the legs 9 could be telescoping legs that lock into place when extended. Other means of combining leg portions together could be used as well, such as joining two threaded ends together or using a temporary fastener.
The bottom portion 11 of each leg 9 is pinned into a receiver 14 of an anchor 4 . The receiver 14 is welded to a toe 17 which is formed by a mechanical break in the base plate 16 of the anchor 4 . Each plate also includes one or two tire stops 18 which make contact with the tires 20 of the vehicle 6 being protected and displayed under the canopy 2 . If the anchor 4 employs a single stop 18 , it would be located toward the front edge of the base plate 16 . Once the tire makes contact with the stop, the driver is notified by the impact that the tire is fully located on the anchor 4 . In the case of two stops 18 , the driver would drive over the first stop such that the tire is located between both stops (see FIGS. 3 and 4 ). The cross section of a stop could vary in shape. A triangular cross section, half-moon cross section, or even square or rectangular cross section would suffice.
The covering 8 is intended to protect the vehicle 6 from the sun. Car shows may last all day long, and the sun can cause paint to fade and wear. Paint jobs on show-cars can be extremely expensive, and car owners want to protect their vehicles from any and all elements. Similarly, the covering could be waterproof to protect the vehicle from rain. The cover could partially or fully roll down the sides of the canopy 2 , snapping to or otherwise being connected to the legs to form an enclosed tent.
The canopy 2 would cast a shadow around the vehicle, depending on the sun's position in the sky. Chairs could be placed in the shaded area provided by the canopy. As the sun moves, the shade may shift, and chairs could be moved to follow this shaded space.
FIG. 1A shows the connection 22 between the cap 12 of the upper portion 10 of a leg 9 with the canopy covering 8 . A grommet 24 is located at each corner of the covering 8 . As shown in FIG. 1A , a threaded post 28 connected to or inserted into the cap 12 of the upper leg portion 10 is inserted through the grommet 24 and a threaded nut 26 is used to fasten the cover 8 to the leg 9 . FIGS. 5 and 6 show two alternative connecting means in more detail, although these are not the only means by which the cover 8 may be connected to the legs 9 .
FIG. 1B shows the connection between the lower leg portion 11 and the anchor 4 in more detail. Specifically, it shows how the lower leg portion 11 is pinned into the receiver 14 using a removable pin 15 . The pin could be a cotter pin or any other type of connecting means for securing the leg 9 to the anchor 4 while the canopy 2 is in use. The function of the anchor 4 is to use the vehicle's 6 own weight to hold down the canopy 2 , preventing it from blowing over in the wind, which could potentially damage the vehicle 6 or other vehicles in the vicinity. FIG. 1B also shows how the tire 20 could be trapped between two stops 18 , securing the vehicle tire squarely onto the anchor.
FIG. 2 shows how the receiver 14 is welded to the toe 17 . The base plate 16 is broken in the manufacturing process to form the toe 17 , which adds structural stability to the anchor 4 and provides additional surface area for welding the receiver 14 . FIG. 3 shows the receiver 14 connected to the toe 17 via spot weld 21 . FIGS. 3 and 4 provide additional detail of the anchor 4 , showing how the tire 20 interacts with the stops 18 .
FIG. 5 shows an embodiment of the connection 22 between the upper leg portion 10 and the grommet 24 which is connected to the covering 8 . A plug 30 is threaded into the cap 12 of the upper leg portion 10 . The embodiment shown in FIG. 5 includes a threaded post 28 extending from the plug 30 . The post 28 is inserted through the grommet 24 and a threaded nut 26 is threaded onto the post 28 , securing the grommet 24 , and thus the cover 8 , to the upper leg portion 10 .
FIG. 6 shows an alternative embodiment connection 122 . Again, a plug 130 is threaded into the cap 12 of the upper leg portion 10 . The plug 130 includes a threaded receiver 128 . A threaded bolt 126 is inserted through the grommet 24 and is threaded into the receiver 128 , thereby securing the grommet 24 , and thus the cover 8 , to the upper leg portion 10 .
Any other conceivable means of securing the cover 8 to the upper leg portion could also be used. For example, a simple hook, clasp, or carbineer could be used to connect the grommet 24 to a hook or loop located or connected to the cap 12 of the upper leg portion 10 . Similarly, bungee cords or ties could be used.
III. Alternative Embodiment Anchor 104
FIG. 7 displays an alternative embodiment of the anchor 104 which may be used with the same legs 9 and canopy cover 8 as the system described above.
The wheelbase of vehicles can range from around 112 inches to around 129 inches. Thus it may be necessary for a system to accommodate multiple vehicles using the same anchors 104 , legs 9 , and cover 8 . The embodiment shown in FIG. 7 includes a single wheel stop 118 as discussed above. The base plate 116 features a similar break forming a toe 117 . Four receivers 114 are shown aligned along the break and welded to the toe 117 via spot welds 121 . The receivers are shown facing in different directions to further accommodate the different wheel-base lengths of different automobiles; however, they could all point out in the same direction.
Four receivers 114 are shown, however as few as two may be used or as many as are necessary to accommodate all vehicle types. Alternatively, a single receiver on a sliding track may be used. The sliding track could be locked in place against the plate 116 , unlocked and slid into a new position accommodating a larger or smaller vehicle, and then re-locked in the new position.
IV. Alternative Embodiment Display Canopy 202 with Anchor 204
Yet another alternative embodiment display canopy system 202 with anchor 204 is shown in FIGS. 8-11 . This embodiment includes several features which add strength and utility to the embodiments disclosed above.
FIG. 8 shows an anchor 204 having a base plate 216 including a toe 217 featuring several bolt holes 221 . The entire plate 216 and toe 217 are laser cut from a single piece of aluminum or other suitable metals. Aluminum is ideal for weight and functionality. The base plate is further laser cut to form the detent 218 which acts as a wheel stop. The detent 218 is broken from the base plate 216 using a press break. This provides the most affordable and effective way of placing a wheel stop on the anchor 204 .
A selectable receiver plate 220 is bolted to the toe 217 via several bolts 225 passing through a set of bolt holes 223 located on the receiver plate 220 along with the bolt holes 221 located on the toe.
A leg post 214 is inserted into a notch 222 of the receiver plate 220 and welded into place. The post is a solid roll pin which slots over the notch via a cap in the receiver, and includes a pin hole 215 for receiving a pin. A leg segment 210 of the canopy 202 is placed over the leg post 214 , and a pin is inserted through the leg and the receiver, thereby locking the leg to the anchor 204 . Again, the leg segments 210 would ideally be aluminum, though other suitable metals could also be used.
As shown in FIG. 11 , a preferred embodiment includes at least eight leg segments 210 , which allows for two segments per leg. The segments are interchangeable and fit together using a connecting post 228 and a pin in the same way that a leg portion 210 connects with the leg post 214 . The connecting post 228 ideally is simply a swedged end of the leg portion 210 , although the post 228 could be a separate element. The connecting post 228 of the top-most leg segment 210 is fitted through the grommet 24 of the canopy 8 and a pin is used to prevent the grommet 24 from slipping off of the post 228 . As the leg portions 210 are interchangeable, any such leg portion could connect to the leg post 214 or the grommet 24 .
It is to be understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects.
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An automobile display canopy with an anchor system for securing the canopy to the ground using the automobile itself. The general components of the present invention are a collapsible canopy including at least four canopy legs, and four anchor platforms which hold the canopy in place and allow a vehicle to drive onto the plates, thereby securing the entire system to the ground. The anchors may include a single tire stop, signaling to the driver when the wheel reaches a stopping point. An alternative embodiment may include both a front stop and a rear stop. The legs of the canopy must be collapsible. They may telescope or be disassembled temporarily.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to an improved hinge, in particular to a hinge for a lighting mast of the type which comprises an upper mast portion and a base, which upper mast portion is rotatable about a horizontal pivot axis in the base of the mast.
The present invention further rotates to an improved arrangement for the raising and lowering of masts, in particular lighting masts, which require to be raised and lowered for repair and routine maintenance.
In known mast systems, for example those described in GB Patent No 2 349 653, unauthorised lowering of the mast is prevented by the combination of a docking system preventing lowering of the mast when the docking system is engaged, a locking system manually operable selectively to allow or prevent disengagement of the docking system and a hinge operable to allow pivoting of the mast when the locking system is unlocked and the docking system is disengaged.
Currently available systems for raising and lowering masts of this type, for example the systems described in in GB Patent No 2 349 653, are manually operated and controlled, rather than automatic, and are suitable for use with the previously used smaller systems, but are not ideally suited for the raising and lowering of the larger systems, because of the need for manual intervention by an operator working in close proximity to the base of the mast.
It is an object of the present invention to provide a hinge mechanism in which the above disadvantages are reduced or substantially obviated.
SUMMARY OF THE INVENTION
The present invention provides a hinge mechanism which comprises first and second chock plates and an adjustable shaft, each of the chock plates including an aperture in the form of a figure of eight, the first and second circular portions of which are similar and are connected by a neck portion of a width less than the diameter of the circular portions and the shaft is longitudinally adjustable between a first retracted position in which the sections of the shaft aligned with each of the chock plates have a cross-section which corresponds to the circular portion of the aperture, and a second extended position in which the sections of the shaft aligned with each of the chock plates have a cross-section the diameter of which is less than the width of the neck portion.
In a preferred embodiment of a hinge according to the invention, the shaft comprises a set of two cam rams, one mounted at either end of a pivot shaft, each of the cam rams comprising a cylinder, a ram shaft which extends through the cylinder and is slideable therein and a circular cam plate mounted on a first end of the ram shaft, the ram shaft having a diameter less than the width of the neck portion and the cam plate having a cross-section which corresponds to a circular portion of the figure of eight aperture.
The present invention further provides an arrangement for the raising and lowering of a mast, which comprises an upper mast portion and a base, which upper mast portion is rotatable about a horizontal pivot axis, located in the base of the mast, which arrangement comprises
(i) docking means for restraining the upper mast portion against rotation; (ii) attachment means for attaching drive means for driving the docking means between a first engaged configuration wherein the upper mast portion is restrained against rotation and a second disengaged configuration wherein the upper mast portion is free to rotate and (iii) locking means selectable via an intermediate unlocked configuration between a first locked figuration wherein the docking means is engaged and a second unlocked configuration wherein the docking means is disengaged characterised in that the locking means comprises a hinge mechanism which comprises first and second chock plates and an adjustable shaft, each of the chock plates including an aperture in the form of a figure of eight, the first and second circular portions of which are similar and are connected by a neck portion of a width less than the diameter of the circular portions and the shaft is longitudinally adjustable between a first retracted position in which the sections of the shaft aligned with each of the chock plates have a cross-section which corresponds to the circular portion of the aperture, and a second extended position in which the sections of the shaft aligned with each of the chock plates have a cross-section the diameter of which is less than the width of the neck portion.
In a preferred embodiment of the arrangement according to the invention the shaft comprises a set of two cam rams, one mounted at either end of a pivot shaft, each of the cam rams comprising a cylinder, a ram shaft which extends through the cylinder and is slideable therein and a circular cam plate mounted on a first end of the ram shaft, the ram shaft having a diameter less than the width of the neck portion and the cam plate having a cross-section which corresponds to a circular portion of the figure of eight aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
A hinge according to the invention and an arrangement for the raising and lowering of a lighting mast will now be described with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a mast (upper mast portion truncated) in the raised, docked and locked position, with hydraulic lift rams attached;
FIG. 2 is a perspective view of a pair of cam rams, with the rams retracted;
FIG. 3 is a view corresponding to FIG. 2 , with the rams extended;
FIG. 4 is a perspective view of a hinge assembly, including a ram according to FIG. 2 , forming part of a mast according to Figure, with the ram retracted;
FIG. 5 is a view corresponding to FIG. 2 , with the ram extended;
FIG. 6 a is a view of the attachment face of a mast of FIG. 1 in the raised, docked and locked position, with hydraulic lift rams attached;
FIG. 6 b is a section on the line B-B of FIG. 6 a;
FIG. 6 c is an enlarged view of the region C of FIG. 6 b;
FIG. 6 d is a side view of the mast of FIG. 6 a;
FIG. 6 e is a section on the line A-A of FIG. 6 d;
FIGS. 7 a to 7 e are views corresponding to FIGS. 6 a to 6 e in the raised, docked and unlocked position;
FIGS. 8 a to 8 e are views corresponding to FIGS. 6 a to 6 e in the raised, undocked and unlocked position;
FIGS. 9 a to 9 e are views corresponding to FIGS. 6 a to 6 e in the raised, undocked and locked position; and
FIGS. 10 a to 10 e are views corresponding to FIGS. 2 a to 2 e in the lowered, undocked and unlocked position.
DETAILED DESCRIPTION
As can be seen from FIG. 1 , a mast shown generally at 10 comprises an upper mast portion 2 and a base portion 4 . The upper mast portion 2 is in the form of a hollow tapering cylinder and is shown truncated in the drawings.
The base portion 4 comprises an upper base portion 6 and a lower base portion 8 . The upper base portion 6 is in the form of a substantially hollow square section box. The upper mast portion 2 extends into the upper base portion 6 and is secured thereto. The lower base portion 8 is secured to the ground (not shown). A docking latch 12 is formed at the lower end of the upper base portion 6 , for engagement with a co-operating notch 14 in the upper end of the lower base portion 8 .
As can be seen more clearly in FIGS. 1 to 5 , a horizontal pivot axis 16 extends through the upper base portion 6 and terminates at each end in a cam ram 18 , each of which cam rams 18 comprises a cylinder 20 , a shaft 22 which extends through the cylinder 20 and is slidable therein and a cam plate 24 mounted on a first end of the shaft 22 . The diameter of the shaft 22 varies along its length. The second end of the shaft 22 terminates in a spigot 29 of smaller diameter than the shaft 22 and projects through an aperture in the end of the cylinder 20 remote from the cam plate 24 . One external end face only of one cam plate 24 is visible in FIG. 1 .
A mounting groove 27 , the function of which will be described below, is provided in the outer wall of the cylinder 20 . The cylinder 20 is further provided in a manner known per se with an inlet 20 ′ and an outlet 20 ″ for the supply and removal of hydraulic fluid.
A chock plate 26 , having an aperture 28 in the form of a figure of eight, is provided on a side wall of the upper base portion 6 . A similar chock plate 26 is located on the opposite sidewall of the upper base portion 6 in alignment with the first chock plate 26 .
Each circular portion of the figure of eight aperture 28 has an internal diameter corresponding to the diameter of the cam plate 24 .
In the position shown in FIGS. 1 , 3 and 5 , the cam plate 24 of the cam ran 18 engages in the upper circular portion of the figure of eight aperture 28 .
The neck portion of the aperture 28 is sized so as to allow the shaft 22 of the cam ram 18 to pass freely between the circular portions of the aperture 28 .
In the configuration shown in FIG. 2 , the cam ram 18 is in the retracted configuration, with the cam plate 24 in contact with the cylinder 20 .
As can be seen from FIG. 4 , the shaft 22 extends through the cylinder 20 . The cam plate 24 is mounted on the free end of the shaft 22 .
In the configuration shown in FIG. 3 , the cam ram 18 is in the extended configuration, with the cam plate 24 spaced from the cylinder 20 and supported by the shaft 22 .
FIGS. 4 and 5 show a cam ram according to FIGS. 2 and 3 , in situ in a lighting mast as shown in FIG. 1 . A mounting bracket 31 for sensors, the function of which will be described later, is located within the upper base portion 6 .
In the configurations shown in FIGS. 1 , 4 and 5 , the cam ram 18 is shown aligned vertically with the upper circular portion of the aperture 28 , which corresponds to the raised, docked and locked position of the mast 10 .
In the configuration shown in FIG. 5 , the cam ram 18 is in the extended configuration, with the cam plate 24 spaced from the cylinder 20 and supported by the ram shaft 22 .
The upper base portion 6 of the mast 10 includes a collar 33 for mounting engagement in the mounting groove 27 .
In the position shown in FIG. 1 , the cam plate 24 of the cam ram 18 engages in the upper circular portion of the figure of eight aperture 28 .
The neck portion of the aperture 28 is sized so as to allow the shaft 22 of the cam ram 18 to pass freely between the circular portions of the cam ram 18 . Upper U-shaped mounting brackets 32 and lower mounting brackets 34 are located on the upper base portion 6 and lower base portion 8 respectively, for receiving lift ram cylinders 36 . The left ram cylinders 36 are supplied in a manner known per se by a manifold 38 mounted on a bracket 40 secured to the cylinders 36 by means of yokes 42 .
In FIG. 1 , the hydraulic ram cylinders 36 are shown in a partially extended configuration with the mast in a raised, docked and locked position.
FIG. 6 a is a view of the mast of FIG. 1 in the same configuration, but showing the attachment face 44 of the upper base portion 6 .
A second manifold 46 , for supply to the cam ram 18 is provided.
As can be seen from FIGS. 6 c and 6 e , the mast is provided with a plurality of sensors S 1 to S 8 , which have the following functions:
Sensors S 1 and S 2 together sense the start of the extension of the lift rams 36 and full closure of these rams;
Sensors S 1 and S 3 together sense the vertical alignment of the mast 10 ;
Sensors S 1 and S 4 together sense the full extension of the lift rams 36 and the start of closure of these rams;
Sensors S 5 , S 6 and S 7 together sense the extension and closure of the cam rams 18 ;
Sensors S 1 , S 2 and S 4 together sense the engagement/disengagement of the docking latch 12 relative to the notch 14 and
Sensor S 8 senses the proximity to the ground of the lowered mast.
As can be seen from FIGS. 6 e and 7 e , a pair of cam rams 18 are located aligned on the horizontal pivot axis of the mast 10 .
Each of the cam rams 18 is moveable between a first, locking position as shown in FIG. 6 d and 6 e , in which the cam plate 24 of the cam ram 18 is engaged in the upper cylindrical portion of the aperture 28 in the chock plate 26 , and an intermediate position, which can be seem most clearly in FIG. 7 e , in which the cam plate 24 of the cam ram 18 projects from the side wall 30 of upper base portion 6 and the shaft 22 of the cam ram 18 extends through the aperture 28 .
The operation of the system will now be described with reference to FIGS. 6 to 10 of the accompanying drawings.
The normal operational position of the mast 10 is shown in FIGS. 6 a to 6 e . In this position, the mast 10 is raised, locked by means of the cam plate 24 in engagement with the upper circular portion of the aperture 28 in the chock plate 26 . The vertical alignment of the mast 10 is checked by sensor S 2 and the extension of the lift rams 36 is sensed by sensors S 1 , S 2 and S 4 . The control system then extends the cam rams 18 until full extension is confirmed by the sensors S 6 , S 7 .
The position of the mast 10 is now as shown in FIGS. 7 a to 7 e , i.e., raised, docked and unlocked. The control system then extends the lift rams 36 so as to lift the upper mast portion 2 and the upper base portion 6 relative to the lower base portion 8 and to disengage the docking latch 12 from the notch 14 . The sensors S 1 and S 4 confirm that the disengagement is complete.
The position of the mast 10 is now as shown in FIGS. 8 a to 8 e , i.e., raised, undocked and unlocked. The control system then retracts the cam rams 18 and hence the cam plates 24 into engagement with the lower circular portion of the aperture 28 and the sensors S 5 and S 6 confirm that the retraction is complete.
The position of the mast 10 is now as shown in FIGS. 9 a to 9 e , i.e., raised, undocked and locked. The control system then retracts the lift rams 36 , and the mast is lowered about the horizontal pivot axis 16 until the ground proximity sensor S 8 senses a predetermined proximity to the ground, and retraction of the lift rams 36 is terminated.
The mast 60 is now in the position shown in FIGS. 10 a to 10 e , i.e., lowered, undocked and locked.
After the required repair or maintenance work has been carried out, the lowering sequence is repeated in reverse, so as to return the mast 10 to the position shown in FIGS. 6 a to 6 e.
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A hinge mechanism comprises first and second chock plates and an adjustable shaft. Each of the chock plates includes an aperture in the form of a figure of eight, the first and second circular portions of which are similar and are connected by a neck portion of a width less than the diameter of the circular portions. The shaft is longitudinally adjustable between a first retracted position in which the sections of the shaft aligned with each of the chock plates have a cross-section which corresponds to the circular portion of the aperture and a second extended position in which the sections of the shaft aligned with each of the chock plates have a cross-section of a diameter which is less than the width of neck portion.
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This application claims benefit of Applicants pending Provisional entitled “MECHANICAL CONVEYOR ROLLER ASSEMBLY INSTALLING SYSTEM” filed Feb. 3, 2006 as No. 60/765,151.
BACKGROUND OF THE INVENTION
1. Field
This invention is directed to an apparatus for lifting and placing heavy items in precise position for installation such as installing heavy mine belt roller assemblies which include, for example three heavy rollers mounted on a steel frame, as repair or for belt extensions or the like in underground tunnel mining operations.
In the field of underground mining, most mines transport material from the mining faces to the outside of the mine by means of belt conveyors. Even in shaft mines, conveyor belts usually transport the material to the shaft skips. As an example of one typical situation, as mining progresses, conveyor beltlines must be extended by installing conveyor belt, top run and return run idler rollers, and support structure therefor. In the higher production mines which have wider belts, larger and much heavier roller assemblies and frame structure are required to support the conveyor belts.
2. Prior Art
Heretofore, installing the roller assemblies, for example, has been very difficult for the workers, to the point of being a chronic safety issue. A single top roller assembly can weigh over 300 lbs. requiring four or more workers to lift and manipulate the assembly in precise mounting position on supporting rails of a conveyor. Medium size idler assemblies weighing 100 lbs. or so each are still a safety issue. A single back injury can cost a mining company over $500,000.
Installing the larger belt components is also a production efficiency issue. Work accomplished per hour in making an installation is slow, and considerable production can be lost due to the extended time required to make, for example, a belt advancement (extension). Needed for years has been a good mechanical means to lift, manipulate and precisely position the larger roller assemblies and frame structure to reduce difficulty, number of workers, man hours, injuries, and downtime encountered in the installation. Further, in the case of coal mining, which is the largest segment of underground mining in general, the tunnel width is limited, by law, to 20 feet. The belt lines are usually installed with the edge of the belt line on the center line of the shaft entry leaving a maximum of about 10 feet lateral space in which to accomplish a mechanical installation of roller assemblies or other structure. Also involved in developing a viable mechanical alternative to the human back is the limited vertical room to the mine roof such that large equipment may not fit into the shaft.
SUMMARY OF THE INVENTION
A vehicle supported lifting system for placing, for example, heavy mining conveyor belt items such as roller assemblies, conveyor frame side rails, frame sections or the like in precise positions for attachment to other conveyor structure, wherein the vehicle can get into cramped quarters in the mine alongside the conveyor and extend, retract, rotate and further manipulate an item pick-up crane mounted on the vehicle, whereby the crane with item pick-up means mounted on an end thereof can pick up and place, e.g., a roller assembly in a precise position and posture on a conveyor frame for making said attachment, and further in a preferred embodiment, the apparatus is provided with second crane means for lifting a moving conveyor belt off of a roller assembly for replacement of said assembly with or without stopping the belt, whereby worker lifting and manipulation of heavy roller assemblies or other heavy mining structures is eliminated.
As used herein:
Conveyor belt: is the conveyor belting itself;
Top Roller Assembly: this is the frame and one horizontal and two side angle rollers built into a roller assembly that supports the conveyor belt top run;
Return Roller Assembly: is usually one single roller that supports the return side (bottom run) of the conveyor belt;
Support Structure: are the stands and rail system that the roller assemblies are mounted on and fastened to. The support structure can stand on the mine floor or can be suspended from the mine roof.
The present system is designed primarily to remove or install the top roller assemblies since they are the heaviest and most difficult items to handle and affix. The conventionally used top roller assemblies are not required to be changed or modified to accept the mechanical means of the present invention in order to allow precise positioning and maintenance of the roller assemblies on the conveyor frame while affixing them thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become understood further from the drawings and description thereof, wherein:
FIG. 1 is a top down perspective view of the present positioning apparatus in a mine shaft or mine tunnel in the process of picking up a conveyor belt roller assembly from a fork lift pallet;
FIGS. 2-4 are subsequent progressions of FIG. 1 of the process of placing a roller assembly in precise position on a conveyor frame by use of the present apparatus;
FIG. 5 is a side view of FIG. 1 taken along line 5 - 5 in FIG. 3 ;
FIG. 6 is a perspective view showing the present apparatus placing a conveyor rail section in position for installation;
FIG. 7 is an enlarged view of an embodiment of the present apparatus showing a preferred clamping device for holding a roller assembly precisely and securely on the present apparatus;
FIG. 8 is a perspective view of a preferred base structure for the present apparatus;
FIG. 8A is an end view taken along line 8 A- 8 A in FIG. 8 ;
FIG. 8B is an end view, slightly in perspective, taken along line 8 B- 8 B in FIG. 8 ;
FIG. 9 is a partially cross-sectioned view of one working embodiment of the present primary crane with first stanchion means and lifting boom;
FIG. 9A is a view of elements of embodiments of the present invention, taken along the reference lines 9 A- 9 A in FIG. 9 ;
FIG. 9B is a view of elements of embodiments of the present invention;
FIG. 9C is a view of elements of embodiments of the present invention, taken along the reference lines 9 C- 9 C in FIG. 9 ;
FIG. 9D is a view of alternative embodiments of the first and second sections of the present invention;
FIG. 10 is a side view of an embodiment of a universal motion power system for the item gripping means;
FIG. 10A is a partially sectioned view taken along line 10 A- 10 A in FIG. 10 ;
FIG. 10B is a view taken along line 10 B- 10 B in FIG. 10 ;
FIG. 11 shows the present apparatus mounted on a pallet trailer wherein the hydraulic power source is mounted on a connected or separate trailer;
FIG. 12 is a top view of a variation of the power means for moving section 43 on section 38 ;
FIG. 13 is a longitudinal cross-section taken along line 13 - 13 in FIG. 8A showing another variation of the power means for moving section 43 on section 38 ;
FIG. 14 is a side view of the belt lifting mechanism taken along line 14 - 14 in FIG. 1 ;
FIG. 15 is a top down view taken along line 15 - 15 in FIG. 8B showing the back to back dual cylinder mounting; and
FIG. 16 is a perspective view showing the mining item placement crane and the belt lifting crane both in action.
DETAILED DESCRIPTION
The present invention will be understood further with reference to the drawings and to the claims herein wherein the invention comprises an apparatus generally designated 20 for picking up heavy structural items such as individual roller assemblies 22 , pallets 24 loaded with such assemblies, conveyor railing 26 and/or floor stands therefor 26 F, roof supports, air stoppings and the like, particularly as used in coal mines or other mines, especially where the items are to be manipulated into confined spaces for assembly, and then placing the items in precise positions for assembly onto structures located in said confined quarters.
The lifting is done by a crane generally designated 19 which is mounted on a base means generally designated 34 of the apparatus, which base means is adapted for attachment to a vehicle such as an articulated power mine tractor 28 , a mine supply vehicle, trailer 30 , fork lift truck, farm tractor, skid steer or the like, including a non-wheeled skid, all having a transport axis 32 . A hydraulic power system 29 is preferably provided on the vehicle or the base means. The base means 34 has a first base section 36 adapted for attachment (by mounting plate 36 A or other similar structure), either permanent or removable, to said vehicle at, for example, a face plate 36 B thereof. The base means 34 further has a second base section 38 mounted on said first section 36 for movement with respect thereto in a generally horizontal first plane 40 . A first power means 42 is provided for controllably moving said second section 38 relative to said first section 36 in said first plane 40 . A third base section 43 is mounted on said second section 38 for movement with respect thereto in a generally horizontal second plane 44 by second power mans 46 . By means of these three base sections, a greater lateral reach can be achieved by the positioning of the second and third sections without requiring a berth greater than the width of the vehicle. For example, double sliding bases with a 60 inch frame can provide an 84 inch total slide.
A first stanchion means 48 is pivotally mounted on a generally vertical axis 50 on said third section 43 for movement with said third section in said second generally horizontal plane 44 , and third power means 52 is provided for pivoting said first stanchion means about said substantially vertical axis 50 . A lifting boom 54 having a longitudinal axis 56 has an inner end portion 58 pivotally mounted on an upper end portion 60 of said first stanchion means for pivoting of said boom in a generally vertical plane 62 . A fourth power means 64 is provided for controllably pivoting said boom in said generally vertical plane 62 .
A structural item gripping means generally designated 66 is mounted on an outer end 68 of said boom by fifth power means generally designated 70 for pivoting said gripping means into a desired posture relative to said boom, and wherein said boom is constructed with extendable-retractable boom sections of any number such as 2 - 6 , but preferably three such as 72 , 74 , 76 for elongating or shortening said boom respectively, and wherein sixth power means is provided for extending and retracting said sections.
Referring further to base mans 34 and FIGS. 8 , 8 a , 8 b and 9 b , this base structure is preferably constructed of heavy steel components, e.g., ½-¾ in. thick steel sections welded together to form a plurality of I-beam frames 36 I and 38 I, as depicted in monolithic form as in the figures. The second base section 38 is provided with longitudinally extending slide bars 80 of low friction, readily slidable, tough plastic material such as poly tetra fluoroethylene (Teflon), polyoxymethylene (Delrin), high density polyurethane or the like which can resist the wear of long term sliding in channels 82 of the first base section. These bars are held in place in the channels preferably by steel strips 84 having bolts 86 spaced longitudinally therealong and welded thereto. In assembling these bars on section 38 , strips 84 are slid longitudinally into slots 88 to where the ends of the strips and bars substantially coincide. The bolts, affixed to strips 84 , are then inserted thru holes which were predrilled thru 38 at the same longitudinal spacing as the bolts. Nuts 92 are then tightened to securely and immovably fasten the bars to 38 .
As a variation, strips 84 with the bolts welded thereto can be mounted within the bars at the same position as shown by casting the plastic around the strips rather than employing slots 88 . Also, as shown in FIG. 9D roller bearings (or CAM Followers) such as 94 or the equivalent mounted on supports 96 which is welded in strategically longitudinally spaced positions on section 38 can be used to rollably support section 38 on section 36 , both upper and lower portions thereof. Conversely, such rollers can be mounted on section 36 rather than section 38 by bearing means known to the art.
The above described bars 80 and their mountings are also preferably employed for the third base section 43 and the equivalent structures are numbered the same. The above described roller bearing variation is also applicable for the third base section.
Referring to FIGS. 8 , 8 A and 8 B, the opposed hydraulic cylinders 35 , 37 for powering the sliding motion of section 38 on section 36 are fixed relative to each other in a housing 39 which is longitudinally movable and free floating within a channel 41 of section 36 . Piston 45 is fixed at its end to section 36 by pin 47 and piston 49 is fixed at its end to section 38 by pin 122 . With this structure, simultaneous extension of both pistons 45 , 49 will move section 38 longitudinally along section 36 toward position A on 36 , and simultaneous retraction of these pistons will move section 38 toward piston B on 36 ( FIG. 7 ).
In similar manner the opposed hydraulic cylinders 55 , 57 for powering the sliding motion of section 43 on section 38 are fixed relative to each other in a housing 53 which is longitudinally movable and free floating within a channel 117 of section 38 . Piston 118 is fixed at its end to section 38 by pin 119 and piston 120 is fixed at its end to section 43 by pin 121 . With this structure, simultaneous extension of both pistons 118 , 120 will move section 43 (and crane 19 ) longitudinally along section 38 toward position C on 38 ( FIG. 7 ), and simultaneous retraction of these pistons will move section 43 (and crane 19 ) toward position D on 38 . All of the above pistons are double acting.
Two useful alternative power means for moving section 38 on section 36 and for moving section 43 on section 38 are shown in FIG. 12 for sections 38 and 43 as an example. In FIG. 12 a gear rack 123 of a rack and pinion set is longitudinally affixed to section 38 and an electric or hydraulic motor 124 is mounted on 43 such that its drive gear 125 meshes with rack 123 . Section 43 is slidably mounted on 38 in the manner shown for example in either of FIG. 8A or 9 D.
In FIG. 13 the power means comprises a roller chain or V-belt or the like 126 fixed as by link means 129 to a depending bracket 130 of base section 43 , and mounted on sprockets or pulley wheels 127 respectively, either or both of which sprockets or pulley wheels is driven by, e.g., hydraulic or electric motors. For the chain or belt a supporting slide plate such as 128 affixed to 38 is preferably provided.
Referring further to FIGS. 9 , 9 A, 9 B and 9 C, a mounting structure and rotative power means for the first stanchion means 48 is shown as a main gear 98 welded to the bottom of a lower section 100 of the stanchion wherein the outer portion 101 of the bottom of 98 is circularly grooved to accommodate a ring of ball bearings 102 which also rest in an adjacent circular groove in a stanchion base 104 . The base 104 is bolted as at 106 to third base section 42 for sliding movement therewith. It is noted that section 42 can be used as the stanchion base 104 . A hold down rim 108 and a brass or the like ring shaped wear bushing 110 slidingly engages the upper surface of gear 98 and holds stanchion 48 in its upright posture. An electric motor 112 or equivalent is mounted on bracket 114 bolted as at 115 to stanchion base 104 and its output shaft carries a drive gear 116 engaged with gear 98 for rotating stanchion 48 in response to operator signal.
Stanchion 48 preferably is formed of two sections, lower 100 and upper 59 . A hydraulic cylinder 61 , single or double acting, is affixed to stanchion 48 or to gear 98 and to upper section 59 for adjusting the vertical position of boom 54 . The upper section 59 is pivotally mounted by pin 63 to the boom, and a hydraulic cylinder 64 is pivotally affixed to section 59 and the boom for controllably pivoting the boom in plane 62 .
In the example shown, boom 54 is formed by any number of mutually slidable sections and three sections 72 , 74 and 76 are preferred. These sections may be provided with internal rollers 65 , 67 mounted for rotation on the outer ends of sections 72 and 74 , respectively and with external rollers 69 , 71 mounted for rotation on the inner ends of section 74 and 76 respectively. Double acting hydraulic cylinder 73 is affixed to inner end cap 75 of section 74 and to inner end cap 77 of section 76 for controllably extending and retracting section 76 . The hydraulic lines 79 , 81 extend rearwardly thru opening 83 in cap 75 and exit thru bottom opening 85 over roller 87 rotatably mounted on section 72 . A tension spring 89 is affixed by clamp 91 or equivalent to lines 79 , 81 in order to maintain sufficient tension on these lines to prevent kinking thereof as the piston 93 of hydraulic cylinder 95 is retracted. This piston is affixed to cap 75 and double acting cylinder 95 is affixed to end cap 97 of section 72 . The hydraulic lines 103 , 105 for cylinder 95 exit thru openings 99 in cap 97 . Manually operable lever operated control valves for all of the hydraulics is provided in conventional manner.
The item contact portions of the gripping means 66 can take a variety of configurations depending on the shape of the item, and a highly preferred configuration for gripping a typical belt roller assembly is shown in FIGS. 7 , 10 , 10 A and 10 B wherein a fork lift type gripping means is shown. A hydraulic cylinder 103 or heavy duty solenoid is mounted on the top frame portion 105 and with a sliding clamp 103 A serves to clamp the roller assembly frame 107 against the forks 109 , 111 .
A part of the gripping means 66 is the articulating devices therefor, generally designated 21 . These devices, preferably, with reference to the roller assembly and to FIG. 7 give universal articulation in endwise up and down rotation 23 , in sideways rotation 25 , and in up and down tilt 27 . These devices can be electrical motor-gear type, hydraulic cylinder type, but preferably a hybrid (combination) of rotary hydraulic actuators 29 and 33 , and electrical motor-gear types 31 . A typical rotary hydraulic actuator useful in the present invention is disclosed in U.S. Pat. No. 5,447,095 the disclosure of which is hereby incorporated herein by reference in its entirety. In FIGS. 7 and 10 , actuator 33 tilts the forks as 27 , actuator 29 rotates the forks sideways as 25 , and electrical motor-gear 31 (by means of a tilt rotator ring gear 31 A) rotates the forks as 23 . For certain uses all three power devices may not be necessary, in which case whichever motion is not needed, its associated device can be eliminated.
Referring to FIGS. 14 and 16 , the belt lifting crane generally designated 131 , in a preferred embodiment is constructed the same as item lifting crane 19 as described above except that the lateral slide base mans 36 , 38 , 43 , the item gripping means 66 , and the articulating device 21 are not needed; however, a sliding bracket 131 B may be provided, as shown in FIGS. 1-3 . In that regard the end 133 of boom (or telescoping arms) 134 can be fixed to the belt lift frame 135 since only generally lateral extension and retraction of the boom sections and possibly vertical pivoting of the boom by hydraulic piston 136 is needed in order to move frame 135 underneath the belt and out from under the belt. Attached to frame 135 is a central roller 137 and side rollers 138 , 139 , the latter being mounted on frame 135 for up and down pivoting about pins 140 such that in the down positions they can lie on the rotational axis 141 of roller 137 for supporting a flat belt, and in the up position can accord to a conventional cradled belt. Arms 144 are fixed to the roller shaft body of 138 and 139 such as to give the up and down positions. Brackets 142 and 143 on frame 135 are provided with, e.g., bolt holes and bolts for retaining the arms in a selected one of the aforesaid positions. This element is shown in use in FIG. 1 wherein a conveyor belt (top side) 150 is lifted up away from the conveyor belt (return side) 151 by the belt lift frame assembly 135 hereinabove described, said frame extending from the boom of the lifting crane 131 . In one embodiment side rollers 138 and 139 are about 9 inches long, the central roller 137 is about 34 inches long, the lateral distance between the lower portion of arms 144 is about 20 9/16 inches, and the distance between the top of the side rollers 138 and 139 and the bottom of the lower portion of arms 144 is about 14½ inches.
As shown in FIGS. 1-3 , a fork lift 160 may further be incorporated between the base 34 and the vehicle so as to facilitate transportation of pallets of conveyor rails and the like.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications will be effected with the spirit and scope of the invention.
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A vehicle supported mine item positioning apparatus for placing, for example, heavy mining conveyor belt items such as roller assemblies, conveyor frame side rails, frame sections or the like in precise positions for attachment to other conveyor structure, wherein the vehicle can get into cramped quarters in the mine alongside the conveyor and extend, retract, rotate and further manipulate an item pick-up crane mounted on the vehicle, whereby the crane with item pick-up means mounted on an end thereof can pick up and place, e.g., a roller assembly in a precise position and posture on a conveyor frame for making said attachment, and further in a preferred embodiment, the apparatus is provided with second crane means for lifting a moving conveyor belt off of a roller assembly for replacement of said assembly with or without stopping the belt, whereby worker lifting and manipulation of heavy roller assemblies or other heavy mining structures is eliminated.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/243,508 filed Sep. 17, 2009, which is hereby incorporated herein by reference.
FIELD OF INVENTION
The present invention relates to hydraulic drive systems for spreaders used to distribute a road surface treatment material, such as sand or salt, across a road surface.
BACKGROUND
Hydraulic drive systems have been used to drive a feed auger and spinner of a spreader typically carried by a vehicle for spreading a road surface treatment material, such as sand or salt, across a road being traversed by the vehicle. The feed auger delivers the road surface treatment material from a supply thereof, such as a hopper, to the spinner which distributes the material across a road surface.
Many of these systems are designed as self-contained units that can be mounted in the bed of a pickup dump truck. Pressurized hydraulic fluid is supplied by a hydraulic pump typically driven by a gasoline engine. Cab-mounted, manually operated hydraulic flow control valves have been used to adjust the rotary speeds of the material conveyor (auger) and spinner fan (spinner).
Electrically-operated hydraulic valves have been used for spreading applications. These systems have used a parallel type flow configuration for supplying hydraulic fluid to the hydraulic motors that drive the auger and spinner. These systems require relatively large pumps to supply adequate flow to the auger and spinner motors.
U.S. Patent Application Publication No. 2005/0204587 discloses a microprocessor-controlled hydraulic system for snow-ice removal trucks that uses digital hydraulic valving control responsive to the instantaneous speed of the truck. According to this document, a binary form of digital valving removes a requirement for vulnerable feedback lines and associated sensors. As disclosed, the hydraulic motors for driving the auger and spinner are serially connected. The valves are either in an open position or a closed position depending on the desired amount of hydraulic flow. When no hydraulic pressure is to be supplied to the auger and/or spinner motors, i.e. when the digital control valves are all closed, hydraulic flow is routed back to reservoir by a bypass valve. When the bypass valve is open, pressure cannot buildup at the inlets to the auger and spinner motors.
SUMMARY OF INVENTION
The present invention provides a hydraulic drive system for a spreader used to distribute a road surface treatment material, such as sand or salt, across a road surface. The hydraulic drive system enables the use of pressure-compensated proportional control valves in series relationship with the auger and spinner motors, and thus eliminates the need for digital valving equipped with a bypass valve that prevents pressure buildup in the system when hydraulic fluid is not being supplied to the auger motor and/or spinner motor.
A preferred embodiment of the invention is characterized by the use of a lower cost and smaller displacement hydraulic pump that enables installation in the engine compartment of a vehicle so it can be driven by the engine's fan belt. This eliminates the need for and cost of a gasoline-powered auxiliary engine, as well as the associated noise, pollution, and maintenance requirements. The hydraulic pump need only be sized to provide hydraulic flow satisfying the larger of the flow requirements for the auger and spinner motors, rather than the sum of the requirements as in the case of parallel systems.
More particularly, a hydraulic system for operating the feed auger and spinner of a spreader includes first and second fluid motors for driving the feed auger and spinner. The fluid motors are connected in series with one another and first and second solenoid-operated pressure-compensated proportional control valves each including a pressure compensating spool. The first valve has an inlet configured to receive pressurized fluid from a source thereof such as an engine compartment mounted hydraulic pump, a regulated flow outlet connected to the inlet of the first fluid motor, and a bypass flow outlet, whereby operation of the valve controls the volume of flow of pressurized fluid supplied to the inlet of the first fluid motor via the regulated flow outlet with the balance of flow bypassing the first fluid motor. The second valve has an inlet connected to the outlet of the first fluid motor and the bypass flow outlet of the first valve, a regulated flow outlet connected to the inlet of the second fluid motor, and a bypass flow outlet, whereby operation of the second valve controls the volume of flow of pressurized fluid supplied to the inlet of the second fluid motor via the regulated flow outlet of the second valve with the balance of flow bypassing the second fluid motor. The system additionally includes first and second pressure-relieving restricted flow passages respectively connected between the regulated flow outlets and bypass flow outlets of the first and second valves for preventing pressure buildup at the regulated flow outlets of the first and second valves, thereby to assure proper operation of the compensator spools of the first and second valves.
In a preferred embodiment, the first and second restricted flow passages include an orifice of no greater than about 0.020 inch in diameter. In another preferred embodiment, the first and second restricted flow passages each is sized to accommodate the leakage flow through the respective valve that exceeds the leakage flow through the respective fluid motor. In another preferred embodiment, the first and second restricted flow passages are sized to provide a leakage flow of about 0.12 gallons per minute.
In another preferred embodiment the restricted flow passage includes an orifice and a filter upstream of the orifice to prevent clogging of the orifice.
The system may further include the pump that provides pressurized fluid to the inlet of the first valve. The pump may be configured for mounting in the engine compartment of the snow-ice control vehicle and for being driven by an engine-driven fan belt in the compartment.
The invention also provides a snow-ice vehicle including the hydraulic drive system as well as the engine, wherein the engine has an engine-driven belt, and the pump is driven by the belt.
In still another preferred embodiment, the system is employed in combination with the auger and spinner that are connected to the first and second motors, respectively.
The invention also provides a corresponding method of operating the hydraulic drive system.
The foregoing and other features of the invention are hereinafter described in greater detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a snow-ice control vehicle including a hydraulic drive system for operating a feed auger and spinner in the snow-ice control vehicle in accordance with the invention;
FIG. 2 is a cross-sectional view of an exemplary manifold assembly according to the invention; and
FIG. 3 is a cross-sectional view of a valve in the hydraulic drive system.
DETAILED DESCRIPTION
Referring now to the drawings in detail, and initially to FIG. 1 , a snow-ice control vehicle 10 includes a hydraulic system 12 for operating a feed auger 14 and spinner 16 of a spreader carried by the snow-ice control vehicle. The hydraulic system can be installed in various snow-ice control vehicles, such as a pickup dump truck, and allows pressure-compensated proportional control valves in series relationship to be operated from the cab of the vehicle to provide independent control of the feed auger 14 and spinner 16 . Accordingly, the system can be used in combination with the snow-ice control vehicle 10 , having an engine 18 , wherein the engine 18 has an engine-driven belt 20 that in conjunction with pulleys 22 and 24 , couples the engine 18 to a pump 26 , thereby allowing the pump 26 to be driven by the belt 20 . The pump 26 may be configured for mounting in an engine compartment of the snow-ice control vehicle 10 to allow the pump 26 to be driven off the engine 18 .
The pump 26 supplies pressurized fluid to a solenoid-operated pressure-compensated proportional control valve 28 when driven by the engine 10 . Pumps suitable for use as the pump 26 are conventionally available and often sold as kits with engine compartment mounting hardware. As is typical, the outlet of the pump may be provided with a pressure relief valve 78 to prevent damage to the system.
The solenoid-operated pressure-compensated proportional control valve 28 , herein also referred to as an auger control valve, has an inlet 30 , a regulated flow outlet 32 , and a bypass flow outlet 34 . The auger control valve 28 also includes an orifice spool 35 biased by a spool spring 36 toward its closed position, i.e. its position blocking flow from the inlet 30 to regulated flow outlet 32 . As described further below, the valve has a compensator for compensating for pressure variations whereby the position of the orifice spool is a function of current applied to a solenoid 28 of the auger control valve. As energization of the solenoid 38 is increased, the orifice spool 35 will move a corresponding amount permitting flow of hydraulic fluid from the inlet 30 to the regulated flow outlet 32 , while the balance of flow exits through the bypass flow outlet 34 .
Accordingly, the inlet 30 receives pressurized fluid from the pump 26 (or other source), and the regulated flow outlet 32 controllably delivers the pressurized fluid to a fluid motor 40 . The fluid motor 40 , herein also referred to as the auger motor, includes a fluid inlet 42 connected to the regulated flow outlet 32 and a fluid outlet 44 connected to a solenoid-operated pressure-compensated proportional control valve 46 , herein also referred to as a spinner control valve. Operation of the auger control valve 28 controls the volume of flow of pressurized fluid supplied to the inlet 42 of the auger motor 40 via the regulated flow outlet 32 with the balance of flow bypassing the auger motor 40 via the bypass flow outlet 34 .
Upon receiving the pressurized fluid supplied by the regulated flow outlet 32 , the auger motor 40 is configured to drive the feed auger 14 (or other device). When the fluid exits the auger motor 40 via the fluid outlet 44 , it is combined with the fluid from the bypass flow outlet 34 to provide essentially all the fluid flow from the pump 26 to the spinner control valve 46 . If an operator wishes to bypass the auger 14 (or other device), the pressurized fluid may be supplied to the spinner control valve 46 solely from the bypass flow outlet 34 .
The spinner control valve 46 operates in manner similar to that described above in respect to the auger control valve 28 for controllably driving the spinner 16 . The spinner control valve 46 has an inlet 48 , a regulated flow outlet 50 , and a bypass flow outlet 52 . The spinner control valve 46 also includes an orifice spool 53 biased by a spool spring 54 toward its closed position, i.e. its position blocking flow from the inlet 48 to regulated flow outlet 50 . The valve has a compensator for compensating for pressure variations whereby the position of the orifice spool is a function of current applied to a solenoid 56 of the auger control valve. As energization of the solenoid 56 is increased, the orifice spool 53 will move a corresponding amount permitting flow of hydraulic fluid from the inlet 48 to the regulated flow outlet 50 , while the balance of flow exits through the bypass flow outlet 52 .
Accordingly, the inlet 48 of the spinner control valve 46 , which is connected to the outlet 44 of the auger motor 40 and the bypass flow outlet 34 of the auger control valve 28 , receives the pressurized fluid from the outlet 44 and the bypass flow outlet 34 , and the regulated flow outlet 50 controllably delivers the pressurized fluid to a fluid motor 58 . The fluid motor 58 , herein also referred to as the spinner motor, includes a fluid inlet 60 connected to the regulated flow outlet 50 and a fluid outlet 62 connected to a reservoir 64 .
Operation of the spinner control valve 46 controls the volume of flow of pressurized fluid supplied to the inlet 60 of the spinner motor 58 via the regulated flow outlet 50 with the balance of flow bypassing the spinner motor 58 via the bypass flow outlet 52 . Upon receiving the pressurized fluid supplied by the regulated flow outlet 50 , the spinner motor 58 is configured to drive the spinner 16 (or other device). Fluid exiting the spinner motor 58 via the fluid outlet 62 is directed back to the reservoir 64 as is the fluid exiting the bypass flow outlet 52 . If an operator wishes to bypass the spinner 16 , the pressurized fluid may be returned to the reservoir 64 solely from the bypass flow outlet 52 .
Pressure compensated valves, even when de-energized, have some leakage flow through the regulated flow outlets. The inventor recognized that this can result in pressure buildup at the inlet of the respective motor, particularly when the auger/spinner motor has low leakage. This is particularly a problem with new fluid motors when tolerances are very tight. As a result of this pressure buildup, the pressure compensated valves may not work properly and can result in pressure buildup at the outlet of the pump. To prevent pressure buildup at the regulated flow outlets of the valves, thereby assuring proper operation of the compensators, pressure relieving restricted flow passages 66 and 72 are connected, respectively, between the regulated flow outlets 32 and 50 and bypass flow outlets 34 and 52 . The restricted flow passages 66 and 72 can each be sized to accommodate the difference between leakage flow through the regulated flow outlets 32 and 50 of the respective valves 28 and 46 and the respective fluid motor 40 and 58 when the valves 28 and 46 are de-energized and flow is directed to the bypass outlet.
The restricted flow passages 66 and 72 may include respective orifices 68 and 74 to restrict flow from the regulated flow outlets 32 and 50 to the bypass flow outlets 32 and 50 . In one embodiment, the restricted flow passages 66 and 72 can have an orifice having a diameter no greater than about 0.020 inch and provide a leakage flow of about 0.12 gallons per minute. Additionally, the restricted flow passages 66 and 72 can include respective filters 70 and 76 upstream of the orifices 68 and 74 to help prevent clogging of the orifices 68 and 74 .
The restricted flow passages 66 and 72 may be provided in a respective manifold block 80 , 82 in which the valves are installed, as depicted by the broken lines in FIG. 1 . The manifold blocks may be different or they may be the same. In the illustrated embodiment, the manifold blocks are the same. An exemplary manifold assembly 100 , including the valves and orifices is illustrated in FIG. 2 .
Turning now to FIGS. 2 and 3 , the solenoid-operated pressure-compensated proportional control valve is indicated at 102 and is of a cartridge type threaded into the manifold block indicated generally as 104 . The valve 102 may be of any suitable type, such as a valve available from Parker Hannifin Corporation under part number DFA125C31SN. As seen, the valve 102 has a valve body 106 having a central bore housing the valve components. The valve body 106 is threaded into the manifold 104 to secure the valve 102 in the manifold block 104 . The valve 102 includes an inlet 110 , a regulated flow outlet 112 , and a bypass flow outlet 114 that are coupled to an inlet 111 , a regulated flow outlet 113 and a bypass flow outlet 115 of the manifold 104 , respectively. The valve 102 also includes a pressure compensating spool 108 that is biased by a spool spring 116 , the compensating spool compensating for pressure variations in the valve. A sense port 123 , which is connected by a sense line (as illustrated in FIG. 1 ) to the outlet 112 of the valve, allows the compensating spool 108 to sense the pressure on both ends of the spool 108 to compensate for the pressure variations in the valve.
The valve 102 additionally includes an orifice spool 117 , which is biased by spool springs 119 and 121 toward its closed position, i.e. its position blocking flow from the inlet 110 to regulated flow outlet 112 . A radial flow path 128 is provided between the inlet 110 and regulated flow outlet 112 that opens during axial movement of the orifice spool 117 to allow the fluid to flow from the inlet 110 to the regulated flow outlet 112 .
A solenoid 118 is provided including a solenoid plunger 120 that is configured to be axially movable under the magnetic influence of a solenoid coil 122 toward and away from the orifice spool 117 . The solenoid plunger 120 is coupled to a rod 124 and guided in a pole piece 126 , thereby allowing the plunger 120 to move the orifice spool 117 a corresponding amount and permit fluid flow from the inlet 110 to the regulated flow outlet 112 when the solenoid 118 is energized. The position of the orifice spool 117 is a function of current applied to the solenoid 118 by a control device. The solenoid 118 is coupled to the control device by a coupling device 130 , the control device preferably being located in the vehicle cab. The control device includes suitable controls that may be operated by the vehicle operator to vary the speed of the auger and spinner by varying the current supply to the auger control valve and spinner control valve. This may be implemented by a suitable microprocessor controller.
The manifold block 104 also has a flow passage 132 connected between the regulated flow outlet 113 and bypass flow outlet 115 . The passage has disposed therein an orifice 134 and a filter 136 upstream the orifice, as described above. The restricted flow passage 132 can be sized to accommodate the difference between leakage flow through the valve 102 and the respective fluid motor when the valve is de-energized. To mount the manifold assembly 100 in different positions in the snow-ice vehicle 10 , the assembly 100 includes mounting holes 138 .
Although the auger is shown upstream of the spinner, it should be appreciated that the positions may be reversed.
Principles of the invention can be applied to other applications and thus, it should be appreciated that devices other than the auger or spinner may be driven by the fluid motors.
Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.
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A hydraulic drive system for a spreader used to distribute a road surface treatment material, such as sand or salt, across a road surface. The hydraulic drive system enables the use of pressure-compensated proportional control valves in series relationship with the auger and spinner motors, by the provision of small restricted flow passages across the outlets of the valves.
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FIELD OF THE INVENTION
This invention relates to the characterization of the quality and condition of reservoir rock during the extended exploration and further developmental drilling operations of a petroleum reservoir using data obtained from the pyrolysis of rock cuttings.
BACKGROUND OF THE INVENTION
Various methods have been employed for determining the porosity of petroleum-bearing reservoir rock. Such porosity measurements are used quantitatively in characterizing the reservoir rock for the purpose of determining hydrocarbon productivity and calculating reserves. One long-standing method is the direct analysis of cylindrical core samples that are taken during the drilling operation. Methods of analysis based on core samples have the advantage of being able to provide detailed and very accurate data of the reservoir quality at precisely known depths. The principal disadvantages of relying on core samples is that collecting the samples is both time-consuming and expensive, as is the processing of the core slabs to prepare samples for the one or more eventual analytical processes from which the data can be developed.
Down-hole "electric" or petrophysical logs are the most common means of assessing reservoir quality. The advantages of this technique are that the data is available immediately after the drilling of the well and the data can be obtained over the entire portion of the "open" well-bore. The disadvantages of this technique are that the data is not available until after the well is drilled, and this information cannot be used to assist in making drilling decisions. Measurement While Drilling ("MWD") or Logging While Drilling ("LWD") techniques partially overcome this deficiency; however, the cost for this service is very high and not all petrophysical tools can be utilized.
Another method for evaluating reservoir rock is based on the pyrolysis of rock cuttings that are carried to the surface during drilling operations by the drilling fluid, or "mud." Collection of rock cuttings associated with known depths is a well established procedure in petroleum drilling operations. Depth assignment to the cuttings is based on calculations which take into account drilling fluid circulation rate, hole geometry, fluid viscosity and weight, and other parameters. Collecting cuttings and assigning a depth to those cuttings are routine procedures during drilling operations.
The pyrolysis of reservoir rock and/or rock cuttings has been employed to determine the API gravity of oil and the composition of reservoir rock extracts. The pyrolytic method involves the heating of the sample in an inert atmosphere at an initial temperature of about 180° C. When the sample is inserted in the heated chamber, the light volatile hydrocarbons are removed and analyzed. The temperature is subsequently increased and heavier free oil is thermovaporized. Above approximately 400° C., hydrocarbons that have not been vaporized are thermally "cracked" to lighter hydrocarbons which are vaporized. The sample is heated to a maximum temperature of 600° C. in the inert atmosphere. The hydrocarbons released during these heating stages are quantified, as by a flame ionization detector ("FID"). If a complete analysis is required, the sample is contacted with a stream of oxygen or air at about 600° C. and the resulting CO 2 is analyzed by a thermal conduction detector ("TCD".)
Data plots of hydrocarbons released as a function of temperature can be produced on commercially available equipment. One such pyrolysis device and related analytical equipment is commercially available from the Institut Francais du Petrole through its distributor Vinci Technologies, (both of Rueil-Malmaison, France) under the trademark ROCK-EVAL. Another supplier of pyrolytic instrumentation is Humble Instruments & Services, Inc., of Humble, Tex.
As used in this specification and claims, the following terms have the meanings indicated:
HC means hydrocarbons.
ln means natural logarithm.
LV is the weight in milligrams of HC released per gram of rock at the static temperature condition of 180° C. (when the crucible is inserted into the pyrolytic chamber) prior to the temperature-programmed pyrolysis of the sample.
TD is the weight in milligrams of HC released per gram of rock at a temperature between 180° C. and T min ° C.
TC is the weight in mg of HC released per gram of rock at a temperature between T min ° C. and 600° C.
LV+TD+TC represents total HC vaporizing between 180°-600° C. A low total HC indicates rock of lower porosity or effective porosity. A low value can also indicate zones of water and/or gas.
POPI o is the value of the pyrolytic oil productivity index as calculated for a representative sample of crude oil of the type which is expected to be found in good quality reservoir rock in the region of the drilling and chosen as a standard.
T min (°C.) is the temperature at which HC volatization is at a minimum between the temperature of maximum HC volatization for TD and TC and is empirically determined for each sample. Alternatively, a temperature of 400° C. can be used for samples where there is no discernable minimum between TD and TC. The latter sample types generally have very low total HC yields.
Phi is the average porosity of the rock.
Sxo is the saturation of drilling mud filtrate and represents the amount of HC displaced by the filtrate, and therefore, movable HC.
Phi*Sxo vs depth plot--the area below the curve represents the proportion of porosity which contains movable HC.
Phi vs depth plot--the area between the Phi curve and the Phi*Sxo curve represents immovable HC, or tar.
Gamma--the naturally occurring gamma rays that are given off by various lithologies while measuring directly in the well bore by the prior art petrophysical tools and are reported in standard API (American Petroleum Institute) units.
Caliper--the measured diameter of the well bore taken at the time of running petrophysical logs.
Density porosity--the porosity calculated by prior art methods from the petrophysical bulk density tools using an assumed fluid and grain density.
Neutron porosity--the porosity measured by prior art methods from petrophysical neutron tools.
Deep resistivity--the resistivity measured by deep invasion (long spacing between source and receiver), lateral log or induction petrophysical tools which is used as a measurement of undisturbed formation resistivity.
Medium resistivity--the resistivity measured by medium invasion (medium spacing between source and receiver), lateral log or induction petrophysical tools which is used as a measurement of resistivity of the formation that has been flushed by mud filtrate from the drilling fluid.
Shallow resistivity--the resistivity measured by shallow invasion (short spacing between source and receiver), lateral log or induction petrophysical analytic techniques which is used as a measurement of the resistivity of the mud filtrate from the mud cake that forms on the interior of the well bore during drilling operations.
Neutron-density cross-plot porosity (N-D Phi)--the porosity determined from a common prior art method which compensates for the effects of lithologic and fluid changes that lead to inaccuracies in employing either density or neutron porosity measurements by themselves.
Core plug permeability--the permeability measured by prior art methods from cylindrical rock samples that are cut from cores taken from the drilling process that is reported in units of millidarcys (md).
In a typical pyrolytic data plot of oil-productive reservoir rock prepared in accordance with prior art methods, the first peak, which is detected when the sample is first placed in the pyrolysis oven at the initial temperature of 180° C. and before the temperature program begins, is from the volatile components still present in the sample after sample preparation. These will be referred to as the Light Volatile Hydrocarbons, reported in milligram per gram rock sample, and represented by LV or LVHC. As the temperature program proceeds, a plot of temperature vs. released hydrocarbons detected results in a curve that first increases from the starting point at 180° C., then gradually falls off to a minimum value in the vicinity of 400° C.±20° C. where thermocracking of the heavier petroleum components begins to occur. As thermocracking proceeds with increasing temperature, released hydrocarbons detected increase to a maximum and then fall off as the rock cutting sample reaches a maximum temperature of about 600° C. For any given sample, the minimum temperature point between the two peaks is referred to as T min . The area under the first peak between 180° C. (i.e., the starting point) and T min represents the total weight of hydrocarbons released in that temperature range, generally reported as milligrams per gram ("mg/g") of rock sample, and are referred to as the Thermally Distilled Hydrocarbons and represented as TD or TDHC. The area under the second peak between T min and 600° C. represents the total weight of hydrocarbons that are first thermally cracked before thermal distillation from the substrate and detection and are reported in mg/g of rock sample, and are referred to as the Thermally Cracked Hydrocarbons (TC or TCHC). Various techniques for analyzing the pyrolysis data represented by LVHC, TDHC and TCHC have been practiced in the art.
In the pyrolytic analysis process, small samples (e.g., ≦100 mg) of powdered rock are placed in a steel crucible. The crucible is placed in a furnace and the sample is heated in a stream of helium gas to an initial temperature of 180° C. After heating at 180° C. for about three minutes, the temperature is increased. The rate of increase in the temperature is about 25° C./min. or less, and preferably about 10° C./min, and progresses from 180° C. to about 600° C.
The helium gas carries hydrocarbon products released from the rock sample in the furnace to a detector which is sensitive to organic compounds. During the process, three types of events occur:
1) Hydrocarbons that can be volatilized at or below 180° C. are desorbed and detected while the temperature is held constant during the first 3 minutes of the procedure. These are called light volatile hydrocarbons (LVHC or LV).
2) At temperatures between 180° C. and about 400° C., thermal desorption of solvent extractable bitumen, or the light oil fraction, occurs. These are called thermally distilled hydrocarbons or "distillables" (TDHC or TD).
3) At temperatures above about 400° C., pyrolysis (cracking) of heavier hydrocarbons, or asphaltenes, occurs. The materials that thermally crack are called thermally cracked hydrocarbons or "pyrolyzables" (TCHC or TC).
These events give rise to three `peaks` on the initial instrument output (referred to as a pyrogram). The peak for the static 180° C. temperature is a standard output parameter of either the Vinci or Humble instruments. It is referred to as either S 1 or volatile total petroleum hydrocarbons (VTPH), respectively. In the present invention, the value will be referred to as LV, as described above. Data generated from the temperature programmed pyrolysis portion of the procedure is reprocessed manually by the operator to determine the quantity of hydrocarbons in milligrams per gram of sample above and below T min . This reprocessing is a trivial exercise for an experienced operator and can be accomplished routinely with either the Vinci or Humble instruments. The first peak above 180° C. represents the amount of thermally distillable hydrocarbons in the sample and is referred to as TD, the second peak above 180° represents the amount of pyrolyzables or thermally "cracked" hydrocarbons in the sample and is referred to as TC. In the case of lighter hydrocarbons or the analysis of oil samples directly for calibration, T min may not be discernable. In this case, if the sample analysis is repeatable at 400° C., the values of LV, TD, and TC employed in the method of the present invention are with respect to the specific temperature ranges defined above.
In other pyrolytic methods known to the prior art, measurement of released hydrocarbons was undertaken in the range up to 180° C. and identified as S 1 , or volatile total petroleum hydrocarbons (vTPH) while S 2 or pyrolyzable total petroleum hydrocarbon (pTPH) was the value associated with hydrocarbons released between 180° C. and 600° C.
The prior art methods for collecting and analyzing the data obtained by pyrolytic analysis have been found to be of limited value in making reliable determinations of the quality and condition of reservoir rock, particularly in regions of tar mats and occlusions.
It is often the case that tar mats are found between productive reservoir regions. Tar mats can be defined as high concentrations of bitumens enriched by asphaltenes. They form more or less continuous layers in the porous medium of the reservoir rock that can range from several feet to tens of feet in thickness and constitute barriers impermeable to the flow of crude oil.
Delays in obtaining information on the character and condition of reservoir rock can be especially costly when the drilling operation is being conducted "horizontally." As used hereafter in reference to well drilling operations, the term "horizontal" means wells bored outwardly from the nominally vertical well shaft or bore leading from the earth's surface. These horizontal wells are drilled for the purpose of exploring areas horizontally displaced from the vertical well shaft. Horizontal drilling is typically undertaken in an effort to increase the total footage of productive reservoir rock encountered by the well bore. Because of the potential for rapid changes in conditions from one area to another in the horizontal plane, it is desirable to characterize the reservoir rock as quickly as possible. Discontinuing drilling operations while awaiting analytical data can incur significant costs, and the costs of utilizing the MWD or LWD analytical techniques described above are also very high.
As will be apparent to one familiar with the costs involved, it would be particularly advantageous to be able to identify the presence of tar mats on something approaching a "real time" basis as the horizontal drilling operation proceeds. This information would permit the direction of the drill to be changed "on the fly" once the tar mat was detected.
It is therefore an object of this invention to provide an improved method, that is timely and cost efficient, for determining the quality and condition of reservoir rock during petroleum exploration drilling operations.
It is another object of the invention to provide a method for utilizing pyrolytic analysis data to differentiate between good and excellent quality reservoir rock.
It is also an object of the invention to provide an improved method of employing data from the pyrolytic analysis of rock cuttings for determining the character and quality of reservoir rock, including the existence of zones of low porosity rock and rock of low effective porosity.
It is a further object of the invention to provide a method from which information concerning the quality and condition of the reservoir rock can be quickly derived in the field and at the drilling site so that any changes in the direction of drilling can be made "on the fly" to maintain the position of the drill bit in the stratigraphic region of optimum production.
It is yet another object of the invention to provide a method by which the presence of tar mat in the vicinity of the drilling bit can be quickly and reliably determined by analysis of rock cuttings.
It is also an object of this invention to provide a reliable method for determining when the well bore has proceeded from oil-productive reservoir either structurally higher into a gas cap, if present, or downward below an oil-water contact.
SUMMARY OF THE INVENTION
The above objects and others are met by the method of the invention.
What we have found is data obtained from the pyrolytic analysis of rock cutting samples can be utilized to provide an extremely reliable indicator of the character and quality of reservoir rock. Data points have been identified using the method of the invention for delineating and distinguishing between (a) oil productive, (b) marginally oil productive/marginal reservoir rock and (c) tar-occluded/non-reservoir rock. These data points can be determined in real time during drilling operations, so that changes in the direction of horizontal boring can be made.
The method of the invention provides data that are at least as reliable as conventional log data based on time-consuming and relatively complex analytical techniques that are only available long after the directional drilling decisions have been made.
In the practice of the method of the invention the following expression is used to provide one or more data points:
ln(LV+TD+TC)×(TD÷TC)=POPI (I)
In the above expression, the term "ln(LV+TD+TC)" means the natural logarithm of the value and the term "POPI" is used as shorthand for Pyrolytic Oil Productivity Index. The term POPI is also used more broadly hereinafter as a reference to the method of the invention.
In one preferred embodiment of the invention, the method includes the sampling of reservoir rock cuttings from known depths and locations in an active drilling site, processing the cuttings to prepare the cuttings for analysis, obtaining data from the pyrolysis of each of these specially processed reservoir rock cutting samples, and producing a tabular or graphic representation or plot based on the sampling and pyrolytic data which representation indicates the character and quality of the reservoir rock with respect to its oil production potential.
More specifically, the method is directed to the steps of:
(a) collecting the rock cuttings from a first location;
(b) preparing the rock cuttings for pyrolytic analysis;
(c) subjecting the prepared rock cuttings to pyrolytic analysis to provide data corresponding to LV, TD and TC;
(d) graphically plotting the relationship expressed by the value of:
ln(LV+TD+TC)×(TD÷TC) versus measured depth for said first location;
(e) repeating said steps (a)-(d) above for rock cuttings obtained from a plurality of different locations displaced known distances from said first location to provide a graphic plot; and
(f) identifying the vertical intervals on said graphic plot corresponding to POPI values as determined by formula (I) of:
(i) 0 to about 1/2POPI o as tar-occluded and/or non-reservoir rock,
(ii) from 1/2POPI o to POPI o as marginal oil-producing reservoir rock and
(iii) above about POPI o as oil-producing reservoir rock.
If the depth is plotted horizontally, the POPI values corresponding to 0, 1/2POPI o and POPI o are entered as horizontal lines. The same data can be entered in tabular form. Graphic and tabular forms resulting from the practice of the method of the invention can be prepared manually or by a typical spreadsheet or graphical software on a suitably programmed general purpose computer.
The value of POPI o refers to the POPI value that has been determined using formula I for typical good quality reservoir rock containing oil of known composition from the region in which the drilling is proceeding. The composition or type of the oil in the region will have been determined previously and represents historical information from the original exploration of the region, e.g., via vertical drilling operations. Similarly, the characteristics of good quality reservoir rock will likewise have been determined relative to the region in which the horizontal drilling is planned or is proceeding. Thus, the value of POPI o as a standard for use in practicing the method of the invention can be determined before the horizontal drilling is commenced.
Oil composition is known to vary significantly in its specific gravity (gm/cc) or API gravity. This variance is due to differences in the relative quantities of the light molecular weight (typically hydrocarbons with less than 15 carbon atoms in each molecule), medium molecular weight (typically hydrocarbons with greater than 15 and less than 40 carbon atoms in each molecule), and high molecular weight components (typically hydrocarbons with greater than 40 carbon atoms and non-hydrocarbons with molecular weights between 500 and 1500 gm/mole). The specifics of these variations are not important to this invention. However, as will be understood by one of ordinary skill in the art, it is important to determine the value of POPI o .
Determining Value of Standard--POPI o
The value of POPI o can be determined from rock samples from an oil-filled reservoir, similar to the drilling target, that are of good reservoir quality, or from a sample of oil that is similar to the expected composition of the well's targeted zone. In the case where similar rock samples are used, steps a-c as previously described are employed to determine the value of POPI o . Where an oil sample is used to determine POPI o , the following procedure is followed:
1) To 1 cc of the oil sample, add 9 cc of a suitable solvent, such as methylene chloride, dimethyl sulfide or other suitable solvent that will completely dissolve the oil sample and that is readily evaporated at 60° C. Characteristics of solvents?!
2) Prepare 9 steel crucibles with approximately 100 mg of clear silica gel.
3) Apply to the silica gel, using an accurate syringe, three samples each of the solution of the oil in solvent in quantities of 10, 20, and 30 micro-liters.
4) Dry the samples at 60° C. in a vacuum oven for 4 hours.
5) Subject the samples to pyrolytic analysis, using 100 milligrams as the required input sample size for the instrument, to provide data corresponding to LV, TD, and TC.
6) Utilize standard spreadsheet and graphics software to input the data and prepare a plot with the y-parameter being the POPI value and the x-parameter being the sum of total hydrocarbons (LV+TD+TC).
7) Select the range for the value of POPI o from the chart where the value of total hydrocarbons is between 4-6 milligrams per gram of sample.
This value is a fairly typical value of the residual staining that remains after sample preparation from oils that are less than 42 API gravity. Oils of higher API gravity may require the use of lesser values for total hydrocarbons, since the residual hydrocarbon staining may be significantly lower due to evaporation of the light components and lower amounts of the medium and heavy components. Evaluation of good quality and productive reservoir rock is the preferred means of determining the value of POPI o for reservoirs yielding oil having an API greater than 4Z.
Sample Preparation
In accordance with methods known to the prior art, cutting samples can conveniently be collected from the shale shaker on the drill rig. The wet cuttings are sieved to obtain about 1-2 gms of particles between 40/120 mesh.
In accordance with the method of the invention, the sieved samples are rinsed with water and then with an aqueous solution of hydrochloric acid at a pH of about 5 to remove any water-soluble polymer components carried over from the drilling mud. The washed cuttings are dried in a vacuum oven at about 60° C. (approximately one hour.)
The dry cuttings are ground, e.g., using a mortar and pestle, and can now be processed in the same manner as ground core samples for pyrolytic analysis in any one of the known instruments.
In the interests of reducing the time between sample collection and the generation of the graphic plot, the drying step can be expedited by use of a mechanical shaker or other means that will agitate or tumble the rock fragments comprising the cutting sample and expose the individual surfaces. The ability to rapidly process the samples is a significant factor since under some conditions up to a 100 feet interval can be drilled horizontally during a two-hour test and data processing period.
Using known methods and apparatus the prepared reservoir rock sample is subjected to pyrolytic analysis. The data discussed below were obtained using the instrument sold by IFP under the trademark ROCK-EVAL in combination with a general purpose computer. The computer was programmed (using existing software provided by the manufacturer) to calculate the quantitative values for the hydrocarbons released from the prepared samples corresponding to the values of SI (or vTPH or LV) and S 2 , which is then reprocessed by the operator to determine the values corresponding to TD and TC. The data values of the consecutive analyses were transferred to a spreadsheet for further manipulation and evaluation.
Having obtained the quantitative values for LV, TD, and TC for a given sample, the method of the invention is used to calculate the following parameter for a sample "X":
ln(LV.sub.x +TD.sub.x +TC.sub.x)×(TD.sub.x ÷TC.sub.x)=POPI.sub.x (II)
In a preferred embodiment, this data point is entered on a graphical plot of POPI versus the measured depth corresponding to the location of that sample to provide a permanent record. Alternatively, the data can be entered in tabular form, e.g., on a chart. The data can also be stored in the memory device of a preprogrammed general purpose computer for the purpose of generating graphic and/or tabular data outputs after analysis of all samples has been completed.
As will be understood, the process is repeated for cutting samples obtained from adjacent locations. The number of samples collected and analyzed, and their relative proximity, will determine the precision of the data obtained and the eventual graphic plot. A graphic plot of the data points provides a convenient mode for visualizing the regions demarked by the POPI values derived from formula (I).
What we have found is that certain values of the POPI can be used to reliably indicate the condition and quality of reservoir rock. The values are as follows:
A POPI greater than about POPI o , indicates oil-producing reservoir rock;
a POPI between 0 and 1/2POPI o indicates tar-occluded or non-reservoir rock; and
a POPI between about 1/2 POPI o and POPI o indicates marginally oil-producing reservoir rock.
The unique reliability of the POPI is based on the fact that it combines different aspects of pyrolysis output parameters into a single number that has a practical utility in assessing reservoir quality. The first term in the equation, ln(LV+TD+TC), reflects the total quantity of hydrocarbons remaining in a rock sample after the effects of in-reservoir alteration, hydrocarbon flushing by the drilling fluid, evaporation of the light components, and losses due to cleaning and processing the sample, as described above. The second term, TD/TC, reflects the ratio of the quantity of light and heavy components in a sample, or the "quality" of the oil. The proximity of this number to the values of hydrocarbon fluids actually produced indicates whether significant alterations to the composition of the fluid have occurred. Thus, when the POPI method yields values that approximate, or are close to the value of POPI o , it is consistent with: (1) a favorable reservoir quality that reflects the migration of petroleum migration into the rock, and (2) a alteration effects that are generally associated with a variety of reservoir conditions that result in poorer oil productivity.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is the typical instrument output or pyrogram (prior to reprocessing the data) from an oil sample, indicating the areas associated with the data used to calculate the POPI values in accordance with formula (I).
FIGS. 2A 2B and 2C are plots of typical data obtained from the pyrolytic analysis of reservoir rock indicating the regions associated with the values TD and TC for tar-occluded reservoir rock, marginally productive reservoir rock, and oil productive reservoir rock, respectively.
FIG. 3 is a comparative graphic plot of data obtained by the method of the present invention and petrophysical log data obtained by prior art methods with interpreted zones indicated for the quality of the reservoir rock.
FIG. 4 is a graphic cross-plot of total hydrocarbons (LV+TD+TC) versus the Pyrolytic Oil-Productivity Index (POPI) used to determine the value of POPI o .
FIG. 5 is a cross-plot of Phi*Sxo versus POPI for data obtained from the well in the example shown in FIG. 4.
FIG. 6 is a comparative graphic plot of POPI and neutron-density cross-plot porosity (N-D Phi) versus depth for a well exhibiting both gas-oil and oil-water contacts.
FIG. 7 is a comparative graphic plot of POPI and core plug permeability versus depth.
FIG. 8 is a comparative graphic plot of depth profiles for pyrolytic data and petrophysical log data obtained by prior art methods for a well exhibiting both gas-oil and oil-water contacts.
DETAILED DESCRIPTION OF THE INVENTION
The graphical plot of the typical output pyrogram obtained by employing theRock-Eval instrumentation in accordance with methods well-known in the prior art is shown in FIG. 1. The curve represents the flame ionization detector's (FID's) response for the initial static temperature conditions and the later temperature-programmed pyrolysis of the sample. The area under the curve represents the relative values or quantities of light volatile hydrocarbons (LV), thermally distilled hydrocarbons (TD) and thermally cracked hydrocarbons (TC), which values are used to calculate toPOPI. The value of LV is obtained directly from the instruments sold by Humble and Vinci with no further reprocessing, while the values of TD and TC require additional processing of the initial output data by the operator.
Reprocessed graphic plots of hydrocarbons versus temperature of typical quantitative analyses of rock samples from a well which are indicative of tar-occluded, marginal, and oil-productive reservoir rock are shown in FIGS. 2A-2C. The plots represent straight-forward manipulations of data obtained employing the ROCK-EVAL instrumentation in accordance with methods well-known in the prior art.
As is indicated on the plots, FIG. 2A represents tar-occluded rock, 2B marginally productive reservoir rock and 2C oil productive reservoir rock.In the plots of FIGS. 2A-2C, the TD peak corresponds to the thermovaporization of approximately C18-C40 hydrocarbons present in the reservoir rock sample, and the TC peak mainly corresponds to the thermovaporization and cracking of approximately C40 and greater hydrocarbons, including the cracking of the resins and asphaltenes.
As noted above, the expression Pyrolytic Oil-Productivity Index, or POPI, is determined as follows:
POPI=ln(LV+TD+TC)×(TD÷TC). (I)
By employing the values of LV, TD and TC obtained for rock samples from a horizontal well and the equation (I), the graphic plot of FIG. 3A was prepared in accordance with the method of the invention.
In FIGS. 3A and 3B, the abscissa is the measured depth in feet and the ordinate values are various pyrolytic and petrophysical parameters. The plots of FIGS. 3A and 3B provide a comparison of predicted reservoir performance for a horizontal well by petrophysical logs (3B) and the Pyrolytic Oil-Productivity Index (3A). The POPI interpretation identifies the same changes in reservoir quality that are interpreted from the well logs as plotted in FIG. 3B. The minor differences that are present are a thin marginal bed at 8480 ft., a thin tar-occluded bed at 9940 ft., and the shifting of some oil-productive to marginally oil-productive boundaries to deeper apparent depths. These shifted boundaries resulted from the mixing of cuttings and can be prevented by stopping to circulate "bottoms-up" cuttings during drilling operations. The horizontal lines at POPI values of about 1/2 POPI o and POPI o demark the following regions: oil-productive rock (above POPI o ), marginally oil-productiverock (between about 1/2POPI o , and POPI o ), and tar-occluded and/ornon-reservoir rock (between about 1/2POPI o and zero.)
The value of POPI o can be obtained by subjecting an oil of a composition that is similar to the expected oil in the reservoir to the procedure set forth in steps 1-7 of the method as described above. FIG. 4 is a cross-plot of the POPI and total hydrocarbons showing the separate trends that are characteristic three typical oils of two distinct different oil-types. From these data, the POPI o (the POPI that is expected for a sample from a typical good quality oil reservoir with a given oil type) can be estimated as the value of POPI that corresponds to a total hydrocarbon yield of around 4-6 mg/g of rock.
Again, with reference to FIGS. 3A and 3B, the reliability of the results ofthe pyrolytic analysis method of the invention is confirmed by comparison with petrophysical data for the same region. The data were obtained and analyzed for Region "A" in drilling a horizontal oil well which penetratedpartially occluded/partially productive and oil-productive portions of a tar mat. The results from Region "A" confirm the strong correspondence between the pyrolytic and petrophysical data. From 8,460 ft. to 8,970 ft.,the formation was dominated by a completely tar-occluded region and some marginal regions, as is evident from the combination of high porosity (Phi), high total HCs (LV+TD+TC), and correspondingly low TD/TC, Phi*Sxo, and POPI plots. While the lower porosity areas do contain tar, they are not completely occluded because the low porosity inhibits filling the porespace. Both the TD/TC and POPI plots differentiate the oil-productive and the tar-occluded/non-reservoir portions of the formation.
The POPI method is also utilized to effectively differentiate between oil-productive and marginal reservoir quality. For example, the marginal reservoir quality zone from 9,775 to 9,925 ft. is distinguished from oil-productive reservoir by the POPI but not by the TD/TC ratio. Note thatthe reservoir quality boundaries are displaced to greater depths in this area. This shifting is due to drilling ahead and not stopping periodicallyto circulate "bottoms-up." The POPI also does a better job of identifying non-reservoir rock that is tight but contains staining of normal hydrocarbons. This is evident in the low porosity zone form 9,200 to 9,500ft., where the TD/TC ratio indicates marginal quality reservoir, but the POPI clearly identifies this region as non-reservoir rock. Also, Phi*Sxo can be especially misleading in lower permeable reservoir rock. This is caused by inefficient mud-cake formation in the well bore. Because mud-cake does not form as quickly over lower permeability rock, the mud filtrate water can invade the formation over a much longer time period, and thus, invade farther. This produces an exaggerated assessment of the moveability of hydrocarbons (as is seen in the intervals from ˜8,600ft to 8,700 ft., ˜8,875 to 8,925, and from ˜9,075 ft. to 9,200 ft (FIG. 3) that is overcome by the POPI method.
The general correspondence between the reservoir quality as determined by the POPI and prior at methods from FIG. 3, is shown in FIG. 5 by plotting Phi*Sxo versus POPI. While there is some scatter in the data, this is typical of the scatter found when employing cross-plot graphics with petrophysical data. The importance of this general relationship is that relative differences seen in the POPI have significance in determining reservoir performance.
Moreover, a detailed analysis of productive formation elsewhere shows that the POPI can also be used to differentiate between good and excellent reservoirs. FIG. 6 is a plot of measured depth versus neutron density cross-plot porosity, (N-D Phi), and POPI, in which the reservoir was characterized based on the combination of the pyrolytic and petrophysical data. The trend in increasing POPI from approximately 10,433 ft. to 10,447ft. corresponds to porosity that increases from about 8% to 14%.
An increase of 6% in porosity corresponds to a substantial improvement in reservoir performance, establishing that the POPI method has potential forassessing differences between good and excellent reservoirs prior to running well logs.
The same correspondence between the POPI and reservoir performance is observed when comparing it to core plug permeability. FIG. 7 shows that variations in the POPI and core plug permeability mirror each other and that the highest values of POPI correspond to permeability over 100 millidarcys ("md") and lowest values correspond to permeability less than 10 md. Thus, by a variety of different petrophysical measurements, the POPI yields the same interpretation of reservoir performance, but in a timely and cost efficient manner not previously available to the art. Using the method of the invention to optimize the value of the POPI duringhorizontal drilling greatly increases the likelihood of staying within the most productive portion of the reservoir. The use of the method leads to greater productivity for individual wells by substantially increasing the length of the well path in that part of the reservoir exhibiting optimum conditions.
FIG. 8 is a comparison of POPI, TD, and TC depth profiles to standard petrophysical data for a well with gas-oil and oil-water contacts. In thisplot, the OWC as interpreted from well logs has been obscured by a dramaticchange in the formation's water salinity from below the oil column, This has been caused by a later incursion (post oil migration) of fresh meteoric ground water that has been well documented by laboratory analysesfrom wells in the area. The problem of predicting the type of formation fluids (oil or water) in this geographical area of operations is common.
FIGS. 7 and 8 also demonstrate how the data can be used to determine when the drill-bit has moved downward structurally through an oil-water contact(OWC). When this situation occurs, the value for POPI becomes negative. This transition can reliably be interpreted where at least poor quality oil-productive reservoir is present. A gas-oil contact (GOC) can also be interpreted in a similar manner, except that the change is from low positive or negative numbers to values that are indicative of oil-productivity as one moves downward through the reservoir. These are interpretations that can routinely be made, even by well-site geologists with limited experience. In these cases, the examination of drill cutting samples would assist in confirming that major lithologic changes were not responsible for differences in the POPI.
The plot of FIG. 8 shows how the POPI can yield a more accurate interpretation of the oil-productive reservoir than the petrophysical tools. With respect to the particular site, it was well known that ground water flow through oil-productive reservoirs had occurred over the last 50,000 years. This relatively fresh water had displaced the original, relatively salty, low resistivity water that was present during marine deposition of the sandstone reservoirs. These historical events obscured the resistivity response to the OWC and now show no discernible differencein the invasion profile above and below the OWC. (Invasion profile refers to the separation of the data curves from the shallow, medium, and deep radius of investigation resistivity tools and is more obvious between 10,420 and 10,462 ft.). In this case, the use of expensive logging-while-drilling ("LWD") tools would not have correctly interpreted the lack of oil productivity between 10,450 and 10,462 ft.
The close relationship between the petrophysical and POPI data plots confirms the validity of the use of the method of the invention in predicting reservoir performance, particularly where tar mats and reservoir fluid contacts are encountered. Furthermore, the ability to effectively differentiate more subtle changes in reservoir performance from the POPI data has been established empirically. The method of the invention can be used more cost-effectively than prior methods and data asa basis for directing the forward movement of the drill bit during continuing horizontal drilling operations. Analytical utilization of all of the data generated from the POPI method can be used to delineate not only tar-occluded and non-tar-occluded sections, but also to indicate low porosity or low effective porosity zones.
More importantly, the method of the invention also differentiates between good and excellent reservoir rock. These distinctions are important indicators of changes in stratigraphic conditions within a reservoir and can be used to maintain the position of the drill bit in the "sweet spot" of the target reservoir.
The limitations of prior art methods in assessing the effects of the invasion of mud filtrate in low permeability zones are overcome by the POPI method of the invention. In cases where the low permeability is due to a generally lower porosity zone, the poorer reservoir is evident from lower total hydrocarbon value for LV+TD+TC and yields a lower POPI value. In the case of lower permeability due to substantial tar occlusion, the TD/TC ratio lowers the POPI value. Conversely, the interpretation of a lower POPI value can be made more conclusive by referring to the values ofthe POPI component variables: low total hydrocarbons (LV+TD+TC) point to lower porosity or effective porosity in the reservoir, while low TD/TC ratios indicate tar occlusion or other oil degradation processes.
From the standpoint of operations, the method of the invention can be practiced on site at the location of the drilling rig. This is an important factor in minimizing the turn-around time from collection of cutting samples to generation and interpretation of the data from the pyrolytic analysis of those samples. An average turn-around time of two hours for continuous operations has been achieved using standard equipment. A reduction in sample preparation time, as by the use of specialized vacuum dryers, can lead to further substantial reductions in the turn-around time. This makes the method of the invention an invaluabletool for predicting reservoir performance when the data are needed, that is, while the well is still being drilled.
A factor that can affect the accuracy of the method of the invention for predicting the quality and condition of the reservoir rock at a specified depth is a caving or sloughing of the drill cuttings. The effect of cavings on POPI is the apparent shifting of some boundaries of reservoir performance deeper in the well as seen in FIG. 3. In analyzing the data, it will be understood that a change in reservoir character from oil-productive to tar-occluded/non-reservoir quality may be partially masked by cavings until representative cuttings are collected for an interval, either by stopping to circulate "bottoms up" when an important change in reservoir character is detected, or by drilling ahead until a sufficient thickness of similar quality reservoir has been drilled to result in a more homogenous sample. The second practice is discouraged because it decreases the value of the information that is obtained prior to getting representative cuttings, thereby, decreasing the resolution of the data.
In any event, the art has developed methods for determining the extent and effect of cavings on depth calculations and these techniques can be used to correct data entries associated with apparent measured depth plots or tables in practicing the present invention.
As noted above, the values for the LV, TD, and TC parameters were determined on pyrolytic instrumentation known as Rock-Eval®. Data obtained from different instrumentation may not be identical. This is because the furnace geometry, design of the heating mechanism and the efficiency of heat transfer, and crucible geometry all play a role in quantifying the LV, TD, and TC parameters. However, the fundamental relationship on which the POPI method is based remains valid. Since the POPI may be somewhat different for the same sample if different pyrolysis instrumentation is used, the limits for characterizing the reservoir rock may vary. The methodology described above will enable one of ordinary skill in the art to determine the equivalent parameters without departing from the scope and spirit of the invention.
There are a variety of ways in which the teachings and spirit of this invention may be practiced which include the steps of sample preparation, instrument input parameters, and the way that the output data are reported. For example, an experienced worker in the field of the present art, could select different temperature cut-off values, that in turn couldbe used to develop new indices that combine components that relate to the quantity and nature of the hydrocarbons present in rock samples. Such variations in methodology will be understood to fall within the scope of the present invention and, in fact, might be necessary for the applicationof the technique to specific field conditions.
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Data from the pyrolytic analysis of rock samples obtained from drilling operations in an existing oil field are used to characterize the quality and condition of reservoir rock by comparison of the values of an index for the unknown reservoir rock samples with the value of the index for a known type and quality of petroleum reservoir rock sample, the index being denominated Pyrolytic Oil Productivity Index ("POPI") and defined by the expression:
ln(LV+TD+TC)×(TD÷TC)=POPI (I),
where the terms of the equation are determined empirically and the resulting POPI values can be used to direct horizontal drilling operations in real time to optimize the position of the drilling bit in the reservoir.
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