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FIELD OF ART
[0001] The field of the invention relates to the sealing of openings, such as perforations, holes, cracks or the like and, more particularly, to a method and device for sealing an opening of an equipment arranged in a wellbore of a subterranean formation in order to improve the recovery of formation fluids and/or gases. A preferred application of the invention concerns sealing at least one perforation of a metallic casing arranged in a wellbore.
BACKGROUND
[0002] In the art of well boring, a borehole is drilled into the earth through the oil or gas producing subterranean formation or, for some purposes, through a water bearing formation or a formation into which water or gas or other liquids are to be injected.
[0003] Completion of a well may be carried out in a number of ways dependent upon the nature of the formation of interest. In particular, it is known to arrange a casing into the wellbore to control formation elements. Once installed into the wellbore, the casing is then perforated in a plurality of areas for allowing the passage of oil and/or gas from the formation into the casing.
[0004] When the casing suffers damage, corrosion or leaks, metal patches may be used to repair the casing and enable production to be improved. Similarly, in depleted wells nearing the end of viable production, a metal patch may be used to seal some of the perforations of the casing to improve the recovery of oil and/or gas. In some cases, such sealing may be the only economic means of safely returning the well to production.
[0005] Two main techniques are known to apply a metal patch on a casing arranged in a wellbore: mechanical expansion and hydraulic pressure. An example of mechanical expansion is described in patent U.S. Pat. No. 6,668,930 and consists in arranging a coiled tubing into the casing then using a tool for pressing the coiled tubing against an area of the casing in order to create a patch on said area. An example of solution using hydraulic pressure is described in patent U.S. Pat. No. 6,775,894 and consists in loading a coiled tubing into a delivery tool comprising a plunger then applying hydraulic pressure for pushing the plunger against the coiled tubing in order to release the coiled tubing into the casing and therefore sealing the openings of the casing in the corresponding area. The utilization of such mechanical or hydraulic pressure tools is complex, time-consuming and costly. Moreover, such methods of sealing openings may be unreliable as the pressure may not be sufficient to solidly fix the patch and properly seal the openings.
[0006] It is therefore an object of the present invention to provide an improved method and system for efficiently, rapidly, easily and effectively sealing an opening of a equipment arranged in a wellbore of a subterranean formation in order to improve the recovery of formation fluids and/or gases. Another and further object of the present invention is to provide an improved method and system for sealing a tube arranged in a wellbore. Another and further object of the present invention is to provide an improved method and device for sealing a perforation of a metallic casing arranged in a wellbore.
SUMMARY
[0007] To this end, the present invention concerns a method for sealing at least one opening of a wellbore equipment arranged in a wellbore of a subterranean formation in order to improve the recovery of formation fluids and/or gases, said method comprising the steps of:
positioning a metal patch between said wellbore equipment and a shock wave generation device, said metal patch facing the at least one opening to be sealed; generating, using a shock wave generation device, at least one electrical discharge into said wellbore in order to propagate toward said metal patch at least one shock wave adapted to deform and fix the metal patch onto the wellbore equipment, sealing therefore the opening.
[0010] The method according to the invention allows thus efficiently, easily and rapidly for sealing an opening of a wellbore equipment arranged in a wellbore. Such opening may be a perforation, a hole, a crack or the like. The wellbore equipment may be a metallic casing. Thus, for example, the method may be advantageously used to seal perforations, previously made in a metallic casing disposed in a wellbore for recovering oil or gas for a subterranean formation, allowing therefore stimulation the recovery.
[0011] The method according to the invention provides an electrohydraulic forming (EHF) process for solidly fixing the metal patch to the wellbore equipment as the metal constituting the patch penetrates into the opening, allowing strongly fixing the metal patch to the wellbore equipment. In other words, electrohydraulic forming allows pushing the material constituting the metal patch enough into the opening to fix the metal patch solidly onto the wellbore equipment and improve significantly the recovery of oil and/or gas.
[0012] The metal patch may take any adapted shape such as; e.g., a tube or a plate such as a curved plate. A plate may be used to seal a unique perforation. A tube may be used to seal a plurality of perforations at the same time.
[0013] In an embodiment according to the invention, a series of at least ten shock waves, preferably twenty shock wave, is generated for efficiently fixing the patch to the wellbore equipment.
[0014] In a preferred embodiment, a plurality of series of shock waves is generated. Advantageously, each series of shock waves is generated repeatedly at different locations along the wellbore equipment, for example different heights of a casing. Preferably, the different locations correspond to different locations of openings. Using a plurality of series of shock waves allows advantageously fixing solidly the patch to the wellbore equipment.
[0015] Preferably, the at least one shock wave propagates radially. For example, when the metal patch is shaped as a tube, this allows sealing simultaneously a plurality of openings.
[0016] In another embodiment, the at least one shock wave propagates in a predetermined direction toward the metal patch, for example using a reflector. In this case, the metallic patch may be a curved plate which is positioned in front of a unique perforation and the at least one shock wave is propagated in a predetermined direction toward said curved plate.
[0017] In a preferred embodiment, the at least one shock wave is generated in a transmitting fluid, such as e.g. water or oil.
[0018] In an embodiment, the at least one shock wave is generated in a transmitting liquid. Preferably, the transmitting liquid is at least partially delimited by a membrane and the at least one shock wave is propagated through said membrane toward the metal patch for sealing the at least one opening.
[0019] The invention also concerns a shock wave generation device for sealing with a metal patch at least one opening of a wellbore equipment arranged in a wellbore of a subterranean formation in order to improve the recovery of formation fluids and/or gases, said shock wave generation device comprising a discharge unit configured for generating at least one electrical discharge that propagates at least one shock wave toward said metal patch at least one shock wave adapted to deform and fix the metal patch onto the wellbore equipment, sealing therefore the at least one opening.
[0020] The shock wave generation device is a source of electrohydraulic energy, which allows the metal patch to be solidly fixed on the wellbore equipment to seal the at least one opening by electrohydraulic forming (EHF).
[0021] Preferably, the discharge unit comprises a first electrode and a second electrode for generating a high voltage arc, preferentially in a shock wave transmitting liquid.
[0022] In an embodiment, the discharge unit is configured for generating at least one electrical discharge that propagates at least one shock wave radially.
[0023] In another embodiment, the discharge unit is configured for generating at least one electrical discharge that propagates at least one shock wave in a predetermined direction.
[0024] According to an embodiment, the shock wave generation device comprises a chamber which is at least partially filled with a shock wave transmitting liquid and a membrane delimiting at least partially said chamber. In particular, such membrane isolates the liquid in the chamber from elements of the wellbore surrounding the shock wave generating device, such as e.g. mud or other fluids, while maintaining acoustic coupling with the control equipment, improving thus the propagation of shockwaves while preventing external fluids from damaging the discharge unit. Such flexible membrane prevents in particular the deposits and other elements from damaging electrodes and other components (insulators) of the discharge unit.
[0025] Preferably, the membrane is deformable and/or flexible and/or elastic in order to prevent the at least one shock wave to bounce on it and to conduct efficiently the at least one shock wave toward the metal patch.
[0026] In an embodiment according to the invention, the membrane is made of fluorinated rubber or other fluoro elastomer.
[0027] In an embodiment according to the invention, the relative elongation of the membrane is at least 150%, preferably at least 200% in order to be used efficiently in oils, fuels, liquid reservoirs, aliphatic or aromatic hydrocarbons etc.
[0028] In an embodiment according to the invention, the membrane is operable between −35° C. and 250° C. in order to be used in oils, fuels, liquid reservoirs, aliphatic and/or aromatic hydrocarbons etc.
[0029] In another embodiment, the shock wave generation device comprises at least one metallic wire mounted between the first electrode and the second electrode for creating a pressure wave. When a current circulates between the first electrode and the second electrode, the at least one metallic wire heats until vaporization, generating therefore a pressure wave that propagates into the fluid.
[0030] In a preferred embodiment according to the invention, the shock wave generation device further comprises a power conversion unit, a power storage unit and a control unit.
[0031] The invention also concerns the use of a shock wave generation device as previously described for sealing with a metal patch at least one opening of a wellbore equipment arranged in a wellbore of a subterranean formation in order to improve the recovery of formation fluids and/or gases.
[0032] The invention also concerns a system comprising a shock wave generation device as previously described, a wellbore equipment comprising at least one opening to be sealed, e.g. such as a casing, arranged in a wellbore of a subterranean formation and at least one metal patch arranged in said wellbore, between said shock wave generation device and said wellbore equipment, and facing said at least one opening to be sealed.
[0033] In an embodiment according to the invention, the system further comprises a connection mean coupled to the shock wave generation device for inserting said shock wave generation device in the wellbore nearby the wellbore equipment, a voltage source located external of the wellbore and an electrical circuit within said wireline for connecting said voltage source to the shock wave generation device.
[0034] For example, the connection mean may be a wireline for a vertical wellbore, a wireline tractor for pushing the device into both vertical or horizontal wellbores or a coiled tubing for both vertical or horizontal wellbores. In the case of a coiled tubing, the device is mounted on the coiled tubing which is then introduced into the wellbore.
[0035] The invention also concerns a wellbore for recovering formation fluids or gases from a subterranean formation, said wellbore comprising at least one wellbore equipment arranged into said wellbore and comprising at least one opening to be sealed, a shock wave generation device as previously described and at least one metal patch arranged in the wellbore between said shock wave generation device and said wellbore equipment, facing said at least one opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] These and other features, aspects, and advantages of the present invention are better understood with regard to the following Detailed Description of the Preferred Embodiments, appended Claims, and accompanying Figures, where:
[0037] FIG. 1 schematically illustrates a cross-sectional view of a wellbore comprising a casing and a shock wave generation device;
[0038] FIG. 2 schematically illustrates a cross-sectional view of an embodiment of a shock wave generation device according to the invention positioned into the casing of the wellbore of FIG. 1 and facing a first plurality of perforations;
[0039] FIG. 3 illustrates the wellbore of FIG. 2 further comprising a metal patch;
[0040] FIG. 4 illustrates shockwave generation by the shock wave generation device of FIGS. 2 and 3 ;
[0041] FIG. 5 illustrates sealed casing perforations following shockwave generation by the shock wave generation device of FIGS. 2 to 4 ;
[0042] FIG. 6 illustrates the shock wave generation device of FIGS. 2 to 5 positioned at a different height in the wellbore, facing a second plurality of perforations;
[0043] FIG. 7 illustrates shockwave generation by the shock wave generation device of FIG. 6 ;
[0044] FIG. 8 illustrates sealed casing perforations following shockwave generation by the shock wave generation device of FIG. 6 ;
[0045] FIG. 9 illustrates an embodiment of the method according to the invention.
[0046] In the accompanying Figures, similar components or features, or both, may have the same or a similar reference label.
DETAILED DESCRIPTION
[0047] The Specification, which includes the Summary of Invention, Brief Description of the Drawings and the Detailed Description of the Preferred Embodiments, and the appended Claims refer to particular features (including process or method steps) of the invention. Those of skill in the art understand that the invention includes all possible combinations and uses of particular features described in the Specification.
[0048] Those of skill in the art understand that the invention is not limited to or by the description of embodiments given in the Specification. The inventive subject matter is not restricted except only in the spirit of the Specification and appended Claims.
[0049] Those of skill in the art also understand that the terminology used for describing particular embodiments does not limit the scope or breadth of the invention. In interpreting the Specification and appended Claims, all terms should be interpreted in the broadest possible manner consistent with the context of each term. All technical and scientific terms used in the Specification and appended Claims have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs unless defined otherwise.
[0050] As used in the Specification and appended Claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly indicates otherwise. The verb “comprises” and its conjugated forms should be interpreted as referring to elements, components or steps in a non-exclusive manner. The referenced elements, components or steps may be present, utilized or combined with other elements, components or steps not expressly referenced. The verb “couple” and its conjugated forms means to complete any type of required junction, including electrical, mechanical or fluid, to form a singular object from two or more previously non-joined objects. If a first device couples to a second device, the connection can occur either directly or through a common connector. “Optionally” and its various forms means that the subsequently described event or circumstance may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur. “Operable” and its various forms means fit for its proper functioning and able to be used for its intended use.
[0051] Spatial terms describe the relative position of an object or a group of objects relative to another object or group of objects. The spatial relationships apply along vertical and horizontal axes. Orientation and relational words including “uphole” and “downhole”; “above” and “below”; “up” and “down” and other like terms are for descriptive convenience and are not limiting unless otherwise indicated.
[0052] Where the Specification or the appended Claims provide a range of values, it is understood that the interval encompasses each intervening value between the upper limit and the lower limit as well as the upper limit and the lower limit. The invention encompasses and bounds smaller ranges of the interval subject to any specific exclusion provided.
[0053] Where the Specification and appended Claims reference a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously except where the context excludes that possibility.
[0054] The invention is described hereunder in reference to a well for producing formation fluids or gases such as e.g. oil wherein the formation is a sand formation. This does not limit the scope of the present invention which may be used with any type of formation wherein formation elements arranged on or between control particles of a formation control apparatus could prevent the passage of formation fluids or gases.
[0055] FIG. 1 shows a subterranean formation 1 comprising a treatment zone 3 . For example, such a treatment zone 3 may be made of rock. In this example, treatment zone 3 has an upper bound 5 and a bottom bound 7 . The treatment zone 3 comprises a porous zone 9 that constitutes a reservoir of hydrocarbons, such as oil or gas.
[0056] The porous zone 9 is accessible through a wellbore 10 extending from the surface 11 through to the treatment zone 3 . The uphole bound 5 is the uphole-most portion of treatment zone 3 accessible through wellbore 10 and the downhole bound 7 is the downhole-most portion of treatment zone 3 accessible through wellbore 10 .
[0057] The treatment zone 3 interfaces with the wellbore 10 at wellbore wall 12 and extends radially from wellbore 10 . In this example, the wellbore 10 is vertical, but this does not limit the scope of the present invention as the method and device according to the invention may advantageously be used in any type of wellbores such as e.g. horizontal wellbores.
[0058] In the example illustrated on FIG. 1 , this wall 12 comprises a wellbore equipment which is a metallic casing 14 . This metallic casing 14 comprises perforations 16 that allow creating some flow paths within the treatment zone 3 adjacent to the wellbore 10 . Such metallic casing 14 is known from the person skilled in the art.
[0059] A source of electrohydraulic energy in the form of a shock wave generation device 20 is introduced (arrow 21 ) into the wellbore 10 and positioned near the wellbore wall 12 . The shock wave generation device 20 is configured for generating a series of electrical discharges that propagate a series of shock waves.
[0060] FIGS. 2 to 8 illustrates a preferred embodiment of the shock wave generation device 20 according to the invention. The shock wave generation device 20 is coupled to a wireline 22 which is operable to raise and lower said shock wave generation device 20 and to supply power from the surface 11 (in reference to FIG. 1 ) to said shock wave generation device 20 . A voltage source (not shown) located external of the wellbore 10 and an electrical circuit (not shown) mounted within said wireline 22 allow connecting said voltage source to the shock wave generation device 20 . Electrical power is supplied by the low voltage source at a steady and relatively low power from the surface 11 through the wireline 22 to the downhole shock wave generation device 20 .
[0061] In this example, and as already describes in U.S. Pat. No. 4,345,650 issued to Wesley or U.S. Pat. No. 6,227,293 issued to Huffman, incorporated hereby by reference, the shock wave generation device 20 comprises a power conversion unit 30 , a power storage unit 40 , a control unit 50 and a discharge unit 60 .
[0062] The power conversion unit 30 comprises suitable circuitry for charging of the capacitors in the power storage unit 40 . Timing of the discharge of the energy in the power from the power storage unit 50 through the discharge unit 60 is controlled by the control unit 50 .
[0063] In a preferred embodiment, the control unit 50 is a switch, which discharges when the voltage reaches a predefined threshold.
[0064] The discharge unit 60 comprises a first electrode 62 and a second electrode 64 configured for triggering an electrical discharge. The discharge unit 60 may be configured to propagate shock waves radially or in a predetermined direction. Upon discharge of the capacitors in the power storage section through the first electrodes 62 and the second electrode 64 , electrohydraulic shock waves 60 (in reference to FIGS. 4 and 7 ) are generated.
[0065] The discharge unit 60 comprises a plurality of capacitors (not represented) for storage of electrical energy configured for generating one or a plurality of electrical discharges. Other designs of discharge unit 60 are disclosed in U.S. Pat. No. 6,227,293 issued to Huffman which is included hereby reference. According to the electrohydraulic effect, an electrical discharge is discharged in a very short time (few micro seconds).
[0066] In this example, the discharge unit 60 further comprises a membrane 66 delimiting a chamber 68 which is filled with a shock wave transmitting liquid 70 , allowing transmitting shock waves through the membrane 66 toward the metallic casing 14 . In another embodiment, the discharge unit 60 may not comprise a membrane 66 . Such membrane 66 isolates the discharge unit 60 from the wellbore 20 while maintaining acoustic coupling with said wellbore 20 , improving the propagation of shockwaves while preventing external fluids from the wellbore 20 from damaging the discharge unit 60 .
[0067] In a preferred embodiment, the membrane 60 is flexible in order to an efficient propagation of shock waves in many directions and prevent shock waves to bounce on it, allowing therefore an efficient conduction of the shock wave toward a metal patch to be sealed on the metallic casing 14 . To this end, the membrane 40 may be made of fluorine rubber or fluoro elastomer with a relative elongation of at least 150%, preferably at least 200% and being operable between −35° C. and 250° C.
[0068] In reference to FIGS. 3 to 8 , the system according to the invention comprises a metal patch 80 . In this embodiment, the patch 80 is shaped like a tube. Of course, this does not limit the scope of the present invention as the metal patch could be shaped as a plate or any other suitable form. The thickness of the metal patch 80 may range, for example, from 2 to 6 mm. The height and width of the metal patch 80 may range, e.g. from 10 cm to 1 meter of more.
Examples of Operation
[0069] The invention is describes in its application to sealing perforations made in a metallic casing 14 . As described on FIG. 2 , the shock wave generation device 20 is first positioned, in step S 1 , inside the casing 14 in front of a first plurality of perforations 16 A to be sealed. An optimized position of the shock wave generation device 20 is defined by the alignment of the perforations 16 A with the space between the first electrode 62 and the second electrode 64 , as shown on FIG. 2 .
[0070] Then, in step S 2 , as described on FIG. 3 , the metal patch 80 is positioned inside the wellbore 10 between the shock wave generation device 20 and the first plurality of perforations 16 A to be sealed. Of course, steps S 1 and S 2 may be inverted as the metal patch 80 may be positioned in the wellbore 10 before the shock wave generation device 20 .
[0071] In step S 3 , at least one shock wave 90 , preferably a series of shock waves, is generated into the transmitting liquid 70 by the discharge unit 60 of the shock wave generation device 20 . This at least one shock wave 90 propagates in step S 4 through the membrane 40 toward the metal patch as illustrated on FIG. 4 .
[0072] In step S 5 , the at least one propagated shock wave 90 deforms the metal patch 80 in an electrohydraulic forming process so that said metal patch 80 is compressed against the casing 14 on and into perforations 16 A of the first plurality of perforations 16 A, fixing the metal patch 80 to the casing 14 and sealing eventually therefore said perforations 16 A as illustrated on FIG. 5 .
[0073] The shock wave generation device 20 is then moved, in step S 6 , to another position inside the casing in order to seal a second plurality of perforations 16 B as illustrated on FIG. 6 . In this example, position of said second plurality of perforations 16 B is lower than position of the first plurality of perforations 16 A. This does not limit the scope of the present invention as the shock wave generation device 20 could seal the second plurality of lower perforations 16 B first then be moved upwardly to seal the first plurality of higher perforations 16 A.
[0074] In step S 7 , at least one shock wave 90 , preferably a series of shock waves, is generated into the transmitting liquid 70 by the discharge unit 60 of the shock wave generation device 20 . This at least one shock wave 90 propagates in step S 8 through the membrane 40 toward the metal patch as illustrated on FIG. 7 .
[0075] In step S 9 , the at least one propagated shock wave 90 deforms the metal patch 80 in an electrohydraulic forming process so that said metal patch 80 is compressed against the casing 14 on and into perforations 16 B of the second plurality of perforations 16 B, fixing the metal patch 80 to the casing 14 and sealing eventually said perforations 16 B as illustrated on FIG. 8 .
[0076] A series of shock waves preferably comprises at least ten shock waves, for example propagated at a periodic interval of time, e.g. every 5 to 20 seconds. A plurality of series may be advantageously repeated at different heights in wellbore 10 to seal perforations 16 located at different places on the casing therefore improving the recovery of oil or gas and the stimulation of the wellbore 10 .
Supplemental Equipment
[0077] Embodiments include many additional standard components or equipment that enables and makes operable the described device, process, method and system.
[0078] Operation, control and performance of portions of or entire steps of a process or method can occur through human interaction, pre-programmed computer control and response systems, or combinations thereof.
Experiment
[0079] Examples of specific embodiments facilitate a better understanding of opening sealing method and device. In no way should the Examples limit or define the scope of the invention.
[0080] Simulations have been carried out with different metal types and different patch sizes. Aluminum-made patches seem to particularly fit the opening sealing application. In particular, 1 mm-thick circular plate patches with a diameter equal or greater than 15.6 mm reaches a maximum displacement of 1.66 mm in a standard production wellbore casing perforation, which allows efficiently sealing such perforation.
[0081] The method according to the invention is not limited to a casing and may be used to seal an opening such as a crack or a hole on various different wellbore equipment such as e.g. a sand control screen, a slotted liner, a perforated liner, a valve, a port, etc. The method according to the invention is not limited to a production wellbore and may be used into an abandoned wellbore or an injection wellbore such as a chemical or vapor injection wellbore. The invention is not limited to the described embodiment and can be applied to all type of formation fluids or gases transportation means.
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Aspects of the present disclosure include a system and a method for sealing at least one opening of a wellbore equipment arranged in a wellbore of a subterranean formation in order to improve the recovery of formation fluids and/or gases. The method includes the steps of positioning a metal patch between the wellbore equipment and a shock wave generation device. The metal patch faces the at least one opening to be sealed and the method further including generating, using a shock wave generation device, at least one electrical discharge into said wellbore in order to propagate toward said metal patch at least one shock wave adapted to deform and fix the metal patch onto the wellbore equipment, sealing therefore the at least one opening.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Patent Application Ser. No. 60/441,884, filed Jan. 22, 2003, which application is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to automated downhole tools that are remotely movable between a primary and a secondary position. Particularly, the invention relates to computer control of automated downhole tools using an interactive computer touch-screen to facilitate use of a control system that operates the tools. More particularly, the invention relates to a means of monitoring the operation of the downhole tools using computer software to compare variables to known standards.
2. Description of the Related Art
In oil and gas wells, hydrocarbons are collected from at least one wellbore formed in the earth by drilling. In some cases, the wellbore is lined with steel pipe called casing or liner that is perforated at a given location to permit the inflow of hydrocarbons. In other instances, the wellbores are left unlined or “open” to facilitate the collection of hydrocarbons along a relatively long length of the wellbore. When hydrocarbons are collected at different locations within the well, it is useful to control the inflow of the fluid between the different points along the wellbore in order to take advantage of changing wellbore conditions. For example, inflow devices with adjustable sleeves can be placed at different, isolated locations in a tubular string. The sleeves in these devices have apertures formed therethrough that can be placed in or out of alignment with mating apertures in the body of the tool. By adjusting the relative position of the apertures, the sleeves can permit a varying amount of fluid to pass into a production stream for collection at the surface. The ability to control inflow is especially important along a wellbore where the make up of the incoming fluid can change over time. For example, if an unacceptable amount of water begins flowing into production tubing at a certain location, an inflow device at that location can be partially or completely closed, thereby preventing the water from entering the production stream.
Some prior art inflow devices require the sleeves to be set at the surface of the well based upon a prediction about the wellbore conditions. After run-in, changing the position of the devices requires them to be completely removed from the well along with the string of tubulars upon which they are installed. More recently, the inflow devices have been made to operate remotely using hydraulic fluid transported in a control line or some electrical means to shift them between positions. In the most advanced applications known as “Intelligent Completions”, the devices are computer controlled, permitting them to be operated according to a computer program.
A typical computer-controlled apparatus for the operation of downhole inflow devices includes a keyboard that is connected to a computer; solenoid-controlled valves that open to permit control fluid to travel down to the device in the wellbore; a pump; a source of control fluid; and at least two fluid lines traveling downhole to a fluid powered controller that determines which of the more than one hydraulic/mechanical inflow device is supplied with the control fluid. Typically, the controller includes some type of keyable member that can align or misalign fluid ports connected to the devices therebelow. Each such device has at least one fluid line extending from the fluid controller, but may require a multiplicity of fluid lines. The fluid lines provide fluid to the device and a path for return fluid back to the surface. In one arrangement, the computer at the surface provides a source of fluid at a relatively low pressure that can shift an internal valve mechanism in the controller in order to set up a particular alignment of ports to supply control fluid to the proper downhole device. Once the fluid controller is properly arranged, control fluid is provided at a second, higher pressure to the particular device in order to move a shiftable sleeve from its initial position to a second position. In this manner, each device can be operated and separate control lines for each device need not extend back to the surface.
While the computers have made the devices much more useful in wells, there are some realities with computer equipment at well locations that make their use difficult and prone to error. For example, personnel at a well are not typically trained to operate computer keyboards and even the most straightforward commands must be entered with the keyboard, posing opportunities for error. Even the use of a computer mouse requires precise movements that are difficult in a drilling or production environment. Additionally, environmental conditions at a well include heat, dirt, and grime that can foul computer equipment like a keyboard and shorten its life in a location where replacement parts and computer technicians are scarce.
Another issue related to computer-controlled equipment is confirming that the orders given to a downhole device via computer have actually been carried out. For example, in computer-controlled systems, a command is given for a downhole tool to move from one position to another. Ultimately, the software command is transmitted into some mechanical movement within the tool. While there might be a computer-generated confirmation that the command has been given, there is no real way of immediately knowing that the prescribed physical action has taken place. In some instances, movement within a tool is confirmed by monitoring the well production to determine if the flow has been affected by the closing of an inflow device. This type of confirmation however, is time consuming and uncertain.
There is a need therefore for a computer control system that is easier to use when operating automated downhole tools in a wellbore. There is a further need for an apparatus and method of quickly and easily ensuring the automated computer commands to downhole equipment have been carried out.
SUMMARY OF THE INVENTION
The present invention generally includes a computer-controlled apparatus for use in wellbore completions. A touch-screen is provided that facilitates commands and information that is entered by an operator ordering movement of a downhole tool. In another embodiment, real-time information about the status of the downhole tools is transmitted to the apparatus based upon operating variables within the system, like pressure, flow rate, total flow, and time.
In another aspect, the present invention provides a method of operating one or more downhole devices in a wellbore. The method includes disposing the one or more devices in the wellbore, the one or more devices having at least an open and a closed position. Also, a signal is provided to the one or more devices to move the one or more devices between the open and the closed position. Preferably, the signal is computer generated based upon an operator's interaction with a touch screen.
In another aspect, the present invention provides a method of monitoring operation of a downhole tool. The method includes providing a signal to the downhole tool, whereby the signal causes the tool to move between an initial and a second position. Additionally, the method includes monitoring variables within a fluid power system to confirm the position of the downhole tool, the variables including at least one of pressure, time, total flow, or flow rate.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a section view of a wellbore showing some components making up an intelligent completion apparatus.
FIGS. 2-7 are touch screens representing various steps in the operation of the control apparatus of the present invention.
FIG. 8 is another embodiment of a touch screen for operating a control apparatus.
FIGS. 9-11 are touch screens showing the status of the controller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to automated downhole equipment and its control using a touch-screen at the surface of the well to input commands and information. The invention further relates to a quick, simple and reliable means to ensure that computer generated commands to operate downhole tools are successfully carried out.
FIGS. 2-7 referred to in this application illustrate a touch-screen. A basic touch-screen system is made up of three components: a touch sensor, controller, and software driver. The sensor is a clear panel, which when touched, registers a voltage change that is sent to the controller. The controller processes this signal and passes the touch event data to the PC through a bus interface, be it a bus-card, serial, USB, infrared, or wireless. The software driver takes this data and translates the touch events into mouse events.
Resistive LCD touch screen monitors, such as the ones intended by the inventors, rely on a touch overlay, which is composed of a flexible top layer and a rigid bottom layer separated by insulating dots, attached to a touch-screen controller. The inside surface of each of the two layers is coated with a transparent metal oxide coating (ITO) that facilitates a gradient across each layer when voltage is applied. Pressing the flexible top sheet creates electrical contact between the resistive layers, producing a switch closing in the circuit. The control electronics alternate voltage between the layers and pass the resulting X and Y touch coordinates to the touch-screen controller. The touch-screen controller data is then passed on to the computer operating system for processing.
Resistive touch-screen technology possesses many advantages over other alternative touch-screen technologies (acoustic wave, capacitive, Near Field Imaging, infrared). Highly durable, resistive touch-screens are less susceptible to contaminants that easily infect acoustic wave touch-screens. In addition, resistive touch-screens are less sensitive to the effects of severe scratches that would incapacitate capacitive touch-screens. For industrial applications like well production, resistive touch-screens are more cost-effective solutions than near field imaging touch-screens. Because of its versatility and cost-effectiveness, resistive touch-screen technology is the touch technology of choice for many markets and applications.
FIG. 1 is a partial section view of a wellbore 5 showing the components that might be typically used with the present invention. The components (described from the upper wellbore to the lower end thereof) include hydraulic control lines 11 that carry fluid to and from components. A production packer 15 seals an annular area 20 between production tubing 25 and the wall of casing 30 therearound. Below the production packer 15 is the downhole controller 100 referred to as a “hydraulically controlled addressing unit” that is used to control one of various downhole, inflow devices 110 , 120 , 130 . Below the controller 100 and above a zonal isolation packer 115 , is an inflow device 110 referred to in FIG. 1 as a remotely operated sliding sleeve (ROSS). The sleeve 110 is of the type described herein with a sliding member that determines the inflow of fluid into the production tubing 25 . In this embodiment, two additional inflow devices 120 , 130 are disposed in the wellbore 5 . Each of the sleeves 110 , 120 , 130 is located in its own isolated section of the wellbore 5 , and each includes a set of sleeve control cables 111 , 121 , 131 extending back upwards to the controller 100 . Casing perforations 70 are shown that form a fluid path from the formation around the wellbore 5 into the inflow devices 110 , 120 , 130 . It is understood that the inflow devices 110 , 120 , 130 may also be operated to regulate the outflow of fluids from the production tubing 25 .
In the preferred embodiment, the controller 100 is adapted to control all of the inflow devices 110 , 120 , 130 . As shown, the controller 100 is designed to control all three inflow devices. Particularly, information or instructions from the touch screen may initially be transmitted to the controller 100 . In turn, the information or instruction causes an actuating member in the controller 100 to move relative to a park position. As will be discussed below, the actuating member will position itself such that the control lines 11 will align with the sleeve control lines of the selected inflow sleeve 110 , 120 , 130 for operation thereof. According to aspects of the present invention, the control cables 111 , 121 , 131 of the inflow devices 110 , 120 , 130 need only connect to the controller 100 , which is also located in the wellbore 5 . In this respect, it is not necessary to run control lines for each inflow device all the way to the surface, thereby reducing the number of control lines to the surface. In addition to hydraulic control lines, the inventors also contemplate using electric lines, fiber optics, cable, wireless, mechanical or other means known to a person of ordinary skill in the art to communicate or transmit information or instruction between the touch screen, controller 100 , and the inflow devices 110 , 120 , 130 . For example, after election is made on the touch screen, a fiber optics signal may be transmitted to the controller 100 via a fiber optics cable.
FIG. 2 shows the touch-screen 200 that is located at the surface of the well and is used to control the position of the inflow devices 110 , 120 , 130 as well as to monitor operating characteristics and input information. As shown in FIG. 2 , the touch-screen 200 includes an icon 210 , 220 , 230 representing each downhole device 110 , 120 , 130 that is controlled from the surface. In the example of FIG. 2 , there are three downhole inflow devices, each having an adjustable sliding sleeve that is manipulatable from the surface of the well via commands given at the touch-screen 200 . The devices 110 , 120 , 130 are labeled “ROSS 1,” “ROSS 2,” and “ROSS 3,” respectively. In FIG. 2 , the touch screen system is in “stand-by mode” waiting for instructions. Additionally, the status of the inflow devices is “closed.”
In operation, an operator may initially touch a decision screen, e.g., FIG. 2 , to indicate a desire to operate the inflow devices. For example, the operator may touch the icon 210 for the first device (“ROSS 1”) 110 to indicate a desire to send a command to the first device 110 . In another embodiment, the screen 200 could be operated through a wireless remote device utilizing an infrared light source or any other means well known in the art to send commands to a receiver located at a computer.
After the initial selection, another screen 300 , shown in FIG. 3 , prompts the operator to confirm his decision to operate the first inflow device 110 . To confirm, the operator may touch the screen 300 where indicated.
After a response is received, the touch screen 400 , as shown in FIG. 4 , will illustrate the corresponding operation of the fluid controller 100 to align the control lines 11 to the sleeve control lines 111 of the first inflow device 110 . In this respect, a pump at the surface provides a first, low pressure to rotate the actuating member of the controller 110 . In this manner, the actuating member is rotated to align the control line 11 with the sleeve control lines 111 , thereby placing the fluid ports of the pump in fluid communication with the inflow device 110 . As indicated on the screen 400 , the “Selected HCAU Operation” is to “Open ROSS 1” 110 . Additionally, the screen 400 also indicates that the “Current HCAU State” is “Operating Secondary,” which refers to moving the actuating member of the controller 100 into position to align the control line 11 with the sleeve control line 111 . Operational variables shown on this information screen 400 include outlet flow rate 405 in cc/sec, return flow rate 410 , time elapsed during the operation 415 , and fluid pressure 420 . As will be discussed later, the successful alignment of the ports to the inflow device 110 is assured based upon changing conditions in the fluid control system. For example, pressure increases and flow rate decreases in the outlet flow line when the movable member in the controller 100 has moved to its proper position and stopped.
After the control line 11 is aligned with the sleeve control line 111 , the system is ready to open the first inflow device 110 . However, the next screen 500 , shown in FIG. 5 , asks the operator to confirm his desire to operate the first inflow device 110 . Alternatively, the screen 500 also allows the operator to return the controller to the “Stand-by mode.”
After confirmation by touching the screen 500 , the pump at the surface of the well provides fluid at a second, higher pressure. The next screen 600 , shown in FIG. 6 , is another information screen showing an increase in fluid pressure as the pump provides fluid at the higher pressure to manipulate a sliding sleeve in the first inflow device 110 . As indicated on the screen 600 , the “Current HCAU State” has changed to “Operating ROSS 1,” which refers to the opening of the first inflow device 110 . In one embodiment, the pressure needed to operate the controller 100 , i.e., move the actuating member, is between 200-1000 psi. Pressure exceeding 1000 psi is then required to operate the first inflow device 110 . Real-time display shows the increasing, operating and decreasing pressures and flow rates associated with the operation of the first inflow device 110 between an initial and a secondary position. In this example, the first inflow device 110 is moved from a closed to an open position. Although separately operating the controller and the inflow device is disclosed herein, it is also contemplated that the inflow device may be operated by supplying only one pressure to the controller.
After the first inflow device 110 is opened, another screen 700 , shown in FIG. 7 , shows that the icon 210 of the first inflow device 110 now indicates that the first inflow device 110 is open. Additionally, the screen 700 also indicates that the system has returned to a standby mode for commencement of another operation that opens or closes inflow devices 110 , 120 , 130 .
Throughout the automated operations described above, the conditions within the fluid power system can be constantly monitored and compared to standards in order to spot malfunctions or operational characteristics that are outside of a preprogrammed value. For example, if the pressure or flow rate of the fluid operating the controller or an inflow device should drop unexpectedly during an operation, the operator can be alerted of the condition via a warning screen. The condition can mean a fluid leak at either a line or a device and action can be quickly taken to address the problem. Similarly, if an operation is not completed during a preprogrammed time limit necessary for that operation, an operator can be alerted of the condition and take appropriate action. These and other warnings are possible based upon the ability to constantly monitor pressure, flow rate and other variables within the automated system.
FIG. 8 shows another embodiment of a touch screen 800 according to aspects of the present invention. In this embodiment, the wellbore 5 is provided with three inflow devices 110 , 120 , 130 located in three different zones of the wellbore 5 . Each of the inflow devices 110 , 120 , 130 is represented by a respective icon 810 , 820 , 830 on the screen 800 . As shown, the screen 800 is in stand-by mode. The inflow device icons 810 , 820 , 830 may be selected to operate the desired inflow device. If necessary, the controller 100 may be returned to the park position by selecting the tell-tale icon 840 . The screen 800 also includes a controller icon 850 . The controller icon 850 may be selected to view the status of the controller 100 .
FIG. 9 represents an information screen 900 that is provided when the controller icon 850 is selected. As shown, the controller 100 is in the park position 905 or the “Tell-Tale” position. The modes of operation of the controller 100 is arranged to represent the position of the actuating member.
FIG. 10 represents an information screen 1000 that shows the second inflow device 820 as being open. Specifically, the indicator bar 915 extends from the “tell-tale” position to the open position of the second inflow device 820 . This represents that the actuating member of the controller 100 has moved to a position that aligns the control 11 with the sleeve control line 121 of the second inflow device 820 .
FIG. 11 represents an information screen 1100 that shows the third inflow device 830 is closed. From the open position of the second inflow device 820 , an operator may elect to open the closed third inflow device 830 . Specifically, the operator may return to the previous touch screen and select the third inflow device icon. Thereafter, the operator may press the controller icon 850 to return to the controller information screen 1100 to view the status of the controller 100 . Once selected, a second indicator bar 925 will extend from the previous position to the “close” position of the third inflow device 830 . The second indicator bar 925 represents that a second operation was performed, i.e., closing the third inflow device 830 . In this manner, the controller 100 may be operated to control the inflow and outflow of the various inflow devices.
It must be noted that aspects of the present invention may be applied to operate one or more inflow devices. The inflow devices may include any suitable inflow or outflow device known to a person of ordinary skill in the art. Additionally, the one or more inflow devices may be adapted to control the flow of fluid in one or more isolated zones in a wellbore. The wellbore may include a deviated or non-deviated wellbore, a single or multilateral wellbore, or any other types of wellbore known to a person of ordinary skill in the art.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. For example, while the invention has been described for use with inflow devices having slidable sleeves, it will be understood that the invention can be used with any downhole tool that might benefit from computer control and/or real time monitoring.
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A method and apparatus for a computer controlled apparatus for use in wellbore completions. A touch-screen is provided that facilitates commands and information that is entered by an operator ordering movement of a downhole tool. In another embodiment, real-time information about the status of the downhole tools is transmitted to the apparatus based upon operating variables within the system, like pressure, flow rate, total flow, and time.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 60/510,949, filed on Oct. 10, 2003 entitled PARTICULATE MATERIAL SPREADING APPARATUS. Such application is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to material handling and distribution and more particularly to an improved apparatus and method for moving and spreading particulate material from a carrier vessel.
BACKGROUND OF THE INVENTION
Spreaders for particulate material have many uses, and exist in widely diverse configurations. Such spreaders can be mounted on stationary structures for repeatedly spreading material over the same area, or can be mounted for movement such as on or by a vehicle, for selectively spreading material over different areas as directed by movement of the vehicle or parts thereof. For example, sand and road salt spreaders are commonly attached to the back of highway maintenance trucks for spreading the sand or salt over icy or slippery road surfaces. Other applications, as for example in the agricultural, dairy and livestock industries use mobile spreaders for dispersing bedding materials such as wood shavings, chopped straw or sawdust in animal shelters and barn stalls. Such spreaders may be attached to scoops or buckets that are attached to and moved by tractors, skid steered vehicles, or the like. Such spreading equipment can also be used for spreading other particulate materials such as feed corn or grains in animal feed lots, for grain tanks, or for spreading top soil or other particulate landscape materials.
In most such mobile spreading structures, the actual spreader mechanism is generally operatively attached to a movable vessel or container that is configured to retainably hold a quantity or charge of the material to be dispensed. The vessel could, for example, be the bed of a dump truck, a towed trailer bed or tank, or a bucket of a tractor, a front-end loader, or a skid steer vehicle. Such vessels are generally configured to tip or otherwise be moved in a manner such that the material carried thereby is movable within the vessel toward and into an adjacent spreading apparatus. For example, a load of sand carried by a highway maintenance dump truck bed typically slides by gravity toward the back of the truck bed as the bed is raised, and into a spreader mechanism located at the back of the truck. The spreader mechanism typically includes a movable disk or vane member that is rotatable about a generally vertical axis and flings or throws material dropped onto it outwardly in broadcasting dispersing manner away from the spreader, such as across a highway surface behind the truck.
A common problem associated with such vessel supplied spreading equipment is the bridging of the material carried by the vessel as the material is directed by gravity out of the vessel and into the spreader mechanism. In the process of moving along and out of the containment vessel, the material to be spread is generally required to pass through a narrowed-down portion of the vessel or through an outlet port thereof leading to the spreader apparatus. Such material flow restriction and the general cohesive nature of the material to be spread further encourages bridging of the material within the vessel, at a position spaced upwardly from the vessel outlet and the spreader apparatus inlet, thereby disruptively interrupting the spreading process.
One way of breaking the bridged dams of material within the containment vessel is to bang or jerk the vessel body so as to dislodge the bridged material. This process is undesirable, unreliable and not particularly effective in situations where the apparatus operator cannot readily or continually observe the vessel contents during the spreading operation, and may be unaware of a material bridging situation. Another technique that has been employed with tractor or loader buckets has been to fixedly mount an auger adjacent the lower inside surface of the bucket to both direct the material laterally to a spreader located at one end of the bucket and in an attempt to address the bridging problem in the bucket. Such augers did generally not solve the material bridging problems of such buckets, which now enabled the material to bridge at a position overlying the auger surface. The next attempted solution was to place a second or multiple rotatable paddle wheels or beater structures within the bucket, spaced upwardly from and overlying the lower auger in generally parallel manner, to continually move and agitate the material overlying the auger in hope of minimizing bridging thereof. Such systems are generally expensive, are fairly complex and high maintenance structures, and still do not work well or efficiently.
The present invention addresses the described deficiencies of prior art vessel material containment and spreader combination configurations by providing a relatively simple, reliable and cost effective material dispensing and method that minimizes material bridging within the vessel and provides for uniform and smooth spreading dispersal of the material from the vessel.
SUMMARY OF THE INVENTION
The invention provides an improved apparatus and method for spreading materials from a material containment vessel which prevents or minimizes the bridging of the material to be dispersed within the containment vessel. The invention incorporates a rotatable auger positioned in close proximity to a curvilinear inner wall surface of the vessel and having an axis that moves parallel to the curved wall surface in a manner such that the auger flights maintain a close working relationship relative to the curved wall surface as the auger is positioned for movement therealong. The invention covers relative movement and positioning of the auger relative to the vessel inner surface, whether the auger is moved relative to the vessel surface or whether the vessel surface is moved relative to the auger. The apparatus and method of this invention minimizes material bridging within the vessel by enabling removal of material to be dispersed by the spreading apparatus from the upper surface of the contained material within the vessel.
According to one aspect of the invention there is provided a material dispensing apparatus including a vessel configured to retainably hold a change of material to be dispensed and having at least one broad inner curvilinear wall and defining an outlet port through which the material is dispersed from the vessel. An auger is positioned within the vessel with its axis of rotation generally parallel to the vessel's inner curvilinear wall surface and having a plurality of flights operable to move material within the vessel toward the outlet port. An operator apparatus positions the auger and curvilinear wall surface for relative cooperative movement such that the auger flights arcuately move along and in close proximity to the wall surface to dispense material from the vessel.
A spreader apparatus may be positioned to receive material dispensed through the vessel outlet port to broadcast the dispensed material externally of the vessel. Accordingly to one embodiment of the invention, the vessel comprises a bucket member. The vessel may be configured for attachment to a vehicle. The operator apparatus can be configured to move the auger relative to the vessel wall, or to move the vessel wall relative to the auger.
These and other features of the invention will be better appreciated upon reading of the following detailed description of one embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
Referring now to the Drawing, wherein like numerals represent like parts throughout the several views:
FIG. 1 is a left side perspective view of a skid steerable vehicle to which is mounted a spreading bucket configuration incorporating the principles of the invention;
FIG. 2 is a partial right rear perspective view of the skid steerable vehicle and spreading bucket assembly of FIG. 1 , illustrating in more detail the rear portion of the spreading bucket assembly;
FIG. 3 is an enlarged top, side, front perspective view of the spreading bucket assembly of FIGS. 1 and 2 , illustrated the auger assembly thereof at a first, lowermost position, and with a portion of the right wall thereof broken away;
FIG. 4 is a perspective view of the spreading bucket assembly of FIG. 3 , illustrating the auger assembly thereof at an intermediate position;
FIG. 5 is a perspective view of the spreading bucket assembly of FIG. 3 , illustrating the auger assembly thereof at an uppermost position;
FIG. 6 is an enlarged top, side, rear perspective view of the spreading bucket assembly of FIGS. 1 and 2 , illustrating the auger assembly thereof in the first, lowermost position;
FIG. 7 is a perspective view of the spreading bucket assembly of FIG. 6 , illustrating the auger assembly thereof at an uppermost position;
FIG. 8 is a perspective view of the hitch plate portion of the spreading bucket assembly of FIGS. 6 and 7 ;
FIG. 9 is a schematic diagram of a hydraulic circuit for operating the spreading bucket assembly with a skid steerable vehicle such as in FIGS. 1 and 2 ; and
FIGS. 10A , 10 B and 10 C is a diagrammatic side view illustration of three positions of the auger of the spreading bucket assembly of the invention as positioned relative to the curvilinear rear inside wall of the bucket.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the Figs., there is generally illustrated therein a preferred embodiment of a spreading bucket assembly that incorporates the principles of this invention. In FIGS. 1 and 2 , the spreading bucket assembly is illustrated as attached to and being movable by a skid steerable vehicle 10 . It will be understood that the invention is not limited to use with a skid steerable vehicle, or to the particular configuration of the spreading bucket assembly illustrated in FIGS. 1-10 , but that the skid steerable vehicle and the particular spreading bucket configurations illustrated in the Drawing are simply representative of one embodiment of a containment vessel and vessel moving assembly combination that can be used to practice the principles of this invention.
Referring to FIGS. 1 and 2 , the skid steerable vehicle 10 generally includes a chassis 11 containing an engine and power train for moving and operating the vehicle. The vehicle includes a plurality of wheels, generally indicated at 12 , for moving the vehicle over the ground or support surface. In a skid steerable vehicle, the vehicle turns by locking one or more of the wheels while powering the others in a manner well known in the art. The vehicle 10 typically has a cab portion 13 wherein an operator sits to control the vehicle, and a primary pair of pivotably movable lift arms 14 that can be raised and lowered about their rear pivot positions, generally indicated at 15 to raise and lower the forward ends 14 a of the operator arms 14 relative to the ground or support surface. A pair of hydraulic lift cylinders 16 provide the motive force for rotatably moving the operator arms 14 . The skid steerable vehicle 10 also has a universal mounting bracket assembly (not illustrated in the Figs.) pivotably connected to the forward ends 14 a of the operator arms 14 which provides detachable mounting and connection to various implements such as the spreader bucket assembly of the present invention generally indicated at 20 . Other implements such as grading blade configurations, fork lift members, and the like can be detachably secured to the universal mounting bracket assembly in manners well known in the art. The mounting bracket is movable and pivotable relative to the forward ends 14 a of the operator arms 14 by one or more hydraulic cylinders (not illustrated) to pivotally move the mounting brackets and attached implements relative to the forward ends 14 a of the operator arms 14 .
Since configurations and operations of such skid steerable vehicles are well known in the art, further details thereof will not be provided herein, it being understood that those skilled in the art clearly understand the nature of such vehicles and how they operate in numerous versatile situations. Skid steerable vehicles such as that generally illustrated at 10 typically include one or more auxillary pairs of hydraulically operated and controllable lines powered by the vehicle and extending forwardly therefrom for providing sources of hydraulic power that can be controlled by the operator within the vehicle to energize hydraulic motors, cylinders and the like carried by the implement attached to the vehicle, or for other desired purposes. For simplicity in illustrating the invention and for clarity in the figures, such hydraulic lines are not illustrated in the Drawings, but are understood to exist and to extend from and between the vehicle to the various hydraulic devices to be hereinafter described, for effecting proper operation thereof. An example of such a hydraulic circuit as used to energize the hydraulic portions of the present invention will be described in more detail with respect to FIG. 9 .
A more detailed description of the spreader bucket assembly 20 of the present invention is illustrated in FIGS. 3-8 . Referring thereto, the bucket assembly 20 generally includes opposed left and right end plates 21 and 22 , a bottom wall plate 23 extending laterally between the end plates 21 and 22 , a back wall plate 24 , and a lower inside back contour plate 25 laterally extending between the end plates 21 and 22 and forming a curved transition surface between the bottom plate 23 and the back wall 24 . The back wall 24 defines a broad curvilinear surface extending from the bottom plate 23 toward an upper edge 24 a . Secured to the upper edge 24 a of the back wall plate 24 is an angled plate 27 providing a flat upper edge for the bucket. The end plates 21 , 22 and the bottom and back plates 23 , 24 as well as the inside back contour plate 25 , cooperatively define a scoop or bucket cavity or a vessel for retainably holding material, in a manner well known in the art.
In the preferred embodiment of the spreader bucket assembly illustrated, the lower forward edge of the bucket assembly is reinforced by a relatively thicker portion of steel blade edge material 28 which extends across the width of the forward edge of the bottom plate 23 and partially up along the front forward side edges of the end plates 21 and 22 . Additional reinforcement members 29 are mounted on each side of the bucket assembly adjacent the lower forward edges thereof and mount pivot supports 30 for an auger movement assembly to be described in more detail hereinafter. The bucket assembly further includes lower and side reinforced skid wear bars 31 for facilitating sliding motion of the bucket along the ground.
The back wall plate 24 defines a viewing port opening 24 b therethrough which is covered by a transparent plastic member 35 to enable an operator within the vehicle 10 visual inspection through the rear wall of the bucket and into its inner cavity. The right end plate 22 also defines an opening extending therethrough, generally indicated at 22 a and extending from bottom to top of the bucket along the edge of the curvilinear back wall plate 24 , to define a discharge port or chute opening into the spreader apparatus to be hereinafter described. A pair of left and right back support gussets 36 a and 36 b respectively are welded to the outer surface of the back wall plate 24 and provide rigidity and support thereto, as illustrated in FIG. 6 . A lower tubular support 37 extends laterally across the lower back portion of the back wall plate 24 and is secured by the gussets 36 and welded to the back wall 24 to provide additional strength to the bucket. An upper cylindrical cross tube support 38 extends across the upper edge of the back wall 24 and is mounted under and to the upper angled plate 27 and to the upper portions of the back support gussets 36 .
A standard quick hitch mounting plate 40 is welded to a pair of mounting gusset support plates 41 to the rear wall 24 , and to the back support gussets 36 . A more detailed view of the standard quick hitch mounting plate 40 is illustrated in FIG. 8 . Referring thereto, the mounting plate 40 includes a plurality of engagement notches, generally indicated at 40 a in a pair of lower mounting bracket portions 40 b and an angled upper retainer cam member 40 c , which cooperatively engage the universal mounting bracket arms of the skid steerable vehicle, in a manner well known in the art, for enabling detachable secured movement of the bucket assembly by the movable operator arms of the vehicle 10 .
A pair of left and right auger lift arm linkage assemblies 45 and 47 respectively pivotally support an auger 50 for cooperative arcuate movement relative and parallel to and in close proximity with the inner curvilinear surface of the back wall plate 24 . The left auger lift arm linkage assembly, best illustrated in FIGS. 3-5 includes a lower linkage arm 45 a pivotally mounted to the left end plate 21 by means of the auger pivot support 30 , an upper linkage arm 45 b pivotally mounted for rotation about the distal end of the upper cross tube 38 , and an intermediate linkage arm 45 c pivotally mounted respectively to the lower end of the upper linkage arm 45 b and to an intermediate portion of the lower linkage arm 45 a . The right auger lift arm linkage assembly is virtually a mirror image of the above-described left auger lift arm linkage assembly, and moves in unison with the left auger left arm assembly 45 , and is illustrated in FIG. 3 . The auger 50 is mounted for pivotal rotation about its longitudinal axis between the distal ends of the lower linkage arms 45 a and 47 a of the left and right auger lift arm linkage assemblies. The left end of the axially aligned central shaft 51 of the auger 50 is operatively mounted to be driven by a gear and transmission assembly 55 that is driven by a hydraulic motor 56 mounted to the central arm portion of the lower linkage arm 45 a . A protective shroud 57 surrounds and shields the gear assembly 55 from the contents of the bucket. The non-driven distal end of the auger shaft 51 is pivotally mounted for rotation within the movable distal end of the lower linkage arm 47 a.
The upper end of the upper linkage arm 45 b is connected to the movable piston 60 a of a hydraulic cylinder 60 . The lower end of the hydraulic cylinder 60 is secured by a mounting bracket 61 that is secured to the lower tubular support 37 , as best illustrated in FIG. 6 . As controlled by the hydraulic cylinder 60 , the left and right auger lift arm linkage assemblies 45 and 47 cooperatively move the auger 50 along and parallel to the inner curvilinear surface of the back wall of the bucket assembly from a lowermost position as illustrated in FIGS. 3 and 6 , to an uppermost position as illustrated in FIGS. 5 and 7 . An intermediate auger position is illustrated in FIG. 4 . The uppermost, intermediate and lowermost auger positions relative to the rear wall 24 are diagrammatically illustrated respectively in FIGS. 10A , 10 B and 10 C.
A material spreader or slinger apparatus is generally illustrated at 65 . The spreader is mounted to the right side wall or end plate 22 by means of its outer shroud or housing 66 , that is connected to cooperatively surround the discharge port or chute opening 22 a from the bucket interior formed through the right end plate 22 . The back surface of the shroud 66 includes a plurality of openings 66 a formed therethrough which are covered by a transparent plastic or plexiglass member 68 which enables an operator of the vehicle 10 to view into the inner cavity of the material spreader 65 . The right most portion of the spreader shroud 66 defines a discharge port or outlet 69 from the spreader through which material is ejected from the spreader. A disk member 70 with an attached upright impellor assembly 71 are pivotally mounted between the bottom plate of the outer shroud 66 and a hydraulic motor 72 mounted to an upper mounting plate 73 of the shroud housing. The shaft connecting the output of hydraulic motor 72 to the impellor and lower disk members 71 and 70 respectively is illustrated at 74 . As the motor 72 rotates the lower disk end impellor members, any material contained within the shroud housing as directed thereto by the auger, is forcefully ejected through the discharge port 69 of the shroud housing.
The auger motor 56 , the slinger or spreader motor 72 and the auger positioning hydraulic cylinder 60 are energized by means of the auxiliary hydraulic output lines available from the skid steerer vehicle, as schematically illustrated in FIG. 9 . For the system illustrated in FIG. 9 , the skid steerable vehicle 10 has a dual auxiliary hydraulic control system available for use by the spreader bucket assembly. A first pair of hydraulic lines, generally indicated at 80 and 81 , are operatively connected to energize the auger motor 56 and the spreader or slinger motor 72 in series. A second set of hydraulic lines, generally indicated at 82 and 83 , are operatively connected to energize and control the auger positioning cylinder 60 for moving the auger in curvilinear fashion in close proximity to and adjacent to the inner surface of the bucket rear wall.
In the preferred embodiment, the auger 50 generally helical construction secured at its ends by shaft portions 51 aligned along a central longitudinal axis of the auger. In the preferred embodiment illustrated, the auger flighting is 12 inches in diameter and has a 9 inch pitch. It will be understood however, that augers of various sizes and configurations could be used within the spirit and intent of this invention. The auger pivot supports 30 for the linkage arms 45 and 47 are positioned along the left and right end plates 21 and 22 such that an axis drawn through the center of the pivot supports 30 defines a line that is the radial center line for the curvilinear surface defined by the inner surface of the back plate 24 . As the hydraulic cylinder 60 activates the auger lift arm linkage assemblies 45 and 47 , causing the lower linkage arms 45 a and 47 a thereof to pivot about the auger pivot supports 30 , the outer edge surfaces of the auger flighting members move in close proximity to and along the curved inner surface of the back wall plate 24 of the bucket cavity. The speed of the hydraulic motors can be adjusted by adjusting the hydraulic fluid flow rates therethrough, as is well known in the art. In the preferred embodiment, the motors 56 and 72 are connected in series as shown in FIG. 9 and operate at a 14 gallon per minute flow rate. Similarly, the hydraulic fluid flow rate to the auger positioning cylinder 60 can be adjusted to desired design parameters. In the preferred embodiment, the hydraulic cylinder 60 is a 2×8 inch cylinder and operates on a 4 to 5 gallon per minute flow rate.
Operation of the spreader bucket configuration will be clearly understood by those skilled in the art. Once operatively engaged to the operator arms 14 of the skid steerable vehicle 10 by engagement to the quick hitch mounting plate 40 and proper connection of the hydraulic cylinder and motors 60 , 56 and 72 , to the auxiliary hydraulic control lines 80 - 83 of the vehicle, the spreader bucket assembly 20 is ready for operation. It is movable by the pair of vehicle operator lift arms 14 in an up and down manner relative to the ground, and is pivotable around the front mounting bracket portion of the operator arms to pivotally tip the bucket so as to change the inclination of the bottom plate 23 relative to the support surface or ground, in a manner well known in the art.
The transparent viewing panels 35 and 68 enable the operator of the vehicle to effectively and efficiently control the material spreading process. Panel 35 enables the operator to view the auger position within the bucket and relative to the upper surface of the material; whereas the viewing panel 68 provides the operator with a visual observation of how much material has accumulated within the material spreader 65 and its relative position therein.
In operation the bucket 20 is loaded in the fashion that all skid steerable operated buckets use. The vehicle moves the bucket into a position which addresses the pile of material to be loaded. The bucket is pivoted in a manner such that the open end of the bucket is positioned to engage the material to be loaded. Typically in a loading position, the bottom 23 of the bucket would be positioned parallel to the ground and slid therealong as the vehicle pushes the bucket into the pile of materials to fill or load the inner cavity portion of the bucket with a charge of material. Prior to loading the material into the bucket, the hydraulic cylinder 60 would be energized so as to cause the auger lift arm linkage assemblies 45 and 47 to lift the auger 50 into its uppermost position as illustrated in FIGS. 5 and 7 . The material that is then loaded into the bucket will be loaded generally below the auger. After the material is loaded into the bucket, the operator pivots the bucket about the forward ends of the skid steering vehicle operator arms 14 to a position generally illustrated in FIGS. 1 and 2 , to secure the loaded material within the bucket cavity and to position the material spreader or slinger mechanism 65 in a generally vertical orientation, as illustrated in FIG. 2 .
The vehicle then transports the loaded material to the dispersion site, wherein the operator then lifts the bucket assembly by the pair of operator arms 14 to a desired height for spreading of the material. This position is not illustrated in the figures. The lifted spreading bucket is oriented relative to the area in which the material is to be spread such that the discharge outlet port 69 of the material spreader 65 faces the area into which the material is to be ejected. Virtually any particulate type of material can be dispersed by the system. For example, if the material being spread is wood shavings or chopped straw or sawdust that could be used for a bedding material in a barn stall, the bucket would be positioned at a height and position calculated to spread the bedding material uniformly throughout the stall. To initiate the spreading function, the operator energizes the auger positioning hydraulic cylinder 60 to lower the auger flights into engagement with the upper surface of the material if they are not already in such engagement, and energizes the hydraulic auger and spreader motors 56 and 72 so as to begin rotation of the auger and the slinger impellor and disk 71 , 70 at the discharge port 69 .
The rotating auger will direct material it engages toward and through the discharge port and chute 22 a through the right end plate of the bucket and into the material spreader 65 . Such material will fall by gravity onto the spinning disk and impellor assemblies which will eject the material through the spreader discharge port 69 in a broadcasting manner. Since the auger is continually moving the contained material within the bucket or vessel from the material's uppermost surface, bridging of the material is eliminated or minimized. As the material is removed from the bucket during the spreading process, the operator simply periodically activates the auger positioning cylinder 60 so as to downwardly move the auger position along the curvilinear inner surface of the back plate of the bucket, thereby continually removing material from the top of the contained material. The process continues until the operator decides to terminate the spreading function, or until all of the material has been emptied from the bucket. The close cooperative movement association between the auger flights and the inner curvilinear surface of the back of the bucket does not allow the material to stick to the inner bucket surfaces in a manner that causes bridging. Further, the auger is never submerged below or buried by the material contained within the bucket during rotational operation of the auger. Therefore, the auger is not subjected to heavy forces or stresses caused by the material weight, providing a more efficient and reliable system.
In the preferred embodiment, the spreader bucket assembly is configured from relatively light-weight materials and is a fairly large bucket capable of handling significant quantities of material to be spread. It will be understood by those skilled in the art, however, that the configuration of the vessel which holds the material to be spread can assume many different configurations. While a movable bucket configuration has been illustrated with respect to the preferred embodiment description of the invention, the invention is not limited to any particular bucket configurations or to a bucket-type vessel, but could also apply to other types of vessels. Further, while the preferred embodiment of the invention has employed an auger assembly that moves relative to the wall of the bucket, the invention would also apply to a system wherein the wall of the vessel moves relative to the auger. The significance of the invention is the concept of relative cooperative movement between the auger and the curvilinear surface of the material containing vessel so as to direct material from the vessel through an outlet port or into a spreader or slinger assembly in a manner that eliminates or minimizes bridging of the material within the vessel. Other forms of vessels such as trailable or towed vessel configurations can be configured to incorporate and practice the principles of this invention.
It will be appreciated that while a preferred embodiment, description and application of the invention have been disclosed, other modifications of the invention not specifically disclosed or referred to herein will be apparent to those skilled in the art in light of the foregoing description. This invention is intended to provide a specific example of a preferred embodiment structure and application which clearly discloses the apparatus and method of the present invention and its operative principles. Accordingly, the invention is not limited to any particular embodiment or configuration or component parts thereof or to the use of any particular materials for their construction. All alternatives, modifications, and variations of the present invention which fall within the spirit and broad scope of the appended claims are covered.
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To prevent or minimize bridging of material to be dispersed within a containment vessel, a rotatable auger is positioned in close proximity to a curvilinear inner wall surface of the vessel. The auger has an axis that moves parallel to the curved wall surface in a manner such that the auger flights maintain a close working relationship relative to the curved wall surface as the auger is positioned for movement therealong. A spreader apparatus is positioned to receive material dispensed through the vessel outlet port to broadcast the dispensed material externally of the vessel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cleaning devices for removing debris from the bottom and side wall surfaces of swimming pools and hot tubs; and more particularly, to an open-air filtration cleaning device that dislodges the debris from such swimming pool and hot tub surfaces and forces the debris containing water through a filter at or near the pool water surface in a manner so efficient that debris dislodgement and filtering does not deteriorate as a function of pool filtration usage.
2. Description of the Prior Art
Many patents address issues related to pool and hot tub filters and scrubbing devices that loosen dirt from the pool walls and bottom surfaces. They employ either the high-pressure water from pool filter delivery line or an electrical motor to drive the scrubbing brushes, and pass the dirty water through the pool filter which may clog as a function of time thereby decreasing the pool filter operating efficiency.
U.S. Pat. No. 3,886,616 to Hays discloses a hand propelled swimming pool cleaner. It comprises a wheeled frame having a motor driven pump. The pump is adapted to pick up dirt particles from the pool floor and discharges the pumped water with debris through an accordion type filter within the device. An elongated handle is secured to the cleaning device to permit a person at poolside to manually maneuver the cleaner to clean the bottom of the pool. Since the filter in the device is within the motor driven cleaner and is in line with the pressurized water, any clogging of this filter reduces the filtering efficiency. It does not have any scrubbing brush and relies entirely on water flow to dislodge dirt particles from the pools' surfaces.
U.S. Pat. No. 4,338,697 to Broadwater discloses a simplified pool cleaning apparatus. The apparatus comprises a self-contained pool cleaning apparatus having a filter body with dirt and debris collectors positioned on the filter body front and back. During forward movement of the pool cleaning apparatus, the front debris collector is lowered to come into contact with the pool surface by rearward movement of a wheel assembly mounted on the filter body bottom and forward pressure exerted on the filter body by way of handle mounted on the filter body. At the same time, the rearward oriented debris collector is raised away from the pool surface. During backward movement of the pool cleaning apparatus, the wheel assembly moves forward relative to the center of the filter body, resulting in the back debris collector being lowered into operating position engaging the pool surface while the front debris collector is lifted away from the pool surface. During both forward and backward movement, the debris collectors collect dirt and debris carried by the pool water and pass them through a filtering zone. The filtering zone removes the dirt and debris from the pool water and the pool water exits through the top of the filter body. A foraminous partitioned insert and a cloth type filter element are provided within the filter zone for removing the dirt and debris. The disclosed device is manually operated with filters on the front and back sides and is designed to sweep dirt during forward movement and backward movement, respectively. The user can not readily detect filter clogging and there are no scrubbing brushes to loosen dirt adherent to the pools inner surfaces.
U.S. Pat. No. 4,692,956 to Kassis discloses a pool vacuum. This manually operated pool cleaning device is connected to water suction means and has a chamber with partitions wherein the flow of water rotates an agitation member that is fitted with bristles attached to it. The suction action carries debris loosened by the bristles with the pool water. The suction means and filtration means of the debris is not disclosed. Clogging of the filter may reduce suction significantly and will reduce or stop the rotation of the agitation member and the cleaning action of bristles.
U.S. Pat. No. 4,786,334 to Nystrom discloses a method of cleaning the bottom of a pool. The pool cleaner travels along the bottom of the pool and collects material lying on the surface thereof. The pool cleaner is arranged to travel to and fro in straight parallel paths between two opposite walls of the pool using a self-propelled motorized drive mechanism. At the walls the pool cleaner is turned by rotating a half turn so that, after turning, it will have been displaced laterally perpendicular to the initial direction of travel. This motorized device has a drive motor, a pump connected to the motor, and two brushes driven by the motor. The dislodged debris and the pool water mixture are pulled into the pump inlet and are filtered at the pump outlet. The pool cleaner has only a single collection means due to the single travel path of the pool requiring a low capacity pump. When the filter at the pump exit clogs the water suction is reduced, even when the brushes operate effectively. In this automatic self-propelled pool cleaning device the clogging of the filter and subsequent loss of cleaning efficiency are essentially undetectable.
U.S. Pat. No. 5,044,034 to Iannucci discloses a swimming pool vacuum cleaner with a rotary brush. The swimming pool vacuum cleaner has a water-powered turbine and a rotary brush directly and rigidly connected to the turbine so that rotation of the turbine imparts corresponding rotation to the rotary brush. A stationary brush partially surrounds the rotary brush and a foraminate screen is positioned upstream from the brushes to trap residue loosened by the brushes. The swimming pool vacuum cleaner is entirely powered by the external suction of water and means of this suction is not disclosed. The debris loosened by the brush is collected in the foraminate screen positioned upstream from the brushes. As the debris accumulates on the surface of the foraminate screen, clogging occurs. Suction efficiency is reduced and the drive turbine slows down.
U.S. Pat. No. 5,093,950 to Heier discloses a self-propelled vacuum driven swimming pool cleaner. The self-propelled vacuum driven swimming pool cleaner has an outer cover or shroud. The shroud contains a vacuum motor driven by a pool water recirculation system and is connected to a reduction gear train, to rotate a brush assembly, that frictionally engages a surface to be cleaned, and propels the cleaner while scrubbing and then vacuuming loosened dirt and debris from the surface. The pool recirculation system has to filter the debris scrubbed by the self-propelled vacuum driven swimming pool cleaner. When the filter in the pool recirculation system clogs, the efficiency of the vacuum water suction is reduced. This, in turn, reduces the speed of the vacuum water motor that provides self propulsion and scrubbing action.
U.S. Pat. No. 5,293,659 to Rief et al. discloses an automatic swimming pool cleaner comprising a suction head having a housing that is open at its lower side and inclined bristles attached to its' lower edge for support on the cleaning surface. The housing has a rotary sleeve mounted to its' top for the connection of a suction hose in turn to be connected to a water suction pump. Said sleeve opens into a chamber within the housing in which a vibratory element is pivotally mounted, said element having a crescent or air-foil shape. By a flow of water sucked through said chamber, the vibratory element is automatically brought into a vibrating movement which imparts pulsations on the suction head. Thereby, the inclined bristles are bent and straightened repetitively, resulting in a forward thrust moving the suction head over the surface to be cleaned. At least one foot is disposed in the housing which is cyclically displaced vertically by a driving mechanism driven by the movement of the vibratory element and returned by return springs. Said foot cyclically lifts off the suction head at one side, resulting in a rotational movement of the suction head about a vertical axis so as to change the direction of forward movement of the suction head. The disclosed device is operated by water (vacuum) suction which causes a brush to vibrate promoting scrubbing action. The loosened dirt together with the pool water is carried by water suction and has to be cleaned by a filter at the water (vacuum) suction unit. Filter clogging results in reduced water (vacuum) suction and poor movement of vibratory debris dislodging devices.
U.S. Pat. No. 5,351,355 to Chiniara discloses a swimming pool cleaner. The majority of currently available submersible swimming pool cleaners operate in a random manner, following no set path of travel along the bottom of a swimming pool. As a result, a lengthy period of time and a large amount of power consumption are required to clean an entire swimming pool. This problem is resolved by using a submersible swimming pool cleaner, comprising a casing that tapers from one end to the other thereof, a pair of wheels at the wide end of the casing, a single wheel at the narrow end of the casing, a drive system for driving each of the wheels, a cable for connecting the cleaner to a fixed point on one side of the pool, and a cable tensioning device. This cable tensioning device is found within the casing and is utilized for changing the length and tension on the cable whereby the cleaner is caused to follow a predetermined path of travel over the entire inside area of the swimming pool. The swimming pool cleaner is pumped by water (vacuum) suction with an in line filter to remove collected debris. It has two drive wheels on one side and a single drive wheel on the other side driven by a mechanical drive creating a path of motion. There are two rotating scrub brushes on either side of the device. The scrubbing action dislodges the debris and which is then sucked with the pool water and filtered by the in-line filter. When the filter clogs the suction efficiency is significantly decreased. This filter clogging is not easily perceived in this automatic pool cleaning device and therefore the lack of optimal cleaning may not be readily realized.
U.S. Pat. No. 5,435,031 Minami, et al. discloses an automatic pool cleaning apparatus for automatically cleaning submerged surfaces, such as the bottom and sidewalls of a swimming pool. The apparatus includes onboard sensors, and an onboard microprocessor which controls the operation of the apparatus in response to status information supplied from the sensors. The apparatus has an onboard watertight battery and an adjustable inlet nozzle size, and includes left and right track treads which are controllable to enable the apparatus to turn or rotate (clockwise or counterclockwise), or translate in a forward or reverse direction, on a horizontal or vertically inclined submerged surface. A transmission assembly is provided for each track tread, including a cam wheel and a cam follower connected thereto within a sealed control assembly, and a shift link extending through a seal in the control assembly. The apparatus also includes Hall Effect transducers with associated permanent magnets and a microprocessor programmed to execute the selected cleaning program, chosen from a number of available cleaning programs encoded in a punch card. It uses a water suction attachment and a turbine to provide movement. A roller brush powered by the turbine scrubs the swimming pools inner surfaces and the debris containing water is removed through the suction flow stream and filtered. The unit is buoyancy controlled and has the ability to turn in any direction, and thereby matching the pool surface for scrubbing action. Any clogging in the filtering device in the water suction flow stream will reduce the operational efficiency of the turbines and the scrubbing brush.
U.S. Pat. No. 5,569,371 to Perling discloses a system for underwater navigation and control of a mobile swimming pool filter. The underwater navigation and control system for a swimming pool cleaning robot comprises a driver, an impeller, a filter, a processor for controlling the driver, and a signal-producing circuit. The system further includes a signal- detecting circuit mounted on the pool, an interface located on the ground in proximity to the pool, and a detector for receiving and processing data from the detecting circuit and for transmitting signals to the robots processor. Determination of the actual robot location is performed by triangulation in which the stationary triangulation base is defined by at least two spaced-apart signal detectors and the mobile triangle apex is constituted by the signal-producing circuit carried by the robot. The robot is powered by two electrical motors with each motor driving a pair of traction scrubbing brushes. An impeller is used to draw the pool water containing scrubbed debris which is filtered immediately upstream. After filtration, the filtered pool water is returned to the pool. This submerged robot collects all the scrubbed debris in the upstream filter and is subject to clogging. Even though the motors drive the scrubbers and the impeller, the clogged filter prevents efficient filtration of the pool water.
U.S. Pat. No. 5,842,243 to Horvath, et al. discloses a manually propelled pool cleaner. The self-contained manually propelled pool cleaner moves on wheels positioned inboard of the housing, the wheels being supported by axles that extend laterally across the entire width of the housing and are secured at their ends to the side walls and along their length to the lower periphery of the front and rear walls to provide structural integrity and rigidity to the housing. The base plate is provided with pivoting brushes extending diagonally across the direction of travel to move debris towards the intake ports for entrainment in a disposable filter bag. A pivoting off-set connector permits the operator to control the direction of movement by axially twisting the handle while pushing or pulling the cleaner. Electrical power to operate the water pump(s) is supplied from an airtight floating battery case that is tethered to the pool cleaner. This battery powered manually propelled pool cleaner has a motor, a pump, and a scrubbing brush for pumping debris containing pool water through a disposable filter. The clean filtered pool water is released through two ports above the submerged device. When the disposable filter clogs, the user is unaware of the decreased filtering efficiency since the motor continues to pump and drive the scrubbing brushes.
U.S. Pat. No. 5,915,431 to Doussan discloses a pool cleaning apparatus. The pool cleaning apparatus includes a head having a forward portion and a rearward portion, a debris reservoir detachably connected to the rearward portion of the head, a first deflectable blade detachably connected to a lower end of the forward portion of the head being movable downwardly to engage a surface of the pool in response to water flow in the direction of the debris reservoir, and a bracket for connecting a handle to the head. The forward manual movement of the device by the user engages a blade against the pool inner surface scrubbing and loosening debris. The water flow directs the debris containing pool water rearward, where it is filtered in a debris reservoir. There is no water drive or pump suction attached to the device, and therefore there is not a continuous flow of water. When the filter clogs, there is no possibility of debris filtration.
U.S. Pat. No. 5,933,899 to Campbell, et al. discloses a low pressure automatic swimming pool cleaner operating with a pool cleaning system which is not equipped with a booster pump. The apparatus comprises a frame having a forward end and a rearward end with a water inlet mounted on the frame and receiving a supply of water through an inlet. The inlet may comprise a supply mast having a number of openings for supplying water to the various components of the cleaner. The frame is carried on a plurality of transport wheels mounted on the frame. The apparatus further includes a vacuum system including a collection bag positioned on a suction mast having water injection ports positioned such that at least one opening in a water injection port injects water into the collection bag to create suction and draw debris into the bag. A drive system is provided to move the apparatus around the pool. The drive system includes a turbine having a plurality of vanes rotating and mounted in turbine housing. The turbine housing has a first water input and a second water input each oriented to allow a stream of water passing to impact an individual vane at the same angle of incidence as the vane passes through the stream. A drive axle couples to the turbine and at least one set of the plurality of transport wheels. In a further aspect the drive system may include thruster jets positioned on the mast adjacent to the rearward end of the frame. This device is propelled by a turbine driven by a supply of low-pressure water and the collected debris is collected by vacuum suction into a collection bag attached to the swimming pool cleaner. Any blockage of the filter, which decreases the suction and thereby prevents the pool cleaner from sucking the debris in the pool water, is essentially unknown to the pool user.
U.S. Pat. No. 5,961,822 to Polimeni, Jr. discloses a pool cleaner. The pool cleaner floats on the surface of a pool. The cleaner includes a pump and filter, the filter being connected to the discharge side of the pump. The inlet of the pump is connected to a vacuum hose, which is manually moved around inside the pool to suck up debris by directing water from the pool through the pump and filter. Due to the absence of any filter on the suction or inlet side of the pump, the cleaner maintains its efficiency for a longer time. The cleaner may also include a rotary strainer, placed on the discharge side of the pump, for removing large pieces of debris. The strainer includes a slide-able, transparent access cover, which allows visual monitoring of the condition of the strainer, and permits easy access to the interior of the strainer, for removal of debris. The device only removes loose debris from the pool and does not scrub the pool interior surfaces to loosen adhered debris. Since the filter is on the discharge side of the pump it may become clogged and the pump will no longer suck debris efficiently. Furthermore, clogging of this filter is not detected easily by the pool user.
U.S. Pat. No. 6,039,886 to Henkin, et al. discloses a water suction powered automatic swimming pool cleaning system. The automatic swimming pool cleaner is driven by a source of negative pressure, such as an inlet of a pool pump, and is utilized for cleaning the interior surface of a containment wall and the upper water surface of a swimming pool. The automatic swimming pool cleaner includes a unitary body suited for immersion in the swimming pool and a negative pressure source, for producing a water flow in the body, connected by a hose from the pool pump to the chamber. It has a location control subsystem that uses the water flow for producing a vertical force to selectively place the body either (1) proximate to the water surface or (2) proximate to the wall surface below the water surface. The automatic swimming pool cleaner is manually pulled to clean the pool water surface or the pool's inner walls. The cleaner body has a weight/buoyancy characteristic to cause it to naturally rest either (1) proximate to the pool bottom adjacent to the wall surface (i.e., heavier-than-water) or (2) proximate to the water surface (i.e., lighter-than-water). The buoyancy controlled device has no scrubbing brushes and sucks only loose debris, relying strictly on the pool filter to remove the debris. When the pool filter becomes clogged, the device no longer sucks any debris. The clogging of the filter is not observed by the pool user.
U.S. Pat. No. 6,155,657 to Erlich, et al. discloses a drive track for a self-propelled pool cleaner. The submersible self-propelled pool or tank cleaner includes a pair of moving, driven, endless belts or drive tracks mounted on axles, which carry two cleaning brushes. The driven endless belts are provided with moving side-projecting elements that extend from either the moving drive track or the drive wheels, or both, in order to contact the side wall of the pool and other projecting structural elements in the pool. Furthermore, the moving side-projecting elements prevent the stationary structural elements of the pool cleaner from being damaged by scraping the side of the pool and prevent the hard plastic of the cleaner housing from damaging light-weight swimming pool liners. The drive track or belt is provided with raised transverse rib members that terminate into a tip that projects beyond the edge of the belt and extends beyond the projected line of structural elements along the side of the pool cleaner. The hub of the drive wheels around which the belt passes is provided with an extension member that extends outwardly from the hub perpendicular to the longitudinal axis of the cleaner and the direction of travel, a distance that is sufficient to permit the extension member to contact the side and/or bottom of the pool and to prevent the fixed structural elements of the cleaner from contacting the side wall and/or bottom of the pool. It is unclear how the self propelled pool cleaner is driven or what happens to the debris that has been scrubbed. It appears that the scrubbed debris becomes a part of the pool water and has to be eventually filtered by the pool pump and cleaner.
U.S. Pat. No. 6,199,237 to Budden discloses an underwater vacuum. The underwater vacuum includes a housing having an opening which is positioned adjacent the surface to be cleaned. The housing also supports a rotating brush powered by a turbine energized by suction water flow from the pool pump through the underwater vacuum. The housing has a water outlet, which communicates with the suction of the pool's pump at the surface of the water. The inlet to the turbine has a trap which collects large debris that could damage the turbine blades. The vacuum has two rear wheels that are adjustably attached to the interior of the housing, and two front wheels that are adjustably attached to the exterior of the housing. The underwater vacuum can remove sediment from a water storage reservoir without causing turbidity in the water column. A second handheld embodiment is used for cleaning sloping berms, and has rear wheels that are also powered by the turbine. The manual pool vacuum device has a turbine that is powered by suction water flow by a pool pump at the surface of the pool. The turbine is used to power brushes and to drive the rear wheels. Large debris is filtered at the suction inlet of the device but all the fine sediments are carried to the pool vacuum filter. Any clogging of the pool pump filter results in decreased water flow through the underwater vacuum resulting in reduced efficiency in sediment removal. This clogging event is not observed by the manual user.
U.S. Pat. No. 6,473,927 to Sommer discloses a swimming bath cleaning device. The device has a housing with an intake aperture arranged on the base of the housing through which a liquid to be cleaned is conveyed. The liquid is conveyed by means of a pump into an inner chamber partially enclosed by the housing and by a filter separating a contamination-exposed part from a clean part of the inner chamber. The cleaned water is returned to the pool through a motor suction pump, which may or may not be the pool cleaning pump. The swimming bath cleaning device has scrubbing brushes. There is no means to power the brushes or to propel the manually operated device. When the filter clogs the suction of debris becomes inefficient.
U.S. Patent Application 2001/0050093 to Porat, Joseph discloses a motion detection and control for automated pool cleaner. The automated power-driven pool cleaning apparatus is provided with a motion translating member (MTM) that contacts the surface being cleaned, an associated signal transmitter, and a sensor. The sensor is connected to the pool cleaner's programmed electronic control device, or chip, so that when the cleaner is moving, the MTM moves the signal transmitter past the sensor thereby providing an intermittent signal. When the cleaner stops moving, no intermittent signal is received and after a predetermined period of time, the control device causes the cleaner's drive means to move the cleaner in a different direction. This programmed motion translation member controls the movement of a pool cleaning device. There is no disclosure on a specific pool cleaning device.
U.S. Patent Application 2003/0132152 to Illingworth, Lewis discloses a vortex pool cleaner. The improved pool cleaner utilizes toroidal vortex technology to provide efficient fluid flow in a sealed system, creating a low pressure region which attracts debris. The debris free liquid is returned through the annulus. More specific to the separation chamber, a cylindrical vortex is formed such that a circular pattern of flow exiting from the impeller spirals downward along the chamber's outer wall, and then upward along the chamber's inner wall. At the top of the chamber's inner wall is the opening leading fluid out of the chamber and into the annular duct between the outer and inner tubes. The circular flow of the fluid acts as a centrifuge, forcing the higher mass dust particles outward. The spiraling liquid also creates a pressure in the dust collector that is above that in the body of the separation chamber due to kinetic energy of the circulating fluid. This higher pressure pushes the spiraling air inward, maintaining the fluid's circular path. However, the dust particles are not inhibited from traveling straight into the collector. The sealed system prevents dirt from escaping into surrounding fluid and retains kinetic energy of the flowing fluid. The present invention is also quieter, lighter, and simpler than conventional designs. However, this vortex pool cleaner does not have a scrubber to loosen debris from the pool walls. Furthermore, any debris collected stays within the outer chamber of the vortex swimming pool cleaner and collects there with no discharge possibility.
There remains a need in the art for a reliable, long lasting, trouble free cleaning device for pools and hot tubs that utilizes brushes to scrub and remove adhered debris from the walls thereof while collecting and separating debris from the water with minimal clogging of the filtration device, while maintaining substantially constant the scrubbing, suction, and filtration efficiencies of the device as functions of use time.
SUMMARY OF THE INVENTION
The present invention provides an open-air filtration pool cleaning device for pools and hot tubs that is highly reliable in operation, and provides essentially trouble-free cleaning of pool and hot tub surfaces for a prolonged period of time. A plurality of brushes scrub and remove adhered debris from such pool and hot tub surfaces. The debris is then collected and transported to a filtration device, wherein it is separated from the water in an essentially clog-free operation. Scrubbing, suction and filtration efficiencies are increased and cleaning times are decreased. The pool and hot tub surfaces are cleaned quickly and easily, at low cost in a highly reliable manner.
Generally stated, the apparatus comprises a suction chamber, dual scrubbing brushes rotating in opposing directions, and a horizontal impeller. The horizontal impeller forces pool water containing the scrubbed debris through an opening positioned on the top of the suction chamber. Water passing through the opening moves into a flexible tube that connects to a floating, open filtration, device. The filtration device filters debris containing pool water by way of an open-air filter, utilizing gravitational forces. The bottom portion of the suction chamber is composed of flexible rubber-like material having several cut outs to permit entry of pool water into the suction chamber. The flexible rubber like elements at the bottom of the suction chamber bring the brushes in close proximity to the pool surface even when the side walls of the pool are being scrubbed and cleaned, manipulated manually by means of a pole handle attached to the suction chamber or automatically by a conventional state of the art drive mechanism. As thus described, the apparatus is especially suited for cleaning swimming pools, hot tubs, fishponds, decorative water falls or like water containments, which require periodic cleaning.
The open-air filtration cleaning device is entirely powered by the drive which may be an electrical motor or a hydraulic motor, such as a water turbine. The electrical motor is fully protected for operation under water such as that used in submersible immersion pumps. The hydraulic motor is powered by a separate supply of clean water such as that provided by a garden hose. The hydraulic motor may discharge water into the pool providing make-up water. Each of the dual brushes is driven by a belt, which is preferably a timing belt, configured to rotate the scrubbing brushes in opposition so that debris collects within the suction chamber in-between the scrubbing brushes. A horizontal rotating impeller, driven by the same drive, sucks up the debris containing water and pushes it through an opening on top of the suction chamber. The water is moved by the horizontal rotating propeller into flexible tubing in communication with an open-air filtering unit located above the water line that is floating on the surface of the pool water. Alternatively, the flexible tubing may be connected to an open air filtering unit integral with or appended to the pole handle that is attached to the suction chamber. Open air filtration of water containing debris is accomplished by gravity exclusively; whereupon, the filtered and cleaned pool water is discharged into the pool. Decreases in efficiency of filtration, cause the water level in the open to air filtering unit to rise. When, eventually, the filter overflows that the operator is alerted that the filtering element should be changed. Access to the open-air filter is facilitated by its close proximity to the user; hence, any clogging of the filter is immediately detected, and readily remedied. In a second embodiment, an alarm may be incorporated to sound off when the water level rises beyond a set height.
The key features of the open-air filtration cleaning device include, in combination, the features set forth below:
1. A suction chamber for collecting and discharging scrubbed debris in swimming pool or hot tub water; 2. The suction chamber comprising flexible elastomeric elements having cut out pathways in a bottom region contacting an inner surface of the swimming pool or hot tub, thereby enabling free flow of pool water into the chamber; 3. The suction chamber being mounted on four wheels for manual or automatic propulsion of the cleaning device; 4. The suction chamber having an enclosed mechanical drive source which comprises an electrical motor or hydraulic motor; 5. The mechanical drive rotating two scrubbing brushes mounted on the bottom of the suction chamber in opposing directions and scrubbing the pool's inner surface; 6. The suction chamber having a horizontal rotating impeller positioned above the scrubbing brushes and powered by said mechanical drive; 7. The horizontal impeller sucking scrubbed debris with pool or hot tub water and discharging it into a flexible tubing outlet; 8. The flexible tubing outlet connecting to a floating platform or alternatively connecting to an open air filtering unit integral with or appended to the pole handle that is attached to the suction chamber which discharges debris containing water into an open air filtering tube with replaceable filter elements, 9. The open air filtering tube discharging filtered clean water into the pool or hot tub, 10. The water level in the replaceable filter element and the open air replaceable filtering tube being monitored to detect any decrease in the water filtering efficiency; and 11. The filter element being disposed in close proximity to the operator, facilitating its replacement when a decrease in filtering efficiency is observed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood and further advantages will become apparent when reference is had to the following detailed description of the preferred embodiments of the invention and the accompanying drawing, in which:
FIG. 1 is a diagrammatic representation of an open-air filtration cleaning device in an operable position on the bottom surface of a swimming pool, with an electrical or hydraulic (i.e. garden hose) power supply connected to the drive motor that rotates the scrubbing belts and an impeller, so that the debris containing water is filtered through a floating open-air filtration unit located atop the surface of the pool's water;
FIG. 2 is a diagrammatic representation of a front view of the scrubbing unit of the open-air filtration cleaning device;
FIG. 3 is a diagrammatic representation of a side view of the scrubbing unit of the open-air filtration cleaning device;
FIG. 4 is a diagrammatic representation of a floating filtration unit of the open-air filtration cleaning device; and
FIG. 5 is a diagrammatic representation of an open air filtering unit integral with or appended to the pole handle that is attached to the suction chamber.
DETAILED DESCRIPTION OF THE INVENTION
Pool cleaners rely on a filter to remove sediments from the pool water. These sediments may be organic substances, including leaves and other debris, as well as inorganic substances, such as sand. Pool cleaners use a high pressure pool pump forcing debris containing water through a sand filter bed, thereby removing the debris from the water and returning the filtered clean pool water back into the pool. Typically these filters force water through the sand bed or DE filter using diaoginous earth at a pressure of 50–80 psi and filter clogging is observed by increase in back pressure. Today, most sand filter units have been replaced. Unfortunately, heretofore disclosed and utilized pool cleaners do not use scrubbers to clean the pools' inner wall surfaces and therefore these cleaners do not remove debris which has adhered to these surfaces. Pool scrubbers dislodge the debris from the surfaces, leaving the newly loosened debris to mix in with the pool water, making the pool water murky. Due to the excessive debris contained in the pool water it takes a long time to filter the water and clogging of the filtration unit frequently results. On the other hand, some of the pool wall surface scrubbers collect and discharge debris-containing water into the inlet of the pool cleaner pump. This inevitably results in clogging of the pool's filter. The scrubbers powered by water suction cease to work, and the filter's capacity to remove the scrubbed debris deteriorates. The problem is exacerbated if the pool wall scrubbers carry their own filter; since the clogging of these filters and consequent loss of cleaning efficiency are undetected by the user.
Generally stated, the present invention provides an open-air filtration cleaning device that may be used to clean swimming pools or hot tubs, or any like water containment structures. The open-air filtration cleaning device comprises a suction chamber. Preferably, the suction chamber creates its own suction by the action of a rotating impeller driven by a motor drive unit contained within the suction chamber. The suction chamber is mounted on four wheels attached to tow axles and houses two scrubbing brushes positioned directly below the impeller, which are rotated in opposing directions and powered by a belt connected to the drive unit. The suction chamber is also provided with a flexible bottom made from a resilient material, such as rubber, with a multitude of openings for entry of pool water into the suction chamber. The impeller rotation discharges debris containing pool water through an opening located on the top of the suction chamber into a flexible hose that connects to a floating filtration unit. Since the height of water in the pool is typically 15 feet or less, only 7 psi of pressurization needs to be created by the rotation of the impeller. The floating filtration unit receives the debris containing water and passes it through an open filtration chamber that filters the debris containing water using gravitational force solely, and returns the filtered water into the pool. An appreciable reduction in filtration efficiency of the filter causes the water level in the filter to rise. This condition is easily detected by the user of the clog resistant pool cleaning device. The filter element can be easily replaced and the filtration efficiency readily restored. In an alternative embodiment, the water level in the filtration unit is monitored. When the water level reaches a preset value, an alarm is triggered to alert the operator that replacement or restoration of the filtration unit is required.
The open-air filtration cleaning device is entirely powered by the drive unit. Such a drive unit can comprise an electrical motor or a hydraulic motor, such as a water turbine. The electrical motor is fully protected for operation under water, such as units used in submersible immersion pumps. The hydraulic motor is powered by a separate supply of clean water, typically provided by a garden hose. The hydraulic motor may discharge water into the pool providing make-up water. The drive to the brushes is provided by a belt drive, which may be a timing belt configured to rotate the scrubbing brushes in opposition so that debris collects inside the suction chamber in between the scrubbing brushes. A horizontal rotating impeller, driven by the same drive, draws up the debris containing water and forces it through an opening on the top of the suction chamber into flexible tubing that connects to a filtering unit that is floating on the pool water surface. The open to air filtering unit filters debris containing water only by gravity and discharges cleaned pool water into the pool. If there is any decrease in efficiency of filtration, the water level in the open-air filtering unit rises; until eventually the filter overflows, indicating that the filtering element in the filter needs to be changed. In a second embodiment, an alarm may be incorporated to provide an audible or visible signal when water level rises beyond a set height.
Referring to FIG. 1 , there is shown generally at 10 a swimming pool 15 with a scrubbing unit suction chamber 20 having four wheels, two scrubbing brushes and an impeller, all driven by a single drive unit. The suction chamber 20 discharges water containing debris, which passes through a flexible hose 21 that attaches to a floating platform 23 . The floating platform 23 has a spout 24 which discharges the water containing debris into an open-air filtration tube 25 , which is fitted with a filtration element 26 . The filtered water discharges directly below the filtration element 26 and the liquid level in the filtration tube 25 is maintained by the balance between the amount of water containing debris passing through the spout 24 and the amount of filtered water discharged from the filtration element 26 . Any reduction in filtration efficiency will result in increased water levels in the filter tube 25 and may even lead to overflow, signaling that the filter element 26 should be replaced. The scrubbers and impellers continue to work efficiently despite reduction in filtration efficiency and the debris containing water is returned to the pool water due to the overflow of the filter tube 25 . The suction chamber 20 is pulled by a pole 28 attached to the suction chamber's 20 side wall. The connection 29 provides power to the motor drive unit in the suction chamber 20 which may be driven by an electrical power cord connected to a rechargeable battery or by a hydraulic power cord connected to a garden hose.
In one embodiment, a filter tube 25 has a diameter of 6 inches (150 mm) and a water level height of 6 inches (150 mm). The velocity of water through tube 25 with no filter is 5.68 feet per second (173 cm/sec). The volume discharged by the 6 inch (150 mm) diameter filtration tube is 2.08 gallons/sec (7.9 lit/sec). The filter restricts the flow by 75 percent, causing the flow rate of filtration to be 0.5 gallons/sec (1.9 lit/sec). The weight of water in the filtration tube 20 is 6.12 pounds (2.78 kg), which is easily handled by the floatation platform. In a second embodiment of the invention, the filter tube 20 is directly attached to the end of pole 28 . This presents no problem in manipulating the suction chamber 20 , owing the reduced weight of water in the filter tube 20 at 6 pounds (2.78 kg).
Referring to FIG. 2 , there are shown generally at 10 the details of the front view of the suction chamber 20 . The suction chamber 20 has a metallic or polymeric shell and a flexible rubber or elastomeric element 38 at the bottom, which may have a multitude of openings 39 for entry of pool water into the suction chamber 20 . A motor 30 , which may be electric or hydraulic, is mounted within the suction chamber 20 with a shaft 31 driving a right angle drive 32 and an impeller 35 . The motor 30 is powered by supply line 29 . The right angle drive 32 has a shaft on which a belt drive pulley 33 is mounted and connects to two pulleys 33 mounted on scrubbing brushes 36 . The belt drive rotates the scrubbing brushes 36 in opposition, while the wheels are unattached to the scrubbing brush 36 , and are thereby free to rotate when the suction chamber 20 is pulled using pole 28 . In another embodiment, the four wheels may be geared to provide automatic propulsion of the suction chamber 20 or propulsion assist for climbing the side walls of the swimming pool.
Referring to FIG. 3 , there are shown at 10 the details of the side view of the suction chamber 20 . The suction chamber 20 has a metallic or polymeric shell and a flexible rubber or elastomeric element 38 at the bottom, which may have a multitude of openings 39 for entry of pool water into the suction chamber 20 . A motor 30 , which may be electric or hydraulic, is mounted within the suction chamber 20 with a shaft 31 driving a right angle drive 32 and an impeller 35 . The motor 30 is powered by supply line 29 . The right angle drive 32 has a shaft on which a belt drive pulley 33 is mounted and connects to two pulleys 33 mounted on scrubbing brushes 36 . The belt drive rotates the scrubbing brushes 36 in opposition, while the wheels 37 are unattached to the scrubbing brushes 36 , and thereby free to rotate when the suction chamber 20 is pulled using pole 28 .
Referring to FIG. 4 , there are shown at 10 the details of the floating open-air filtration tube 25 . The floating open-air filtration tube 25 receives debris-containing water from below through a flexible hose 21 connection. The water containing debris comes up through the flexible hose 21 and exits through a spout 24 . The water containing debris is received by the floating open-air filtration tube 25 , which has a filter element 26 . The filtration of the water containing debris occurs by gravitation force only and discharges the filtered water down below into the swimming pool. The spout 24 , the filtration tube 25 , and the filter element 26 are attached to the flotation platform 23 , which floats above the water line 27 in the swimming pool.
Referring to FIG. 5 , there is shown generally at 10 a swimming pool 15 having a scrubbing unit suction chamber 20 that comprises four wheels, two scrubbing brushes and an impeller, all driven by a single drive unit. The suction chamber 20 discharges water containing debris. Such debris passes through a flexible hose 21 within the pole 28 , which is used to manually manipulate the scrubbing and suction device. The flexible tube discharges water-containing debris into an open-air filtration tube 25 , which is fitted with a filtration element 26 . The filtered water discharges directly below the filtration element 26 , which is located above the pool water level 27 . The liquid level in the filtration tube 25 is maintained by the balance between the amount of water-containing debris passing through the flexible tube 21 and the amount of filtered water discharged from the filtration element 26 . Any reduction in filtration efficiency will result in increased water levels in the filter tube 25 , and may even lead to overflow through opening 40 , signaling that the filter element 26 should be replaced. The scrubbers and impellers continue to work efficiently despite a reduction in filtration efficiency, and the debris containing water is returned to the pool water due to the overflow of the filter tube 25 . The connection 29 provides power to the motor drive unit in the suction chamber 20 , which may be driven by an electrical power cord connected to a rechargeable battery or by a hydraulic power cord connected to a garden hose.
The key features of the open-air filtration cleaning device include, in combination, the features set forth below:
1. A suction chamber for collecting and discharging scrubbed debris in swimming pool or hot tub water; 2. The suction chamber being provided with flexible elastomeric elements having cut out pathways in a bottom region contacting swimming pool or hot tub inner surfaces for free flow of pool water into the chamber; 3. The suction chamber being mounted on four wheels for manual or automatic propulsion of the open-air filtration cleaning device; 4. The suction chamber having an enclosed mechanical drive source which comprises an electrical motor or a hydraulic motor; 5. The mechanical drive rotating two scrubbing brushes mounted on the bottom of the suction chamber in opposing directions, for scrubbing an inner surface of the pool or hot tub; 6. The suction chamber having a horizontal rotating impeller positioned above the scrubbing brushes, and powered by the mechanical drive; 7. The horizontal impeller sucking scrubbed debris with pool or hot tub water and discharging it into a flexible tubing outlet; 8. The flexible tubing outlet connecting to a floating platform or alternatively connecting to an open air filtering unit integral with or appended to the pole handle that is attached to the suction chamber which discharges debris containing water into an open air filtering tube with replaceable filter elements, 9. The open to air filtering tube discharging filtered clean water into the pool or hot tub, 10. The water level in the replaceable filter element and the open to air replaceable filtering tube being monitored to detect any decrease in the water filtering efficiency; and 11. The filter element being replaced when a decrease in filtering efficiency is observed.
Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to, but that additional changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.
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An open-air filtration device cleans swimming pools and hot tubs in an efficient, reliable manner. An open-air filter with a suction chamber unit comprises two scrubbing brushes and an impeller powered by a motor drive. Water containing debris is pumped to a level above the swimming pool or hot tub surface. The debris containing water is discharged through a spout into a filter tube. A filter element associated with the filter tube, and open to atmosphere filters the debris containing water by gravitational forces solely. The spout and filter tube are, optionally, attached to a pole that manually propels the suction unit. They may alternatively be attached to a floating platform that floats on the water surface of the pool or hot tub. If filter efficiency decreases, the water level in the filter tube rises, indicating that the filter element must be replaced. A rise in water level is visually observed or detected automatically and communicated using a visible or audible alarm.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to a device for driving a closing or sun-protection screen, as well as to a closure or sun-protection installation incorporating such a device.
A closure installation is understood to mean structures having openings that are closed or covered by doors, blinds, shutters and equivalent devices.
BACKGROUND OF THE INVENTION
In an installation having an opening, a screen, which may be a supple screen body or a rigid or semi-rigid panel, is displaced opposite the opening in order to selectively obturate the latter. In order to make the movement of the screen automatic, it has been proposed in the past to equip it with means for automatically detecting a position and/or a displacement of the screen and thus to use pre-defined positions to control electrical power supply to a screen drive motor, particularly the top and bottom ends of stroke and possibly intermediate positions in which the electrical supply to the motor is interrupted or modified in order to stop the screen or vary its speed and/or its drive torque.
An example of such an automatic drive device is given in FR-A-2 654 229.
Although the afore-mentioned device is satisfactory as to its function of automatic control of the drive of the screen, it presents a drawback concerning its tightness or sealing of components, particularly the tightness or sealing of the electronic processing unit that it contains with respect to the ambient environment. In effect, this type of device is likely to be installed outside and thus to be subjected to bad weather. This results in considerable risks of water infiltrating inside the tube and therefore reaching the electronic processing unit and the electric motor, particularly via the opening necessary for the kinematic links between a transmission means and a ring that rotatably supports the tube. It is difficult to seal this opening tight due to the mobility of the ring which, in addition, must present axial and radial clearances sufficient in order, on one hand, to match winding tubes of various origins whose dimensions are imprecise due to their mode of manufacture and, on another hand, to compensate for clearances of expansion associated with the functioning of the motor and climatic conditions.
In order to overcome this problem, one or more O-rings may be interposed between the ring and the fixed head and it may be attempted to adjust the ring around the fixed head as best possible. Furthermore, as described in EP-A-0 965 724, a ring of magnets of alternate polarities may be mounted around a circular support. These solutions are not economical as they require more voluminous parts, particular geometries at the level of the elements in contact and/or a complex process of assembly. In the device known from EP-A-0 965 724, the ring of magnets is expensive and the precision of measurement depends on the angular deviation between the peripheral magnets. This deviation being fixed by the diameter of the support which depends on the type of motor used, it cannot be adjusted easily.
In the domain of automatically controlled electric motors, U.S. Pat. No. 4,952,830 proposes embedding in an appropriate resin electronic sensors for detecting the displacement of the rotor of a motor, these sensors being kinematically linked to the stator. The tightness of the sensors is thus ensured but this solution does not guarantee tightness of the conductors connecting the sensors to an electronic unit for processing the signals furnished by these sensors. In other words, the potential problems of tightness do not affect the sensors as such but concern the more remote electronic components of the processing unit.
It is an object of the present invention to propose a device of the afore-mentioned type, in which the parts of the device sensitive to water are efficiently protected, particularly the electronic components of this device.
SUMMARY OF THE INVENTION
To that end, the invention relates to a device for driving a closing or sun-protection screen that includes a gear motor unit mounted within a winding tube for displacing the screen and which is controlled in rotation about an axis by the gear motor unit. A head is fixedly mounted on a bearing structure and supports the winding tube, a rotatable part having elements that are representative of a position and/or a displacement of the tube and which part is kinematically linked to rotate with the tube by mechanical transmission means, and sensor means for detecting the position and/or the displacement of the part. The sensor means is connected to an electronic processing unit adapted to determine the position and/or the displacement of the tube. A partition secured to and extending from the head defines, on one side, a first compartment for receiving at least the rotatable part and, on another side, a second compartment for receiving at least the electronic processing unit. The partition effectively seals the electronic processing unit from the rotatable part and thus the ambient environment.
The tightly sealed partition of the device according to the invention makes it possible hermetically to define respective hollow housings for the mobile part having elements representative of the position and/or the displacement of the tube and for at least the electronic processing unit that is sensitive to humidity and water coming from outside the device. This partition is secured to or integral with the head fixed with respect to the bearing structure. Such a structure does not complicate assembly and installation of the device.
Other characteristics of this device, taken separately or in all technically possible combinations, are set forth in claims 2 to 9 .
The invention also relates to a closure or sun-protection installation which comprises a screen adapted to be driven by a device as defined hereinabove.
Such an installation is economical, reliable and long-lasting.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood on reading the following description given solely by way of example and made with reference to the accompanying drawings, in which:
FIG. 1 schematically shows a partial longitudinal section of an installation according to the invention.
FIGS. 2 and 3 are plane sections along arrows II-II and III-III indicated in FIG. 1 .
FIG. 4 is a view in perspective of a part of the installation of FIG. 1 ; and
FIGS. 5 and 6 illustrate a variant of the drive device according to the invention, FIG. 6 being in part a section along plane VI-VI indicated in FIG. 5 .
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, the installation of FIG. 1 comprises a closing or sun-protection screen E, intended to be selectively wound around a substantially horizontal tube T of axis X-X fixed with respect to the masonry of a fixed structure S in which is made an opening O to be obturated with the screen E. The winding tube T constitutes a member for displacement of the screen E and is mounted on a device 1 for reversible drive of the screen E.
This device 1 comprises a head 2 rigidly mounted on the masonry of the structure S. As shown in FIGS. 1 to 4 , this head 2 comprises a solid base 4 in the form of a disc centered on axis X-X and mounted on the masonry and, on the side opposite the structure S, an annular skirt 6 centered on axis X-X.
For convenience, the term “front” in the following description will mean “directed towards the masonry”, i.e. directed towards the left in FIG. 1 , while the term “rear” corresponds to the opposite direction. Moreover, for reasons of visibility, the skirt 6 is shown in solid lines in FIG. 4 , while, in this view, the major part of this skirt should be masked by the base 4 shown solely in dashed and dotted lines.
The skirt 6 is constituted by a front part 6 A detailed hereinafter and by a cylindrical rear part 6 B of axis X-X. The outer face of the rear part 6 B is provided, at its front end, with a projecting rib 6 B 1 which extends over the whole periphery of the skirt. This rib 6 B 1 thus defines with the rest of the outer face of the part 6 B, a shoulder 6 B 2 .
Unlike the rear part 6 B, the front part 6 A of the skirt 6 does not extend, in cross section, over the whole of the circular periphery of the base 4 , but is interrupted in the upper part, i.e. in the upper parts of FIGS. 1 to 3 , with the result that a partition or rib 8 connects the interrupted opposite skirt parts.
The partition 8 comprises, on the one hand, an axial wall 8 A which projects towards the rear of the base 4 essentially in the direction X-X and which presents a substantially U-shaped cross section ( FIGS. 2 and 3 ) and, on the other hand, a radial wall 8 B parallel to the base 4 , from which the axial wall 8 A projects forwardly and which extends radially upwardly up to the rear part 6 B of the skirt 6 , forming the front end of the rib 6 B 1 .
The axial wall 8 A is constituted by a front part 8 A 1 and by a rear part 8 A 2 of which the depth, with respect to the level where the front part 6 A of the skirt 6 is interrupted by the partition 8 , is less than that of the front part 8 A 1 . A transverse part 8 A 3 connects the front ( 8 A 1 ) and rear ( 8 A 2 ) parts of the axial wall 8 A.
In this form of embodiment, the partition 8 and the skirt 6 form one piece, integral with the base 4 . In other words, the head 2 constituted by the base 4 , the skirt 6 and the partition 8 is a one-piece part, preferably made of a synthetic material. This part is, for example, obtained by molding.
A sleeve 10 of axis X-X is rigidly mounted, for example by force-fitting, around the rear part 6 B of the skirt 6 , being axially wedged against the shoulder 6 B 2 and with the possible interposition of an O-ring or the like (not shown). This sleeve internally receives a motor 12 and its associated reduction gear 14 from which extends an output shaft 16 in engagement with a distance piece or a transverse disc 18 of the winding tube T. On the structure S side, the tube T is supported by the front part 6 A of the skirt 6 , with the interposition of an annular ring 20 centered on the axis X-X and kinematically linked to the tube.
The ring 20 is provided with an inner toothing 20 A in mesh with a cylindrical double-tooth pinion 22 at its rear toothing 22 A. This pinion is mounted to rotate freely about a shaft 24 parallel to axis X-X and supported by the radial wall 8 B of the partition 8 . The front toothing 22 B which is of smaller diameter than that of the pinion rear toothing 22 A is in mesh with a toothed wheel 26 mounted to rotate freely about a shaft 28 supported by the base 4 of the head 2 . The diameter of the toothing 22 B is smaller than that of the toothing 22 A, such that the movement of rotation of the wheel 26 is geared down with respect to that of the ring 20 , i.e. that of the winding tube T.
In order to render the mechanical part constituted by the pinion 22 and the wheel 26 as compact as possible, the wall 8 is advantageously dimensioned both so that the depth of the rear part 8 A 2 of the axial wall 8 A is substantially equal to the outer diameter of the rear toothing 22 A of the pinion 22 , for the axial distance separating the base 4 from the transverse part 8 A 3 of the axial wall 8 A to be substantially equal to the axial dimension of the wheel 26 , this ensuring axial wedging of the latter, and so that the axial distance separating the base 4 from the radial wall 8 B is substantially equal to the sum of the axial dimensions of the wheel 26 and the pinion 22 , this ensuring the axial wedging of the pinion. By respecting the detailed dimensioning hereinabove, it is possible, by way of variant (not shown), to dispense with the shafts 24 and 26 , the partition 8 ensuring guiding of the pinion 22 and the wheel 26 in rotation. The spacings of the respective branches of the U's formed by the transverse sections of the front ( 8 A 1 ) and rear ( 8 A 2 ) parts of the wall 8 A, as well as the curvature of the bottom of these U's, then correspond to the respective diameters of the wheel 26 and of the toothing 22 A of the pinion 22 and to their respective curvature.
The wheel 26 is polarized, i.e. it is provided along its periphery with a succession of magnetic poles, in a predetermined geometry. This wheel is for example made of plastoferrite magnetized after injection. By noting the position and the displacement of these magnetized zones about shaft 28 , it is possible to determine the position and corresponding displacement of the tube T.
To that end, the device 1 comprises two Hall effect sensors 30 connected to an electronic processing unit 32 . More precisely, the device 1 is equipped with a printed circuit board 34 , connected to the head 2 and projecting from the base 4 in the direction X-X in part below the partition 8 . The board is for example slid and retained in appropriate notches 6 A 1 provided on the inner face of the skirt 6 as shown in FIGS. 2 and 3 . On this board are mounted, on the one hand, sensors 30 which, when the board is connected to the head 2 , are disposed substantially in the median transverse plane of the magnet wheel 26 so as to react to the magnetic fields generated by the magnetized zones of the wheel, and, on the other hand, the electronic components of the unit 32 , the sensors 30 being connected to this unit for example by electrical conductors provided in the board 34 .
The processing unit 32 is adapted to analyze the signals emitted by the Hall effect sensors 30 so as to determine the position and the movement of the magnet wheel 26 and consequently those of the winding tube T, as well as to control, if necessary, the electrical supply of the motor 12 , via a control link 36 .
In order to ensure tightness of the electronic components of the device 1 , i.e. the sensors 30 and the unit 32 , these components are located on the side, turned towards the motor 12 , of the partition 8 while the wheel 26 and the pinion 22 are located on the other side. In this way, any infiltration of water or of humidity penetrating between the tube T and the ring 20 remains limited to the level of the pinion 22 and of the wheel 26 , without being able to pass through the tight partition 8 to attain the sensors 30 and/or the unit 32 . In order not to disturb the Hall effect sensors 30 , the matter constituting the partition 8 does not induce any noteworthy electromagnetic disturbance.
In other words, the partition 8 defines on either side of its axial ( 8 A) and radial ( 8 B) walls two distinct compartments, namely a first, upwardly open compartment 40 which essentially receives the pinion 22 and the wheel 26 and which is axially closed at the front by the base 4 and at the rear by the radial wall 8 B and, on the other hand, a second compartment 42 closed radially by the skirt 6 , which essentially receives the sensors 30 , the electronic unit 32 and the board 34 and which is closed at the front by the base 4 and open at the rear.
It will be noted that the term “compartment” generally covers any hollow housing which, in transverse section, is defined at least in part by a substantially concave wall.
Along a transverse section of the device 1 , for example the section of FIGS. 2 and 3 , these compartments 40 and 42 are advantageously superposed, the axial wall 8 A of the partition 8 being interposed therebetween. In this way, the space requirement of the device 1 in length is reduced. Moreover, as the magnet wheel 26 is axially located between the base 4 and the pinion 22 , the axial space requirement of the compartment 40 is reduced and the sensors 30 located in the compartment 42 are brought as close as possible to the base 4 in order to detect the magnetic fields generated by the wheel so as to disengage a considerable free volume in the compartment 42 to arrange the board 34 and the electronic components of the unit 32 . Furthermore, by molding the base 4 , the skirt 6 and the partition in one piece, a part is obtained which determines both the position of the magnet wheel 26 and the position of the sensors 30 , this making it possible to master, as best possible, the tolerances determining the relative positioning of the wheel and the sensors.
The part 8 A 1 of the wall 8 A is concave seen from the housing 40 and convex seen from the housing 42 . In this way, the wheel 26 is partially surrounded by the partition 8 . In practice, the partition 8 surrounds the wheel 26 over about 180°.
The housing 40 , which is concave around the wheel 26 , is compact and extends only over a relatively small angular sector with respect to the periphery of the skirt 6 .
The geometry of the partition 8 makes it possible, particularly thanks to its portions 8 A 1 and 8 A 2 , to receive in the housing 40 the transmission formed by elements 22 and 26 which constitute a movement multiplier assembly allowing a detection of the rotation of the tube T with high precision, while this assembly is compact.
The use of a multiplier assembly 22 , 26 which has a relatively large pole pitch, makes it possible to space the sensors 30 from the wheel 26 without risk of interference between the poles of the wheel 26 . In this way, the sensors 30 do not have to be in the immediately vicinity of the wheel 26 , this making it possible to design the wall 8 with a sufficient thickness to ensure good solidity of the assembly.
The geometry of the partition 8 also means that the sensors 30 , the board 34 and the unit 32 may be localized in a central part of the tube T. These elements 30 , 32 and 34 therefore do not have to be especially configured to be disposed in the vicinity of the internal wall of the tube which is not planar.
The device 1 functions as follows:
When the screen E is wound around the tube T or unwound from that tube, the latter drives in rotation, in a corresponding movement, the annular ring 20 whose movement is transmitted to the magnet wheel 26 via the pinion 22 . The position and the displacement of this wheel, representative of the position and the displacement of the tube T, are detected by the sensors 30 of which the signals are transmitted to the processing unit 32 which then determines by calculation the position and the displacement of the tube. As a function of a pre-determined setting, the unit 32 then controls, if necessary, the stopping or slowing down of the motor 12 , for example if the unit concludes that the screen E has arrived at the end of stroke.
By using two Hall effect sensors 30 as in device 1 , it is possible to identify the direction of rotation of the magnet wheel 26 , and consequently that of the winding tube T. By way of variant, one sole Hall effect sensor 30 is provided, particularly if the determination of the direction of rotation is not necessary or if it is determined by other means.
FIGS. 5 and 6 show a variant of the drive device 1 of FIGS. 1 to 3 . In this variant, the magnet wheel 26 is replaced by a disc-shaped optical wheel 50 , which bears over its periphery eight bevelled reflecting surfaces 52 . In order to allow detection of the position and the movement of this wheel 50 , the sensors 30 of the device of FIGS. 1 to 3 are replaced by one or more assemblies constituted by an emitter 54 of light beams and a corresponding receiver 56 connected to a processing unit similar to unit 32 , able to process electronically the signals furnished by this receiver. This receiver is adapted to detect the reflection of the light beam emitted by the emitter 54 on one of the reflecting surfaces 52 .
In this variant, the tight partition 8 is interposed between the optical wheel 50 and the or each emitter 54 /receiver 56 assemblies, as shown in FIG. 5 .
The partition 8 , or at least that part of the partition located on the path of the light beams, i.e. opposite the emitter 54 and the receiver 56 , is constituted by a material transparent to the light beams employed. The partition 8 is in that case made, for example, by means of a molding technique with two materials or by the addition of a transparent welded element.
Various arrangements and variants to the drive devices described hereinabove may in addition be envisaged. By way of example:
the partition 8 is connected tightly on the base 4 of the head 2 , by screwing, clipping or adhesion for example. the detection means, such as the Hall effect sensors 30 , may be embedded in the material constituting the partition 8 ; and/or that part of the base 4 which closes the front of the compartment 40 may be axially pierced to allow the introduction of the pinion 22 and the wheel 26 in this compartment; in that case, the transverse section of the axial wall 8 A 1 may be more closed on itself, for example shaped as a C, while remaining open in a zone of its periphery to ensure meshing of the toothings 20 A and 22 A.
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A device including a tube for winding and unwinding a screen which is controlled in rotation by a gear motor and which is supported on a fixed head and wherein a rotational part mounted within the tube is kinematically linked to rotate with the tube with the part including elements that are used to reflect a position of the rotational part and which elements are detected by senors that are connected to an electronic processing unit. A tightly sealed partition secured to the head is further provided to define, on one side, a first compartment for receiving at least the rotational part and, on the other side, a second compartment for receiving at least the electronic processing unit.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] 1. Field of the Disclosure
[0002] Embodiments of the present disclosure relate generally to motors attached to a drillstring and used for drilling an earth formation. More specifically, the embodiments disclosed herein relate to a multi-stage thrust bearing assembly capable of equal load distribution.
[0003] 2. Background Art
[0004] Drilling motors are commonly used to provide rotational force to a drill bit when drilling earth formations. Drilling motors used for this purpose are typically driven by drilling fluids pumped from surface equipment through the drillstring. This type of motor is commonly referred to as a mud motor. In use, the drilling fluid is forced through the mud motor(s), which extract energy from the flow to provide rotational force to a drill bit located below the mud motors. There are two primary types of mud motors: positive displacement motors (“PDM”) and turbodrills. The following disclosure focuses primarily on turbodrills; however, one of ordinary skill in the art will appreciate that thrust bearings disclosed herein may be similarly used in PDMs.
[0005] FIG. 1 shows a prior art turbodrill which is used to provide rotational force to a drill bit. A housing 45 includes an upper connection 40 to connect to the drillstring. Turbine stages 80 are disposed within the housing 45 to rotate a shaft 50 . A stage in this context may be defined as a mating set of rotating and stationary parts. A turbine stage typically includes a bladed rotor and a bladed stator. At a lower end of the turbodrill, a drill bit 90 is attached to the shaft 50 by a lower connection (not shown). A radial bearing 70 is provided between the shaft 50 and the housing 45 . Stabilizers 60 and 61 disposed on the housing 45 help to keep the turbodrill centered within the wellbore. A turbodrill uses turbine stages 80 to provide rotational force to drill bit 90 . In operation, drilling fluid is pumped through a drillstring (not shown) until it enters the turbodrill. The drilling fluid passes through a rotor/stator configuration of turbine stages 80 , which rotates shaft 50 and ultimately drill bit 90 .
[0006] While providing rotational force to the shaft 50 through the rotor (not shown), the turbine stages 80 also produce a downward axial force (thrust) from the drilling fluid. Upward axial force results from the reaction force of the drill bit 90 , also called weight on bit “WOB.” To transfer axial loads between the housing 45 and the shaft 50 , thrust bearings 10 are provided. As shown in FIG. 2A , multiple stages of thrust bearings 10 are “stacked” in series; FIG. 2A shows a portion of a bearing stack in which four bearing stages can be seen. A bearing stage in this context may comprise a rotating bearing subassembly and a stationary bearing subassembly. A bearing subassembly as defined may simply comprise the bearing itself, for example a bearing comprised of polycrystalline diamond compacts inserted into a ring, or may additionally comprise components, including but not limited to spacers, frames, wear plates, pins, and springs.
[0007] It is necessary to positionally arrange the bearing stages in series in order to fit them within the confines of the turbodrills tubular body. Though the bearing stages are positionally in series, the axial load, at least in principle, is carried in parallel by the bearing stages and shared to some extent by each bearing stage. The bearing stages are held in position in the stacks by axial compression. The primary purposes of compression are to allow the components to transfer torque and to provide a sealing force between components. The compression may be maintained by threaded components on one or both ends of the inner and outer bearing stacks. In a free, uncompressed state, all stage lengths may be nominally equal. Ideally, all stages have identical lengths so the load is distributed evenly among all stages.
[0008] A limitation of prior art bearings has been that beyond normal manufacturing variances, differences in compressive preloads, working loads, stage component geometry, and materials may cause the stage heights to depart from the “nominally equal” condition when in use to an unequal condition. This unequal condition may degrade the load sharing capacity of the bearing stack. In most cases one of the stacks (typically the inner stack) is less stiff than the other stack. When under load, the less stiff stack deflects more than the stiffer stack, causing unequal load distribution. The stiffness of the stacks is driven by functional and/or structural requirements and limited by space constraints within the surrounding mechanical system. Furthermore, as additional stages are added to accommodate greater working loads, the lengths of the stacks increases and the cumulative effect of unequal stage length increases accordingly, amplifying the problem of unequal load distribution.
[0009] Some prior art bearing stacks utilized rubber bearings, and the compliance of the rubber bearings themselves allowed thrust load to be somewhat evenly distributed. With the advent of polycrystalline diamond compact (PDC) bearings, it became necessary to support the bearings on springs to achieve a degree of load sharing. FIG. 2B shows a typical PDC bearing stage in which the stationary bearing is supported by a disc, or Belleville, spring. However, it has been found that in long bearing stacks (for example, more than 10 bearing stages) the cumulative effect of unequal stage length is such that one stack (typically the outer stack) is much longer than the inner stack. In the event that the difference in stack lengths exceeds the travel limits of the springs, the springs at one end of the stack bottom out and the bearings at the other end of the stack share little, or even zero load.
[0010] Unequal load sharing or distribution in the thrust bearings may have serious effects on the operation of the turbodrill. First, the higher loaded stages may wear out prematurely and limit the run life of the drill. Second, the load threshold that will cause one or more of the compressive springs to reach its travel limit (solid height) is greatly reduced. Once a compressive spring reaches its solid height, the load for that stage dramatically increases to the extent that catastrophic failure of the contact surfaces is inevitable. Accordingly, there exists a need for improved load distribution among the thrust bearing stages of a turbodrill.
SUMMARY OF THE DISCLOSURE
[0011] In one aspect, embodiments disclosed herein relate to a drilling motor including an upper end connection adapted to connect to a drill string, and a lower end connection adapted to connect to a drill bit, a thrust bearing assembly having a plurality of stages assembled in a stack, each stage including at least one rotating inner bearing subassembly configured to contact at least one corresponding stationary outer bearing subassembly, wherein axial loads among the plurality of stages are substantially equal under normal operating conditions.
[0012] In another aspect, embodiments disclosed herein relate to a method of improving a load distribution in thrust bearings of a drilling motor, the method including providing a multi-stage thrust bearing assembly having a plurality of rotating inner bearing subassemblies configured to contact a plurality of stationary outer bearing subassemblies, and providing a bearing subassemblies having substantially equal axial loads under normal operating conditions.
[0013] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is an assembly view of a conventional turbo drill.
[0015] FIG. 2A is a section view of a multi-stage thrust bearing assembly in accordance with embodiments of the present disclosure.
[0016] FIG. 2B is a section view of an individual thrust bearing stage in accordance with embodiments of the present disclosure.
[0017] FIG. 3 is a chart showing load distributions across multiple stages of a turbodrill in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
[0018] In one aspect, embodiments of the present disclosure relate to a turbodrill with improved load sharing in the thrust bearing assembly. An improvement in the load sharing ability of a multi-stage thrust bearing assembly that accounts for individual stage height deflections caused by assembly pre-loads and working loads would be well received in industry.
[0019] Referring to FIG. 2A , a section view of a thrust bearing assembly 100 in a turbodrill 50 is shown in accordance with embodiments of the present disclosure. Thrust bearing assembly 100 is housed within an outer housing 55 of turbodrill 50 , and includes individual stages 110 arranged in a series along a central axis 51 of turbodrill 50 . The individual stages 110 may also be referred to as a “stack” when arranged in series in turbodrill 50 .
[0020] Referring now to FIG. 2B , a section view of an individual stage 110 of thrust bearing assembly 100 is shown in accordance with embodiments of the present disclosure. Stage 110 includes an inner stage 112 (typically rotating) and an outer stage 114 (typically stationary). During operation, axial loads are transferred from inner stage 112 to outer stage 114 or visa versa. Load transfer may occur through low friction, wear resistant contact surfaces 116 , typically polycrystalline diamond. A compressive spring 118 is used beneath contact surfaces 116 within each stage 110 to compensate for normal manufacturing variations, alignment, and some load sharing.
[0021] Sealing requirements between outer stack 114 and outer housing 55 , and inner stack 112 and a shaft (not shown) rotating about central axis 51 of turbodrill 50 , determine the amount of compression applied to the inner stack 112 and outer stack 114 . The sealing requirements between these components are needed to keep fluid from leaking between them and accumulating between either outer stack 114 and housing 55 , or inner stack 112 and the shaft. Likewise, the requirement to transfer torque from one stage to another, through compression load and friction, has been another factor in determining the amount of compression. Embodiments of the present disclosure are provided to address axial load sharing requirements between the multiple thrust bearing stages of the turbodrill. Therefore, in embodiments disclosed herein, axial load sharing requirements are considered in addition to torque transmission and sealing requirements to determine the amount of compression applied to inner stack 112 and outer stack 114 during assembly.
[0022] Load distribution, as used herein, may be defined as a spectrum of the axial loads applied to each individual thrust bearing stage during operation of the turbodrill. These axial loads are a result of externally applied working loads that include downward hydraulic thrust and weight on bit. The compressive preload applied to the stacks during assembly affects the sharing, or distribution, of these external loads through the stacks. Embodiments of the present disclosure, either one or a combination thereof, may be employed to improve the load sharing ability of the multi-stage thrust bearing assembly.
[0023] Referring still to FIG. 2B , in a first embodiment, the inner stage and the outer stage may be configured to have unequal stage free lengths to improve the load sharing ability of multi-stage thrust bearing 110 . As shown, an outer stage 114 length may be defined by an axial length “A” and an inner stage 112 length may be defined by an axial length “B”. Inner stage 112 and outer stage 114 may differ in cross-sectional area, material, and/or length. Therefore, when a compressive load is applied to inner stage 112 and outer stage 114 , the deflection rates of the two components may be different. As each of the inner and outer stacks are comprised of inner and outer bearing stages, the deflection rate of each stack is a function of the deflection rate of the individual stage of which it is comprised. The stack deflection rate as used herein may be defined as the amount of axial deformation of either the inner stack or the outer stack in proportion to a compressive load applied along the same axis.
[0024] Because of the dissimilar deflection rates between the inner stack and the outer stack, inner stage 112 length B and outer stage 114 length A may be configured so they are substantially equal after assembly preloads are applied and when under a particular working load. To achieve this configuration, inner stage 112 length B and outer stage 114 length A may, therefore, be unequal in a free, or non-operating, state. A free state may be defined as before compressive assembly preloads are applied to the stacks of the turbodrill. Therefore, initially, the outer stage 114 free length A and inner stage 112 free length B may be unequal, however, after applying a compressive force, outer stage 114 length A and inner stage 112 length B are substantially equal due to the set differences in length. As the length of each stack is the sum of the length of its stages, if inner and outer stage lengths are equal in the compressed state then it follows that the overall lengths of the inner and outer stacks will also be equal.
[0025] For example, in certain embodiments, outer stage 114 may deflect less than inner stage 112 due to outer stage 114 having a larger cross-sectional area. Therefore, inner stage 112 may be configured with a free length B that is greater than free length A of outer stage 114 . As a result, when placed under a compressive load, inner stage 112 will deflect greater than outer stage 114 , and ultimately, compressed length A of outer stage 114 and compressed length B of inner stage 112 should be substantially equal. One of ordinary skill in the art will understand that the differences in the deflection rates of inner and outer stages may also be attributed to variances in materials used for the inner and outer stacks.
[0026] Referring to FIG. 3 , a line chart illustrating comparisons between load distributions in a modified turbodrill having inner and outer stages with set unequal free lengths versus an unmodified turbodrill is shown in accordance with embodiments of the present disclosure. Lines 304 , 306 , and 308 represent the load distribution in an original turbodrill with unmodified inner and outer stage free lengths, and lines 314 , 316 , 318 , and 320 represent the load distribution in a modified turbodrill having inner and outer stage free lengths that are unequal. In this modified version, the outer stage is configured having a free length A ( FIG. 2B ) that is 0.04 mm less than the inner stage free length B ( FIG. 2B ).
[0027] As shown, the unmodified turbodrill 304 , 306 , 308 shows an uneven load distribution across the stages of the bearing assembly. The upper stages have greater axial loads present, after which the axial loads begin to decrease towards the bottom stages. In contrast, the modified turbodrill 314 , 316 , 318 , 320 employing unequal pre-assembly inner and outer stage free lengths, shows axial loads which are more evenly distributed across the bearing assembly of the turbodrill.
[0028] Additional improvement may be made by setting unique inner and outer stage lengths based on relative position within a stack. For example, the free state length of the inner stages at the top of the stacks may be slightly longer than the free state lengths of the inner stages at the bottom of the stack. Alternatively, if needed, this configuration may be reversed such that the free state length of inner stages at the bottom of the stack may be slightly longer than the free state lengths of the inner stages at the top of the stack.
[0029] In a second embodiment, deflection rate values of different components may be used to improve the load sharing ability of a multi-stage thrust bearing. Every component has a deflection rate, or “k”, similar to a spring constant of a common helical compressive spring. The deflection rate is defined as the rate at which the length of the component changes in proportion to the load applied to it along the same axis. Within a range, this rate is linear and proportional to variables which include: the cross-sectional area (A) perpendicular to the axis, the length along the axis (L), and the modulus of elasticity of the material (E). In equation form, the variables are arranged as such:
[0000]
k
=
AE
L
[0030] In this embodiment, the geometry and/or materials of the inner and outer stages may be modified to “pair” or “match the k's,” such that the k of the inner stage is paired or matched to the k of a corresponding outer stage. The values of k for the inner and outer stages may be matched or paired by machining the components to change the cross-sectional geometry, or by using materials for the inner and outer stages that have a different modulus of elasticity. The “k matching” between the inner and outer stages may result in the inner and outer stage lengths being similar when the stacks are assembled in the free state as well as when under working load conditions.
[0031] In a third embodiment, the inner bearing stack and outer bearing stack may be assembled with different compressive loads (“compressive load compensation”) to achieve similar deflections between the inner stack and the outer stack. A compressive load will deflect the stacks proportional to the stack “k” value, which as previously mentioned, depends on the cross-sectional area (A) perpendicular to the axis, the length along the axis (L), and the modulus of elasticity of the material (E). The normal compressive loads may be adjusted such that the deflection of the outer stack is substantially equal to the deflection of the inner stack. The stiffer stack (typically the outer stack) will require a greater compressive load than the less stiff stack (inner stack), such that the resulting deflections are substantially equal. A spacer length adjustment may be used to achieve differing compressive loads.
[0032] For example, in a 4¾″ turbodrill having 14 hydraulic bearing stages, it may be desired that deflection of each outer stack stage be equal to the deflection of each inner stack stage. Calculations show that a compressive load of 221 kN on the inner stack stage will yield an inner stack stage deflection of 0.123 mm, and a total inner stack deflection (includes all 14 stages) of 1.722 mm. A similar amount of deflection is desired in the outer stack stage such that the inner and outer stacks have equal lengths. Calculations show that a compressive load of 406 kN on the outer stack stage yields an outer stack stage deflection of 0.123 mm, and a total outer stack deflection (includes all 14 stages) of 1.722 mm. Thus a compressive load of 406 kN on the outer stack is shown to provide similar deflection as 221 kN compressive load on the inner stack. In comparison, in a particular example of prior art design, a compressive load of 221 kN was applied to the outer stack, resulting in a deflection of only 0.940 mm. The free length of the stacks was equal, but the difference between outer and inner stack lengths when compressed was 1.722−0.940=0.782 mm. This condition significantly affected the ability of the bearing stages within the stack to share load equally. This example is simplistic in that its operating loads are not considered, and only compression preload is adjusted to achieve load sharing. Those skilled in the art will appreciate that a complete analysis must include operating loads and that compressive preloads, stage lengths, materials, and geometries of the components of the inner and outer stacks may be varied to improve load sharing.
[0033] Embodiments of the present disclosure may provide a load distribution through the multiple bearing assembly stages of the turbodrill, such that when under normal operating loads, the load on the most lightly-loaded bearing is within 25% of the load on the most highly-loaded bearing. Further, embodiments disclosed herein may provide a load distribution through the multiple bearing assembly stages of the turbodrill, such that when under normal operating loads, the load on the most lightly-loaded bearing is within 15% of the load on the most highly-loaded bearing.
[0034] Advantageously, embodiments of the present disclosure provide for more even load distribution among stages throughout the length of the bearing assembly because the inner and outer stack heights are equal under compression preloads and working loads. The even load distribution may lead to less bearing wear, higher load capacity for the same number of stages, and reduced likelihood of catastrophic failure. The unequal stage free length method may be advantageous as a simple method, because once the length difference is calculated, stage lengths may be modified to easily achieve the desired results. Further, by matching the deflection rate values of inner and outer stack components, the free state heights of the stacks may be equal, and the load distribution will be more consistent over a broad range of compressive and working loads, because both the inner and outer stack will deflect at a similar rate. Finally, the compressive load compensation method may be advantageous because it does not require any modification of the components, only of the assembly values used when applying the compressive pre-loads.
[0035] While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims.
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A drilling motor includes an upper end connection adapted to connect to a drill string, and a lower end connection adapted to connect to a drill bit, a thrust bearing assembly having a plurality of stages assembled in a stack, each stage including at least one rotating inner bearing subassembly configured to contact at least one corresponding stationary outer bearing subassembly, wherein axial loads among the plurality of stages are substantially equal under normal operating conditions.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a metallic covering for the roof of buildings, which is laid on an unventilated roof support, for example formed of rigid concrete forming a flat receiving surface. The covering is constructed of rigid plates, usually formed of metal preferably a corrosion-resistant metal such as zinc. The plates are designed to interlock in a mating fashion with each other forming troughs running in the direction of the slope of the roof. It also relates to right-angled supports for the covering in accordance with the invention.
Roof coverings in zinc are now employed for roofing or boarding or guttering in highly corrosive industrial environments and in very polluted urban environments. The roof frames for such roof coverings are in general no longer made of wood wood provided ventilation for high-priced or city roofs in previous centuries. The roof frames are now made of concrete which in theory constitutes a stronger, longer lasting material than wood. Numerous instances of corrosion in such roofs laid on supports in concrete have nevertheless been reported. Such corrosion is not only the result of the aggressive atmosphere to which such roofs are exposed but also results from the supports which are inserted between the metallic plates (zinc, copper, galvanized or stainless steel, aluminium, etc.) and which most commonly are not wood and comprise, rather, roofing felts and non-woven materials. These materials foater acid reactions when soaked with the aqueous medium resulting from condensation.
In order to overcome the difficulties currently encountered in coverings such as roofing, boarding or guttering constructed using rigid plates laid on unventilated and rigid supports, such as concrete sections, it appeared to be necessary to improve ventilation between the under part of the roof and the rigid plates in order to avoid condensation, and if the plates are formed of metal, to isolate them from the unventilated roofing support, particularly in the case where the support is is formed concrete, using a neutral material which is more resistant to acid and corrosive reactions in an aqueous medium.
SUMMARY OF THE INVENTION
To this purpose, in accordance with the invention, intermediate plates are fixed directly to an unventilated support forming a continuous vapor-tight, planar receiving surface. The intermediate plates are formed of a soft and elastic material which absorbs expansion, which maintain its strength for long periods of time and is electrically and chemically non-corrosive with regard to the rigid plates. The intermediate plates can be a plastics material. The plates are fixed directly onto the unventilated support using tubular fastening means or screws which pass through the plate in a sealing manner. The head of the screw bears against the plate. The rigid plates are attached to support members laid on the intermediate plates and fixed to the rigid support using tubular fastening means or screws passing in a sealed manner through said intermediate plates surface protuberances or spacing elements which are regularly distributed on said intermediate plates are interposed between the rigid plates and the intermediate plates so as to provide a ventilation space under the rigid plates. The assembly of intermediate plates can be used as an under-roof assembly adapted to recover leaks and possible condensation from the main roofing structure formed by the rigid plates.
In another embodiment of the invention, the support members for the rigid plate are fixed to the intermediate plates and bear on surface protuberances or spacing elements thereby forming a ventilation space under the support members. A members, for the rigid plate are fixed to the intermediate plates whilst bearing on surface irregularities or spacing elements with the interpositioning, at least in some places, of a sealing and/or support element such as a seal formed of an elastomer foam can be positioned between the support members, and the intermediate plate. The surface protuberances or spacing elements are preferably an integral part of the intermediate plate and may accomodate, at least in part, the expansion of said intermediate plate. The surface protuberances or spacing elements integral with the intermediate plate are advantageously formed of studs of hollow frustro-conical shape having a substantially planar head which are regularly distributed in a projecting manner on one side of the planar plate suitably, formed of a thin plastic material.
In yet a further embodiment of the invention, support members exhibit a right-angled cross section one arm of which is adapted to be laid flat on the planar heads of several adjacent studs of frustro-conical shape said arm is provided with frustroconical-shaped cavities the minor base of which is directed to the side opposite the other arm of the support member. The other arm is adapted to cooperate with the rigid plates. The cavities of frustro-conical shape project by an extent which is substantially equal to the height of projection of the frustro-conical shaped portions of the intermediate plate, so that said arm is able to bear simultaneously on the planar heads of the frustro-conical portions of the intermediate plate and, at the base of these frustro-conical shaped cavities, directly on the intermediate plate. The minor base of the frustro-conical shaped cavities of the arm of the support members generally includes a hole into which a tubular fastening means or screw is engaged in order to fix the support member onto the unventilated support. The tubular fastening means or screws passing through the intermediate plates are substantially sealed at the point of passage through the plates by virtue simply of the tight fit between the periphery of these tubular fastening means or screws and the wall of a circular hole provided in the plates, the material of which is much more yielding than the metal forming said tubular fastening means or screws.
The invention also provides a support for a rigid covering, having a generally right-angled cross-section and being adapted to be fixed by one of its arms onto a receiving surface, and in which the arm intended for said fixing is provided with cavities of frustro-conical shape the minor base of which is directed to the side opposite the other arm of the right-angled section and in which the substantially flat surface of the minor base constitutes an abutment and fixing surface onto this receiving surface. The minor base of the frustro-conical portions include a hole for the passage of a fixing means providing attachment to the receiving surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aims advantages and characteristics of the invention will become more clear from the description which follows of several embodiments of the invention which should be considered as having a non-limiting nature and with reference to the attached drawings in which:
FIG. 1 is a top view of a portion of intermediate plate used for a metallic covering in accordance with the invention,
FIG. 2 is a sectional view of the portion of intermediate plate shown in FIG. 1 on which a right-angled support piece has been layed, fixed by screws to a rigid roofing support in concrete;
FIG. 3 is a perspective view of the support piece seen in section in FIG. 2;
FIG. 4 is a perspective view, partially torn away and on a smaller scale of two metallic plates which are mutually interconnected, for a roofing in accordance with the invention layed on an intermediate plate carrying studs in the form of truncated cones;
FIG. 5 is a perspective view, partially torn away and on a smaller scale of a roof in accordance with the invention constructed using metallic plates in the form of trays assembled pairwise on a joining strip or batten which is raised and employed for conventional zinc roofs.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference first to FIG. 4, the main components of a zinc roofs are shown, the roof being laid an unventilated concrete support 1 which forms a rigid flat receiving surface. Adjacent zinc plates 2 and 3 form a central trough 4 which runs in the direction of slope of the roof in order to discharge rainwater to a drain. These zinc plates 2 and 3 which can overlap at the end portions, exhibit, on their lateral sides, differing folds which interfit. The right hand fold 5 (in the sense of the drawing) exhibits a right-angled wall with an edge 6 folded over on itself once. The left hand fold 7 (shown on plate 3) is folded back on itself twice on the edge 8, in order to surround the edge 6 of the plate 2 and to prevent any overrunning of water in the case of heavy rain.
The right and left hand folds 5 and 7 of the two adjacent zinc plates 2 and 3 engage a support piece 9 (see FIG. 3) which takes the general form of a right-angled piece one arm 10 of which is arranged vertically between the two vertical walls of the folds 5 and 7. The arm 10 is provided with a longitudinal slot 11 into which the tabs 12 of hook members (not shown) engage, the hook members being crimped onto the vertical walls of the edge folds 5 and 7.
In accordance with the invention, the metallic plates 2 and 3 are laid on intermediate plates 14 in the form of a a sheet laid flat on the rigid concrete support 1. The sheets have protrusions on their surface which are directed towards the metallic plates 2 and 3. The surface protuberances can be in the form of studs 15 having a generally frustro-conical shape with their flat minor base 16 uppermost. In FIGS. 1 and 2 it can be seen how each intermediate plate 14 comprises a continuous plate formed of a plastic material 14a. Surface protuberances 15 are suitably formed in the body of the sheet by thermoforming. The protuberances 15 in the form of truncated cones constitute, on the back surface of the plate 14, projecting studs of limited height h comprised between 5 and 10 mm. In an advantageous embodiment, a plate formed of plastic material can be used which takes the form of a sheet having a thickness comprised in the range 0.5 to 1 mm and the truncated conical studs have a major base diameter comprised between 15 and 20 mm and a minor base diameter between 8 and 12 mm, the spacing between the studs being comprised between 25 and 40 mm, the studs being preferably arranged in a square pattern.
In FIG. 2, the fixing arrangement of the support piece 9 onto the rigid concrete support 1 can be seen. The support piece 9 can be made of a material which is highly resistant to corrosion such as stainless steel and can take the the form of a right-angled part 1. The other arm 17 of the support piece 9 is provided with several frustro-conical cavities or recesses 18 formed by cold forming. The cavities 18 are adapted to be positioned in the a spaces 19b provided between series of four frustro-conical studs 15 (see FIG. 1) while the remainder of the arm 17 bears on two adjacent planar surfaces 16 of the frustro-conical studs 15. The base 19 of the cavity 18 (see FIG. 3) is supported on the planar base portion 16 at the intermediate plate 14 where it is fixed by means of a screw 20 passing through a hole 19a provided through the base 19 (see FIG. 3) and which is screwed, for example, into an expansion plug 21 formed of a plastic material, which is force mounted and is provided with anti-pullout hooks 21b inside a hole 22 drilled in the concrete of the rigid support 1.
In order to provide fixing of the intermediate plate 14 at other points onto the rigid concrete support 1, screws 20a are provided which are regularly spaced and screwed into expansion sleeves 21a, if necessary shorter than the sleeve 21. The sleeves are force fitted in holes 22a drilled in the concrete 1. The head 23a of the screws 20a bears on the planar surface of the plate 14a either directly or via a flexible but rigid washer and can if necessary be surrounded by a waterproofing layer suitably formed of an elastomer material 38. The shank of the screws 20 and 20a can pass through a hole in the plate 14 which is drilled to a diameter slightly less than the diameter of the screw shank so that the elasticity of the walls of the hole ensure that the material of the plate 14 provides a sealing clamping effect which is relatively soft nevertheless, on the shank of the screw 20 or 20a. The heads 23, 23a, of the screws 20 and 20a may, if necessary, be rendered water-tight on the base of the cavity 18 by the insertion of an elastomer material surrounding the head of the screw.
In FIG. 4, the various elements of the roof are shown in FIGS. 1 to 3 will be seen again on a smaller scale. Each screw that is placed can be rendered water-tight at its head by the use of a layer of an elastomer-based liquid 38 which spreads around the head of screw 23 or 23a (see FIG. 2).
The roof shown in FIG. 5, which corresponds more closely to a conventional way of laying zinc roof coverings, employs symmetrical zinc plates 24, 25 in the form of trays. Between two adjoining zinc plates in the form of trays, a joining strip or batten 26 generally made of wood, is fixed onto the intermediate plates 14 provided with studs 15. The joining strip 26 which is laid in the direction of slope of the roof, here has a trapezoidal cross-section with its minor base 27 uppermost and its major base 28 lowermost which is laid on the planar sides 16 of the frustro-conical studs 15. The joining strip 26 may also exhibit a rectangular or square cross-section or or the like, and is fixed onto the rigid concrete support 1 by means of screws 29 which are generally screwed into sleeves held rigidly in the concrete such as the sleeve 21 shown in FIG. 2. The screws 29 should pass through the intermediate plate 14 in a sealed manner and a sealing joint 30 formed of elastomer foam can be inserted under the joining strip 26 between the generally planar portion of the intermediate plate 14 and the major base 28 of the joining strip. This sealing joint formed of elastomer material simultaneously ensures better load bearing characteristics of the strip on the plate 14 than those provided by the studs 15 which can suffer spreading out at certain points. While fixing the joining strips 26 onto the intermediate plate 14, under the major base 28, the U-shaped arm 31, of double hooks 32 can be inserted, the upper folded-over portion 33 of which can come into engagement with the raised edge portions 24a and 24b of the trays 24 and 25 thus opposing their extraction in the upward direction. In order to maintain in place a trough-sectioned covering element 34 covering the joining strip 26 and oppose its extraction in the upward sense, hooks 34a which are nailed onto the joining strip 26 can be provided. Each trough-sectioned piece of roof 34 which is also formed of zinc may be provided at its extreme edges with folded-over portions 35a and 36a which engage with the folded-over edges 34b of the hooks 34a. The trough-sectioned portion 34 can also be held in place by hooks fixed onto the bottom of the joining strip 26 and folded over onto one end of the trough-sectioned portion 34.
When mounting the tray-shaped metallic plates 24 and 25, the raised edge portions 24a and 24b of these plates slide under the lateral strip portions 35 and 36 of the trough-sectioned portion 34, and are held in position by double hook members 32 which can obviously be replaced by single hook members which for example are nailed onto the inclined lateral sides 26a and 26b of the wooden joining strip 26. The tray-shaped zinc roofing elements 24 and 25 which are oriented in the direction of greatest slope of the roof are covered by the lateral strip portions 35 and 36 of the trough-sectioned portion 34, which ensures good protection against rising up of water under the action of the wind. Laying of the zinc tray-shaped elements 24 and 25 hence makes provision for free expansion of the metallic plates in all directions which is essential as the temperature of the zinc can vary between 80° C. in the full sun in summer and -20° C. in winter. The zinc tray-shaped members 24 and 25 are moreover laid on the planar heads 16 of the studs 15 which provide a ventilation space 37 of the same vertical height as the degree of projection h of the studs 15 (over the planar portion 14a of the intermediate plates 14) between these intermediate plates and the metallic covering plates (see also the ventilation space 37 in FIG. 4).
The assembly of intermediate plates constitutes a combined assembly which is sealed in regards to the flow of water in the direction of the slope of the roof and which can perform the function of an under-roof surface which recovers small leaks and possible condensation from the metallic plates, and lead such water off to the drain. The method of laying shown in FIG. 5 can be adapted, in certain countries which do not use wood, to the use of wholely metallic battens which are layed as intermediate pieces between the tray-shaped zinc elements having flanged vertical lateral sides. The metallic batten is made up by a U-shaped continuous element also made of zinc and laid using the joining arm of the U (the arms of the U being vertical) on the rigid concrete support 1 upon which it is fixed by any suitable means such as screws or nails.
After fitting the U-shaped member, the vertically-directed arms of which have upper folded over edges which are placed against a flange on the lateral sides of the tray-shaped zinc elements, the projecting arms of the U-shaped element are closed of by means of a covering plate formed of zinc which covers it and also possesses flanges. The successive super-positioning of the flanges of the covering plate, the U-shaped section and the vertical side of the adjacent tray-shaped zinc roofing element are then folded-over together in the vertical sense, in order to simultaneously, seal the tray-shaped element, the covering plate and the joining strip against projected water. When the invention is applied to metallic joining strips or battens having a U-shaped profile as described above, the U-shaped profile of the batten is fixed onto the intermediate plate 14 with local insertion of a simple sealing joint such as the seal 30, in order to also provide a ventilation space 37 under the metallic U-shaped battens.
Laying of a roof according to the invention onto a rigid support such as concrete or a metallic structure starts with the laying of the intermediate plates 14 which mutually overlap at their edges in all four directions and are held onto the metallic support generally by means of screws the passage of which is rendered sealing by direct contact with the plastic material of the intermediate plate 14 or, if needed, with the interpositioning of an elastomer seal 38 between the head of the screw and the intermediate plate. The intermediate plates having been laid, intermediate supports 9 can now be fixed in place, or battens 26 or trough-sectioned elements 34 depending on the type of metallic plate selected. Once the support parts 9 or 26 are in place, the metallic plates can now be laid which are slid laterally one inside the other in the direction of the slope of the roof. The metallic plates come to rest on the planar heads 16 of the studs 15 forming a ventilation space 37 which prevents condensation occurring below the zinc and the starting of corrosion in association with an acidic aqueous phase, the risk of which is reduced due to the fact that the intermediate plates 14 are made of plastic material that does not corrode.
It is well understood that the examples and alternatives given in the foregoing description are adaptable to numerous variants available to those skilled in the art without in any way departing from the scope and spirit of the invention.
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A roof system is provided for buildings having an unventilated roofing support such as concrete forming a planar receiving surface. An intermediate plate formed of an environmental-tight sheet of plastic material is placed on the planar receiving surface. The sheet contains a uniform pattern of protuberances such as frusto-conical studs having planar tops. A rigid roof covering formed of corrosion-resistant metal plates such as zinc is laid on top of the planar surfaces of the studs. The plates have interfitting, bent edges forming troughs. The studs space the rigid roof covering from the intermediate sheet forming a ventilation space for collecting leaks or condensation.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] The invention relates to multifunctional holding devices for toolless attachment to frames, especially ladders, stringers, steps of stepladders or ladder rungs, and for accommodation of working devices without fasteners, for example tools, storage boxes, buckets and the like, with rod-shaped, bar-shaped or plate-shaped holding parts, which have with one another to a frame-shaped article with hook elements for hanging of the holding parts on the frame and for accommodating working devices [sic], the hook-shaped elements coming into contact with the respective parts of the frame, for example stringers, steps or rungs and being supported on these parts.
[0002] Hooks or holding devices of most varied type have become known. The main use of hooks or holding devices consists in hanging an article or attaching it in some way. The simplest and most common execution of a hook is S-shaped, consists of metal, and can be used in a versatile manner for simple purposes.
[0003] In order to perform special tasks however, numerous other hook-shaped articles and holding devices have been developed.
[0004] According to DE 299 10 008 U1 a holding device is placed over the beam on the rung of a ladder. A support arm which proceeds from the holding device is used in this connection as a receiver for a bucket. The disadvantage of this execution is that it can only be used on a limited basis, since both a stringer and also a rung of a ladder are required for hanging. Furthermore the holding receiver on which the bucket can be hung is far from the ladder so that the center of gravity of the bucket is displaced three-dimensionally away from the ladder. The resulting lever action can lead to the construction bending under a greater load, or the position of the ladder becoming unstable. Especially when the device is hung on the side of a ladder facing the user can this constitute a real danger.
[0005] In another type of hanging device as claimed in DE 299 00 960 U1 it is important that the hanging device is adjustable and can be matched to the respective width of the ladder stringer in order to hand a so-called rung cutout on the rung or that the hanging device can be placed on one step. In this connection the decisive feature is considered to be the installation of a pivoting support and blocking lever which in the working position on a connecting joint of a stepladder is used as a support or block against the device possibly sliding out of the stringer region of the stepladder. In this adjustable hanging device what is important is first of all achieving a variable region to which a hanging device can be attached using two stringer enclosures which can be adjusted to one another. In this connection a segment cutout holds another segment insert, and the two parts can be adjusted to one another for matching of the thickness of the stringer. In this hanging device in spite of complex production (cutting, drilling, thread cutting, fitting of segments and rung jaws) a device which may not be unconditionally safe in all applications in its stability and safety is formed.
[0006] Examples of rod-shaped holding devices according to the generic execution of this invention include U.S. Pat. Nos. 5,957,238, 6,131,699, 6,250,595 B1, UK patents 213082 A, 2353064 A, 2375570 A, DE 2121131 OS and U.S. Pat. No. 1,811,065 which relate to rod-shaped holding devices for use in conjunction with ladders and buckets or the corresponding vessels which can be attached to the ladders. These configurations of holding devices are all limited in their possible application to holding devices with a use which does not enable multifunctional uses.
[0007] It is an object of the invention is to devise holding devices for different applications which are as simple and versatile, therefore as multifunctional as possible, in their construction.
SUMMARY OF THE INVENTION
[0008] As claimed in the invention, for generic holding devices it is suggested that two multiple hook arrangements which are made in parallel planes and which are spaced apart from one another consist of one continuous horizontal middle rod each with upper U-shaped hooks and lower U-shaped or L-shaped hooks made on the two rod ends, the multi-hook arrangements each on the side of the planes which is pointed away from the middle rod having an open site between the opposing hook legs for insertion or attachment of the holding device on the frame. Selectively on the face-side ends of the multi-hook arrangements with the middle rods cross connectors are additionally attached which fix the multi-hook arrangements and which on their outer ends each have one L-shaped hook at a time.
[0009] The important advantages of the invention are that in addition to improving the hanging and holding action of a conventional hook, a host of possibilities is created for attaching, fastening or fixing the holding device by a resting, clamping or tilting action on a device which is generally called a frame, especially a ladder or its stringer, step or rung or also on a lashing device. For this purpose the individual component regions or sections of the holding device are made with hooks for achieving the object such that they are arranged symmetrically and/or parallel, or also asymmetrically at a given distance to one another, also in pairs. The type of selected execution ensures that the hook or holding device in addition to its conventional function of a hanger is additionally placed or slipped onto a frame, for example a stringer, a step or a rung of a ladder or the like at a distance which is not defined in detail to the latter, or at least partially surrounds or extends behind this device or parts of it so that twisting around a cross sectional diagonal, for example of a stringer, a step or a rung is prevented by tilting, clamping, positive contact or locking, and on at least one part of the hook device or holding device a working device, for example a tool, a bucket, or the like can be securely hung or attached.
[0010] Another advantage of the invention is that two U-shaped component regions of the hook device or holding device which are located essentially parallel to one another for conventional hanging over a rung in the region of the ladder stringer act to stabilize in all three axes or counteract twisting. Moreover the holding device can be easily and reliably attached without adversely affecting operation and safety on both sides of the ladder, both on the side facing the user and the side facing away from the him.
[0011] Furthermore the invention enables the holding device to be placed or slipped onto a rung or the articulated part which connects the stringers of a stepladder along the lengthwise axis of the connecting region. In this respect it is especially beneficial that a large region at least in two axes comes into contact with them, protected against turning. Furthermore the articulated part is at least partially surrounded; this leads to high stability and outstanding holding capacity. Even larger loads can be easily affixed by this holding capacity, stable execution and closeness to the object.
[0012] When the holding device is slipped or hung on a rung or the step of a stepladder, it is possible to set the tool, for example in the form of a bucket, on the underlying rung or step so that only the handle of the bucket need be hung to protect against tipping. This has the major advantage that the weight of the tool is attached not laterally outside the ladder, but always over the ladder and thus tipping of the ladder even under greater loads can be avoided or at least reduced. If a bucket is hung on the uppermost step of a stepladder, it assumes an ideal and safe working position because it can be optimally reached by the worker when he is standing on the opposite side of the ladder.
[0013] Also in the case of a holding device hung on the top connecting stringer of two lateral stringers of a one-sided stepladder can the tool be optimally positioned for hanging a bucket or for pushing a resting surface into the hook and the bucket or the tool placed on the working surface can always be safely reached.
[0014] With a hose clamp fitting or cable clamp fitting the multifunctional hook itself can be attached quickly and safely and can be used to hang many different devices. Thus the tool for example can likewise be easily hung on a post or a handle. Accordingly a series of tools can be comfortably hung and carried along on a lashing belt or belt using the holding device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention and its practical use are explained below in conjunction with the drawings using embodiments.
[0016] FIG. 1 shows in a perspective of one embodiment of a multifunctional holding device;
[0017] FIG. 2 shows in a side view a one-sided stepladder, on the top intermediate part of the lateral stringers of which a multifunctional holding device, as shown in FIG. 1 is hung;
[0018] FIG. 3 shows a perspective of a combined stepladder in which a stepladder and a rung ladder are movably connected to an articulated region. On the topmost step of the stepladder a multifunctional holding device is hung;
[0019] FIG. 4 shows in a perspective view of the lower rung of a ladder a holding device which is hung vertically offset by 90° to the step of the stepladder as shown in FIG. 3 ;
[0020] The perspective in FIG. 5 shows a holding device 1 which has been slipped on in the articulated region of a stepladder;
[0021] The holding device 1 as shown in FIG. 6 , which is hung with a U-hook on a rung of a ladder;
[0022] FIG. 7 shows in a perspective view a combined stepladder with one section consisting of a stepladder and its other section of a rung ladder;
[0023] FIG. 8 shows a holding device on a rung of a ladder with hooks, which are made flat in an L shape at a connecting site connected to a U-hook;
[0024] FIG. 9 shows one embodiment of a holding device that is fixed on a tubular tool or on which a tool is fixed with a fastener;
[0025] The embodiment as shown in FIG. 10 shows how a holding device can be hung on a lashing belt or a belt;
[0026] FIG. 11 shows a cross sectional diagonal of a rung of a ladder on which the holding device is fixed;
[0027] FIG. 12 shows the cross sectional diagonal of a step of a stepladder;
[0028] FIG. 13 shows the cross sectional diagonal of the articulated region of a ladder;
[0029] FIG. 14 shows a cross sectional diagonal of an intermediate part or of a lateral stringer of a stepladder or a rung ladder; and
[0030] The photographs in FIGS. 15-26 show various practical applications of the holding device of the invention in conjunction with ladder rungs, ladder stringers, etc.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1 shows in a perspective of one embodiment of a multifunctional holding device 1 as claimed in the invention. The holding device 1 consists of two holding elements 1 a and 1 b which are located in two parallel planes E 1 and E 2 and which each consist of a frame-like article which is composed of U-shaped hooks 2 a , 2 b on one end and U-shaped hooks 2 c, 2 d on the other end of a horizontal middle support 4 a , 4 b as the top section, and U-shaped hooks 2 e and 2 f on one end and L-shaped hooks 3 a , 3 b on the opposite end. These hook parts 2 , 3 form receiving, attachment and hanging regions 5 which are assembled, for example welded together, by the U-shaped hooks 2 and L-shaped hooks 3 which are located parallel, symmetrically or asymmetrically to one another to form the entire holding device 1 . In addition, as shown in FIG. 1 , there can be cross connectors 4 c , 4 d , which are connected, preferably welded to the holding elements 1 a, 1 b at the height of the middle bars 4 a , 4 b , and which have L-shaped hooks 2 f, 2 g on their ends in order to achieve other hook devices.
[0032] FIG. 2 shows in a side view a one-sided stepladder 6 , on the top intermediate part 7 of the lateral stringers 8 of which a multifunctional holding device 1 as shown in FIG. 1 is hung or slipped, and the handle 9 of a bucket 10 can be hung both on a U-shaped hook 2 and also on an L-shaped hook 3 . Furthermore the tool 11 is inserted under a U-hook 2 in a receiving, attachment or hanging region 5 and is held or supported by an L-hook 3 . At a sufficient height of the bucket 10 the bottom 12 of the bucket can be rested on the platform 13 of the one-sided stepladder 6 . The lower part of FIG. 2 shows a multifunctional holding device 1 which with a U-hook 2 extends around the step of a stepladder 14 of a one-sided stepladder 6 , on another U-hook of the holding device 1 the handle 9 of a bucket 10 being hung, and the bottom 12 of the bucket is placed on the step 14 of the stepladder 6 .
[0033] FIG. 3 shows a perspective of a combined stepladder 15 in which a stepladder 16 and a rung ladder 17 are movably connected to an articulated region 20 . On the topmost step 14 a of the stepladder 16 a multifunctional holding device 1 is hung or slipped. In the receiving, attachment and hanging region 5 a tool 11 in the form of a horizontal resting surface 11 is inserted and fixed on the U-hook 2 . On the second highest step 14 b a multifunctional holding device 1 is hung or slipped, the handle 9 of a bucket 10 being hung in two U-hooks 2 and the bottom 12 of the bucket 10 sitting on the step 14 c underneath. Furthermore, FIG. 3 shows a multifunctional holding device 1 which has been slipped on one rung 18 of the stepladder 15 and which with reference to the holding device 1 slipped on the step 14 b is seated horizontally by 90° to the lengthwise axis 19 of the step 14 b on the rung 18 .
[0034] FIG. 4 shows in a perspective view of the lower rung 18 c of a ladder a holding device 1 which is hung vertically offset by 90° to the step 14 a of the stepladder 16 as shown in FIG. 3 . Furthermore, FIG. 4 shows a holding device 1 which has been slipped onto the topmost rung 18 a; in the receiving, attachment and hanging region 5 of the device the handle 9 of a bucket 10 is hung, and the bottom 12 of the bucket 10 sits underneath on the rung 18 b.
[0035] The perspective in FIG. 5 shows a holding device 1 which has been slipped on in the articulated region 20 of a stepladder 15 and which with its connecting parts 4 rests both on the articulated region 20 and also laterally adjoining, with hooks 2 which form a receiving region 5 , and extend around the stringers 8 , 21 of the stepladder 15 or its articulated region 20 and are supported thereon against twisting. Furthermore, FIG. 5 shows a holding device 1 with the handle 9 of a bucket 10 hung in its receiving region 5 .
[0036] The holding device 1 as shown in FIG. 6 which is hung with a U-hook 2 on a rung 18 of a rung ladder 22 is fixed such that two U-hooks 2 and two L-hooks 3 at a time laterally encompass the stringer 21 of the rung ladder 22 and protect it against twisting by tilting, the connecting parts 4 coming into contact with the stringer 21 in a stabilizing manner. Furthermore FIG. 6 shows that the handle 9 of a bucket 10 is hung in a U-hook 2 of the holding device 1 .
[0037] FIG. 7 shows in a perspective view a combined stepladder 15 with one section consisting of a step ladder 16 and its other section of a rung ladder 17 . On the topmost step 14 a of the stepladder 16 a holding device 1 is hung or slipped. In this regard the connection region 23 is made flat. On the edges 24 of the connecting region 25 U-hooks 2 or L-hooks 3 are attached at any positions. Furthermore FIG. 7 shows on the step 14 c of the stepladder 16 a holding device 1 which has been hung or slipped on, with U-hooks 2 and L-hooks 3 running parallel to one another and with the respective ends connected to a connecting part 4 . On the step 14 e of the stepladder 16 a holding device 1 is shown slipped or hung, in which two U-hooks 2 are connected to only one L-hook 3 at one connecting site 26 at only one point. On the lowermost step 14 f of the stepladder 16 a single (instead of a double) holding device 1 is shown in which only one U-hook 2 and one L-hook 3 at a time without a connecting part 4 are joined to one another. This holding device is made in one piece. Furthermore, FIG. 7 shows on the step 14 d of the stepladder 16 a single holding device 1 in which two U-hooks 2 are joined to one another without a connecting part 4 and which is made in one piece. On one rung 18 e a holding device 1 of U-hooks 2 or L-hooks 3 which are made rod-shaped is shown. The embodiment of the holding device 1 of U-hooks 25 and L-hooks 32 which are made flat is shown on one rung 18 b. On the rung 18 c of FIG. 7 another version of a holding device 1 is shown with U-hooks 2 and L-hooks 3 which are made rod-shaped, while their connecting region 23 is made flat. Another embodiment of a single holding device 1 of rod-shaped material is shown hung on a rung 18 d. Finally, FIG. 7 shows on the articulated region 20 of a combined stepladder 15 a holding device 1 which is hung and which consists of a U-hook 2 , connecting parts 4 and another U-hook 27 which is made selectively flat or rod-shaped.
[0038] FIG. 8 shows a holding device on a rung 18 f of a ladder with hooks 25 which are made flat in an L shape at a connecting site 26 connected to a U-hook. On the flat hook 25 an adjusting or locking device 31 in the form of a thumb screw is attached.
[0039] FIG. 9 shows one embodiment of a holding device 1 which is fixed on a tubular tool 11 or on which a tool 11 is fixed with a fastener 28 .
[0040] The embodiment as shown in FIG. 10 shows how a holding device 1 can be hung on a lashing belt 29 or a belt.
[0041] FIG. 11 shows a cross sectional diagonal 30 of a rung 18 of a ladder on which the holding device 1 is fixed. This holding device 1 is attached relative to the cross sectional diagonal 30 by clamping, tilting, positively, or rigidly and thus protected against twisting, nonpositively or with locking capacity.
[0042] FIG. 12 shows the cross sectional diagonal 30 of a step of a stepladder 14 ,
[0043] FIG. 13 shows the cross sectional diagonal 30 of the articulated region 20 of a ladder,
[0044] FIG. 14 shows a cross sectional diagonal of an intermediate part 7 or of a lateral stringer of a stepladder or a rung ladder 21 .
[0045] The photographs in FIGS. 15-26 show various practical possible applications of the holding device as claimed in the invention in conjunction with ladder rungs, ladder stringers, etc., which can be fixed by tilting, clamping, encompassing, etc. against rotation with a ladder or the like without using a tool.
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The invention relates to a single- or multiple- or multifunctional holding device that is designed in such a manner that it can be fastened to a support in different ways and can in turn be used as the support for a second object. Differently shaped receiving sections, produced by the arrangement of the structural units in the form of U-shaped hooks, L-shaped hooks, connecting elements and connecting sections in relation to each other allow for the holding device to be fastened to differently shaped supports in a rotationally fixed manner by jamming, blocking, encompassing, engaging behind or positively resting against them and to be used as a support for other objects.
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RELATED APPLICATIONS
This application claims the Paris Convention priority of U.S. Provisional Application No. 60/737,608 entitled “Novel Enhanced Pool Drain Safety Method and Device,” filed Nov. 17, 2005, the contents of which are hereby incorporated by reference in their entirety.
BACKGROUND
The present disclosure relates to safety devices for pools. In particular, the present disclosure relates to a pool drain safety device and related methods. Several attempts to prevent hair and clothing entanglement in drains have been attempted. These include providing drain systems with sharp edges on which the swimmer may sever tangled hair. Other attempts include grating devices that do not allow hair and clothing to enter the drain. However, such highly exclusive filtration gratings significantly restrict the flow of water into the drain or require substantial surface area, reducing the efficiency of the pool circulation system. Thus, there has been a longstanding need for a system that does not restrict the flow of water into the drain and that cuts entangled objects without requiring the swimmer's intervention. However, none of these devices address or overcome those issues ameliorated by the present invention.
The following references are relevant to attempts to address the problem: U.S. Pat. Nos. 4,868,984; 5,031,320; 6,088,842; 6,751,814; and 6,810,537, as well as published Patent Application US 2004/0093666, each of which is incorporated by reference as if fully set forth herein.
SUMMARY
The novel enhanced pool drain safety device of the present disclosure increases safety around pools and prevents unnecessary drowning. The apparatus is disposed in a pool drain system and has at least one blade connected to an axle and moved by the suction force provided by the filter system. As water moves from a pool to an intake duct via a drain, the combination of moving water and vacuum force turns blades, which cut foreign materials, such as hair, that comes through the drain grating.
The present disclosure relates to a device comprising at least one movable blade disposed in a pool drain, wherein the force of water causes the blade to move.
Similarly disclosed is a method for cutting foreign objects coming into a pool drain system comprising providing at least one moveable blade disposed in a drain system, wherein the at least one moveable blade cuts foreign objects entering the drain system.
Finally, a business method of increasing safety in water recreation environments is disclosed comprising providing at least one moveable blade disposed in a drain system, allowing the at least one moveable blade to cut at least one foreign object introduced by a human into the drain system that prevent the human from surfacing, wherein the cutting of the at least one foreign object allows the human to surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
FIG. 1 is a schematic of an embodiment of the pool drain safety device system of the present disclosure;
FIG. 2 is a perspective view of an embodiment of the pool drain safety device;
FIG. 3 is a side view of an embodiment of the pool drain safety device;
FIG. 4 is a top view of an embodiment of the pool drain safety device;
FIG. 5 is a bottom view of an embodiment of the pool drain safety device; and
FIG. 6 is a perspective view of an embodiment of the pool drain safety device of the present disclosure.
DETAILED DESCRIPTION
As used in the present disclosure, “pool” shall be understood to mean any artificial or natural body of water connected to a drain system where a swimmer's hair, clothing, or other objects that may be sucked into the drain system.
The present inventor has solved a long-standing need by providing a simple and mechanically elegant solution to the issue of pool drains becoming fouled with, for example, human hair and clothing.
The present disclosure is directed to an enhanced swimming pool drain safety method and device that satisfies these needs. The following is a summary of various aspects and advantages realizable according to various embodiments of the enhanced pool drain safety method and device according to the present disclosure. It is provided as an introduction to assist those skilled in the art to more rapidly assimilate the detailed discussion of the device that ensues and is not intended to limit the scope of the claims.
A feature of the present disclosure is to release swimmers who become entangled in pool drains by cutting the swimmer's hair, clothing, and other objects attached to a swimmer as they are sucked into the drain.
An additional object of the present disclosure is to release the entangled swimmer without requiring the swimmer to perform any act. This is accomplished by providing a cutting tool that provides the force to cut the entangled objects rather than providing a tool that requires the swimmer to provide the force.
Another object of the present disclosure is to perform the cutting without requiring a motor to operate the cutting tools. This is accomplished by driving the movement of the cutting tools by the flow of water. In an embodiment, rotating blades cut objects entering the drain. The blades may be angled such that the water flowing into the intake duct applies a force to the blades, which causes them to rotate. Alternatively, a turbine may be attached to the blades to cause them to rotate by using the flow of water over the turbine. Thus, the blades would not require a separate motor to operate.
Yet another feature of the present disclosure is to maintain flow rate efficiency of a circulation system while preventing larger objects, such as swimmer's appendages, from entering the drain. By providing a drain cover with a grating that allows only water and small objects to pass, this objective is accomplished. While pool drain covers are well known in the art, its combination with cutting tools to increase swimmer safety and improve filter efficiency comprises a novel system without compromising the function of the drain or the flow rate of the water moving through it.
The present disclosure relates to swimming pool drain safety methods and devices. According to an embodiment of the present disclosure, a pool drain safety device is disposed at the entrance of an intake duct such as a pool drain. While a pool circulation system operates, it draws water through the drain which creates a strong suction force at the entrance to the drain. A swimmer that approaches the drain too closely risks having hair or clothing sucked into the drain among other known maladies associated with pool drain suction, such as disembodiment. Hair and clothing may get tangled in the drain after being sucked into the drain, causing death by drowning or other injuries. The present devices are designed to cut hair and clothing as they come through the drain, preventing tangling or releasing the swimmer whose hair or clothing has been caught and tangled by the suction of the drain. The device also cuts other objects entering the drain into smaller pieces for more efficient filtration later in the pool circulation system. No limitations of the applicant's subject matter are intended by this illustrative example; similar devices may be applied to other intake ducts where suction force may pose a danger due to the potential for hair or clothing entanglement.
In the United States, drowning is the second leading cause of accidental death among children under 15 years of age. Every year, hundreds of children in this age group die as a result of accidental drowning and thousands more are injured. Entanglement, which occurs when a swimmer's hair or clothing is caught by an underwater drain, causes many of these deaths and injuries. At least about 41 percent of all entanglement incidents involve the victim's hair. The need to protect children from entanglement is particularly great because since 1990, 93 percent of hair entanglement deaths and injuries have been among children ages 15 and under.
Using the system disclosed herein may therefore reduce incidence of death and injury by pool drain entanglement. The safety benefits are accomplished without substantial restriction the flow rate efficiency of the circulation system by filtering objects that may otherwise tangle in the drain 12 (see for example FIG. 1 ). Further, the present disclosure does not require its own motor for operation, but rather may be driven by the flow of water. Further still, the present disclosure does not require that the entangled swimmer perform any act to operate the device.
As shown in FIG. 1 , there is shown pool drain safety device 1 of the present disclosure used in conjunction with a pool water circulation system. Artisans are well aware of a plurality of conventional makers, systems, and types of such pool water circulation systems. During operation, the water from pool 16 is drawn through drain 12 and into intake duct 13 due to suction provided by pool pump and filter system or circulation system 14 . Pool drain safety device 1 may be installed at or near drain 12 . When circulation system 14 is engaged, water passes from pool 16 to intake duct 13 . Blades 2 of pool drain safety device 1 rotate due to the flow of water against blades 2 , which act similar to a turbine. Blades 2 may also be rotated with a dedicated turbine 11 (see FIG. 6 ). As a swimmer nears drain 12 , hair or clothing that enters the drain are cut by blades 2 , preventing them from tangling in drain 12 and holding the swimmer under water. No limitations on blade shape and configuration are intended by the demonstrative embodiments shown.
Turning now to an embodiment shown in FIG. 2-5 , a pool drain safety device 1 is shown. Pool drain safety device 1 comprises a plurality of blades 2 connected to axle 4 . The blades 2 extend radially outward from the axle 4 , such that each imaginary line bisecting a blade 2 is substantially equidistant from the imaginary lines bisecting the adjacent blades 2 .
Cover 7 connects to rim 5 . Water is permitted to pass through cover 7 . A plurality of grating holes 8 prevent large objects from entering circulation system 14 . Nevertheless, smaller objects such as hair and clothing strings are often small enough to fit through grating holes 8 . As used in the present disclosure, cover 7 should have grating holes 8 large enough to allow fluid and small objects to freely travel through, but small enough to prevent entrance of a swimmer's digit or appendage. The exact specifications of cover 7 and grating holes 8 are well known in the art in many variations. The present disclosure is suited and applicable to many, if not all, of the current cover 7 variations used.
Rim 5 is provided of such shape and size that it conforms to the shape and size of drain 12 . Rim 5 connects to cover 7 . A plurality of support arms 6 extend inward from rim 5 and converge at the center of the area defined by rim 5 . Support arms provide support for axle 4 and blades 2 . One end of axle 4 connects to lower cavity 9 , which is disposed at the point of convergence of the support arms 6 . The other end of axle 4 connects to upper cavity 10 , which is disposed at the center of cover 7 . Thus, axle 4 is disposed in and spans the imaginary line between lower cavity 9 and upper cavity 10 . Each end of axle 4 connects to lower cavity 9 and upper cavity 10 such that axle 4 may rotate while rim 5 , support arms 6 , the cover 7 remain stationary relative to the movement of axle 4 .
According to embodiments, the devices of the present disclosure are adapted to commercially available covers 7 . According to these embodiments, rim 5 of pool drain safety device 1 is of such shape and size as to conform to the shapes and sizes commercially available covers 7 . Rim 5 connects to the commercially available cover 7 . According to embodiments, axle 4 connects solely to lower cavity 9 and does not require modification or adaptation of the commercially available covers 7 . Thus, according to these embodiments, no upper cavity 10 is provided. Instead, the lower cavity-axle-blade unit operates stably without substantial articulation with the commercially available cover 7 apart from the connection to rim 5 . According to similar embodiments, however, the inventors of the present disclosure expressly contemplate modification or adaptation of commercially available covers to successfully practice the teachings of the present disclosure. Moreover, the teachings of the present disclosure may be combined with preexisting anti-entanglement designed covers.
Because axle 4 may rotate rapidly, friction and excessive wear considerations must be taken into account. According to an embodiment, a pair of sealed bearings may be disposed in each of lower cavity 9 and upper cavity 10 to dissipate friction and extend the useful life of pool drain safety device 1 . It is intended that such a system would require little to no maintenance over the life of the drain component.
According to similar embodiment, axle 4 may be designed where it does not rotate with blades 2 . Rather, a blade sheath (not shown) to which blades 2 are connected, which extends a substantial length of axle 4 between lower cavity 9 and upper cavity 10 , rotates about axle 4 . Both axle 4 and axle sheath would be made of durable materials to provide a long functional life. To prevent friction between axle sheath and axle 4 , fluid, a lubricant, lubricious surface, or a sealed bearing system may be disposed between axle sheath and axle, according to embodiments. The actual implementation of such modifications and variations would be understood and known to a person of skill in the art.
According to embodiments, blades 2 are disposed radially outward from axle 4 , and one end of axle 4 is connected to upper cavity 10 of the cover 7 . Blade 2 connects to the other end of axle 4 . The entire blade-axle system requires no lower cavity 9 or support arms 6 , but functions rather as a free unit without the need of lower support.
One or more blades 2 are connected to axle 4 an axle sheath. Blades 2 rotate, when circulation system 14 is activated, with enough force to sever hair, clothing, and other small objects passing through grating holes 8 . Consequently, blades 2 must be strong enough to withstand cutting events, the chemical environment of pools, and extended service life. More particularly, blades 2 should be hard and sharp enough to cut hair, strings, and other objects. Similarly, blades 2 should be durable enough to withstand numerous cutting events over a long period of time. Cutting edges 3 therefore must remain sharp throughout this period. Naturally, blades 2 may be made from metals such as stainless steel; other strong, non-corrosive metals; plastics; or polymers. The choice of the particular blade material is understood and known to a person of ordinary skill in the art. The material used to make the blades 2 should not corrode, rust, or otherwise oxidize in fresh or salt water. Moreover, the blades 2 should not react or be affected by pool additives, such as chlorine, bromine, and other pool chemicals.
Cutting edge 3 of each blade 2 is oriented in the same direction as all other cutting edges 3 with respect to direction of rotation and cutting plane. The cutting plane is defined to be an imaginary cylinder, where the cylinder's radius is defined to be the greatest of the radii measured as the length of each blade 2 from the center point of axle 4 to the point on each blade 2 furthest from the center point of axle 4 . The height of the imaginary cylinder is measured as the cylinder height defined by the distance measured from the point of blades 2 closest to cover 7 to the point of blades 2 furthest from the cover 7 . The present disclosure contemplates at least one cutting plane. Cutting edges 3 defines the point where hair, clothing, and other objects are cut.
According to embodiments, cutting edges 3 of blades 2 are disposed to contact an inside surface of cover 7 during rotation of blades 2 about axle 4 . As the blades 2 rotate, cutting edge 3 of blades 2 moves along inside surface similar to the operation of an electric razor. As hair, clothing, or other foreign objects pass through grating holes 8 , they are sheared, such as by a scissoring effect, between the inner surface of cover 7 and cutting edge 3 before they are able to tangle and trap a swimmer or soon after a tangle is formed so that the swimmer may escape to the surface.
According to an embodiment, blades 2 are shaped and angled such that when water moves from pool 16 into the intake duct 13 , the force of the flow of water over the blades 2 turns them in the same way that water turns a turbine. Cutting edges 3 of blades 2 are oriented to be the leading edge with respect to the rotation.
Some pools have drains 12 with larger surface areas designed to reduce the suction force per area unit. For these types of drain systems, angling blades 2 to induce rotation may fail to provide the requisite blade velocity to enable blades 2 to sever hair, clothing, and other objects passing through grating holes 8 and into drain 12 . Consequently, turbine 11 must be introduced into the system to produce the requisite blade velocity to sever hair, clothing, and the other potential objects entering the circulation system. In these type systems, turbine 11 may be disposed in intake duct 13 pipes where the force of water aggregates to rotate blades 2 at sufficient speed to sever the hair, clothing, and other objects. Thus, it should be clear to artisans that turbine 11 and blades 2 need not be disposed in close proximity to each other.
According to an embodiment shown in FIG. 6 , turbine 11 is connected to axle 4 which turns blades 2 . The flowing water turns the turbine 11 , which applies torque to axle 4 . Axle 4 then applies a torque to the blades 2 , which causes them to turn. Because blades 2 may rely on turbine 11 for rotation, blades 2 need not act as a turbine and provide rotation for themselves. Thus, the shape and angle of blades 2 is then irrelevant, except with regard to flow rate efficiency. Indeed, in the exemplary embodiment shown in FIG. 6 , blades 2 are thin to prevent inefficiencies in the flow of water and to reduce potential cavitation effects.
In addition to hair and clothing of trapped swimmers, the system of the present disclosure also cuts foreign objects small enough to pass through the grating holes 8 prior to entering circulation system 14 . Thus, the present disclosure also contemplates a device that reduces the size of matter passed into the pool pump and filter. Embodiments of this type have application to filters on ponds, aquariums, and other applications where human safety isn't always at issue, but where filters potentially suck in detritus and larger type materials through their intakes. Consequently, filtering efficiency improves by reducing the size of the filtered materials, which extends the life of filters and filtering materials, as well as prevent clogs of larger objects, such as algae and other organic matter, in the filter pipes.
Referring again to FIG. 1 and an embodiment of a method, pool drain safety device 1 automatically activates when circulation system 14 of pool 16 is activated. As water flows from pool 16 into intake duct 13 , it passes through drain cover 7 through grating holes 8 . The force of the water being sucked into intake duct 13 caused by the operation of the pump of circulation system 14 forces water to pass over blades 2 or turbine 11 , effective rotation of blades 2 . The rotation of blades 2 or turbine 11 causes blades 2 to rotate with sufficient speed to cut foreign objects, such as hair and clothing, that come through grating holes 8 . Consequently, hair and clothing that would otherwise potentially trap a swimmer under water, are severed before they tangle and trap the swimmer or soon thereafter.
Moreover, according to an embodiment of a business method, the system of the present disclosure may be provided in pool systems to increase the safety of recreators. As disclosed above, the system may be disposed in a pool. When a swimmer's hair or clothing becomes tangled in the drain due to suction force, the blades of the system will cut the hair or clothing, allowing the swimmer to surface, providing a safer environment in which to recreate.
While the apparatuses and methods have been described in terms of what are presently considered to be the most practical and effective embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims.
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The novel enhanced pool safety device of the present disclosure increases safety around pools and prevents unnecessary drowning. The apparatus is disposed in a pool drain system and had been at least one blade connected to an axle and moved by the suction force provided by the filter system. As water moves from a pool to an intake duct via a drain, the combination of moving water and vacuum force turns blades, which cut foreign materials, such as hair, that comes through the drain grating. The cutting of these materials prevents loss of life that may arise as humans and other objects become entangled in pool drains.
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CROSS-REFERENCES
Technical Field
[0001] This invention relates generally to the field of construction of buildings and other structures, and more specifically to the construction of green or sustainable buildings using modular segments.
BACKGROUND
[0002] Constructing a green or sustainable building or another structure is a complex process that requires significant amounts of time, resources, and collaboration from many fields of endeavor. Through the years, different techniques have been developed to try to maximize the efficiency and economy of the process. The most common current building techniques involve the use of standardized building components that are shipped to the construction site in small pieces and assembled on site.
[0003] However, when such methods are used, a green or sustainable building or other structure can take months or even years to build. The building project is consequently subjected to unpredictable weather conditions, and great exertions must be made to store and protect tools and resources. Resources may be wasted. Furthermore, even though efficient modern assembly techniques have driven down prices for many industrial and consumer products—such as cars, machinery, clothing, and electronics—such techniques are not fully taken advantage of in constructing green or sustainable buildings. Overall, the current methods lose the potential benefits of quality, precision, efficiency, and optimal timing that are possible through the manufacture of modular building segments in a controlled environment as described herein.
[0004] In view of the foregoing, what is needed is a green or sustainable and efficient building design that will allow the main infrastructure of a building or another structure to be manufactured in a controlled off-site environment and then be transported to a building site and quickly assembled on site to form the finished building or other structure. Such a technique would need to preserve or improve the structural integrity of the building, use efficient building techniques, provide for efficient temperature control and access to utilities within the building, and optimize the use of resources by integrating the infrastructure into the overall functionality of the building. Furthermore, unlike current modular green or sustainable building systems, such a building design should allow for an infinite variety of configurations to appeal to myriad preferences and needs.
SUMMARY OF THE INVENTION
[0005] The disclosed invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available components and methods. Accordingly, efficient structural components and methods have been developed to allow the infrastructure of green or sustainable buildings and other structures to be built using a new style of conjoining modular building segments that may be constructed in an off-site, controlled environment.
[0006] Consistent with the foregoing, a green or sustainable building constructed with conjoining modular building segments is disclosed. In one embodiment, such a building comprises a plurality of prismatic box-like structures having at least three walls. A space inside the walls measures at least one square foot. In one embodiment, a first selection of the prismatic box-like structures are placed side by side horizontally and mechanically attached to form at least a length and width of one ceiling. A second selection of the prismatic box-like structures are placed side by side horizontally and mechanically attached to form a length and width of at least one floor. A third selection of the plurality of prismatic box-like structures are placed side by side vertically and mechanically attached to form a plurality of walls of the building infrastructure. The prismatic box-like structures comprise an apparatus suitable for disposition of a stored item. The prismatic box-like structures provide for the efficient use of space and, in certain embodiments, have certain dimensions, comprise specific materials, or are constructed or conjoined in specific ways. A corresponding method is also disclosed and claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A more particular description of the invention briefly described above is made below by reference to specific embodiments depicted in drawings included with this application, in which:
[0008] FIG. 1 depicts a perspective view of a finished building built in accordance with the invention;
[0009] FIG. 2 depicts a perspective view of a building infrastructure comprising a plurality of conjoining modular building segments;
[0010] FIG. 3 depicts a perspective view of the plurality of conjoining modular building segments arranged to create the building infrastructure;
[0011] FIG. 4 depicts perspective views of different embodiments of the conjoining modular building segments, which are prismatic box-like structures;
[0012] FIG. 5 depicts a perspective view of the first and second selections of the plurality of prismatic box-like structures that are placed side by side horizontally and mechanically attached to form at least a length and width of one ceiling and at least a length and width of one floor in the building infrastructure;
[0013] FIG. 6 depicts a perspective view of the third selection of the plurality of prismatic box-like structures that are placed side by side vertically and mechanically attached to form a plurality of walls for the building infrastructure;
[0014] FIG. 7 depicts an exploded view of one prismatic box-like structure;
[0015] FIG. 8 depicts an exploded view of mass loaded vinyl (MLV) attached to at least one side of the walls of the prismatic box-like structures;
[0016] FIG. 9 depicts a front and a back exploded view of the square-shaped steel bars that are secured in each perpendicular corner of each prismatic box-like structure;
[0017] FIG. 10 depicts an exploded view of two configurations of the square-shaped steel bars and a method for attaching two prismatic box-like structures vertically;
[0018] FIG. 11 depicts an exploded view of a method for attaching two prismatic box-like structures horizontally; and
[0019] FIG. 12 depicts a perspective view of a finished building built in accordance with the invention and how a space within each prismatic box-like structure can be used for storage.
DETAILED DESCRIPTION
[0020] A detailed description of the claimed invention is provided below by example, with reference to embodiments in the appended figures. Those of skill in the art will recognize that the components of the invention as described by example in the figures below could be arranged and designed in a wide variety of different configurations. Thus, the detailed description of the embodiments in the figures is merely representative of embodiments of the invention, and is not intended to limit the scope of the invention as claimed.
[0021] FIG. 1 depicts a perspective view of one embodiment of a building 100 built in accordance with the invention. As shown, the outer finish of building 100 may be a façade with any variety of architectural embellishments. Inside the outermost walls, though unseen, is the building infrastructure comprising a plurality of conjoining modular building segments.
[0022] FIG. 2 depicts building infrastructure 200 , which comprises a plurality of conjoining modular building segments, the plurality of conjoining modular building segments being prismatic box-like structures.
[0023] FIG. 3 depicts building infrastructure 300 , but each individual prismatic box-like structure 310 is visible. Building infrastructure 300 further depicts a first selection 320 of the plurality of prismatic box-like structures, placed side by side horizontally and mechanically attached to form a length and width of at least one ceiling. A second selection 330 of the plurality of conjoining modular building segments are placed side by side horizontally and mechanically attached to form a length and width of at least one floor. A third selection 340 of the plurality of conjoining modular building segments are placed side by side vertically and mechanically attached to each other and to at least one ceiling and at least one floor to form a plurality of walls for the building infrastructure.
[0024] FIG. 4 depicts perspective views of different embodiments of the prismatic box-like structures. The prismatic box-like structures may comprise different shapes, including shapes like cubic 4 A, rectangular 4 B, triangular 4 C, and hexagonal 4 D. Each prismatic box-like structure comprises at least three walls 400 . Each prismatic box-like structure comprises an apparatus suitable for disposition of a stored item. A space 410 inside the walls measures at least one cubic foot. It is crucial that the space within the walls be at least one cubic foot in order that items can be stored within the prismatic box-like structures, thus maximizing space and overall efficiency and sustainability of the building infrastructure.
[0025] FIG. 5 depicts a single prismatic box-like structure 500 from the first and second selections of prismatic box-like structures that are placed side by side horizontally and mechanically attached to form at least a length and width of at least one ceiling and a length and width of at least one floor. Height, length, and width measurements of the first and the second selection of prismatic box-like structures are about four feet and one and one-half inch (1.295400 meters). A top wall or a bottom wall may be removed for storage purposes. A volume of the space 510 within the walls of the first selection of prismatic box-like structures measures about 64 cubic feet (1.81228 cubic meters). The volume of the space 510 within the walls is crucial in order that items can be stored within the prismatic box-like structures, thus maximizing space and overall efficiency and sustainability of the building infrastructure. The items that may be stored in the space within the walls include furniture, appliances, utilities, food, clothing, personal items, and so forth.
[0026] A single prismatic box-like structure 600 depicted in FIG. 6 is one of a plurality of prismatic box-like structures that comprise the third selection of prismatic box-like structures that are placed side by side vertically and mechanically attached to each other and to at least one ceiling and at least one floor to form a plurality of walls of the building infrastructure. In one embodiment, at least one wall of the third selection of prismatic box-like structures comprises an optically transparent or semi-optically transparent material, such as glass. The third selection of prismatic box-like structures 600 measure about fourteen feet (4.2672 meters) in height. Length and width measurements are about four feet and one and one-half inch (1.295400 meters). In one embodiment, prismatic box-like structure 600 is constructed from three prismatic box-like structures 610 , 620 , and 630 joined together, each having only five full walls 640 , with the front wall 650 open for a purpose of storing items such as kitchen appliances, elevators, or bathroom hardware. A volume of the space 660 within the walls of the third selection of prismatic structures measures about 224 cubic feet (6.34297 cubic meters). The volume of the space 660 within the walls is crucial in order that items can be stored within the prismatic box-like structures, thus maximizing space and overall efficiency and sustainability of the building infrastructure. A variety of items may be stored in the prismatic box-like structures, including furniture, appliances, utilities, elevators, carousels, food, clothing, toilets, tubs, showers, beds, movable walls, and so forth.
[0027] FIG. 7 depicts one embodiment of a single prismatic box-like structure 700 . In one embodiment, walls 710 of prismatic box-like structure 700 comprise OSB, reinforced OSB, or lightweight OSB. In other embodiments, the walls 710 comprise other engineered materials, such as engineered wood, composite board, particle board, press board, plywood, wood laminate, chip board, gypsum board, cement board, carbon fiber materials, or combinations thereof. In still other embodiments, the walls 710 of prismatic box-like structure 700 comprise an optically transparent or semi-optically transparent material, such as glass, or at least one wall comprises a translucent material. Walls 710 of prismatic box-like structure 700 are joined together by means of metal plates 720 and brackets 740 mechanically secured along the perimeter of the walls. The metal plates 720 are wrapped around two adjoining wall edges and secured with connectors 730 . The connectors 730 may include screws, bolts, rivet nuts, T-nuts, or other durable connectors, some of which are removable, and some of which are not. The walls 710 of the prismatic box-like structures are joined together at top and bottom edges with metal brackets 740 that are secured by connectors 750 .
[0028] Referring to FIG. 8 , a mass loaded vinyl (MLV) material 810 is limply attached to at least one side of the walls 800 of the prismatic box-like structures. The MLV material comprises a thickness of about one-thirty-second (0.079375 cm) to about one-fourth inch (0.635 cm). The MLV is limply attached with connectors 820 and an adhesive. One purpose of the MLV is for blocking sound.
[0029] Referring to FIG. 9 , the walls of the prismatic box-like structures are joined in each perpendicular corner by means of square-shaped steel bars 900 mechanically attached to the walls. The square-shaped steel bars 900 are secured in each perpendicular corner of each prismatic box-like structure, spanning a length of each corner, by bringing edges of two adjoining walls 910 and 920 together at approximately a ninety-degree angle, touching two adjacent sides of the square-shaped steel bars 900 . This configuration is secured by wrapping a metal plate 930 around the square-shaped steel bars 900 and edges of two adjoining walls 910 and 920 . The metal plate 930 is secured with connectors 950 . At top and bottom edges of the walls, this configuration is secured using metal brackets 940 and connectors 950 .
[0030] As depicted in FIG. 10 , the square-shaped steel bar may comprise one of two configurations, a first configuration 1010 having a protrusion that extends beyond the prismatic box-like structure in length, and a second configuration 1020 having a hollow indentation. The two configurations comprise male and female ends of the square-shaped steel bar. The prismatic box-like structures that are vertical and used to form the plurality of walls of the building infrastructure, such as prismatic box-like structures 1030 and 1040 , are mechanically attached by being stacked and pinned by inserting the first configuration 1010 into the second configuration 1020 . The second configuration 1020 also allows for telescoping, so that, in one embodiment, top walls of the prismatic box-like structures can be raised or lowered, allowing access to the space within the walls of the prismatic box-like structures. The space within the walls can be used for storing a variety of items.
[0031] Referring to FIG. 11 , prismatic box-like structures 1110 and 1120 are mechanically attached horizontally by being fastened together with connector 1130 spanning between two areas 1140 designated for connecting any two horizontally adjoining prismatic box-like structures. The connectors 1130 may be screwed or fastened by robots, so that this process is automated and can be accomplished very quickly.
[0032] Referring to FIG. 12 , the space within the walls of each prismatic box-like structure 1210 is available for storage. A variety of items may be stored in the prismatic box-like structures, including furniture, appliances, utilities, elevators, carousels, food, clothing, toilets, tubs, showers, beds, movable walls, and so forth.
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A green or sustainable building infrastructure comprising conjoining modular building segments. The purpose of the invention is to increase the precision, quality, and timing of building projects by allowing modular building segments to be constructed in an off-site controlled environment, transported, and quickly assembled on site. The conjoining modular building segments are prismatic box-like structures conjoined in a variety of configurations, each having at least three walls. The prismatic box-like structures are arranged and attached horizontally to create ceilings and floors, and they are arranged and attached vertically to create walls for the infrastructure. Some of the walls may be removed and the space inside each prismatic box-like structure is available for storage. The prismatic box-like structures may have certain dimensions, comprise specific materials, or be constructed or conjoined in specific ways.
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RELATIONSHIP TO OTHER APPLICATIONS
This application is a divisional application of U.S. application Ser. No. 13/438,575, filed Apr. 3, 2012, which application is incorporated by reference for all purposes and from which priority is claimed.
BACKGROUND
Residential wooden stairs are usually purchased as a prefabricated unit with the risers (vertical elements) and the treads (horizontal elements) fastened to stringers in their final form. In the prior art, these prefabricated staircases are installed in, for example a home construction, and construction on a home continues with workmen walking up and down the staircase to perform their construction tasks. Even if the treads (the horizontal surfaces) are covered with a protective material, they can suffer damage during the construction process.
After all major construction in the home is completed, workmen must come in and finish the staircase by sanding the treads and risers and applying appropriate finish coatings to them. If the risers and treads are damaged in any way because of months of foot traffic, the refinishing process takes longer and is more expensive.
BRIEF SUMMARY
Embodiments of the invention to be searched avoid the problem by installing a prefabricated staircase where the risers and treads are not the final materials to be used. Rather the tread is a “sub-tread” and the riser is a “sub-riser” meaning that another surface will be applied on top of the sub-tread and sub-riser in order to finish the staircase.
The present invention solves prior art problems by creating a prefabricated staircase that is “double routed” to allow an initial set of sub-treads and sub-risers to be installed. The purpose of the double routing is to provide additional space for a final capping tread and riser to be installed by inserting the capping riser or tread in the routed space. This provides for a simpler installation process where little to no cutting and or fitting of the final treads and risers (referred to herein as “capping treads” and “capping risers”) is required.
The double routing is made to a depth that permits a capping tread or riser to be inserted into the routed space and shifted to the right or left in a small amount so that the tread remains in the routed space on either side of the staircase. This allows for a finished look without having to butt the final tread and riser up against the side of the stringer that is secured to the sub-risers and sub-treads. Once the capping riser and/or capping tread is in place, it is secured to the sub-riser or sub-tread (as appropriate) via adhesive or mechanical means (or both) known in the art.
This has several advantages. First, a fully functional staircase is installed so that workmen can proceed with finishing the home or structure without having to worry about whether the finished treads or finished risers are being damaged
Second the owner can decide what finish and material to apply to the final tread or riser that is applied over the sub-tread or sub-riser and those capping risers and treads can simply be installed over the sub-tread and sub-riser after all major construction is completed thereby avoid any potential for damage to the capping risers and treads while keeping the stair compliant with appropriate building codes. Other advantages of the various embodiments disclosed herein will be apparent to those of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a Closed stringer routing used on Boxed and Single Open staircase designs of an embodiment;
FIG. 2 illustrates a finished installation of treads and risers into a double routed stringer;
FIG. 3 illustrates a view of an embodiment having a sub-tread installed in stringers;
FIG. 4 illustrates a view of an embodiment having sub-tread and capping tread installed in stringers;
FIG. 5 illustrates an enlarged view of the finished installation of sub-tread and sub-riser;
FIG. 6 illustrates the final installation of a sub-riser and the capping riser;
FIG. 7 illustrates a side view of an embodiment of an assembled staircase;
FIG. 8 illustrates an embodiment of the routing for sub-risers and sub-treads;
FIG. 9 illustrates an embodiment of the open riser and tread layout; and,
FIG. 10 illustrates an embodiment of a staircase having the double routed channels of differing depths.
DETAILED DESCRIPTION
Referring now to FIG. 1 a closed stringer routing embodiment is illustrated. The stringer 102 forms the main support for a set of stairs. A stringer is the long piece that the stair treads and risers attach to on either side, and which goes diagonally up the wall. In an embodiment, stringer 102 comprises a double-routed channel shown generally as 104 . The double routed space comprises a routed channel wide enough to support a tread and sub-tread (in the horizontal orientation), and a riser and sub-riser (in the vertical orientation) and as further illustrated in FIG. 2 below). The double-routed channel 104 comprises a sub-tread 106 and sub-riser 108 routing areas. Note in this FIG. 1 the illustration is to the routed area. In addition, the double-routed channel 104 further comprises a routing space for a capping tread 110 and a routed space for a capping riser 112 . Additionally, the double-routed channel 104 also comprises sufficient room for the insertion of wedge blocks that, in an embodiment, support the sub-tread and sub-riser. These wedge blocks will be discussed below. The double routed spaces are located on the stringer at varying and in some cases uneven locations that eventually provides for the capping treads and risers to be positioned in the staircase such that applicable building codes are met. Double routing as illustrated herein is accomplished using a model CSR-750CNC Stair Router available from US Concepts although this is not meant as a limitation. Other CNC routers may also be appropriate for the double routing illustrated herein.
FIG. 2 illustrates a finished installation of treads and risers into a double routed stringer. The double-routed channel ( FIG. 1 , 104 ) is illustrated together with a sub-riser 202 , a sub-tread 204 , a capping riser 206 , a capping tread 208 , sub-tread wedge blocking 210 and a sub-riser wedge blocking 212 .
In normal practice of an embodiment, a staircase is constructed using 2 stringers, each of which has double routed channel ( FIG. 1 , 104 ) for risers, sub-risers, treads and sub-treads. However, the staircase is initially constructed as a prefabricated staircase or as a staircase kit which can be field assembled into a unit comprising double routed channels and sub-treads and sub-risers. The application of capping treads and risers occurs later as discussed below.
FIG. 3 illustrates the installation of a sub-tread 302 in stringers 102 A and 102 B. Double-routed channel 104 allows sub-tread 302 to be recessed and secured into each stringer, 102 A and 102 B. Because the double-routed channel 104 is double routed, there is sufficient room left for the placement of a capping tread. Channel spaces for capping treads are illustrated as 304 and 306 . During construction of the staircase, multiple sub-treads are secured into the stringers 102 A, and 102 B in as many steps as necessary to span a particular vertical distance. For purposes of this Figure, a single sub-tread is illustrated.
FIG. 4 illustrates the installation of the capping tread. Once the sub-treads 302 and stringers 102 A and 102 B are assembled, the installation of a capping tread can occur. The capping tread 402 is cut to a length that is less than the full length of sub-tread 302 . This allows the capping tread 402 to be inserted into the remaining open section of the double-routed channel 304 . Because the capping tread is shorter than the full length of sub-tread 302 it can be inserted fully into the double-routed channel for capping-tread 304 to house the capping tread lowered into place and then shifted laterally so that the capping tread is surrounded by and contained in the double routed capping tread channel yet still is embedded in stringers 102 A and 102 B. The capping tread 402 can then be secured to sub-tread 302 with adhesives or fasteners known in the art.
FIG. 5 illustrates an enlarged detail of the final installation of the capping tread 402 and sub-tread 302 . In this illustration stringer 102 A is shown with the double-routed channel 304 (illustrated in phantom) with sub-tread 302 installed into stringer 102 A. Capping tread 402 is shown in its final position where it has been initially inserted into double-routed channel 304 and moved laterally to fit partially into double-routed channel 304 of stringer 102 A and double-routed channel 306 of stringer 102 B (not shown). While this leaves a slight unfilled portion 406 of double routed channel 304 , the capping tread 402 is still completely embedded in and surrounded by stringer 102 A and similarly in stringer 102 B.
FIG. 6 illustrates the final installation of a sub-riser and the capping riser. In this Figure, sub-riser 602 is installed in stringer 102 A in the same manner described above with respect to the sub-treads. Once the staircase is fully fabricated with sub-risers and sub-treads, capping risers and capping treads can be installed. As illustrated in FIG. 6 sub-riser 602 is installed in double routed riser channel 604 . Sub riser 602 is illustrated in horizontal hatching. Capping riser 603 can then be inserted into double routed riser channel 604 and then moved laterally to engage a similar channel in stringer 102 A. Thus, while capping riser 603 does not fully occupy double-routed riser channel 604 it is still surrounded by stringer 102 A and similarly on the opposite side is surrounded by stringer 102 B (not shown).
FIG. 7 illustrates a side view of the assembled staircase of an embodiment. In this embodiment, sub-tread 702 is in place in the double routed tread channel. A capping tread 704 is installed in the double routed tread channel over the top of sub-tread 702 and the combination of sub-tread 702 and capping tread 704 is held in place by tread wedge blocking 712 . Similarly, sub-riser 706 is in place in the double routed channel with capping risers 708 installed on top of sub-riser 706 . The combination of sub-riser 706 and capping riser 708 are held in place by sub-riser wedge block 710 .
FIG. 8 illustrates the routing for sub-risers and sub-treads. Routing channel for sub-riser 806 is illustrated together with the routing channel for capping riser routing channel 802 . Similarly the sub-tread routing 808 is illustrated together with the capping tread routing channel 804 . It should be noted that while capping tread routing channel 804 is shown with a “bullnose” design, this is merely a design choice. The capping tread routing channel 804 may have other edge designs that equally fall within the scope of the various embodiments illustrated herein.
In an embodiment, the first riser of a staircase of the various embodiments illustrated herein will be shorter than other risers in the staircase by an amount equal to the thickness of the first capping tread. That thickness of the capping tread will add to the height of the first step. In order to have all steps of a similar height, it is therefore necessary to have the first riser of the staircase be shorter by the same amount as the thickness of the first capping tread. Thereafter, all riser heights will be the same for subsequent steps in the staircase.
It should be noted that multiple configurations of staircases falling within the various embodiments illustrated herein are possible. For example, and referring to FIG. 9 an open riser and tread layout is illustrated. In this case the floor level stair stringer is set on floor level 906 . However the first sub-riser height 902 will be will be shorter by the same amount as the thickness of the capping tread. Thus for example, and without limitation, in a sample staircase the first riser height would be 7⅜ inches. All successive sub-riser heights 904 will be 8 inches in height. When the first riser 902 has a ⅝ inch thick oak tread installed at the top of the riser, this will make that riser height 8 inches. Thus each step will have the same height. In this fashion the “first staircase step” height will be the combination of the first riser height plus the thickness of the first sub-tread, plus the thickness of the first capping tread.
Referring now to FIG. 10 , a staircase is illustrated having the double routing channels of differing depths. In this embodiment, stringer 1002 comprises double routed channels for sub-treads, sub-risers capping treads and capping risers. It should be noted that it is not a requirement that the depth of the routed channels be the same. For example sub-riser channel 1008 may, in an embodiment, be ½ inch deep. Similarly the sub-tread channel 1010 may also be ½ inch deep. However in this embodiment, the capping riser channel 1006 may only be ¼ inch deep. Similarly the capping tread channel 1004 may also be only ¼ inch deep. Other combinations of channel depths are also considered to be within the scope of the various embodiments disclosed herein.
A method for creating and building a staircase has been described. It will be understood by those skilled in the art that the present invention may be embodied in other specific forms without departing from the scope of the invention disclosed and that the examples and embodiments described herein are in all respects illustrative and not restrictive. Those skilled in the art of the embodiments illustrated herein will recognize that other embodiments using the concepts described herein are also possible. Further, any reference to claim elements in the singular, for example, using the articles “a,” “an,” or “the” is not to be construed as limiting the element to the singular.
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A staircase and method for producing the same. The staircase is produced by double routing channels for sub-treads and sub-risers and capping risers and capping treads. These sub-treads and sub-risers are assembled into staircase stringers that have pre-routed channels that are sufficient to install sub-treads and sub-risers having a particular thickness and having room for subsequent placement or installation of capping treads and risers by sliding them laterally into the channels created by the double routing of the stringers. This creates a more finished look to be (the) staircase while avoiding damages to the capping treads and risers that might occur during building construction.
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[0001] This application claims foreign priority benefits from Canadian Patent Application 2,515,124 filed Aug. 4, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to a tread member for a staircase, in which the tread member is preassembled from strips of wood material and includes an integral nosing member for covering an existing tread of the staircase.
BACKGROUND
[0003] When finishing traditional stairs with hardwood floor material, it is typical to make use of commercially available elongate wood strips with tongue and groove profiles on respective lengthwise edges thereof. When covering stairs in this manner, the hardwood floor material must be installed on the treads at the same time as a surrounding floor area when the required tools and equipment available by the flooring installer are already available. Careful attention is then further required to protect the stairs from other trades when constructing a building for example. Installation is time consuming as each individual piece must be cut to length then nailed into place as it is installed. A lot of waste is generated as many boxes of material must be opened to find full length straight boards which can be used to span a full length of each tread being covered. When picking through boxes of hardwood floor material, of the type which are commercially available to include various lengths of wood strips, the installer will typically end up with too many leftover short pieces which are either wasted or which are required to be installed on surrounding floor areas. Accordingly higher material costs results for the customer.
[0004] The edge of each tread is required to be finished with a nosing member having a groove along one side for fitting with the tongue and groove connections of the hardwood floor material and a rounded free edge of slightly greater thickness for only partially overlapping the front edge of the tread being covered. The depth of the traditional nosing member is typically only 1 inch in thickness at the free edge so that when used in conjunction with ¾ inch hardwood floor material, the nosing member only covers approximately ¼ inch of the 1½ inch thickness of the conventional material used for the treads. In addition nosing members are only sold in 8 foot lengths which means that on a traditional 3 foot wide staircase, 2 feet of every 8 foot length is typically wasted.
[0005] Typical tongue and groove hardwood floor material also includes a bevel along the edges which requires refinishing by a professional due to the difficult sanding and filing required to refinish beyond the thickness of the bevel in order to have a flush finished floor surface.
[0006] Due to the minimal overlap of the nosing along the front of each tread, conventional nosing members tend to loosen or teeter as the nosing is made from a separate piece added onto the flooring boards and anchored in place separately. The resulting covered treads of the stairs are thus formed of several pieces which in time will move and result in gaps in the step. In addition any warping or cupping in the construction material used to form the treads will translate into a similar cupping of the hardwood floor materials supported on the tread as the individual strips are free to move relative to one another with the warping of the treads. The resulting movement is evident by the squeaking noises which are common to staircases which are covered with traditional hardwood floor material.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention there is provided a preassembled tread member for use on a staircase comprising a plurality of existing treads joined by respective risers, the tread member comprising:
[0008] a rectangular panel having a bottom side defining a length and a width of suitable dimension for spanning a top side of one of the existing treads, the panel comprising a plurality of elongate strips of wood material joined to adjacent ones of the strips by adhesive; and
[0009] a nosing member joined along a lengthwise side of the panel by adhesive, the nosing member including a rear surface which projects downwardly beyond the bottom side of the panel for covering a front edge of the respective existing tread.
[0010] According to a second aspect of the present invention there is provided a method of covering an existing tread on a staircase comprising a plurality of existing treads joined by respective risers, the method comprising:
[0011] providing a plurality of elongate strips of wood material;
[0012] forming a rectangular panel by joining each strip to adjacent ones of the strips using adhesive;
[0013] joining a nosing member along a lengthwise side of the panel by adhesive such that a rear surface of the nosing member projects downwardly beyond a bottom side of the panel; and
[0014] securing the bottom side of the panel onto the existing tread such that the nosing covers a front edge of the existing tread, subsequently to the nosing meber being joined to the panel.
[0015] The tread member according to the present invention is formed of a plurality of strips of wood material and a nosing member which are preassembled into a single integrated laminated piece of material which is simpler to install and which maintains its unitary construction over time to prevent teetering of the nosing member or squeaks and deformations which result from strips of hardwood floor material which are individually mounted in place onto the treads. Due to the simplicity of the installation which does not require a special hardwood floor installation related tools, the tread member can be readily installed by a home owner or an onsite carpenter at the end of a building project to reduce the risk of damage to the stairs by other trades. Only basic tools are required to install the tread member resulting in easier installation and considerable time savings. By preassembling the tread member prior to installation, almost no waste results as the materials can be laminated together at a factory using long pieces of source material cut to near exact length. The stair can be distributed unfinished but pre-sanded so that the top surface is already flush requiring minimal effort and causing minimal mess to the surrounding area when installing as no significant onsite sanding is required other than to remove minor scratches. Preassembly of the nosing ensures that the nosing is properly anchored to the strips of the wood material forming the panel of the tread member and accordingly the nosing does not rely on independent mounting to prevent it from teetering over the life of its installation. By laminating all of the components of the tread member, including the nosing member, the resulting one piece construction covers minor surface imperfections of the tread and squeaking or gaps in the installed tread members are not of concern.
[0016] The nosing member may include a flat rear surface which abuts the lengthwise side of the panel such that a seam between the nosing member and the panel lies in a common plane with the rear surface projecting downwardly beyond the bottom side of the panel.
[0017] The nosing member may project downwardly beyond the bottom side of the panel between 1½ and 1¾ inches, but preferably by 1⅝ inch for fully covering 1½ inch thick existing tread material.
[0018] There may be provided a plurality of screw fasteners joining the nosing member to the rectangular panel, the screw fasteners being inserted through the bottom side of the panel and into the rear surface of the nosing member so as to remain hidden from the top side of the panel or the front side of the nosing member.
[0019] Preferably the nosing member has a depth between the rear surface and a front surface thereof which is less than 1 inch, in the order of ¾ inch such that only a small portion of the assembled tread member is cantilevered in its mounted position on the existing tread.
[0020] A front surface of the nosing member, opposite the rear surface, may include an irregular shaped profile routered therein, by routering the nosing member prior to joining with the panel.
[0021] A top side of the rectangular panel is preferably pre-sanded such that the strips of wood material are flush with one another along the top side, but unfinished, prior to delivery to the customer.
[0022] Each of the strips preferably comprises a cut piece of a hardwood which is less than 12 centimetres in width and which span a lengthwise direction of the pane. Accordingly, each strip of wood material preferably spans a full length of the panel, a full thickness of the panel and only part of a width of the panel.
[0023] One or more strips may include a pattern routered in a top side thereof which spans a full length of the panel. The pattern is preferably routered after assembly and flush sanding of the top sides of the strips.
[0024] One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a partly sectional side elevational view of a staircase upon which the tread member is installed.
[0026] FIG. 2 is a top plan view of the staircase upon which the tread member is installed.
[0027] FIG. 3 is a perspective view of the tread member.
[0028] FIG. 4 is a sectional view of the nosing member.
[0029] FIG. 5A through 5D are sectional views of various profiles of nosing members.
[0030] FIGS. 6A through 6F are top plan views of various examples of routered patterns in the tread member.
[0031] In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
[0032] Referring to the accompanying figures there is illustrated a stair covering kit generally indicated by reference numeral 10 . The kit 10 is particularly suited for covering a set of stairs 12 with hardwood floor material to provide a finished appearance to the stairs.
[0033] The stairs 12 are typically of the type including a pair of elongate stringers 14 which support a plurality of horizontal existing treads 16 spanning between the stringers at vertically spaced positions therealong. Existing risers 18 span vertically between the forward edge of each tread and the rear edge of the next adjacent tread therebelow. The treads are typically manufactured of conventional 1½ inch thick commercially available lumber.
[0034] The kit 10 includes plurality of tread members 20 for covering the existing treads 16 and a plurality of riser members 22 for covering the existing risers of the stairs respectively.
[0035] The tread member 20 comprises a plurality of elongate strips 24 of hardwood floor material which span a full length of the tread member in the order of approximately three feet in a conventional stair case and a full depth of three quarters of an inch. Each strip has a width which is less then twelve centimetres between adjacent side edges thereof. The strips of wood material are formed of solid wood which is laminated to adjacent strips by adhesive to form a rectangular panel having dimensions which span the full top side of the respective existing tread 16 to be covered. Typical panels 26 which are assembled from the strips are generally rectangular having a width of approximately 12 inches and a length of either thirty-seven, forty-nine or sixty-one inches to accommodate three foot, four foot and five foot wide staircases respectively with sufficient additional material to accommodate any misalignment of the existing staircase.
[0036] The strips 24 forming the panel 26 are oriented in the lengthwise direction of the panel to span the full length thereof but only a portion of the width. The side edges of each strip define a perpendicular surface which is flat between the top and bottom sides of the strip. The sides are abutted against the sides of adjacent strips when fastened by adhesive with no additional fasteners being required to assemble the strips into the panel 26 .
[0037] A nosing member 28 is secured along a lengthwise edge 30 of the assembled panel 26 for covering a front edge 32 of the existing tread 16 . The nosing member has a depth of approximately ¾ inch in the widthwise direction of the panel 26 so that the overall width of the assembled tread member is approximately 12¾ inches. The nosing member 28 has a flat rear surface 34 which abuts one of the sides of the strips 24 along the lengthwise edge 30 of the panel such that the flat rear surface 34 projects downwardly beyond a bottom side 36 of the panels by a distance of approximately 1⅝ inches as a result of an overall height of approximately 2⅜ inches. Accordingly a tread of commercially available 1½ inch thick lumber will be fully covered by the nosing member.
[0038] The abutting seam between the nosing member and the strip 24 along the lengthwise edge of the panel is co-planar with the remainder of the rear surface 34 projecting downwardly beyond the bottom side of the panel so that the overall thickness of ¾ inch of the nosing member along with the rear flat surface thereof permits the opposing front surface 38 to be easily routered prior to assembly of the nosing member onto the panel.
[0039] In addition to adhesive which secures the nosing member onto the panel, a castle drill is used to form two sloped bores 40 projecting from the bottom side 36 of the panel near the lengthwise edge 30 to which the nosing is attached. The bores 40 extend at an upward and forward incline towards the nosing member 28 and has a sufficient depth that a screw 42 received therein is fully hidden flush with the bottom surface of the panel so that nothing projects past the bottom side and interferes with mounting of the bottom side on the top side of the existing tread. The internal end of the bore 40 is spaced inwardly from the lengthwise edge 30 mounting the nosing member thereon such that when the screw is received in the bore, the screw overlaps a portion of the last strip 24 of the panel as well as the nosing member into which it projects to ensure a firm grip across the seam therebetween. The screws 42 are inserted through the bores in the bottom side of the panel and subsequently into the rear surface of the nosing member such that the screws are not visible from the top side of the panel or the front side of the nosing member.
[0040] All of the strips 24 are assembled into the panel 26 with the nosing secured thereto by adhesive prior to installation. The preassembled thread member can be sanded smooth on the top and bottom sides thereof once assembled at the factory prior to being received by the customers so that only minimal sanding is required upon installation at the construction site. Also at the factory prior to installation, one or more of the strips 24 may include a pattern 44 which is routered in a top side thereof to span in a lengthwise direction. The pattern is preferably routered after assembly and flush sanding of the adjacent strips and nosing member so that the flush sanding does not remove a significant portion of the routered pattern 44 . A light sanding to remove scratches afterward will not significantly affect the pattern 44 .
[0041] The tread member is distributed to the customer in a form in which the strips and nosing member have been assembled and sanded along the top sides thereof to be flush with one another but without stain or other finishing material being applied thereto so that a customer can customize whatever type of finish is desired in the environment of the installation.
[0042] The riser members 22 comprise panels which are substantially identical to the panels 26 which form a portion of the tread members. Each riser member 22 is thus formed of a plurality of strips 24 which are laminated to one another by adhesive. The strips are similarly oriented in a lengthwise direction.
[0043] In order to install the kit, the tread members are first measured and then cut for mounting in place overtop of the existing treads of the staircase. For each existing tread, the width is measured between the front and back edges thereof and 1 inch is added to this measurement. The additional inch accommodates for the ¾ inch thickness of the nosing plus an additional ¼ inch buffer to accommodate minor misalignments. Any suitable table saw may be used to cut the side edge of the panel forming the tread member opposite the longitudinal edge supporting the nosing member thereon.
[0044] The length of the existing tread between the stringers is then measured to determine the overall length of the tread member. The squareness of the front edge of the tread relative to the stringer is checked before cutting the tread member to length as both ends may require some cutting if the existing the tread is not square to the stringers. Once the length and width of the tread member are cut, the tread member is dry fit into place overtop of the existing tread so that the bottom surface of the panel forming the tread member rests on top of the topside of the existing tread. Any cupping of the top surface of the existing tread is covered by the rigid preassembled panel of the tread member.
[0045] To complete the installation, two strips of double sided, pressure activated tape are applied in a length wise direction at spaced apart positions along the existing tread to span generally between the two stringers. Flooring adhesive is applied between the strips, for example PL 400 adhesive. The tread member is then dropped in place onto the existing tread at which point weight applied to the step will activate the tape to secure the tread member in place until the adhesive sets. In some instances, nails may be used to secure the tread member in place on the existing tread, however these are only required to be small placement nails as the adhesive alone would be sufficient to hold the tread member in place on the existing treads.
[0046] Similar steps are accomplished for mounting each individual riser in place between the adjacent treads. The panel forming the riser member is measured and cut to height and is subsequently measured and cut to length to be first dry fit between an adjacent pair of existing treads. For installation, double sided tape and flooring adhesive is similarly applied to either the existing riser or the riser member being mounted thereon. Pressure will again activate the tape to hold the riser member in place until the adhesive sets.
[0047] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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A tread member for a staircase is preassembled from strips of wood material which are laminated to one another by adhesive to form a panel with an integral nosing member attached thereto. The preassembled tread member need only be cut to width and length for installation on an existing tread of a staircase for covering a staircase with hardwood floor material more quickly and with a better finished result as compared to traditional methods in which individual tongue and groove strips of wood material are attached to the staircase. A riser member comprises a panel formed of strips of wood material laminated together is also provided for covering the existing risers spanning between the adjacent treads of the staircase.
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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 subsea valve apparatus to control the flow of fluid in a pipe. More particularly, this invention relates to a subsea valve that is insensitive to ambient hydrostatic pressure and automatically closes to stop fluid flow in a pipe when a loss of hydraulic operating pressure occurs.
2. Description of the Prior Art
As the production of oil and gas expands to deeper water depths, the use of fixed offshore structures which extend from the sea floor to above the water surface eventually becomes economically infeasible. One of the more practicable alternatives is the use of a subsea production system (see U.S. Pat. No. 3,777,812). However, in deep water environments it is essential that all the valves on a subsea production system used to control the flow of oil and gas be insensitive to the ambient hydrostatic pressures. That is, the operation of the valve under all conditions should not be affected by the local water pressure. In addition, it is important that these valves be fail-safe. If the hydraulic or pneumatic operating pressure fails, the valve should automatically close the pipe or pipeline to prevent further fluid flow.
Pressure insensitive (sometimes referred to as "balanced"), fail-safe valves which close or shut off the flow of fluid in pipelines during the loss of hydraulic operating pressures or the like are known in the art (see, for example, U.S. Pat. No. Re. 30,115). Such underwater valves generally include a piston-operated valve stem which reciprocates within a cylinder to open and close a gate. In a single acting valve, hydraulic pressure or power fluid forces the piston in one direction, commonly referred to as a power stroke, and a spring means returns the piston to its starting position, commonly referred to as an exhaust stroke. In the event the hydrostatic pressure acting on the exposed end of the piston (the difference between the operating pressure and the valve pressure multiplied by the piston stem diameter) is greater than the spring load in the piston operator, the valve will remain in the open position. If an opposing valve stem capable of contacting the valve element is added as illustrated in Reissue 30,115, the unwanted hydrostatic force exerted against the stem is balanced thereby permitting the spring to close the valve even when the ambient pressure is greater than the internal valve pressure. Reissue 30,115 discloses a balanced stem, fail-safe valve system which includes a balancing stem detached from the main valve element but engagable with it, thereby permitting the stem to balance the valve when the hydrostatic pressure is greater than the internal pressure. However, since the stem is detached, the valve operates as a conventional fail-safe valve when the ambient hydrostatic pressure is less than the internal operating pressure.
While fail-safe, pressure insensitive valves such as that disclosed in Reissue 30,115 are available, a need exists for a remotely operable, fail-safe, pressure insensitive valve which can be quickly attached and detached from a pipeline with a subsea manipulator tool or the like. This need is accentuated as oil and gas is produced in deeper water depths requiring the use of subsea valves which are not readily installed, maintained or removed by conventional diving techniques.
SUMMARY OF THE INVENTION
The present invention substantially satisfies the needs discussed above by providing a remotely operable, pressure insensitive valve that is capable of being attached and detached from a submerged pipeline by a manipulator tool and that will close the pipeline when the operating pressure is lost.
Briefly, the valve of the present invention comprises closure means for movement across the pipeline and reciprocating means to move the closure means across the pipeline. The closure means includes a valve element or gate for sealing off the pipeline and a valve stem extending outwardly from the element. The valve also includes means for encasing the valve in a waterproof manner to protect it from the ambient hydrostatic pressure.
More specifically, the valve comprises a housing that engages a receiving or mounting hub of the submerged pipeline and a valve body securably attached to the housing. Internally, the valve is partitioned into at least two end chambers, one within the valve body and a second within the housing at the opposite end of the housing from the valve body. A valve element is supported within the chamber of the valve body. A valve stem is attached to the valve element and extends longitudinally through the housing into the chamber of the housing. The valve stem is hollow thereby permitting fluid communication between the two chambers. In this manner, the pressure in each chamber is equalized and the forces against each end of the valve stem is substantially the same.
As mentioned above, the valve includes a reciprocating or biasing means located within an intermediate chamber between the two end chambers. Preferably, the reciprocating means comprises an annular piston positioned around the valve stem and compression springs positioned around the valve stem within the intermediate chamber. The spring means is positioned so as to longitudinally displace the valve element across the pipeline during a loss of the operating pressure. This provides for a fail-safe mechanism to shut the pipeline off.
Preferably, the reciprocating means also includes pressure means to operably displace the piston longitudinally within the housing in opposition to the force of the compression springs. In this manner, the pressure means and compression springs work in a counterbalancing manner to displace the piston and, therefore, the valve element in a reciprocating manner which thereby opens and closes the pipeline.
Examples of the more important features of this invention have been summarized rather broadly in order that the detailed description which follows may be better understod. There are, of course, additional features of the invention which will be described hereafter and which will also form the subject of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to more fully understand the drawings used in the detailed description of the present invention, a brief description of each drawing is provided.
FIG. 1 is a sectional view of a valve of the present invention wherein the valve is in the open position to permit fluid flow through the pipeline.
FIG. 2 is a sectional view of the valve shown in FIG. 1 wherein the valve is in the closed position to prevent fluid flow through the pipeline.
FIG. 3 is a schematic view of the moving components of the valve of the present invention illustrating the internal forces associated with the operation of the valve.
FIG. 4 is a sectional view of the valve similar to FIG. 2, but attached to the submerged pipeline. FIG. 4 also schematically illustrates the hydraulic components that may be used to operate the valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a valve of the present invention which comprises a housing 10, an actuator end 12 and a valve body 28. The actuator end includes an upper cap 14, a lower cap 16 and a sleeve element 18 therebetween. The upper and lower caps 14 and 16 are held together by screws 20a. The lower cap 16 is secured to the housing 10 by screws 20b (only one of each of the screws 20a and 20b are illustrated in FIG. 1; however, several such screws would be located peripherally about each cap 14 and 16). The housing 10 includes a valve bonnet 22 and a hollow cylindrical member 24 which are preferably integral components. The valve bonnet 22 is attached to the valve body 28 by screws 26 (only one screw 26 is shown in FIG. 1).
The valve of FIG. 1 also includes a lower sleeve 32 which provides a continuously flush outer lower surface for the valve. The lower sleeve is held in place along one edge by a retainer ring 34 and along the other edge by a locking ring 36. The ring 36, which is rotatable with respect to the valve bonnet 22 and body 28, includes threads 38 thereby permitting the engagement of the valve with a mounting hub on the pipeline (see FIG. 4).
Referring still to FIG. 1, the valve body 28 has a cylindrical passageway 30 which forms part of a first chamber 40. The chamber 40 also includes all fluid space within the valve body up to a front face 42 of the bonnet 22. For purposes herein, the term "chamber" means an open region which may vary in size depending on the movement of the internal components of the valve.
The valve includes a valve element 44 having an aperture 45 to open and close the passageway 30. Preferably, the valve element 44 is made up of two gates 44a and 44b separated by a fluid gap 31. A bifurcated gate system is preferred because when the passageway 30 is closed (see FIG. 2), the high pipeline pressure on one side of the valve body will affect only the downstream gate. The other gate on the high pressure side of the pipeline will usually be substantially friction-free. The operation of a bifurcated gate system is discussed in greater detail below. For purposes of the operation of the valve, the valve element 44 does not need to be bifurcated. Indeed, a single gate having a single aperture for alignment with the passageway 30 is sufficient.
The valve also includes a self-sealing system 33. The self-sealing system 33 ensures that a fluid-tight seal exists between the valve body 28 and the valve element 44. An example of a suitable self-sealing system is that manufactured by the McEvoy Oil Field Equipment Company and described at page 4608 of volume 3 of the Composite Catolog of Oil Field Equipment and Services by World Oil, 1978-79 edition.
The valve element 44 is supported within the first chamber 40 by lifting lugs 46. The lifting lugs (such as that manufactured by McEvoy and illustrated in valve Model C described at page 4610 of volume 3 of the Composite Catalog of Oil Field Equipment and Services by World Oil, 1978-79 edition) are connected to a valve stem 48. The valve stem extends from the first chamber 40, through an aperture 58 of the bonnet 22, an aperture 17 of the lower cap 16 and into a second chamber 50 at the other end of the valve. The second chamber 50 is formed by a pressure cap 52 secured between the upper and lower caps 14 and 16.
The valve stem 48 includes a hollow passageway 54 which extends throughout its entire length. The passageway 54 provides fluid communication between the first chamber 40 and the second chamber 50. In this manner, the pressure acting against the end of the valve stem 48 in the first chamber 40 is substantially the same as the pressure against the other end of the valve stem 48 in the second chamber 50. The valve stem 48 does not need to be a separate component from the valve element 44 and the lifting lugs 46 for purposes of this invention. The stem, lifting lugs and element (or gate) may be an integral component.
When a bifurcated gate system is used, as previously discussed, compression springs are located between the gates 44a and 44b to maintain the gates against the sides of the sealing system 33. Compression springs are not shown in FIGS. 1-4, but they are illustrated on the gates of valve Model C at page 4610 of volume 3 of the Composite Catalog and discussed in note 13 at page 4611 of volume 3 of the Composite Catalog. When the passageway 30 is closed by the gates 44a and 44b (see FIG. 2), one side of the passageway 30 will have a higher pipeline pressure than the other side. The compression forces of the springs between the gates are chosen so that the gate immediately adjacent the high pressure side of the passageway 30 is displaced slightly. This permits the high pressure to enter the first chamber 40, passageway 54 and second chamber 50. However, the sealing system prevents the high pressure from leaking past the other gate into the low pressure side of the passageway 30 (see discussion of the sealing system at page 4608 of volume 3 of the Composite Catalog).
The valve also includes a reciprocating system 55 for operably moving the valve stem 48 and, therefore, the valve element 44 across the passageway 30. The reciprocating system is within a third or intermediate chamber located within the cylindrical member 24 and between the lower cap 16 and the valve bonnet 22.
The reciprocating system includes an annular piston 56, attached to the valve stem 48, and a spring cartridge. The spring cartridge comprises two mounting heads 60, inter-connected by two sliding sleeves 62a-b, and three concentric helical springs 64a-c mounted in compression between the heads 60. Thus, the piston 56 is biased outwardly with respect to the valve body 28. The sleeves 62a-b prevent the full extension of the springs 64a-c when the screws 20a and 20b and the caps 14 and 16 are removed. Due to the springs cartridge, the springs can be maintained in a pre-stressed condition for ease of assembly and disassembly.
Referring still to FIG. 1, the valve further includes a conduit 65 which extends from a first compartment 66 of the intermediate chamber, through the wall of the cylindrical member 24, the valve bonnet 22 and into the valve body 28. The first compartment 66 varies in size and is defined to be between a first face 68 of the piston and the lower cap 16. The conduit 65 terminates into a quick-disconnector 71 such as model MJC69307-12 manufactured by the Aeroquip Corporation of Jackson, Mich.
The valve also includes a second conduit 70 which extends from a second compartment 72 of the intermediate chamber (the second compartment 72 also varies in size and is defined to be beteen a second face 74 of the piston and the valve bonnet 22), through the valve bonnet 22 and valve body 28 into a quick-disconnector 73 similar to quick-disconnector 71. For reasons of clarity, the conduits 65 and 70 and quick-disconnectors 71 and 73 are shown 90° out of phase in FIGS. 1, 2 and 4. Actually, these conduits are quick-disconnectors are aligned co-axially with the valve system 48 so that the conduits need not include a U-shaped section to pass around the passageway 30.
Preferably, the valve also includes pressure seals 77a-c to maintain the pressure integrity of the chambers 40 and 50 and the compartments 66 and 72. The seals 77a-c are used to prevent leaks between the chambers and compartments along the outer surface of the valve stem. Such seals should be located between the first chamber 40 and the second compartments 72 on the inner wall of the bonnet at aperture 58, between the first and second compartments 66 and 72 on the inside surface of the piston 56, and between the first compartment 66 and the second chamber 50 on the inner walls of the lower cap 16 and the pressure cap 52.
As noted above, the valve of FIG. 1 is in the "open" position. The piston 56 is illustrated in its "inward" position contacting a lip 76 of the cylindrical member 24. The lip 76 prevents further inward displacement of the piston and forms a metal-to-metal seal with the shoulder of the piston. The lip 76 limits the maximum stroke of the piston, valve stem and valve element. In order to aid quick closing of the valve when the operating pressure in compartment 66 is lost, the piston may include an orifice 69 which permits a relatively small leak between the compartments 66 and 72 when a metal-to-metal seal beteen the lip 76 and the shoulder of the piston is not achieved.
FIG. 2 is similar to FIG. 1 except that the piston 56 is in its "outward" position, contacting the bottom surface 82 of the lower cap 16. The valve stem 48, lifting lugs 46 and valve element 44 are advanced outwardly with respect to the valve body 28, closing the passageway 30.
To advance the valve element 44 across the passageway 30, hydraulic or pneumatic pressure is introduced through the conduit 65 into the first compartment 66 (see FIG. 1). When the pressure force, within the first compartment acting against the first face 68 of the piston, exceeds the compressive force of the springs 64a-c and the reservoir pressure, within the second compartment 72 acting against the second face 74 of the piston, the piston moves inward. In this manner, the valve element 44 is also advanced inward and the passageway 30 is opened.
FIG. 3 is an enlarged schematic view of the major moving components of the valve except for the valve element 44 which has been removed for clarity. The hollow passageway 54 provides for the same pipeline pressure (P p ) to be exerted on both ends 104 and 106 of the valve stem 48. Since the second chamber 50 is isolated from the ambient hydrostatic pressure (P a ) and since the pipeline pressure (P p ) is the same on both ends of the valve stem, the force (F p , not shown in FIG. 3) against both ends of the valve stem will be the same provided the cross-sectional areas of both ends of the valve stem are the same. This is the pressure balanced feature of the valve. And, as discussed above, the valve is pressure balanced even when the passageway 30 is closed because the bifurcated gate system admits pressure from the high pressure side of the passageway 30 only. The lifting lugs 46 will not prevent pressure in the first chamber from contacting the entire cross-sectional end area of the valve stem because the connection between the valve stem and lifting lugs is a loose fitting lug-in-groove connection. If the valve stem, lifting lugs and valve elements are manufactured as an integral component, as mentioned above, the geometry of the valve stem is chosen so that the cross-sectional end area of the valve stem within the first chamber is substantially the same as the cross-sectional end area of the valve stem within the second chamber.
Referring still to FIG. 3, to move the valve element 44 inward, operating pressure (P o ) is introduced into the first compartment 66. Once the operating force (F o , not shown in FIG. 3 but resulting from the operating pressure, P o , acting against the first face 68) exceeds the spring force (F s ) and the reservoir force (F r , not shown in FIG. 3 but resulting from the reservoir pressure, P r , acting against the second face 74), the piston is advanced inwardly. Thus, the valve stem and element are also advanced inwardly to open a pipeline 102 to fluid flow. Because the valve stem is protected from the ambient pressure (P a ) by the pressure cap 52, a large hydrostatic pressure will not influence the overall operation of the valve. Thus, the piston is displaced inward when:
F.sub.o >F.sub.s +F.sub.r (1)
The valve is referred to as being fail-safe because the valve closes any time the operating pressure (P o ) is lost. Loss of operating pressure causes the piston to advace outward due to the force of the spring which is the only unbalanced force. Any friction between the valve element 44 and valve body 28 which might dampen the biasing of the springs 64 is minimized by the friction-reducing effect of the self-sealing system 33, previously discussed.
FIG. 4 illustrates the engagement of the valve to a mounting hub 100 of the pipeline 102. FIG. 4 is substantially similar to FIG. 2 except that the valve is rotatably connected to the mounting hub by the locking ring 36 and the hydraulic operating components are also illustrated schematically.
The mounting hub 100 includes a passageway 30a which is an extension of the passageway 30 in the valve body 28 and of the interior of the pipeline 102. The mounting hub may include a flange 107 which is bolted to a matching flange 109 of the pipeline. Alternatively, the mounting hub may be an integral component of the pipeline (not shown).
FIG. 4 also illustrates the hydraulic components which could be used to operate the present invention. The operating pressure (P o ) is supplied by a pump 110 which charges a hydraulic accumulator 112. The accumulator maintains a pre-selected operating pressure. In normal operation, the operating pressure passes from the accumulator or pump, if the accumulator is being charged, through a conduit 118, a two-phase valve 114, a conduit 118' (which extends through the mounting hub to the quick-disconnector 71), conduit 65 and into the first compartment 66. The piston is displaced inwardly when the operating force (F o ) exceeds the spring force (F s ) plus the back-up reservoir force (F r , see equation (1)).
The hydraulic system also permits the evacuation of excessive reservoir pressure within the second compartment 72. The conduit 70 (which extends from the second compartment 72 through the bonnet 22) connects with a conduit 120 by means of the quick-disconnector 73. The conduit 120 passes through the mounting hub 100 and the two-phase valve 114 to a reservoir equalizer 116. The reservoir pressure within the second compartment 72 is maintained at ambient hydrostatic pressure (P a ) by the reservoir equalizer 116. Since the reservoir is maintained at ambient pressure, the operating pressure must exceed the ambient pressure (not to mention the force of the springs) to displace the piston. Thus, the hydraulic system is capable of balancing ambient pressure on both sides of the piston and capable of eliminating the influence of the ambient pressure on the housing at substantially the same time. Alternatively, the reservoir equalizer 116 may be housed in a pressure vessel (not shown) and maintained at less than ambient pressure. This would then require a lesser operating pressure to displace the piston inward.
With a loss of operating pressure or other emergency, the two-phase valve 114 automatically shifts under the bias of a spring (not shown) to its other position. In this position, the operating pressure in the conduit 118 flowing from the pump 110 or the accumulator 112 is blocked. Thus, the operating pressure remaining in the first compartment 66 is exhausted through the conduit 120 along with the reservoir pressure in the second compartment 72, which is exhausted through the conduit 118', into the equalizer 116. Since the pressures in the compartments 66 and 72 are balanced, the unbalanced spring force biases the piston outward, closing the pipeline off.
The valve is capable of being remotely installed and removed by a manipulator tool. an example of such a manipulator tool is reference numeral 103 in U.S. Pat. No. 3,777,812 (see also column 4, lines 24 to 44 of U.S. Pat. No. 3,777,812).
In a normal installation, the tool grasps the valve housing and initially positions the valve body adjacent to the opening of the mounting hub 100. Since it is necessary that the correct quick-disconnectors (71 or 73) engage to properly operate the hydraulic system, a nose 130 of the valve body 28 is fabricated in a rectangular or similar cross-sectional shape so that it will fit into an open channel 122 of the mounting hub in only one or two positions. If two positions are possible, the operator of the manipulator tool would initially position the valve, once adjacent to the mounting hub, so that the correct quick-disconnectors would engage when the nose 130 of the valve body is fully extended into the channel 122. The manipulator tool would then rotate the locking ring 36 engaging the threads 38 and securably fastening the valve to the mounting hub. To remove the valve from the mounting hub, the same procedure would be performed in the reverse order.
The valve has been described in terms of a preferred embodiment. Modifications and alternations to this embodiment will be apparent to those skilled in the art in view of this disclosure. It is, therefore, intended that all such equivalent modifications and variations fall within the spirit and scope of the present invention as claimed.
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A pressure insensitive, fail-safe subsea valve is disclosed. The valve is manipulator operable for deep water application and does not require conventional diving techniques to install, maintain or remove. The valve is pressure balanced by employing a hollow valve stem which equalizes the pressure on both ends of the stem.
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CROSS-REFERENCES TO RELATED APPLICATION(S)
This application is an expansion of Disclosure Document No. 099,762, filed Apr. 8, 1981.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to devices for suspending plants in sunlet areas, and more specifically to frames adapted to be attached to the inside of window frames for suspending potted houseplants adjacent to the glass pane.
2. Description of the Prior Art
A number of plant holders are known in the art. U.S. Pat. No. 172,011 discloses a horizontal rail permanently secured to each side of the window frame and having sliding pot supports disposed thereon. U.S. Pat. No. 328,926 discloses a set of rings for supporting frusto-conical pots in a cantilevered position in front of the window sill. U.S. Pat. No. 342,476 discloses a vertical pole supported by horizontal rods attached to brackets on the window frame and in turn supporting radial clusters of pot-supporting disks. U.S. Pat. No. 2,051,241 discloses a shelf suspended by hooks from the top rail of the lower window sash. U.S. Pat. No. 3,007,582 discloses screw-extensible vertical poles, with extending pegs, for car windows. U.S. Pat. No. 3,978,612 discloses a bracket affixed to the top rail of the lower window sash and pivotally supporting rod members terminating in hooks. U.S. Pat. No. 4,068,761 discloses a vertical spring-loaded pole which stands on the window sill and provides projecting pegs for supporting plants. However, most conventional plant holders suffer from the defect that they interfere with the opening and closing of the window or with the placement of curtains and draperies. Many of them also do not adapt to different sizes of windows.
SUMMARY OF THE INVENTION
Accordingly, a primary object of the present invention is a framework for supporting plants which does not interfere with normal operation of the window and placement of curtains. Another object of the invention is to make a plant holder which adjusts to fit windows of different sizes. A further object of the invention is to provide a plant holder which collapses into a small space for storage or transport. Yet another object of the invention is to provide plant holders which can be connected together in series to accomodate double or triple windows.
To accomplish these and other objects, the present invention has among its many features a trapezoidal array of telescoping diagonal members pivotally connected together. The top corner of the trapezoid is suspended by a chain from an L-shaped bracket attached to the vertical face of the top of the window frame. The left and right corners of the trapezoid are secured to brackets screwed into the outside vertical face of the window frame which is perpendicular to the plane of the wall surrounding the window. The top and bottom corners of the trapezoid are each provided with a depending hook for supporting a flowerpot on straps or wires.
Each diagonal member comprises a central section and two end sections. Each central section is provided with a depending hook or ring for supporting another flowerpot. Thus, the framework is capable of supporting at least six different plants in a stepped configuration, or more, depending upon the number of hooks placed in each diagonal member.
The end sections of the diagonal members are adapted to telescope with the middle sections, so that the trapezoid will fit wider or narrower windows. In addition, since the diagonal members are pivotally interconnected, the height/width proportions of the trapezoid can be varied for proper fit. The vertical placement of the trapezoid in relation to the window frame can be varied by choosing a longer or shorter chain between the top mounting bracket and the top corner of the trapezoid.
BRIEF FIGURE DESCRIPTION
These and other objects, features and advantages of the invention will appear from the following description of a preferred embodiment, as shown in the attached drawings, in which:
FIG. 1 is a front view of the framework and brackets of the present invention, mounted on a window frame;
FIG. 2 is an enlarged, cross-sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is an enlarged cross section taken along the line 3--3 of FIG. 1;
FIG. 4 is a cross-sectional view of a tapered window frame and side mounting brackets attached thereto; and
FIG. 5 is an end view of a side mounting bracket, taken along line 5--5 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a plant hanger framework 10 mounted on a conventional rectangular window frame 12, which may surround either a fixed pane of glass or movable upper and lower sashes (not shown). The framework 10 is preferably trapezoidal or diamond-shaped and is suspended by a chain 14 from a top mounting bracket 16. In its preferred form the framework is square.
As shown in FIG. 2, bracket 16 comprises two L-shaped angle members 17, 19 with screws 18 extending through their short legs for securing them to top plank 20 of window frame 12. As detailed in FIG. 5, there is a longitudinal slot 22 along the length of horizontal long leg 21 of member 17. A hook 24, having threads along its straight portion, is held vertically in slot 22 by a pair of nuts 26, 27 having diameters greater than the width of slot 22, which are tightened adjacent the upper and lower surfaces of bracket 16 on the threads of the hook 24 until they fasten the hook immovably in the bracket 16. By temporarily loosening either or both nuts 26, 27, the hook 24 can be moved toward or away from window frame 12 to place the framework 10 in the desired position.
As shown generally in FIG. 1, the trapezoidal framework 10 comprises four diagonal members 28, pivotally interconnected by ear brackets 30. As shown in FIG. 4, topmost ear bracket 32 includes a horizontal planar surface 34 pierced by a hook 36 projecting vertically upward and a hook 38 projecting vertically downward. Upward hook 36 fits through and is preferably crimped around the bottom-most link of chain 14 to support the framework 10 on the top mounting bracket 16. Downward hook 38 is adapted to receive straps or wires from a hanging flowerpot 40 or the like. The hooks 36 and 38 may be secured to the ear bracket 32 by a pair 42 of nuts and lock washers.
Ear bracket 32, in addition to the planar section 34, further comprises depending left and right ears 44. These ears are preferably integrally formed with planar section 34 and project to the left and right of downward hook 38, either with their axes perpendicular to section 34 and parallel to hook 38, or at an angle to hook 38 of between 90° and 150°. These ears 44 are preferably of lesser thickness front to back than planar section 34 and are provided with holes front to back at their lower extremities.
Each diagonal member 28 is forked at each end, with the tines 46 of the forked end adapted to be pivotally secured to one of the ears 44 by a rivet 48 passing through both tines 46 and the ear disposed between the tines. The combined thickness of the ear 44 and the tines 46 approximates the thickness of planar section 34.
Each of the other ear brackets 30, at the left, right and bottom corners of the framework 10, has a configuration similar to that of topmost bracket 32, except that the left and right brackets have no attached hooks, while the bottom bracket has only a downwardly projecting hook.
Each diagonal member 28 includes two end sections 50 and a central section 52, so that adjustment of the length of the member 28 is possible by telescoping the sections together. Although the question of which section or sections should be hollow is a matter of choice, in the preferred embodiment central section 52 is hollow so that end sections 50 can be telescoped into it as far as desired. A set screw or knob 54 with a knurled edge radially penetrates each end of central section 52 and bears against the end section 50 inside to secure it in place.
Each central section 52 is also provided with at least one depending hook 56, preferably attached near the middle of the section's length, for receiving straps or wires from a hanging plant. If the diagonal members 28 are mounted at right angles to each other, the depending hooks 56 to be vertical should be disposed at a 45° angle to the diagonal member 28. Of course, for mounting on elongated rectangular window frames, it may be desirable to mount the framework 10 so that the upper diagonal members are at an acute angle with respect to each other and at an obtuse angle with respect to the lower members.
For installation on a single window, each left and right ear bracket 30 is bolted to a set of side mounting brackets 58. To allow for the different widths of the boards on each side of a window frame, each set 58 comprises a pair of angle members 60, 62 similar to top mounting bracket 16. As shown in FIGS. 3 and 5, a portion 69 of member 60 parallel to window frame 12 is provided with a longitudinal slot 64, so that members 60 and 62 can telescope together to allow for differences in window frame width. The short leg of each angle member 60, 62 is screwed to the side of the window frame, with the axes of the screws parallel to the window pane. The legs 64, 66 of the angle members 60, 62 are fastened together by a fastener 68 which screws through portion 69 into slot 64 and bears against leg 66 of angle member 62. This procedure guarantees that the long legs of the angle members will remain parallel to the window pane and the wall, even if the window frame is tapered thinner as it approaches the window pane, as shown by dashed lines 70 and 72 in FIGS. 2 and 3. For installation on double or triple windows, the brackets 30 of adjoining frameworks 10 can be fastened together for stability, forming a decorative lattice.
It will be appreciated that the depending hook on each of the top and bottom ear brackets and a single hook 56 on each of four diagonal members will allow the hanging of six plants on a single framework, which can be installed or removed with only a few screws. Since the diagonal members 28 telescope, the framework 10 will fit a number of different sizes of windows and can be moved by its owner from one dwelling to another. The pivotal interconnection of the diagonal members means that the framework will collapse into a single linear unit for transport or storage.
From the foregoing description, those skilled in the art will appreciate that numerous variations may be made of this invention without departing from its spirit. Therefore, I do not intend to limit the scope of this invention to the single embodiment shown and described. Rather, it is my intention that the scope of this invention be determined by the appended claims and their equivalents.
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A trapezoidal framework for suspending houseplants in front of a window pane. The framework attaches to a window frame and has diagonal members equipped with hooks for supporting pots on straps or wires. The diagonal members are pivotally interconnected and telescopically adjustable, so that the framework can be made to fit a variety of window sizes. Brackets securing the framework to the window frame will accommodate window frames of either rectangular or rounded-off cross-sections. The framework will not interfere with opening and closing of the window or with placement of curtains and draperies.
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FIELD OF THE INVENTION
[0001] The invention relates to a method for generating an electrical signal by means of a sensor device as a function of a change from an active phase to a passive phase in a space filled with a fluid, wherein a sensor element of the sensor device detects the heat transfer between the sensor element and the fluid over time. The invention further relates to a sensor device for executing the method, and to the use of such a sensor device.
BACKGROUND OF THE INVENTION
[0002] Automatically operating flushing devices are preferably used for flushing urinal bowls in public restrooms. These are understood to be flushing devices which either perform flushing at defined time intervals, regardless of whether the bowls had been used or not, or flushing devices, wherein flushing is started based on any arbitrary, for example mechanical or electrical, signal, for example, which is generated when the bowls are used.
[0003] The disadvantage of the flushing devices operating at time intervals lies in that, when the bowls are intensely used, they are flushed too seldom, which leads to a lack of sanitation and the emission of odors while, in case of little use, flushing operations take place without the bowls having been used, which means a waste of water. Furthermore, periodically occurring flushing operations also take place while the bowls are being used, which can be unpleasant for the user of toilet bowls in particular. Flushing devices, which are started by signals generated by sensors when the bowls are used, do avoid the disadvantage of too few, too many or chronologically undesired flushing operations. Systems with photoelectric barriers are most frequently employed, wherein a beam impinging on a optical sensor is reflected by the user, wherein the flushing device is activated immediately or after the user has stepped back out of the range of the beam. The disadvantage of such and other sensor-controlled flushing devices lies mainly in that the easily visible sensor devices often do not operate well or not at all, because they are purposely or inadvertently disrupted or destroyed, and that flushing is also triggered by persons present in the range of the beam, even if the bowl has not been used at all.
[0004] In addition to this, there is the danger of water damage, both with periodically operating and controllable flushing devices, because of overflowing bowls, because the flushing operations continue to be performed even if the drains are plugged.
OBJECT AND SUMMARY OF THE INVENTION
[0005] It is therefore the object of the invention to prevent the mentioned disadvantages and to propose a method with which electrical signals for activating the flushing are generated, wherein the danger of water damage because of overflowing or plugged up drains is avoided.
[0006] It is a further object of the invention to create a sensor device operating in accordance with the novel method, whose production and installation is simple and cost-effective and which operates with few malfunctions, or respectively almost maintenance-free.
[0007] A still further object of the invention is to propose the use of such a device.
[0008] This object is attained p 1 in connection with the method by means of the features of the characterizing portion of claim 1 ,
[0009] in connection with the device by means of the features of the characterizing portion of claim 6 ,
[0010] in connection with the use of the device by means of the features of the characterizing portion of claim 13 .
[0011] Advantageous further developments of the method in accordance with the invention, the device in accordance with the invention and the use in accordance with the invention are defined in the respective dependent claims.
[0012] The principle of the invention resides in generating an electrical signal as a function of a voltage change. The changing voltage can be picked up at a sensor element to which a voltage has been applied. Essentially, the sensor elements consist of a material with a temperature-dependent electrical conductivity, which is located in a space filled with a fluid. In a passive phase, i.e. when no electrical signal is to be generated and therefore the voltage is to remain constant, this sensor element is continuously heated or cooled, so that it is brought to a passive temperature, which in any case lies outside the temperature range of the fluid in the following active phase, and generally also outside of the temperature range of the fluid in the passive phase. This has the result that in the passive phase a heat transfer either from the sensor element to the fluid or from the fluid to the sensor element takes place, which becomes stationary after a certain time. If now a change occurs in the vicinity of the sensor element in the space filled with fluid, which increases the heat transfer, the temperature of the element changes because of the greater or smaller amounts of heat being absorbed or given off per unit of time, since it is heated or cooled not to a constant temperature, but with a constant output. Within the framework of the present invention, such a change in the fluid-filled space is to be understood not only to be a change in the temperature of the fluid, but also a change of the chemical consistency, and therefore of the heat-absorption capability of the fluid. In other words, a replacement of the fluid present in the state of rest by another fluid, and/or a change of the aggregate state of the fluid, and/or a change in the flow rate of the fluid, and/or a change in the level of a liquid fluid. It is known that the amount of heat absorbed over time by the fluid is not only a function of the temperature difference between the element and the fluid, but also of the capacity of the fluid for absorbing heat, essentially therefore of the flow rate of the fluid, wherein a rapid flow increases the heat transfer because of convection occurring in the course of this. The active phase starts with the change, i.e. that, as already mentioned, the heat transfer between the sensor element and the fluid is changed because of the change in the fluid-filled space, which results in a change in the temperature of the sensor element and therefore a change in the output voltage. The latter is used directly or indirectly as a signal, for the generation of which the novel method, or respectively the novel sensor device, is used.
[0013] A preferred use of the novel sensor device is the automated flushing of urinal or toilet bowls. Here, water damage because of overflowing is prevented, even when the outlet is plugged up. If the outlet of the urinal or toilet bowl is plugged up, it is automatically provided that no change in the amount of heat given off by the element, and therefore no heating or cooling of the element, no change of the output voltage and no further flushing operation takes place at all. Moreover, flushing is only triggered if the urinal or toilet bowl is actually used.
[0014] Installing the novel sensor device, for example in existing urinal bowls, is simple. The sensor device, or possibly elements thereof, can be easily replaced in case of outages.
[0015] The sensor device, or respectively the sensor element, can be cast into a wall simultaneously with the construction of the latter. However, in this case it can generally not be exchanged, so that this concept can only be used for sensor elements with a very long service life and very slight tendencies to become defective. The problems regarding the service life, or respectively the tendency to become defective, become moot if, in place of the sensor device itself, only a holding arrangement for the latter is integrally provided in the wall, in which an exchangeable sensor device can be fastened.
[0016] The sensor device, or respectively the sensor element can be installed in various locations. Fastening locations can be provided ahead of or behind the odor barrier on a lower, or a lateral or, suspended from an upper, fastening surface, wherein the latter has the advantage that the danger of a covering of dirt over the sensing area is less. In any case, it is advantageous if the sensing area of the sensor device is not arranged in a depression of the wall, but flush with the wall or projecting slightly into the interior, so that it is actually washed by the flushing water. In this way the formation of a sump of urine deposits and/or other soiling is prevented in an efficient manner.
[0017] It is particularly advantageous to mount the sensor device, or respectively the sensor element, at a location which is not accessible to the users. In this way the purposeful or possibly also inadvertent damage is prevented. In public restrooms in particular it is prevented in this way that the sensor device, or respectively the sensor element, and therefore the flushing device, become the victims of acts of vandalism.
[0018] Up to now, the use of the novel device has been mainly addressed in connection with urinal bowls. Such a sensor device can of course also be employed in other ways, in the sanitary field not only with toilet bowls, but also in sinks of the most diverse different kinds. Outside of the sanitary field, the sensor device can also be used in the most diverse ways, for example as a leak detector for liquid media, for example oil catch basins, as a low filling level detector, in particular in the field of aquarium keeping, as a protection of pumps against dry running, as an alternative to floats for measuring the level of liquids, as well as a replacement for mercury switches. It should be pointed out that the sensor device is also suitable in cases in which flammable or explosive fluids are involved.
[0019] In connection with toilet bowls it is necessary to prevent a seated or crouching user from being splashed in an undesirable manner when flushing is actuated. To this end flushing can be delayed, for example. Another option lies in actuating flushing immediately, wherein the toilet bowl must be shaped in such a way that the user is not splashed, by means of which odor emissions are minimized. Finally, the invention can also be used in combination with an automatic device, such as the one known by the name “Klosomat”, for example.
[0020] The device advantageously has a regulator, by means of which the chronological flushing behavior can be affected, possibly in an adjustable manner. For example, in connection with urinal bowls it is advantageous to provide wetting of the wall, on which the stream of urine impinges, by means of pre-flushing immediately when they are used, in this way the reflection and spraying of the stream can be prevented and the problem-free run-off along the wall wetted by the pre-flushing can be assured. To prevent too long a time without flushing, it is also advantageous to trigger flushing at defined periods of time, even if the bowl had never been used since the previous flushing. Such flushing can also take place with an increased amount of water, if necessary, and can be used as periodic cleaning flush, so to speak, or can assure the suppression of odors. It is also possible to add a cleaner, or respectively disinfectant or a deodorizing agent to the flushing water for a cleaning flush for increasing the sanitary standards, or respectively for preventing offensive odors.
[0021] Preferably the signal has a strength which does not require further, or at least no significant amplification.
[0022] The reaction of the sensor element to changed conditions of its environment, which result in a change in the terminal voltage, takes place all the faster, the faster the required temperature change of the NTC, or respectively PCT resistor takes place. To achieve this it is advantageous if the mass is low and the temperature difference between the temperature at rest and the initiating temperature is great. A small mass is also advantageous because it reduces the energy used for heating, or respectively cooling it. But a large temperature difference has the result in principle that the energy requirement for heating or cooling is comparatively great. However, this is not very important because of the heating or cooling energy required which, absolutely considered, is small.
[0023] The sensor device itself is simple to manufacture and cost- effective. It can be produced in such a way that it is not attacked by either urine or chemicals, such as strong cleaning agents, for example. As already mentioned, it is also suitable for contact with explosive and flammable materials, since no spark, which touches the fluid(s), is generated by the electrical signal.
[0024] Heating or cooling of the sensor element, whose electrical resistance is a function of the temperature, can be provided directly or indirectly. With indirect heating, or respectively cooling, a heating, or respectively cooling element is heated, or respectively cooled, which in turn heats the element by heat conduction, convection and/or radiation. The heat transfer between the heating resistor and the sensor element is preferably aided by a material with good heat conduction, which connects the two. This material can also fill the entire free space inside the housing. With direct heating, or respectively cooling, the sensor element itself is electrically heated, or respectively cooled, which has the advantage that only two cables are needed for wiring in place of three or four cables with indirect heating, or respectively cooling, but with the disadvantage of the non- independent voltage.
[0025] In general, the sensor element and, if desired, the separate heating, or respectively cooling element, as well as the wiring, are arranged in a sensor housing made of a material which is insensitive to the fluids with which it comes into contact, and which is hermetically sealed. Suitable materials are glass, plastics, such as teflon, for example, and metals which are resistant to the respective fluids.
[0026] It is further possible to design the sensor element and the housing integrally, wherein the element is embodied housing-like, so to speak, and only needs to receive the wiring and, if required, i.e. with indirect heating, or respectively cooling, also the heating, or respectively cooling element.
Further details and advantages of the invention will be explained in what follows by means of exemplary embodiments of the invention, making reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 shows a first exemplary embodiment of a sensor device with indirect heating of the sensor element and with four lines;
[0028] [0028]FIG. 2 shows a second exemplary embodiment of a sensor device with indirect heating of the sensor element and with three lines;
[0029] [0029]FIG. 3 shows a third exemplary embodiment of a sensor device with direct heating of the sensor element;
[0030] [0030]FIG. 4 shows a fourth exemplary embodiment of the sensor device with a cell filled with a sealing compound;
[0031] [0031]FIG. 5 shows a fifth exemplary embodiment of the sensor device without a cell;
[0032] [0032]FIG. 6 shows a sixth exemplary embodiment of the sensor device with two heating elements;
[0033] [0033]FIG. 7 shows a siphon with sensor devices in various installed positions;
[0034] [0034]FIG. 8 shows the siphon of FIG. 7 with sensor elements in further installed positions;
[0035] [0035]FIGS. 9A, 9B show a further siphon in various installed positions in a vertical sectional view, or respectively in a lateral view;
[0036] [0036]FIGS. 10A, 10B show the siphon of FIGS. 9A, 9B with sensor devices in further installed positions in a vertical sectional view, or respectively in a lateral view;
[0037] [0037]FIG. 11 shows a drain pipe of a sanitary installation with sensor devices in various installed positions;
[0038] [0038]FIG. 12 shows a urinal bowl with sensor devices in various installed positions;
[0039] [0039]FIG. 13A shows a container for liquids with a sensor device for monitoring a first extreme level;
[0040] [0040]FIG. 13B shows a container for liquids with a sensor device for monitoring another extreme level;
[0041] [0041]FIG. 14 shows a tank in a collecting tub with a sensor device for detecting a leak;
[0042] [0042]FIG. 15 shows a pump with sensor elements in various installed positions for detecting and preventing dry running;
[0043] [0043]FIG. 16 shows an aquarium tank with a reserve tank with a sensor device as a level monitor;
[0044] [0044]FIGS. 17, 18, 19 show three examples of the use of respectively several sensor devices as replacements for mercury switches;
[0045] [0045]FIG. 20 is a block diagram of a suitable circuit in connection with the sensor device;
[0046] [0046]FIG. 21A is a diagram for schematically representing the progression of the output signal over time;
[0047] [0047]FIG. 21A is a further diagram for representing the progression of the output voltage over time when the sensor is immersed in water millimeter by millimeter;
[0048] [0048]FIG. 22 shows a table with results of measurements indicating the behavior of two different sensor devices; and
[0049] [0049]FIGS. 23A, 23B represent diagrams with results of measurements to show the behavior of the sensor devices in accordance with FIG. 4, or respectively FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] [0050]FIG. 1 shows a sensor device 10 with a sensor element 12 with lines 14 A, 14 B, to which voltage has been applied, as well as a heating element in the form of a heating resistor 16 , which is connected via lines 18 A, 18 B to a current or voltage source, not represented, and is used for heating the sensor element 12 . The sensor element 12 consists of a resistor with a temperature-dependent conductivity, in the present case an NTC resistor. The sensor element 12 , the heating element 16 and a housing 20 , which will be described further down below, are connected by a thermally conducting material, or respectively conductor paste 22 , i.e. the sensor element 12 is being indirectly heated. The sensor device 10 further includes the already mentioned housing 20 consisting of a cell 20 A and a cover 20 C, which enclose the sensor element 12 , the heating element 16 , the conductor paste 22 and the lines 14 A, 14 B, 18 A, 18 B, wherein the lines 14 A, 14 B, 18 A, 18 B are conducted through a sleeve 20 B of the cover 20 C.
[0051] [0051]FIG. 2 shows a further sensor device 10 , which only differs from the sensor device in accordance with FIG. 1 in that in place of the lines 14 A and 18 A only a single line 19 A is provided. The advantage of this sensor device lies in that it is structurally slightly simpler than the sensor device in accordance with FIG. 1, since only the three line connections 19 A, 14 B, 18 B are provided, but on the other hand its function is less precise because of the mutual influence by the common line 19 A.
[0052] A sensor device 10 is represented in FIG. 3 which, like the sensor device in FIG. 1, includes the sensor element 12 with the two lines 14 A, 14 B, the conductor paste 22 , the cell 20 A, the sleeve 20 B and the cover 20 C. The sensor element 12 of this sensor device 10 is directly heated by means of a voltage source, therefore no heating element and lines connecting it with a current source are provided.
[0053] [0053]FIG. 4 shows a sensor device 10 with a sensor element 12 , a heating resistor 16 , the lines 14 A, 14 B, 18 A, 18 B and the cell 20 A. Here, the conductor paste 22 is not only present in the area of the heating resistor 16 , the sensor element 12 and the bottom of the cell 20 A, instead it fills the entire free space of the cell 20 A in the form of a sealing compound and also replaces the cover 20 C, while the sleeve 20 B is also enclosed in the sealing compound.
[0054] A simplified embodiment of the sensor device 10 is represented in FIG. 5, which differs from the exemplary embodiment in FIG. 4 by not having a cell 20 A. Here, the conductor paste, or respectively sealing compound 22 not only has replaced the cover 20 C as in the embodiment of FIG. 4, but also the cell 20 A, wherein the sleeve 20 B is again enclosed in the sealing compound.
[0055] [0055]FIG. 6 shows a further variation of the sensor device 10 , wherein the cell 20 A is completely filled with the sealing compound 22 . One sensor element 12 and two heating elements 16 A, 16 B, which are arranged in a cascade circuit, are provided in this sensor device 10 . It is also possible to provide the sensor device with several heating elements, or respectively several sensor elements.
[0056] With all sensor elements of FIGS. 1 to 6 , the heat transfer from the heating element to the sensor element takes place by heat conduction through the conductor paste, or respectively the heat- conducting material 22 . However, this heat transfer could also take place differently, for example by radiation.
[0057] It is obvious that the elements which come into contact with the fluids, for example in the sanitary field with air, water, urine, cleaning materials, and in other applications with crude petroleum products and chemicals of the most varied types, in particular the cell 20 A, and possibly the sleeve 20 B, the cover 20 C, as well as the heat-conducting material 22 , must be made of materials which are not corroded by the fluids. Inter alia, glass, plastics or resistant metals are suitable for the cell.
[0058] [0058]FIGS. 7, 8, as well as 9 A, 9 B and 10 A, 10 B, show different possibilities for installing a sensor element 10 , for example one of the sensor elements represented in FIGS. 1 to 6 , in the drainage area of a sanitary installation, for example a urinal bowl.
[0059] The cross section of a conventional odor barrier, or respectively a siphon 30 , is represented in FIG. 7 and FIG. 8, wherein in the installed state the upper end 32 is connected with a urinal bowl, not represented, and the lower end 34 with a waste water line, not represented. The water level during the passive phases, i.e. when the urinal bowl is not being used, is identified by p, in the active phase by a. Various sensor devices are represented in the siphons 30 , but this only to show possible installation positions, since in actuality only a single sensor device will be present.
[0060] [0060]FIG. 7 shows sensor devices 10 in installed positions, wherein the fluid surrounding the sensor device in the passive phases consists of the ambient air, while in the active phases it essentially consists of water with slight additions of urine. Here, the change in the fluid consists in that, first, the gaseous fluid, namely the ambient air, is replaced by a liquid fluid, namely essentially water, because of which the heat transfer is greatly increased since the thermal transition resistance drops considerably, and that secondly the temperature of the water is lower than the ambient air, which had been heated by the sensor element during the passive phase, and that thirdly water flows, while the ambient air is practically unmoving. These three facts have the effect that during the active phase a larger amount of heat is emitted over time by the sensor device, or respectively the sensor element, so that the temperature of the sensor elements drops and its electrical conductivity is changed by this, wherein the change in electrical conductivity is converted into an electrical signal, which causes flushing. Flushing preferably only takes place after the use of the urinal bowl is terminated.
[0061] [0061]FIG. 8 shows two possibilities for the installation of the sensor element 10 , whose surroundings are constituted by a liquid fluid, namely water with an admixture of urine, or respectively only water, not only in the active phase, but partially already in the passive phase. The change occurring at the start of the active phase here partially includes the change in the temperature of the fluid and the change in the velocity of the fluid, but only partially the replacement of the gaseous fluid by liquid fluid. Here, too, the thermal transition resistance drops at the start of the active phase.
[0062] A suction siphon 36 is represented in FIGS. 9A, 9B, as well as 10 A, 10 B, having an upper end 38 which, in the installed state, is connected with the drain of a sanitary installation, not represented, such as a urinal bowl, and having a lower end 40 which, in the installed state, is connected with a waste water line, not represented. The possible water levels are identified as in FIGS. 7 and 8 by p, or respectively p and a.
[0063] [0063]FIG. 9A shows sensor elements 10 which, analogously to FIG. 7, are installed in such a way that in the passive phase they are surrounded by still air, in the active phase by flowing water. FIG. 10A shows sensor elements 10 which, analogously to FIG. 8, are installed in such a way that in the passive phases they are surrounded by still water, in the active phases by flowing water.
[0064] In accordance with FIG. 11, the sensor devices can also be arranged downstream of the siphon, i.e. in the area of a siphon drain pipe 42 , whose upper end 44 is connected to the siphon, not represented here, and whose lower end 46 constitutes the drain. Not only are different installed position of the sensor device 10 represented in FIG. 11, but it is also shown that the sensor devices 10 can be also designed to be annular instead of stopper- like. A urinal bowl 50 is represented in FIG. 12, whose lower end terminates in a siphon 52 , represented in a simplified manner. Here, too, several sensor devices 10 are represented in various possible installed positions. Sensor devices which have been installed in a suspended position have the advantage, that no protective cap is formed on them, for example made of scale from urine, hair, small bits of paper, etc., which would prevent correct functioning. While the sensor devices 10 project into the interior of the urinal bowl 50 , the sensor devices 10 . 1 are completely enclosed in the wall of the urinal bowl which, for example, is made of a ceramic material. Both in the passive phase and the active phase, the surroundings of the sensor device here consist of a solid and stationary material. Thus the change occurring in the surroundings of the sensor material during the transition from a passive phase to an active phase consists exclusively of a drop in temperature. Of course a change of the heat conduction because of the change in the material surrounding the sensor device, or a change in the flow speed in the surroundings of the sensor devices 10 . 1 occurs only to a decreased extent.
[0065] While FIGS. 7 to 12 were always related to the use of the sensor device in a sanitary installation, for example a urinal or toilet bowl, FIGS. 13 to 16 show the use of the novel sensor elements for different purposes.
[0066] In FIG. 13A, a sensor device 10 for monitoring a minimum level min is arranged in a container 52 which contains a liquid 53 . In this case, the time in which the actual level p lies above the minimum level min can be considered to be the passive phase. Thus the sensor device as represented in FIG. 13 is contained in the liquid 53 . The active phase is understood to occur when the actual level p falls below the minimum level min, so that the sensor device 10 is no longer in a liquid, but in a gaseous fluid. In this case the heat transfer is reduced during the transition into the active phase. The signal resulting from this in the end causes the supply of fresh liquid 53 to the container 52 until the actual level p again lies above the minimum level min. The sensor device can be arranged in this case either in the interior of the container 52 , as represented, or in the interior of the wall of the container 52 , or possibly on the exterior of the wall of the container 52 .
[0067] In a corresponding manner it is also possible in accordance with FIG. 13B to use the sensor device 10 as a protection against overfilling. In this case the sensor device 10 is in the passive phase when the actual level p lies below the maximum level. The installation position is selected to be such that in the passive phase the sensor device is in air, while with the onset of the active phase it is immersed in the liquid because of the rise of the level to max.
[0068] The sensor device can also be attached in a height- adjustable manner in the container for monitoring a minimum level as well as for monitoring a maximum level.
[0069] [0069]FIG. 14 shows the use of the novel sensor device 10 for monitoring a container for leaks, such as for example a trough 56 surrounding a fuel oil tank 56 . In the passive phase the sensor device 10 is in air, in the active phase in fuel oil.
[0070] The use of a sensor device 10 for preventing dry-running of a pump 58 is represented in FIG. 15. The sensor device can be installed in various positions. In the passive phase it is in a liquid and at the start of the active phase it comes into contact with air. It is possible by means of the signal resulting from the change to either switch off the pump 58 , or to provide more liquid to the pump 58 .
[0071] [0071]FIG. 16 represents the use of the novel sensor device 10 in connection with aquariums. Here, the level p is sensed by the sensor device 10 immersed in the passive phase into the water of an aquarium tank 60 . When the level falls below a minimum level min, the sensor device 10 is no longer in water, but in air. In this active phase additional water, generally processed for the required application, is supplied to the aquarium tanks 60 from a reservoir 62 . By means of this arrangement it is achieved that the water level can be kept constant in a very precise manner, which in the present case is of great importance, since by means of this hard, encrusted lime edges are avoided.
[0072] [0072]FIGS. 17, 18, 19 show how it is possible by means of the novel sensor device to create angle switches as replacements for mercury switches. In contrast with all other representations, wherein only one sensor device per arrangement is provided, even though for the purpose of explanation of possible installation positions sometime several sensor devices are represented, actually several of the novel sensor devices are used in each one of the represented angle switches.
[0073] For the meaningful and successful employment of the novel sensor device it is of great importance in many areas of use that its reaction times be short. For example, short reaction times on an order of magnitude of at most a few seconds and a sufficient amplitude of the generated signal are the goal in the sanitary field. Moreover, to prevent an integration behavior during dynamic operations, the reaction behavior during the transition from the passive to the active phase should be symmetrical to the transition from the active to the passive phase. Finally, in accordance with an ecological operation it is also desirable that the energy consumption be low. For achieving the properties just described, the circuit arrangement represented in FIG. 20, for example, has proven itself.
[0074] [0074]FIG. 20 relates to a sensor device 10 with indirect heating of the sensor element. The sensor element 12 , the heating element 16 , the cell 20 A, possibly including the cover, and the heat-conducting sealing compound 22 are represented. The cell 20 A can also be made of an electrically conducting material and can be heated, so that the arrangement of the heating element 16 can be omitted. Moreover, an electrical switch 15 and a protective resistor 17 have been arranged, whose position can be seen in FIG. 20. The heating voltage is identified by Uq. The output signal, i.e. the signal, for whose emission the novel sensor device 10 is used, is identified by Uomega.
[0075] Indirect heating of the sensor element 12 offers several advantages over direct heating of the sensor element by means of a constant current source. These advantages will be described below. Indirect heating permits a switching operation of the heating element 16 for heating the sensor element 12 . A briefly higher, actually briefly too high load on the heating element 16 , for example of 1.2 W in place of 0.4 W, is possible and results in shorter reaction times and advantageous behavior of the amplitude of the output signal Uomega. With short reaction times the energy consumption becomes minimal, and the additional circuit outlay is also minimal. A possible integration behavior of the output signal Uomega during dynamic operation is compensated. It is achieved by means of an indirect heating of the sensor element 12 by the heating element 16 , that the output signal Uomega is not affected by varying self-heating, such as is the case with direct heating of the sensor element 12 . The only disadvantage of indirect heating lies in that at least three lines 14 B, 18 B, 19 A, or advantageously even the four lines 14 A, 14 B, 18 A, 19 B, are required for connecting the sensor element 12 and the heating element 16 .
[0076] The progression over time of the output voltage Uomega can be seen in the diagram in FIG. 21A. The operating points in liquid fluids are designated by AF, the operating points in gaseous fluids by AG. The electronic switch 15 , represented in FIG. 20, is opened when a predetermined voltage threshold of the output signal Uomega is upwardly or downwardly exceeded. It is possible to fix the operating point at AG 1 in a curve range of great steepness with the aid of the electronic switch 15 , from which short reaction times result. Thus, without an electronic switch the operating point at AG 2 lies in a considerably flatter curve range, so that the reaction time is longer. It is moreover possible by means of the electronic switch 15 to fix the operating point AF 2 at different temperatures of the gaseous fluids surrounding the sensor device 10 .
[0077] The diagram in FIG. 21 B shows the progression of the output voltage Uomega as a function of the immersion depth d of the sensor device 10 in water, namely with the immersion depth d being increased in millimeters.
[0078] The table represented in FIG. 22 contains details regarding the behavior of the sensor devices represented in FIGS. 4 and 5, wherein the two front columns of the table relate to FIG. 4, the two rear columns of the table to FIG. 5.
[0079] Measurement results, which document the function of the novel sensor device, are represented in the diagrams of FIGS. 23A and 23B, wherein FIG. 23A relates to the sensor device in accordance with FIG. 4, and FIG. 23B to the sensor device in FIG. 5.
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A method for generating an electrical signal and a sensor device ( 10 ) for executing the method. The signal is generated because of a change in a fluid-filled space. A sensor element ( 12 ) of the sensor device ( 10 ) detects the heat transfer over time between the sensor element ( 12 ) and the fluid. The sensor element ( 12 ), which has a temperature-dependent electrical conductivity and to which a voltage has been applied, is brought to a temperature which lies outside the range of the fluid temperatures. In the passive phase, the fluid is brought to a constant passive temperature by a heat transfer between the sensor element ( 12 ) and the surroundings. The sensor device ( 10 ) provides a constant passive output voltage. A heat transfer between the sensor element ( 12 ) and its surroundings takes place in the active phase by changes in the fluid-filled space. The sensor device ( 10 ) provides an active output voltage, which is different from the passive output voltage. When a difference between the output voltages is exceeded, the signal is generated. The device can be used for triggering the flushing action in sanitary installations, and for keeping a level constant, for example in aquarium installations.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of U.S. Provisional Application No. 61/427,549, filed Dec. 28, 2010, the contents of which are herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to an abrasive jet drilling assembly. More particularly, embodiments of the present invention relate to a resettable circulation tool for use in the abrasive jet drilling assembly.
[0004] 2. Description of the Related Art
[0005] In the oil and gas industry, a wellbore may be formed by using an abrasive jet drilling assembly. The abrasive jet drilling assembly typically includes a jetting drill device disposed on a drill string. The jetting drill device ejects a high velocity stream of drilling fluid which includes abrasive particles. The high velocity stream of drilling fluid erodes the rock adjacent the jetting drill device to form the wellbore. If the abrasive jet drilling assembly encounters a gas cake (e.g. gas pocket) while forming the wellbore, it is oftentimes necessary to circulate back through a circulation port of a circulation tool. There are circulation tools commercially available that enable a downhole circulation port to be opened from the surface. Current designs of such circulation tools are limited in their number of operation and function by dropping a ball, shearing a pin, or other method that precludes utilizing the circulating function for another event. Many tools function by dropping a ball or plug that impedes further flow as the circulation function is not reversible or resettable. Additionally, these circulation tools stay open without the ability to utilize the flow through the body of the circulation tool as per the initial (pre-deployed) condition. Therefore, there is a need for a resettable circulation tool for use in the abrasive jet drilling assembly.
SUMMARY OF THE INVENTION
[0006] The present invention generally relate to an abrasive jet drilling assembly. In one aspect, a resettable circulation tool for use in an abrasive jet drilling assembly includes an inner body having a first port in fluid communication with a bore; an outer body having a second port; and a cam member configured to move along one or more slots, wherein the bodies move relative to each other to selectively align and misalign the first port and the second port as the cam member moves along the slots.
[0007] In another aspect, a resettable circulation tool for use in an abrasive jet drilling assembly is provided. The resettable circulation tool includes an inner body having a first port in fluid communication with a bore. The resettable circulation tool further includes an outer body having slots formed on an inner surface, wherein the outer body includes a second port. Additionally, the resettable circulation tool includes a cam member configured to move along the slots of the outer body, wherein the bodies move relative to each other to selectively align and misalign the first port and the second port as the cam member moves along the slots.
[0008] In another aspect, a method of using a resettable circulation tool disposed in an abrasive jet drilling assembly is provided. The method includes the step of positioning a jetting drill device in the abrasive jet drilling assembly into contact with a portion of a wellbore. The method further includes the step of applying a first axial force and a first rotational force on the drilling assembly, thereby causing a first port and a second port in the resettable circulation tool to align. The method also includes the step of pumping fluid through the ports of the resettable circulation tool. The method further includes the step of applying a second axial force and a second rotational force on the drilling assembly, thereby causing the first port and the second port to misalign. Additionally, the method includes the step of pumping fluid through the resettable circulation tool and into the jetting drill device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0010] FIG. 1 is a view illustrating a resettable circulation tool in an abrasive jet drilling assembly.
[0011] FIG. 2 is a cross-section view illustrating the resettable circulation tool in the abrasive jet drilling assembly.
[0012] FIG. 3 is a cross-section view illustrating the resettable circulation tool.
DETAILED DESCRIPTION
[0013] The present invention generally relates to a resettable circulation tool for use in the abrasive jet drilling assembly. To better understand the novelty of the resettable circulation tool of the present invention and the methods of use thereof, reference is hereafter made to the accompanying drawings.
[0014] FIG. 1 is a view illustrating a resettable circulation tool 100 in an abrasive jet drilling assembly 200 . Generally, the abrasive jet drilling assembly 200 is used to form a wellbore by ejecting a high velocity stream of drilling fluid which includes abrasive particles. The abrasive jet drilling assembly 200 includes a jetting drill device 205 for ejecting the high velocity stream of drilling fluid. The abrasive jet drilling assembly 200 is connected to a drill string (not shown). The abrasive jet drilling assembly 200 further includes the resettable circulation tool 100 .
[0015] The resettable circulation tool 100 includes a plurality of circulation ports 105 that may be selectively opened during the drilling operation to circulate drilling fluid out of the drill string and then closed. The resettable circulation tool 100 could be operated multiple times during the drilling operation. The resettable circulation tool 100 is normally closed, and may optionally be provided with a shear pin safety system to prevent unwanted operation. The resettable circulation tool 100 is movable between a closed position (normal operation) and an opened position. In the opened position, fluid is circulated out from the resettable circulation tool 100 above the device 205 to eliminate a shot column. To move the resettable circulation tool 100 to the opened position from the closed position, a downward motion will allow the resettable circulation tool 100 to open and allow circulation, and remain in this position until a similar downward motion is utilized to close the resettable circulation tool 100 and resume the drilling operation. The resettable circulation tool 100 can be operated as often as required to accomplish the desired objectives during the drilling operation.
[0016] FIG. 2 is a cross-section view illustrating the resettable circulation tool 100 in the abrasive jet drilling assembly 200 . As shown, a bore 210 of the jetting drill device 205 is in fluid communication with a bore 110 of the resettable circulation tool 100 . During the drilling operation, drill fluid is pumped through the drill string through the bores 110 , 210 and then out of the jetting drill device 205 . The drill fluid includes abrasive particles that are configured to erode the rock to form the wellbore. The resettable circulation tool 100 in the closed position (e.g. normal operation) allows all of the drill fluid to flow though the bore 110 of the resettable circulation tool 100 . The resettable circulation tool 100 in the opened position allows substantially all of the drill fluid to flow though the circulation ports 105 of the resettable circulation tool 100 .
[0017] FIG. 3 is a cross-section view illustrating the resettable circulation tool 100 . The resettable circulation tool 100 generally includes an inner sub 130 and an outer sub 125 . Each sub 125 , 130 has the requisite connection member, such as a threaded connection, that is required to be placed above the jetting drill device 205 , and allows the subs 125 , 130 to be an extension of the jetting drill device 205 . The inner sub 130 has the sector control profile, such as slots, that allows the “ratcheting” function of the sub's operation. As set forth herein, cams 140 are installed into the outer sub 125 to provide the control of the ports 105 to either the opened position or the closed position. In one embodiment, there are three sets of cams 140 and profiles to allow strength to support the resettable circulation tool 100 function. In addition, there may also be a lock collar 160 that adds additional shear strength in tension operations. The outer sub 125 may optionally include shear pins with total WOB (Weight on Bit) loads from 9,500 lbs. to 20,000 lbs. to actuate the circulation function of the resettable circulation tool 100 for the first time.
[0018] The resettable circulation tool 100 is generally a two-position tool, which can be cycled from the closed position to the opened position and back again to the closed position any number of times. The resettable circulation tool 100 is cycled by a downward direction force, arrow 165 , with slight rotation in a first direction. In one embodiment, the first direction is toward the right. Re-pressurization (e.g. by restoring flow) pumps open the tool and open the circulating ports 105 of the resettable circulation tool 100 . In the event that this action needs to be reversed (e.g. moved to the closed position), the downward force 165 is once again applied with slight rotation in the first direction, and re-pressurizing to pump, the circulation ports 105 are closed.
[0019] The resettable circulation tool 100 allows numerous cycles from opened position to closed position as required during the drilling operation. In addition, there is no obstruction to flow in the bore 110 of the resettable circulation tool 100 as compared to current designs of circulation tools which require a ball or a plug to operate. Further, there are minimum maintenance requirements in the resettable circulation tool 100 other than grease flush during cleaning. In one embodiment, shear pins may be included to ensure a minimum operating force (e.g. downward force 165 ) prior to operation; however this feature would be single use only.
[0020] The resettable circulation tool 100 is installed in-line with the jetting drill device 205 (see FIG. 2 ), with appropriate connections and crossovers as required. The inlet 170 is the fluid inlet for the resettable circulation tool 100 and directly provides a flow path to the jetting drill device 205 through a crossover at the bottom. The only other flow ports are ports 105 , 155 .
[0021] During the operation of the resettable circulation tool 100 , the flow ports 105 are either closed or open. The resettable circulation tool 100 is operated by pressure acting as a spring and forcing the outer sub 125 to travel downward and stop. In one embodiment, low pressure operation of around 100 to 300 PSI is used.
[0022] The resettable circulation tool 100 includes cam 140 which drives the outer sub 125 through the slots 145 that control the positioning of the outer sub 125 relative to the inner sub 130 . In one embodiment, the slots 145 extend circumferentially around the inner sub 130 and axially along a substantial length thereof. In one embodiment, the slots 145 extend circumferentially around the outer sub 125 and axially along a substantial length thereof. The slots 145 include guides and shoulders (not shown) that are used to direct the cam 140 along a slot pathway. The slots 145 may include a plurality of longer length slots and a plurality of shorter length slots. In one embodiment, a shear pin 135 may be utilized to prevent the movement of the cam 140 in the slots 140 unless sufficient force, such as 10,000 lbs. to 35,000 lbs., is applied downward.
[0023] The slots 145 have been arranged to have the resettable circulation tool 100 function with applied downward force (e.g. 165 ), but the resettable circulation tool 100 is recommended to have right-hand torque when setting down. The slots 145 provide up and down function but will resist rotating the outer sub 125 relative to the inner sub 120 . The slots 145 provide different slot lengths for open or closed positions. The open position is longer, providing the additional length to open the flow ports 105 , 155 to the bore 110 . In one embodiment, the slot configuration has three dual function segments in the cam surfaces.
[0024] In the closed position as shown in FIG. 3 , flow cannot exit the resettable circulation tool 100 , and the flow is directed into the jetting drill device 205 . If outboard circulation is desired, the force 165 (e.g. WOB) is applied with a slight torque in the first direction. In turn, the cam 140 is reset into a longer length slot of the slots 145 , so that when the pressure is applied to the resettable circulation tool 100 , it will cycle to the opening of the flow ports 105 . The resultant area is 6 times the nozzle area with a corresponding pressure drop. In other words, to move the resettable circulation tool 100 to the opened position, the resettable circulation tool 100 is cycled by a downward direction force, arrow 165 , with slight rotation in a first direction, which causes the cam 140 to move along the guides of the slots 145 and stop at one of the shoulders. At this point, the inner port 155 of the inner sub 120 is aligned with the outer port 105 of the outer sub 125 , and fluid is allowed to exit the resettable circulation tool 100 .
[0025] To move the resettable circulation tool 100 from the opened position to the closed position, substantially the same set down force 165 (e.g. WOB) is applied with a torque in the first direction which allows the outer sub 125 to rotate to a shorter length slot in the slots 145 , and when pressurized, the resettable circulation tool 100 will cycle to the closed position with the flow ports 105 closed again. In other words the inner port 155 of the inner sub 120 is misaligned with the outer port 105 of the outer sub 125 , and fluid is prevented from exiting the resettable circulation tool 100 . Repetition of the same downward action will reset the resettable circulation tool 100 to either the closed or open position as desired. The resettable circulation tool 100 alternatively either opens or closes during activation.
[0026] The resettable circulation tool 100 includes a first seal 115 and a second seal 120 between the inner sub 120 and the outer sub 125 . The seals 115 , 120 are configured to prevent the leakage of fluid between the subs 120 , 125 . The seals 115 , 120 also seal ports 105 , 155 and provide the necessary seal and backup for 10,000 PSI operation for multiple cycles.
[0027] In another embodiment, the threaded collar 160 may be used for tensile strength. Specifically, the threaded collar 160 is used at the bottom of the inner sub 120 to retain the integrity of the resettable circulation tool 100 if the cams malfunction.
[0028] In addition to circulating fluid, the resettable circulation tool 100 may be used to allow for drill string drainage (after shot is circulated out) and subsequent (dry string) to aid in drill string servicing when coming out of the hole. This is enabled by opening the ports 105 in a similar manner, as described herein, for drainage of the drill string.
[0029] The resettable circulation tool 100 may be furnished as a custom tool to match the threaded connections of the jetting drill device 205 and the desired upper connection, as well as larger sizes of jetting drill devices.
[0030] The simplicity and ease of maintenance of the resettable circulation tool 100 are maintained by removing the threaded collar 160 and the three cam pins 140 . Larger resettable circulation tools may have more cam pins. Once removal of the cam pins 140 has been accomplished, the inner sub 120 is removed from the outer sub 125 for cleaning and seal replacement.
[0031] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention generally relates to an abrasive jet drilling assembly. In one aspect, a resettable circulation tool for use in an abrasive jet drilling assembly is provided. The resettable circulation tool includes an inner body having a first port in fluid communication with a bore. The resettable circulation tool further includes an outer body having a second port. Additionally, the resettable circulation tool includes a cam member configured to move along one or more slots, wherein the bodies move relative to each other to selectively align and misalign the first port and the second port as the cam member moves along the slots. In another aspect, a method of using a resettable circulation tool disposed in an abrasive jet drilling assembly includes moving the first and second ports into and out of alignment.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] This invention relates to detection and measurement of gas entrapped in drilling fluids during oil well drilling operations. In particular, the invention relates to methods and apparatuses for extracting and sampling gas from the drilling fluids.
[0002] During drilling operations, drilling mud is pumped down the inner diameter of the rotating drill string. The drilling fluid lubricates and cools the drilling bit as it exits the bit at the bottom of the drill string. The drilling fluid carries cuttings to the surface up the annulus defined between the drill string and the borehole. Thus, the drilling fluid is circulated in a loop, wherein it is pumped from a mud tank, down-hole to the drilling bit, up-hole to the surface, and back to the mud tank.
[0003] As the drilling fluid is circulated down-hole, it entraps oil, gas and water from the penetrated earth formations. Gas entrained in the drilling fluid, such as carbon dioxide and hydrogen sulfide, may contain information indicative of formations containing hydrocarbons. Gas chromatography techniques have been used to separate and quantify different light hydrocarbon gases, such as methane through pentanes. Catalytic combustion, thermal conductivity, and flame ionization detectors have also been used to analyze the extracted gases. The gas content of the drilling fluid may also indicate the pore pressure of the drilled formation to assist in the identification of “oil shows” and “pay zones.” Drilling operators analyze the entrained gas: (1) to determine whether a formation of interest has been penetrated; and (2) to provide warning of dangerous underbalanced drilling conditions indicated by increased gas returns. This process is called “mud logging.”
[0004] To analyze the entrained gas, the gas is first extracted from the drilling fluid. Gas traps with mechanical agitators have been used to liberate the gas from the drilling fluid in a header tank before the drilling fluid flows into the main mud tank. The liberated gas is subjected to a gas analyzer to produce a signal whose value corresponds to the concentration of the component in the gas mixture. By measuring the carrier gas volume flowing into the mud/gas separation device, the flow rate of the mud into the separation device, and the component gas signal, a continuous concentration signal representing the concentration of the component gas in the drilling mud may be obtained.
[0005] Gas traps typically divert a portion of the mud returning from the well bore through an enclosure which provides some mechanism for gas release or separation. The release or separation mechanism may be passive, such as a mud-spreading plate, or may contain a mechanical agitator or vibrator to increase the mud/air contact. The liberated gas is transmitted to analytical equipment by a sample line attached to the enclosure of the trap. To provide continuously updated gas readings, mud residence time within the trap enclosure is typically very short. Only a fraction of the gas is liberated from the fluid. Gas traps designed to allow the observed gas in the sample stream to be easily related to the actual gas content of the return mud provide quantitative operation.
[0006] While the liberated gas is typically transmitted to analytical equipment by a sample line attached to the enclosure of the trap, pumps have been implemented to move the gas through the sample line. These pumps are usually positioned on the downstream side of the sample line and create a slight suction in the sample line and enclosure of the trap.
SUMMARY OF THE INVENTION
[0007] This invention relates to detection and measurement of gas entrapped in drilling fluids during oil well drilling operations. In particular, the invention relates to methods and apparatuses for extracting and sampling gas from the drilling fluids.
[0008] According to one aspect of the invention, there is provided a method for liberating gas from drilling mud, the method having the following steps: agitating the drilling mud with an agitator powered by a motor, whereby gas is liberated from the drilling mud; enclosing the liberated gas in an enclosure; and pumping the liberated gas from the enclosure with a pump powered by the motor of the agitating.
[0009] Another aspect of the invention provides a gas trap having: an enclosure comprising an orifice through which fluid enters the enclosure; an agitator of fluid, positioned within the enclosure; a gas pump in fluid communication with the enclosure; and a motor in power transmitting communication with the agitator and the gas pump.
[0010] According to a further aspect of the invention, there is provided a mud logging system having: a gas trap made up of several components including: a means for enclosing a fluid; a means for agitating fluid inside the means for enclosing so that a gas is liberated from fluid and enclosed within the means for enclosing a fluid; a means for pumping the liberated gas from within the means for enclosing a fluid; and a single means for simultaneously transmitting power to the means for agitating and the means for pumping, and a gas detector.
[0011] The objects, features, and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the embodiments which follows.
BRIEF DESCRIPTION OF THE FIGURES
[0012] The present invention may be better understood by reading the following description of non-limitative embodiments with reference to the attached drawings wherein like parts of each of the several figures are identified by the same referenced characters, and which are briefly described as follows.
[0013] FIG. 1 is a perspective view of a gas trap of the present invention having an enclosure, a motor and a gas pump.
[0014] FIG. 2 is a side view of a gas trap of the present invention having an enclosure, a motor and a gas pump.
[0015] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0016] This invention relates to detection and measurement of gas entrapped in drilling fluids during oil well drilling operations. In particular, the invention relates to methods and apparatuses for extracting and sampling gas from the drilling fluids.
[0017] Referring to FIG. 1 , a perspective view of a gas trap embodiment of the present invention is illustrated. The gas trap 1 has an enclosure 2 , a motor 3 and a gas pump 4 . The enclosure 2 is partially submerged into drilling mud 5 , which is contained in a header tank 6 . The enclosure 2 has an orifice 7 in its bottom to allow drilling mud 5 to flow through the orifice 7 into the interior of the enclosure 2 . The enclosure 2 also has a mud return pipe 8 which extends from a side of the enclosure 2 which allows drilling mud 5 to flow from the interior of the enclosure 2 back to the header tank 6 . An agitator drive shaft 10 extends from the motor 3 into the enclosure 2 . An agitator 9 is attached to the distal end of the agitator drive shaft 10 . The agitator 9 is positioned near the orifice 7 so as to swirl the drilling mud 5 as it enters through the orifice 7 . The gas trap 1 also has a gas pipe 11 that extends from the enclosure 2 to the gas pump 4 . A sample line 12 extends from the down stream side of the gas pump 4 . A pump drive shaft 13 extends from the motor 3 and is connected to the gas pump 4 .
[0018] The gas trap 1 operates by drawing a portion of the drilling mud 5 from the header tank 6 into the enclosure 2 . The agitator 9 is rotated by the agitator drive shaft 10 and the motor 3 . The agitator 9 swirls the drilling mud 5 as it is pulled through the orifice 7 in the bottom of the enclosure 2 . As the drilling mud 5 is agitated within the enclosure 2 , gas liberated from the drilling mud occupies the upper portion of the enclosure 2 . After the drilling mud 5 has been agitated and has released at least a portion of the gas trap therein, the drilling mud 5 returns to the header tank 6 through the mud return pipe 8 . The liberated gas collected in the upper portion of the enclosure 2 is drawn by the gas pump 4 out of the enclosure 2 through the gas pipe 11 . The gas pump 4 then pumps the liberated gas through the sample line 12 to the gas analytical equipment or gas detector (not shown).
[0019] During operation of the gas trap 1 , the motor 3 simultaneously drives the pump drive shaft 13 and the agitator drive shaft 10 . Thus, flow of the drilling mud 5 through the enclosure 2 and flow of the liberated gas from the enclosure 2 to the sample line 12 are simultaneously powered by the motor 3 .
[0020] In the illustrated embodiment, the agitator drive shaft 10 and the pump drive shaft 13 are rotated at the same speed because they are direct power outputs from the motor 3 . In an alternative embodiment, a transmission is incorporated into the apparatus to modify the output speed of either the pump drive shaft 13 or the agitator drive shaft 10 . Depending on the particular embodiment of the invention, the drive speed of the gas pump may be reduced or increased by implementing a transmission between the motor 3 and the gas pump 4 . Similarly, the speed at which the agitator 9 is rotated may be reduced or increased by implementing a transmission between the motor 3 and the agitator 9 .
[0021] Referring to FIG. 2 , a side view of an alternative embodiment of a gas trap is illustrated. The gas trap 1 has an enclosure 2 , a motor 3 , and a gas pump 4 . The enclosure 2 is partially submerged in drilling mud 5 . The enclosure 2 is a cylindrical shaped housing structure that has an open orifice 7 at the bottom. The enclosure 2 also has a plurality of vertical slits 14 in the side walls of the enclosure 2 . An agitator drive shaft 10 extends from the top along the longitudinal central access of the enclosure 2 . A plurality of agitators 9 extend from the agitator drive shaft 10 in the vicinity of the slits 14 . The agitator drive shaft 10 is connected to the motor 3 so as to rotate the agitators 9 . Two gas columns 15 extend from the top of the enclosure 2 on opposite sides of the motor 3 . The gas columns 15 merge together at the top where a gas pipe 11 is connected to the gas columns 15 where the gas columns 15 merge. The opposite end of the gas pipe 11 is connected to the gas pump 4 . The gas columns 15 also contain internal filters 16 . The output of the gas pump 4 is connected to the sample line 12 . A pump drive shaft 13 extends from the motor 3 to the gas pump 4 . A drive guard 17 encircles the pump drive shaft 13 to prevent inadvertent contact with the rotating pump drive shaft 13 .
[0022] The gas trap 1 , illustrated in FIG. 2 , operates by allowing drilling mud 5 to enter into the enclosure 2 through the orifice 7 and/or slits 14 . The motor 3 rotates the agitator drive shaft 10 so that the agitators 9 stir the drilling mud 5 within the enclosure 2 . As the drilling mud 5 is agitated, gas trapped within the drilling mud 5 is liberated and moves to the upper portion of the enclosure 2 . By pump drive shaft 13 , the motor 3 also drives the gas pump 4 . The gas pump 4 draws gases from the upper portion of the enclosure 2 through the gas columns 15 and the gas pipe 11 . The pump 4 creates a slight vacuum, relative to atmospheric pressure, so that the liberated gas in the upper portion of the enclosure 2 is drawn through the internal filters 16 , the gas columns 15 , and the gas pipe 11 . The gas pump 4 then pumps the liberated gas under positive pressure through the sample line 12 to gas analytical equipment or gas detector 18 . The gas analytical equipment may include any gas detector known to persons of skill including a gas chromatograph. In particular, it may include an explosion proof IR gas detector having a sample filter and water dropout. The gas detector 18 may output a signal in response to the detected gas level to a computer 19 .
[0023] In alternative embodiments, the motor may be placed above both the gas pump 4 and the agitator 9 . In particular, a pump drive shaft 13 may extend from the motor 3 down to the gas pump 4 and the agitator drive shaft 10 may extend from the gas pump 4 down to the agitator 9 . In these embodiments, power is transmitted from the motor 4 to the agitator 9 through the gas pump 4 , such that the gas pump 4 has drive shafts extending from both sides of the pump.
[0024] Many of the components of the gas traps of the present invention may be off-the-shelf parts manufactured by various entities known to persons of skill in the art. Further, the components may take a variety of forms and be made of various materials depending on the particular application of the gas trap. For example, the enclosure may take any form so as to allow fluid to flow through one portion of the enclosure and to allow liberated gas to collect in another portion of the enclosure. The enclosure may be made of metal, fiberglass, plastic, or any other material known to persons of skill in the art. The motor may be powered by compressed air, electricity, combustible fuel or any other power source known to persons of skill. The gas pipe and sample lines may be any size and material known to persons of skill. The internal filters in the gas columns may be any filters known to persons of skill capable of trapping solid particulates and allowing the liberated gas to pass therethrough.
[0025] Therefore, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those that are inherent therein. While the invention has been depicted and described with reference to embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alternation, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
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A method for liberating gas from drilling mud, the method having the following steps: agitating the drilling mud with an agitator powered by a motor, whereby gas is liberated from the drilling mud; enclosing the liberated gas in an enclosure; and pumping the liberated gas from the enclosure with a pump powered by the motor of the agitating. A gas trap having: an enclosure comprising an orifice through which fluid enters the enclosure; an agitator of fluid, positioned within the enclosure; a gas pump in fluid communication with the enclosure; and a motor in power transmitting communication with the agitator and the gas pump.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
This invention is directed towards an apparatus and process for increasing the concentric load bearing capabilities for a building foundation support assembly. Various foundation support footings and anchoring systems are known to be used where a bracket, secured to a building foundation, is further supported by a helical anchor which is driven a desired depth below the foundation of the building. The helical anchor is secured to the foundation bracket to provide support to the foundation from settling or uplifting forces. The present invention relates generally to an apparatus and process for improving the concentric load capabilities for each respective anchoring apparatus used with a building.
BACKGROUND OF THE INVENTION
This invention relates generally to foundation support brackets. Buildings often experience foundation settling attributable to loose or sandy soil present around the foundation, overly moist soil, and/or improper construction of the foundation.
It is known in the art to use embedded earth anchors and brackets as a means of supporting foundations. Typically, a screw anchor is positioned beneath a foundation using a torque drive. Respective anchors are positioned at a depth sufficient to support the load of the building structure so as to avoid further settlement of either the screw anchors or the foundation.
The number of screw anchors and foundation supports attached thereto generally correlate to the amount of force needed to support the foundation. Underpinning a foundation using foundation anchors and support brackets is costly in terms of the time and materials needed to install the requisite number of anchors and attached foundation brackets. Any ability to increase the load capabilities of the foundation support apparatus can result in substantial savings of materials and labor by reducing the number of foundation supports needed to shore the foundation. Heretofore, screw anchors were driven by a torque into below ground positions using lengths of square tubing or cylindrical pipe as connectors. As the helical screw is driven further into the foundation subsoil, lengths of tubing or pipe are attached via overlapping ends until the desired depth is obtained. The concentric load bearing capabilities of the tubing or pipe are often the determining factor in the amount of load bearing capability for any single helical anchor and attached bracket. Accordingly, there remains room for improvement and variation within the art in terms of an apparatus and process for increasing the concentric load bearing capabilities of a foundation anchoring system.
SUMMARY OF THE INVENTION
It is one aspect of at least one of the present embodiments to provide for tubular connectors having a series of inner liner sleeves which are positioned between a screw anchor embedded in the soil beneath a building and a foundation bracket where the tubular connectors have improved concentric load capabilities in comparison to an unlined tubular connector.
It is a further aspect of at least one embodiment of this invention to provide for a liner for a tubular connector in which the liner defines along an approximate mid-point a plurality of apertures adapted for engagement with a similar pair of aligned apertures defined in the outer walls of the tubular connector.
It is a further aspect of at least one embodiment of the this invention to provide for a process of securing a foundation bracket to a helical anchor comprising the steps of inserting a helical anchor adjacent a foundation of a building; installing a first push pipe extension to the helical anchor; inserting into an interior of the first push pipe a cylindrical liner which extends substantially about one half a length of the liner into the interior of the first push pipe, the cylindrical liner having a terminal one half length extending from a terminus of the first push pipe; inserting over the terminal length of the liner a second push pipe, the first push pipe and the second push pipe having overlapping ends and having disposed thereon the liner extending therebetween, the first push pipe, the second push pine, and the liner being bolted together through a series of aligned apertures; alternating attaching additional pieces of the push pipe and the liner until a desired depth of the helical anchor is obtained; securing the uppermost end of the liner reinforced push pipe to the foundation bracket; wherein the liner reinforced push pipe has an increased concentric load bearing capability than the push pipe without the liner.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
A fully enabling disclosure of the present invention, including the best mode thereof to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings.
FIGS. 1A through 1C illustrate a helical anchor being inserted into the ground adjacent to a building.
FIGS. 1D and 1E illustrate the components in a respective unassembled and assembled arrangement.
FIG. 1F illustrates the assembled components and partial phantom in relation to a building foundation.
FIG. 1G illustrates a helical anchor attached tubing as seen anchored to a foundation bracket.
FIG. 2 is a perspective view of the components of extension tubes and the extension tube liners which may be used to connect a helical anchor to a foundation bracket.
FIG. 3 is an enlarged view of one section of the load bearing pipe attached to a lower segment of a load bearing pipe.
FIG. 4 is a cross section through FIG. 3 illustrating a final assembly of a load bearing pipe having a reinforcement liner present within the pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present invention are disclosed in the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.
In describing the various figures herein, the same reference numbers are used throughout to describe the same material, apparatus, or process pathway. To avoid redundancy, detailed descriptions of much of the apparatus once described in relation to a figure is not repeated in the descriptions of subsequent figures, although such apparatus or process is labeled with the same reference numbers.
As seen in reference to FIGS. 1A , 1 B, and 1 F, a building 17 having a foundation 15 which, as illustrated here, may be below the surface of the soil, is illustrated. A helical anchor 25 is inserted through rotation to a desired depth below the foundation of the building. The actual depth needed varies depending upon the load bearing requirements of the foundation, the nature of the subsurface soil, and other conditions which are well understood and known by those having ordinary skill in the art. The helical anchor 25 is inserted to the desired depth by the addition of tubular push pipe extensions 20 and may be added sequentially as needed to secure helical anchor 25 to a desired depth below the surface grade.
As seen in reference to FIG. 1F , an individual length of push pipe 20 defines a large diameter coupling along one end which is designed to interengage through a plurality of apertures corresponding to holes 21 along one of either the helical anchor 25 or a previously installed length of push pipe 20 . As additionally seen in reference to FIG. 1B and FIG. 1F , a liner 30 may be inserted within the bore of push pipe 20 and any adjacent push pipe 20 and/or helical anchor 25 . As illustrated, liner 30 defines a plurality of spaced apertures 31 substantially midway along the liner and which traverse the liner on opposite sides. Bolts 40 and corresponding washers and nuts are then used to secure the air liner 30 through apertures 31 while also securing the outer push pipe 20 through apertures 23 defined on the coupling 22 .
In the final arrangement as seen in reference to FIG. 1E , the inner liner 30 traverses approximately half the distance of the adjacent upper and lower portions of the surrounding push pipe and/or helical anchor. Additional interlocking segments of liner 30 and push pipe 20 may be added as needed to extend the helical anchor to the desired depth.
As seen in reference to FIG. 2 , liner 30 may be inserted into an uppermost length of push pipe 20 wherein apertures 21 of push pipe 20 will align with apertures 31 of liner 30 . Nipple 32 of liner 30 is designed to interengage with the larger diameter of the adjacent liner 30 when inserted into push pipe 20 . Prior to securing the push pipe 20 to the liner 30 , an additional length of push pipe 20 is inserted over the liner such that the apertures 23 of coupling 22 also are in alignment with the corresponding apertures 21 of the overlapping portion of the adjacent push pipe 20 and the apertures 31 of liner 30 . Bolts 40 along with associated washers and threaded nuts may be used to secure the interengaged pieces.
In FIG. 4 , a cross section through the assembled push pipe 20 having liner 30 installed therein is illustrated, the cross section take through a coupling 22 as seen in reference to FIG. 3 .
It has been found beneficial to design the length of liner to be slightly less than the individual length of push pipe to account for minor variations in manufacturing tolerances. In this manner, the liners will be assured of adequate play so that the liner apertures 31 may be properly lined up with respect to apertures 21 of an outermost length of push pipe 20 . Additional overlap occurs with an upper portion of push pipe 20 having coupling 22 and corresponding apertures 23 placed in alignment as well.
The alternating segments of push pipe with liners may be assembled to any desired depth and then manually at a desired height so as to secure the anchored push pipe to a foundation bracket 50 as seen in reference to FIG. 1G . It is readily understood by one having ordinary skill in the art that the liner reinforced push pipe as described herein may be used with any number of conventional foundation brackets as are known in the art. Representative brackets include foundation brackets marketed by the assignee such as the Model 99110 sold under the Driverite Piering System™ brand as well as brackets described in U.S. Pat. No. 5,213,448 and U.S. Pat. No. 5,120,163, the teachings and specifications of which are incorporated herein by reference.
The push pipe 20 and liners 30 described herein may be made of conventional metal pipe. It has been found that a 3½″ diameter push pipe having a 4½″ coupling 22 may be used in combination with a liner 20 having a 2⅞″ diameter and end nipple 32 having a reduced diameter of 2⅜″. The combination push pipe and liner as described herein, has been found to have increased concentric load bearing capabilities in comparison to the unlined push pipe. In addition to increased concentric load bearing capabilities, significant improvements are noted in the ability of the flexure plastic moment capabilities which increases from 12,100 lb-ft to 19,100 lb-ft when using a concentric liner in the configurations as described above. Additionally, the increased shaft strength also allows for an increase of installation torque which increases from an unlined value of 10,000 lb-ft to 12,000 lb-ft when a liner 30 is present within the push pipe 20 . Evaluations per ASIC allowable stress design demonstrates that the maximum allowable bending movement upon an unlined sample pipe of 5,860 lb-ft may be increased to 8,650 lb-ft when using a liner as described herein. Similarly, per ASIC criteria, the load and resistance factor design for flexural strength increases from 10,900 lb-ft to 17,200 lb-ft where a liner is present.
For the purposes of illustration in FIGS. 1D through 1F , the liner 30 is seen extending into the interior portion of the helical anchor 25 . It is understood that the insertion is not always required and, depending upon the structure of the helical anchor, may not be possible. However, the similar, overlapping segment construction seen in FIGS. 1D through 1F may be used in which overlapping segments of push pipe 20 are reinforced at the overlapping joints at coupling 22 by a liner secured to the coupling joint along a mid-length portion of the liner. The liner 30 and push pipe 20 have substantially equal lengths such that the alternating arrangement of liners and push pipes are such that each connection between adjacent push pipe lengths 20 are reinforced by a length of liner 30 . By securing liner 30 along a mid-point to the overlapping ends of the adjacent push pipe pieces 20 , the liner provides greater reinforcement than liners which do not substantially traverse half length segments of connecting lengths of push pipe 20 .
Although preferred embodiments of the invention have been described using specific terms, devices, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention which is set forth in the following claims. In addition, it should be understood that aspects of the various embodiments may be interchanged, both in whole, or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein.
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An apparatus and process for increasing the concentric bearing load capabilities of the length of liner is disclosed. Overlapping ends of vertically aligned pipe lengths are joined by a coupling which provides aligned throughholes through the respective pipe ends. A cylindrical liner having a length substantially equal to co-lengths of an individual pipe member is positioned such that a series of throughholes passing through an approximate mid-length portion of the liner are positioned opposite to and aligned with the pipe coupling throughholes. Fasteners are then used to secure the two vertically aligned overlapping pipe ends to the interior liner pipe.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to a mobile accommodation unit in container form. The mobile accommodation unit comprises a box-shaped main box element which has a floor element and a ceiling and normally end and side walls. The main box element may have the standardized dimensions of a conventional container, though this is not necessary, and the dimensions of the main box element may be different from the standardized container dimensions. At least one secondary box element of smaller cross sectional area is provided. In a transport state, this secondary box element is retained within said main box element. This secondary box element can be pulled out of the main box element through a lateral opening of the main box element, in order to provide an accomodation unit of enlarged space and floor area for living or working.
Accommodation units in container form can be used for various purposes. Container can easily and quickly be transported to any desired location by truck, boat, rail, helicopter, airplane or other transport means. Their capacity of quickly providing rooms make the particularly adapted for emergency missions. Container can easily be used as mobile hospital with surgery facilities or as control center for catastrophe or emergency missions. They may also be used, for example, as a command center for military missions. Other applications are work rooms on construction sites, temporary classrooms or simply rooms to live in.
In order to be able to transport containers with conventional transport equipment, the containers are usually made with standardized dimensions. Often, the space available within such containers is not sufficient. It is well known, to place a plurality of such containers side-by-side or one on top of the other. It is possible to connect such containers. To this end, individual side walls of the containers may be removed. This procedure suffers from the disadvantage that a separate vehicle is required for the transport of each container. In some cases, for example if a mobile operating room or a mobile control center is to be established, a rather large, continuous floor area is required, which permits equipment to be installed easily accessible. Such floor areas are not provided by the dimensions of a standardized, mobile container. Often, such continuous floor areas cannot be obtained by modular combination of a plurality of separate containers. Firstly, errecting a construction with a plurality of containers requires quite some time. In addition, such construction will not yield a continuous floor surface of the desired size.
German patent 44 29 927 discloses a mobile accommodation unit in container form, which consists of a main box element and at least one secondary box element, which can be pulled out of the main box element on an open side thereof. A lifting device permits the secondary box element to be lowered, after it has been completely pulled out of the main box element, such that the floor of the secondary box element is lowered to the level of the floor of the main box element. Correspondingly, when retracting the secondary box element, the secondary box element has to be lifted to permit pushing it into the main box element.
A similar design is disclosed by German utility model 0 94 08 060.7. There, a lifting rail is provided, which can be extended from the main box element parallel to the secondary box element and permits the secondary box element to be lowered, in order to bring the floor of the secondary box element to the level of the floor of the main box element.
These prior art mobile accommodation units; suffer from the disadvantage that they are difficult to seal. In order to bring the floors to a common level, the secondary box element has to be removed completely from the main box element, and the the secondary box element has to be lowered as a whole. This results in rather large gaps between main box element and secondary box element. Such gap is difficult to seal. Such seal is, however, imperative, for example, for a sterile operation room. Furthermore, always the whole secondary box element has to be lifted or lowered. This necessitates an expensive an high-power lifting device. This is particularly true, if the secondary box element has heavy equipment such as an operating table fixedly installed therein.
U.S. Pat. No. 3,719,386 has an expansible caravan with a main box element and a secondary box element. The secondary box element is larger than the main box element mounted on a chassis and has no fixed floor. Thereby, the secondary box element can be pushed over the main box element, in the transport state. In the expanded state of use, the secondary box element is pulled laterally from the main box element. A floor for the secondary box element consists of two articulated halves and is folded up, in the transport state. In the state of use, the two halves are straight and close the secondary box element at the bottom.
DISCLOSURE OF THE INVENTION
It is an object of the invention to provide an accommodation unit in container form of the type mentioned in the beginning which permits a continuous floor level to be established after expansion of the secondary box element.
It is another object of the invention to provide an accommodation unit in container form of the type mentioned in the beginning wherein a continuous floor level can be achieved with a minimum of expenditure of equipment or power.
Furthermore, it is an object of the invention to provide an accommodation unit in container form of the type mentioned in the beginning which can easily be sealed.
To this end, the main box element, as means for equalizing the floor levels, has a movable floor element in addition to its basic floor element and means for lifting and lowering this movable floor element.
With such an arrangement, the secondary box element need not be lowered after being pulled out of the main box element. Rather remains the floor of the secondary box element at its floor level, which is higher because the secondary box element has to be movable into the main box element. The floor levels are equalized by appropriate lifting of the movable floor element of the main box element. There is no need, as with the prior art, to completely pull the secondary box element out of the main box element, in order to permit it to be lowered. Instead it is possible to retain the main box element-side edge of the secondary box element within the main box element. This facilitates sealing.
In order to further enlarge the floor area of the mobile accommodation unit in its expanded state, one embodiment of the invention provides a second secondary box element of smaller cross sectional area than that of the first secondary box element. In the transport state, the first secondary box element is retracted into the main box element on one side thereof through a first opening, and the second secondary box element is retracted into the first secondary box element on the opposite side through a second opening of the main box element. The first secondary box element has also a movable floor element which is vertically movable relative to a basic floor element such that the floor levels of both the main box element and of the first secondary box element can be equalized with the floor level of the second secondary box element by appropriate adjustment of the heights of the movable floor elements.
Also here, the floor level of the whole accommodation unit is determined by the highest floor level. Here, this is the floor level of the smallest, second secondary box element which has to be pushed into the first secondary box element, in the transport state. The floor levels of both the main box element and of the first secondary box element are equalized wit this highest floor level by appropriate adjustment of the respective movable floor elements.
Sealing means may be provided between the main box element and each of the secondary box elements. As already explained above, this is facilitated by the fact that main box element and secondary box element retain their relative positions in vertical and lateral direction and are only telescoped into or out of each other.
The sealing may be effected by providing seals between the edges of each lateral opening of the main box element and the secondary box element open towards the main box element along the edges of the secondary box element, such seals sealing the secondary box element in the expanded state relative to the main box element. Cooperating sealing members may be provided on the floor element or movable floor element of each secondary box element and on the movable floor element of the main box element, such sealing members providing a seal between the movable floor element of the main box element and the respective floor elements of the secondary box elements, when the movable floor element has been lifted to the level of the floor element or movable floor element, respectively, of the secondary box elements.
In another embodiment of the invention, again, a second secondary box element of smaller cross sectional area than the first secondary box element is provided. In the transport state, the first secondary box element is retracted into the main box element on one side through a first opening of the main box element, and the second secondary box element is pushed into the first secondary box element on the opposite side through a second opening in the main box element. Here, however, the first secondary box element has a floor element which can be coupled and de-coupled thereto or therefrom, respectively, and the floor level of which in its coupled state is identical with the floor level of the second secondary box element. In the transport state, the de-coupled floor element of the first secondary box element is supported by the movable floor element of the main box element. The movable floor element of the main box element is movable into a fully lowered position, into an intermediate position and into an extended or upper position. In the fully lowered position, the de-copled floor element of the first secondary box element supported thereby is positioned below the floor element of the second secondary box element. In the intermediate position of the movable floor element, the floor element of the first secondary box element is lifted to the floor level of the second secondary box element and can be coupled to the first secondary box element. In the extended or upper position, after both secondary box elements have been expanded or pulled out, the movable floor element of the main box element is lifted to the common floor level of the two secondary box elements.
The height-adjustable movable floor element of the main box element has two functions: Firstly, it forms the floor of the main box element at the same floor level as the floors of the two secondary box elements. Secondly, it serves for lowering the de-coupled floor element of the first, larger secondary box element, such that the second, smaller secondary box element can be shifted into the first secondary box element for the transport state. This permits providing the floor levels of the two secondary box elements in one plane from the beginning.
In the transport state, the secondary box elements are telescoped into the main box element. The floorelement of the first secondary box element is de-coupled therefrom and is supported by the movable floor element of the main box element, the movable floor element being in its fully lowered position. Therefore, the second secondary box element could betelescoped into the first-floor-less-secondary box element without being impeded by the floor element thereof. In order to erect the accommodation unit, at first, the second secondary box element is retracted from the central main box element. The second secondary box element determines the floor level of the accommodation unit. Then, the movable floor element of the main box element is moved by appropriate lifting means into its intermediate position. In this intermediate position, the floor element of the first secondary box element engages the lower edge of the first secondary box element. In this position, the floor level of the first secondary box element is identical with that of the second secondary box element. The floor element is coupled with the first secondary box element. The first secondary box element with the floor element coupled thereto is retracted out of the main box element. Finally, the movable floor element is moved into its extended or upper position, in which the movable floor also is at the floor level of the two secondary box elements.
With such an arrangement, only one hight-adjustable floor element needs be provided, even if two secondary box elements are used.
The coupling of the floor element with the first secondary box element can be effected in the following way: Downwards extending locking bolts having tapered tips are provided along the lower edges of the end walls of the first secondary box element and are vertically movably guided in bushings. Locking balls are retained in lateral openings of the bushings. The floor element of the first secondary box element, which is adapted to be coupled and de-coupled to the first secondary box element, has annular looking members, which have recesses in their inner wall. When the floor element is lifted to engage the first secondary box element, the locking members are shifted over the bushings and locking bolts. The locking bolts can be displaced downwards in the bushings by means of a cam structure, which extend along the lower edges of the first secondary box element. The locking balls are urged radially outwards by the locking bolts and partially extend into the recesses of the locking members. The de-coupling is effected by means of the cam structure in reverse.
The floor elements of the box elements may be guided by rollers, when they are contracted or expanded.
Two embodiments of the invention are described hereinbelow with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, vertical sectional view of a first embodiment of an accommodation unit in container form.
FIG. 2 is a schematic, vertical sectional view of the accommodation unit of FIG. 1 in expanded state.
FIG. 3 is a plan view of the accommodation unit of FIGS. 1 and 2 in its expanded state.
FIG. 4 is a perspective illustration of a main box element wit a guiding system for a secondary box element being in ist operative position.
FIG. 5 is a vertical sectional view of a second embodiment of an accommodation unit in container form, in its transport state.
FIG. 6 is a vertical sectional view of the accommodation unit similar to FIG. 5 after the smaller, second secondary box element has been moved out, the floor element of the first secondary box element still being supported by the movable floor element of the main box element, the latter floor element being in its lowered position.
FIG. 7 is a vertical sectional view similar to FIG. 6, with the movable floor element of the main box element being lifted to its intermediate position and the floor element of the larger, first secondary box element engages the lower edges of the first secondary box element, such that the floor element of the first secondary box element can be coupled with these lower edges.
FIG. 8 is a vertical sectional view similar to FIG. 7 with the larger, first secondary box element, after its floor element has been coupled therewith, being moved out of the main box element.
FIG. 9 is a vertical sectional view of the accommodation unit in its expanded state of use, the movable floor element of the main box element has been lifted to its expanded or upper position and is at the same floor level as the two secondary box elements.
FIG. 10 is a perspective view of the locking mechanism, by means of which the floor element of the first secondary box element can be coupled with the end walls of this secondary box element.
FIG. 11 is a perspective view of the locking mechanism similar to FIG. 10 with lifted and coupled floor element.
FIG. 12 shows a detail “X” of FIG. 8 at an enlarged scale, and illustrates the sealing with fully extended first secondary box element.
FIG. 13 shows a detail “Y” of FIG. 5 at an enlarged scale.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, numeral 10 designates an accommodation unit in container form. In its transport state, the accommodation unit 10 is a box-like unit, which is shown in FIG. 1 in a vertical sectional view. In its retracted state as shown in FIG. 1, the accommodation unit has the dimensions of a conventional, standardized container. The accommodation unit 10 consists of a main box element 12 , a large, first secondary box element 14 and a small, second secondary box element 16 . The secondary box elements 14 and 16 are open on one side towards the main box element 12 and are also box-like. The main box element and the secondary box element may have doors, windows, locks and the like. These elements are not shown in FIG. 1 for clarity. The main box element 12 and the secondary box elements 14 and 16 are marked by different types of hatching. The main box element 12 has rectangular openings 20 and 22 in opposite side walls. The secondary box element 14 and 16 can be moved out of the main box element 12 through the openings 20 and 22 , respectively, by means of a guiding system 18 , as illustrated in FIG. 2 . In FIGS. 1 and 2, only rollers 19 of the guiding system can be seen.
Numerals 24 and 26 designate the rims of the openings 20 and 22 , respectively. The inner edges of the rims 24 and 26 sealingly engage the respective side walls, ceilings and floor elements 32 and 34 , respectively, of the secondary box elements 14 and 16 , respectively. In the retracted transport state, Flanges 40 and 42 of the secondary box elements 14 and 16 , respectively, engage the outer surfaces of the rims 24 and 26 , respectively, and provide an additional seal for the whole retracted container.
A further, movable floor element 38 is ürovided above the floor element 36 of the main box element 12 . Also the larger, first secondary box element 14 has a movable floor element, which is height-adjustable relatibe to the floor element 32 of the secondary box element 14 .
In FIG. 2, the secondary box elements 14 and 16 are expanded or moved out of the main box element 12 . To this end, the secondary box elements 14 and 16 are guided by the guiding system 18 . The guiding system 18 includes guide rails 46 and 48 , which are provided in pairs and can, for example, retracted into or pulled out from housings (not shown) of the main box element 12 . Furthermore, the guiding system 18 has supporting beams 50 and 52 , which can be attached, at their one ends, to the side walls of the main box element 12 in the area of the rims 24 and 26 , respectively, and, at their other ends, to the outer ends of the guide rails 46 and 48 , respectively. When the secondary box elements 14 and 16 are expanded or moved out, they roll on the guide rails 46 and 48 through the rollers 19 . The pairs of guide rails 46 and 48 are interconnected by a longitudinal string piece 54 (FIG. 4) each. The rollers of the secondary box elements 14 and 16 engage a detent device (not shown) to limit their outward movement.
In the present embodiment, the floor element 34 of the small secondary box element 16 has the highest floor level. Both the movable floor element 38 of the main box element 12 and the movable floor element 56 of the large secondary box element 14 are lifted to the floor level of the floor element 34 of the small secondary box element by means of lifting devices 58 and 60 , respectively. Thereby, a continuous, plane floor is obtained throughout the whole floor area of the accommodation unit 10 .
FIG. 3 is a plan view of the accommodation unit 10 . The movable floor element 38 of the main box element 12 is idicated by a cross 62 . The spacing 64 between the end walls 66 of the small secondary box element 16 is selected such that the small secondary box element 16 can be telescoped directly between the end walls of the large secondary box element 14 . The spacing 70 between the end walls 68 of the large secondary box element 14 is dimensioned accordingly. The main box element 12 may have areas 72 and 74 which are not covered by the movable floor element 38 . These areas 72 and 74 may, for example, be used for the drive unit 76 driving the movable floor element 39 or for a air conditioning installation 78 . In FIG. 3, these elements are illustrated merely as boxes.
It can be seen from FIG. 3, that fixedly installed furniture such as control panels, medical cupboards or the like can be mounted substantially only on the side walls 82 . Operation tables or desks can be accommodated in the small secondary box element 16 .
FIG. 4 is a schematic, perspective view of the main box element 12 with the guiding system 18 .
In the transport state, the support beams 52 are unhooked from the guide rails 46 and are accommodated in housing recesses 84 of the side wall 86 of the main box element.
FIGS. 5 to 12 illustrate a second embodiment of an accommodation unit in container form with expandable secondary box elements.
FIG. 5 shows the accommodation unit in its transport state, two secondary box element being telescoped in a main box element.
Referring to FIG. 5, numeral 100 designates a container-like main box element. The main box element 100 has a roof 102 and a floor element 104 . Roof 102 and floor element 104 are interconnected by end walls parallel to the plane of the paper of FIGS. 5 to 9 . In FIGS. 8 and 9, only one end wall 106 with a door is visible. Rectangular openings 114 and 116 are provided in opposite side walls 110 and 112 , respectively.
A larger, first secondary box element 118 is telescoped in the main box element 100 . The secondary box element 118 has a roof 120 , end walls 121 and 123 , of which only the rear end wall 121 is visible in FIG. 5, and a side wall 122 . In FIG. 5, side wall 122 closes the opening 116 . The first secondary box element 118 is open on the side opposite the side wall 122 and defines an opening 124 . In the transport state of FIG. 5, the first secondary box element also has no floor.
A smaller, second secondary box element 126 is telescoped in the first secondary box element 118 . The second secondary box element 126 has a roof 128 , a floor element 130 , end walls, of which only the rear end wall 131 is visible in FIG. 5, and a side wall 132 . In the transport state of FIG. 5, the side wall 132 closes the opening 124 of the first secondary box element 118 .
The main box element 100 has a movable floor element, which can be lifted relatve to the “basic” floor element 104 by a lifting device (not shown). The lifting device may comprise one or more hydraulic jacks or my other type of lifting device well-known to a person skilled in the art. The movable floor element 134 can be moved to a lowered position by the lifting device, as illustrated in FIG. 5, to an intermediate position and in an extended or upper position. A floor element 136 appertaining to the first secondary box element 118 is supported on the lowered movable floor element 134 . This floor element 136 can be coupled with the lower edges of the end walls of the—in FIG. 5 floor-less—first secondary box element 118 , as will be described below.
As can be seen from FIG. 5, the floor element 136 is supported on the movable floor element 134 through rollers 138 .
In this transport state, the accommodation unit has the standardized dimensions of a container and can be transported by conventional transport equipment such as a truck.
In order to set up the expanded accommodation unit, at first, the smaller, second secondary box element 126 ist pulled out to the left in FIG. 5, as illustrated in FIG. 6 . The floor element 130 with its inner or upper surface 140 determines the floor level of the whole accommodation unit. The lower edges 142 of the end walls 121 and 123 of the first secondary box element 118 lie in the plane of the inner surface 140 .
As the next step, the movable floor element 134 of the main box element 100 is lifted to its intermediate position. Thereby, the movable floor element 134 also lifts the floor element 136 supported thereon and brings it into engagement with the lower edges 142 of the end walls 121 , 123 . The floor element 136 is coupled with the end walls 121 and 123 by a locking device to be described below.
In this state, the inner surface of the floor element 136 of the first secondary box element 118 , i.e. the floor level, lies in the same plane as the inner surface 140 of the second secondary box element 126 .
Then the first secondary box element 118 is telescoped to the right in FIG. 7 . This is illustrated in FIG. 8 .
In a final step, the movable floor element 134 of the main box element 100 is then lifted to its extended or upper position. In this position, the surface 144 of the movable floor element 134 lies at the same floor level as the inner surfaces 140 and 142 of the floor elements 130 and 136 of the two secondary box elements 126 and 118 , respectively.
FIGS. 10 and 11 illustrate the coupling of the floor element 136 to the end walls 121 and 123 of the first secondary box element 118 .
Downwards extending bushings 146 are provided at the lower edges of the end faces 121 , 123 of the first secondary box element 118 . Downwards extending locking bolts 148 are slidably guided in the bushings 146 . The locking bolts 148 have tapering tips 150 . The bushings have lateral openings 152 . Locking balls 154 are guided in the lateral openings 152 .
The floor element 136 , adapted to be coupled to or de-coupled from the secondary box element 118 has annular locking elements 156 in alignment with the bushings 146 . The annular locking elements 156 form a bore 158 with an inner wall. The bushings 146 can be inserted into the bore 158 . In their inserted states, the bushings 146 are laterally guided in the bores 158 , as can be seen best from FIG. 11 . The inner wall of each bore 158 has a circumferential groove 160 . When the bushing 146 has been inserted into the bore 158 , the lateral openings 152 of the bushing 146 lie at the level of the circumferential groove 160 .
The locking bolts 148 have an enlarged head 162 . The head 162 is guided in a groove of a cam structure 164 . The cam structure 164 is adjustable along the lower edge 142 by means of an adjusting spindle 166 . In the position of FIG. 10, the locking bolt 148 is retracted. The tapering tip 150 permits the locking balls to yield radially inwards. Then the bushing 146 can be inserted into the annular locking element 156 . If the cam structure 164 is shifted to the front left in FIGS. 10 and 11, the locking bolt 148 will be pushed downwards. The the locking bolt 148 urges the locking balls 156 radially outwards partly into the circumferential groove and prevents yielding of the locking balls 156 radially inwards into the openings 152 . In this way, the floor element 136 is coupled with the lower edges 142 of the end walls 121 and 123 of the first secondary box element 118 .
As can be seen from FIG. 11, a sealing profile 168 of the floor element 136 extends longitudinally to the first secondary box element 118 , i.e. from front right to the rear left in FIGS. 10 and 11, is caused, thereby, to engage a sealing profile complementary thereto of the first secondary box element 118 .
FIG. 12 illustrates the guiding and sealing of the first secondary box element 118 in the main box element 100 , when the secondary box element 118 has been fully expanded.
The floor element 136 of the first secondary box element 118 is guided on rollers 172 , which are provided on the main box element 100 at the lower edge of the opening 116 . A profile 174 extending into the main box element 100 is integrally provided at the inner edge of the first secondary box element 118 . This profile 174 forms a sealing ledge 176 . The sealing ledge cooperates with a sealing ledge 178 complementary thereto of the movable floor element 134 . Thereby, the floor elements 136 and 134 engage sealingly.
An all-around profile 180 at the inner end of the first secondary box element 118 cooperates with a seal 182 extending also all around the opening 116 . The seal is provided on a profile 184 of the man box element 100 extending all around the opening 116 . This profile also carries bearings for the rollers 172 . As the secondary box element 118 is telescoped out of the main box element 100 without relative change of hight, the sealing between main box element 100 and first secondary box element 118 around opening 116 presents no problems.
FIG. 13 shows a detail “Y” of FIG. 5 at an enlarged scale. FIG. 13 shows virtually the same location as FIG. 12, however in the transport state with retracted first secondary box element 118 . A profile 196 extending all around the side wall 122 is provided at the outer end of the first secondary box element 118 . The profile 186 holds a seal 188 also extending all around the side wall 122 . In the transport slate, this seal sealingly engages the profile 184 of the main box element 100 . In addition, the profile 186 bas a horizontal bracket 190 , on which roller 172 is supported.
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A mobile accommodation unit in container form for use as mobile hospital or mobile control or command center or the like has a box-shaped main box element and at least one secondary box element. In a transport state, the secondary box element is telescoped into the main box element. For setting up an accommodation unit of increased floor area, the secondary box element can be pulled out of a lateral opening of the main box element. In order to provide a continuous floor surface, after the secondary box element has been pulled out, the main box element has a movable floor element, which can be lifted relative to a basic floor element so as to equalize the floor levels of the main box element and the secondary box element.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention relates to fire-resistant structures and methods of using same, and more particularly to fire-resistant structures and methods for wellhead outlets and methods of using same.
BACKGROUND OF THE INVENTION
[0002] A wellhead is a component used at the surface of an oil or gas well that provides structural and pressure-containing interface for the drilling and production equipment. Wellheads are often welded to the first string of casing, which has been cemented in place over the well. Thus, wellheads often form an integral part of a well once initially installed.
[0003] Because oil and gas are highly flammable and because the environments in which oil and gas wells are located are often dangerous, it is desirable to provide adequate safety measures to protect wellheads and surrounding structures from potentially-damaging fires. Accordingly, there is a need for fire-resistant structures for wellhead outlets and methods of using same.
ASPECTS OF THE INVENTION
[0004] Additional aspects of the invention include:
[0005] Aspect 1: A kit for retrofitting an existing wellhead outlet, the existing wellhead outlet having at least one exterior surface, the kit comprising at least one spacing assembly, the at least one spacing assembly being attachable at a first end thereof to the at least one exterior surface of the existing wellhead outlet, the at least one spacing assembly further comprising a second end that is spaced apart from the first end; and at least one panel that is attachable to the second end of the at least one spacing assembly.
[0006] Aspect 2: The kit according to Aspect 1, wherein the at least one panel is comprised of a flame-retardant ceramic material.
[0007] Aspect 3: The kit according to either of Aspect 1 or Aspect 2, wherein the at least one spacing assembly is comprised of an insulated material.
[0008] Aspect 4: The kit according to any of Aspects 1-3, wherein each of the at least one panel has a planar exterior surface.
[0009] Aspect 5: The kit according to any of Aspects 1-4, wherein the at least one panel and at least one spacing assembly can fully enclose the wellhead outlet, except for any port that extends from the wellhead outlet.
[0010] Aspect 6: The kit according to any of Aspects 1-5, wherein the at least one spacing assembly includes at least one removable fastener that attaches the at least one spacing assembly to the wellhead outlet.
[0011] Aspect 7: An apparatus comprising: a wellhead outlet having at least one exterior surface; and at least one panel attached to the at least one exterior surface of the wellhead outlet such that the at least one panel is spaced apart from the at least one exterior surface of the wellhead outlet.
[0012] Aspect 8: The apparatus according to Aspect 7, wherein the at least one panel is comprised of a flame-retardant ceramic material.
[0013] Aspect 9: The apparatus according to either of Aspect 7 or Aspect 8, further comprising at least one spacing assembly attached to both the at least one panel and the at least one exterior surface of the wellhead outlet and acts to space the at least one panel apart from the at least one exterior surface of the wellhead outlet.
[0014] Aspect 10: The apparatus according to Aspect 9, wherein the at least one spacing assembly is comprised of an insulated material.
[0015] Aspect 11: The apparatus according to any of Aspects 7-10, wherein the at least one panel can fully enclose the wellhead outlet, except for any port that extends from the wellhead outlet.
[0016] Aspect 12: The apparatus according to any of Aspects 7-11, wherein the at least one panel is attached to the at least one exterior surface of the wellhead outlet using at least one removable fastener.
[0017] Aspect 13: A method of protecting a wellhead outlet, the wellhead outlet having at least one exterior surface, the method comprising: attaching one or more spacing assemblies to the at least one exterior surface of the wellhead outlet; and attaching one or more panels to the one or more spacing assemblies such that the one or more panels are spaced apart from the at least one exterior surface of the wellhead outlet.
[0018] Aspect 14: The method according to Aspect 13, further comprising the step of tapping a threaded hole into the at least one exterior surface of the wellhead outlet, wherein the step of attaching one or more spacing assemblies to the at least one exterior surface of the wellhead outlet comprises attaching one or more spacing assemblies to the threaded hole.
[0019] Aspect 15: The method according to either of Aspect 13 or Aspect 14, wherein the step of attaching one or more panels to the one or more spacing assemblies comprises attaching one or more panels to the one or more spacing assemblies, wherein the one or more panels is comprised of a flame-retardant ceramic material.
[0020] Aspect 16: The method according to any of Aspects 13-15, wherein the step of attaching one or more panels to the one or more spacing assemblies further comprises fully enclosing the wellhead outlet within the one or more panels, except for any port that extends from the wellhead outlet.
[0021] Aspect 17: The method according to any of Aspects 13-16, wherein the step of attaching one or more panels to the one or more spacing assemblies further comprises including one or more holes in the one or more panels to permit one or more ports that extends from the wellhead outlet to extend through the one or more panels.
[0022] Aspect 18: The method according to Aspect 17, further comprising the step of filling any gap between the one or more ports and a respective one of the one or more holes located in the one or more panels with a flame-retardant ceramic material.
[0023] Aspect 19: The method according to Aspect 18, wherein the step of filling any gap further comprises filling any gap with a thermal blanket.
[0024] Aspect 20: The method according to any of Aspects 13-19, wherein the step of attaching one or more panels to the one or more spacing assemblies comprises attaching one or more panels to the one or more spacing assemblies that are removable from the one or more spacing assemblies.
[0025] Aspect 21: The method according to any of Aspects 13-20, further comprising: removing the one or more panels from the one or more spacing assemblies; and reattaching the one or more panels to the one or more spacing assemblies.
[0026] Aspect 22: A method of protecting a wellhead outlet having at least one gasket, the at least one gasket having a circumference, the wellhead outlet having at least one exterior surface, the method comprising: attaching at least one panel to the at least one exterior surface of the wellhead outlet to form an enclosure around the wellhead outlet, wherein the enclosure provides sufficient insulation for the wellhead outlet in order to prevent the at least one gasket from leaking at a rate in excess of 1 ml/in. per minute of mean measurement of the circumference of the at least one gasket when the wellhead outlet has been pressurized to at least 75% of its rated working pressure with water after the enclosure has been exposed to a continuous flame of at least 1000 degrees F. (538 degrees C.) for at least 30 minutes.
[0027] Aspect 23: The method according to Aspect 22, wherein the step of attaching at least one panel to the at least one exterior surface of the wellhead outlet to form an enclosure around at least a portion of the wellhead outlet further comprises attaching one or more spacing assemblies to the at least one exterior surface of the wellhead outlet and attaching the at least one panel to the one or more spacing assemblies.
[0028] Aspect 24: The method according to either of Aspect 22 or Aspect 23, wherein the step of attaching at least one panel to the at least one exterior surface of the wellhead outlet further comprises attaching least one panel to the at least one exterior surface of the wellhead outlet having at least one non-planar surface.
[0029] Aspect 25: A system comprising: a wellhead outlet having at least one exterior surface; and at least one flame-retardant panel that is directly attached to the at least one exterior surface of the wellhead outlet.
[0030] Aspect 26: The system according to Aspect 25, wherein the at least one flame-retardant panel is in contact with the at least one exterior surface of the wellhead outlet.
[0031] Aspect 27: The system according to either of Aspect 25 or Aspect 26, wherein the at least one flame-retardant panel is removably attached to the at least one exterior surface of the wellhead outlet.
[0032] Aspect 28: The system according to any of Aspects 25-27, wherein the at least one flame-retardant panel has at least one non-planar surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention disclosed herein, certain embodiments in accordance with the herein disclosed invention are shown in the drawings. It should be understood, however, that the herein disclosed invention is not limited to the precise arrangements shown. It should also be understood that, in the drawings, the parts are not necessarily drawn to scale. The present invention will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals denote like elements. In the drawings:
[0034] FIG. 1 is a top perspective view of an exemplary wellhead outlet according to the prior art;
[0035] FIGS. 2A and 2B are perspective views of an exemplary wellhead outlet according to the prior art, partially outfitted with a fire-resistant enclosure according to the present invention;
[0036] FIGS. 3A and 3B are perspective views of an exemplary wellhead outlet according to the prior art, fully outfitted with a fire-resistant enclosure according to the present invention;
[0037] FIG. 4 is an exploded view thereof;
[0038] FIG. 5 is a perspective view of an exemplary wellhead outlet according to the prior art, fully outfitted with a fire-resistant partial enclosure according to the present invention;
[0039] FIG. 6 shows a spacing assembly according to the present invention;
[0040] FIG. 7 shows the connection means between an exemplary panel according to the present invention and a prior art wellhead outlet;
[0041] FIG. 8 shows the connection means between exemplary panels according to the present invention; and
[0042] FIG. 9 shows a portion of a wellhead outlet that has been modified to accommodate installation thereto of a fire-resistant structure according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The ensuing detailed description provides preferred exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the herein disclosed inventions. Rather, the ensuing detailed description of the preferred exemplary embodiments will provide those skilled in the art with an enabling description for implementing the preferred exemplary embodiments in accordance with the herein disclosed invention. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention, as set forth in the appended claims.
[0044] To aid in describing the invention, directional terms may be used in the specification and claims to describe portions of the present invention (e.g., upper, lower, left, right, etc.). These directional definitions are merely intended to assist in describing and claiming the invention and are not intended to limit the invention in any way. In addition, reference numerals that are introduced in the specification in association with a drawing figure may be repeated in one or more subsequent figures without additional description in the specification in order to provide context for other features.
[0045] Referring generally to FIGS. 1-9 , embodiments of a system for protecting a wellhead outlet 1 according to the prior art will be described in detail. FIG. 1 is a perspective view of an exemplary wellhead outlet 1 according to the prior art. The wellhead outlet 1 comprises a high pressure bowl 2 having a body 4 and a lid 3 . Extending from one side of the body 4 of the wellhead outlet 1 is a high pressure data port 14 . Connected to another side of the body 4 of the wellhead outlet 1 is a low pressure bowl 9 . The low pressure bowl 9 comprises a body 10 having an exterior surface 11 and an exposed end 12 having an exterior surface 13 . An atmosphere data port 15 extends from the body 10 of the low pressure bowl 9 . Although one embodiment of a wellhead outlet 1 is shown and described in this application, it should be understood that the herein disclosed systems and methods for protecting a wellhead outlet are applicable, mutatis mutandis, to a wellhead outlet of any configuration, and that the particular embodiment of a wellhead outlet 1 shown in the appended figures and described herein is presented only for discussion purposes.
[0046] The herein disclosed systems and methods, in one respect, describe enclosures or partial enclosures (see, e.g., enclosure 30 of FIGS. 3A and 3B and partial enclosure 130 of FIG. 5 ) for protecting the wellhead outlet 1 from fires. In one embodiment, this is accomplished by spacing one or more flame-retardant or protective panels away from exterior surface(s) of the wellhead outlet 1 . These protective panels can be retrofitted to enclose or partially-enclose existing wellhead outlets, or new wellhead outlets could be provided that have pre-existing means to attach the protective panels thereto. Protective panels can be removed from a wellhead outlet to permit the wellhead outlet to be serviced or to allow the protective panels to be reused, for example after a well has run dry or been abandoned. Wellhead outlets may also be protected from flames by applying flame-retardant coatings, films, or other materials directly to the parts of the wellhead outlet.
[0047] As shown in FIGS. 2A and 2B , the enclosure 30 is constructed by first attaching one or more spacing assemblies 32 a - 32 f to the exterior surface(s) of one or more parts of the wellhead outlet 1 . In this embodiment of the enclosure 30 , six spacing assemblies 32 a - 32 f are used, although one of ordinary skill in the art would recognize that a lesser or greater quantity of spacing assemblies can be used based on such factors as the size, dimensions, and geometry of the wellhead outlet to which the spacing assemblies are being attached and the weight and geometry of the protective panels that are being attached to the spacing assemblies. In this embodiment, the spacing assemblies 32 a - 32 f are attached via removable hardware (i.e., bolts), so that the spacing assemblies 32 a - 32 f can be removed from the wellhead outlet 1 . In alternate embodiments, the spacing assemblies 32 a - 32 f could be attached to the exterior surface(s) of one or more parts of the wellhead outlet 1 in other ways, for example by riveting, bonding, or through use of a suitable adhesive.
[0048] In the embodiment shown in FIGS. 2A and 2B , spacing assembly 32 a is attached to the exterior surface 11 of the exposed end 12 of the body 10 of the low pressure bowl 9 , spacing assemblies 32 b - 32 d are attached to the exterior surface 6 of the bottom side 5 of the body 4 of the high pressure bowl 2 , and spacing assemblies 32 e , 32 f are attached to the exterior surface 8 of the rear side 7 of the body 4 of the high pressure bowl 2 . The spacing assemblies 32 a - 32 f thus provide spacing away from the various exterior surfaces of the wellhead outlet 1 in all three primary axes. In alternate embodiments, the panels described below may be located directly adjacent to the exterior surface(s) of the wellhead outlet to which it is attached.
[0049] FIGS. 3A-4 show an enclosure 30 comprising a plurality of panels, each of which is connected either directly to one or more of the spacing assemblies 32 a - 32 f or indirectly to one or more of the spacing assemblies 32 a - 32 f via one or more additional panels. In this embodiment, the panels are removably attached to the spacing assemblies 32 a - 32 f , so that after installation the panels can be removed from and reattached to the spacing assemblies 32 a - 32 f . In this embodiment, the enclosure 30 comprises a top panel 42 , a side panel 44 that is directly connected to spacing assembly 32 a , front panels 48 , 49 , 50 , a bottom panel 55 that is directly connected to spacing assemblies 32 b - 32 d , and a rear panel 53 that is directly connected to spacing assemblies 32 e , 32 f . In FIGS. 3A and 3B (as well as FIGS. 7 and 8 ), the panels of the enclosure 30 are rendered transparent so that the connections between parts located behind the panels, as well as the placement of the wellhead outlet 1 and its parts respective to the panels of the enclosure 30 , can be clearly seen. It should be understood that, in many embodiments, the panels will not actually be transparent. In FIGS. 3A, 3B, and 7 , the lines representing the wellhead outlet 1 are given a lighter weight than that of the lines representing the parts of the enclosure 30 .
[0050] In this embodiment, the panels are a fiber-reinforced composite comprised of a matrix of SiOC (silicon oxycarbide) embedded with Nextel™ fibers produced by 3M Company of St. Paul, Minn., U.S.A. In alternate embodiments, the matrix may be any suitable ceramic material or high-temperature polymer, and the fibers may be carbon fiber, glass fiber, boron nitride fiber, or other suitable fibers.
[0051] In this embodiment, top panel 42 has an exterior surface 42 a and a port hole 43 that permits passage of the atmosphere data port 15 of the wellhead outlet 1 therethrough. Front panel 50 has an exterior surface 50 a and a port hole 51 that permits passage of the high pressure data port 14 of the wellhead outlet 1 therethrough. Side panel 44 has an exterior surface 44 a , front panel 48 has an exterior surface 48 a , front panel 49 has an exterior surface 49 a , side panel 46 has an exterior surface 46 a , rear panel 53 has an exterior surface 53 a , and bottom panel 55 has an exterior surface 55 a . In this embodiment, each of the exterior surfaces 42 a , 44 a , 46 a , 48 a , 49 a , 50 a , 53 a , 55 a of the respective panels 42 , 44 , 46 , 48 , 49 , 50 , 53 , 55 is planar. In alternate embodiments, at least a portion of the exterior surface of at least one panel of the enclosure is planar. In further alternate embodiments according to the present invention, the panels of the enclosure may include no planar portions.
[0052] FIG. 6 depicts the parts of one of the spacing assemblies (i.e., spacing assemblies 32 a - 32 f ). Each of the spacing assemblies 32 a - 32 f comprises a spacing fastener 33 (which in this embodiment is a bolt), the spacing fastener 33 having a head 34 and a shaft 35 , an exterior washer 36 , an interior washer 38 , and spacing blocks 40 a - 40 c . The spacing blocks 40 a - 40 c are placed adjacent the exterior surface of the wellhead outlet 1 and the interior washer 38 is placed adjacent the spacing blocks 40 a - 40 c . In this embodiment three spacing blocks 40 a - 40 c are used, and each spacing block 40 a - 40 c is tubiform in shape. In alternate embodiments, a greater or lesser number of spacing blocks may be used, and/or the spacing blocks 40 a - 40 c may have a different shape. In this embodiment, the spacing blocks 40 a - 40 c are made of the same fiber-reinforced composite material as the panels. In alternate embodiments, the spacing blocks 40 a - 40 c may be comprised of any suitable insulative material. In alternate embodiments, the spacing fastener may comprise some part other than a bolt, for example a lag, screw, rod, pipe, or tube that is connectable to both the wellhead outlet 1 and the enclosure 30 .
[0053] In this embodiment, the interior washer 38 is located adjacent to the interior surface of the respective panel. The exterior washer 36 is located around the shaft 35 of the spacing fastener 33 and adjacent the exterior surface of the respective panel, and the shaft 35 of the spacing fastener 33 is passed through a spacing hole located in the respective panel, the interior washer 38 , and the spacing blocks 40 a - 40 c and then connected to the wellhead outlet. The head 34 of the spacing fastener 33 and the exterior washer 36 collectively form the exterior portion 39 of the spacing assembly, which is located external to the enclosure 30 (i.e., external to the respective panel). The spacing blocks 40 a - 40 c and the interior washer collectively form the interior portion 37 of the spacing assembly, which is located internal to the enclosure 30 (i.e., internal to the respective panel). A portion of the shaft 35 of the spacing fastener 33 is located within the spacing fastener hole in the respective panel. FIG. 7 shows the connection of the side panel 44 to the exterior surface 13 of the exposed end 12 of the body 10 of the low pressure bowl 9 of the wellhead outlet 1 via the spacing assembly 32 a.
[0054] As best seen in FIG. 4 , rear panel 53 includes spacing fastener hole 54 a and spacing fastener hole 54 b , which accommodate, respectively, spacing assembly 32 f and spacing assembly 32 e ; bottom panel 55 includes spacing fastener holes 56 a - 56 c , which accommodate, respectively, spacing assemblies 32 b - 32 d ; and side panel 44 includes spacing fastener hole 45 , which accommodates spacing assembly 32 a . As noted previously, the side panel 44 is directly connected to the wellhead outlet 1 via spacing assembly 32 a , the bottom panel 55 is directly connected to the wellhead outlet 1 via spacing assemblies 32 b - 32 d , and the rear panel 53 is directly connected to the wellhead outlet via spacing assemblies 32 e , 32 f . These panels 44 , 53 , 55 are then connected to the additional panels 42 , 46 , 48 , 49 , 50 via spacing blocks and panel attachment fasteners to form the enclosure 30 . All of the spacing blocks and panel attachment fasteners of the enclosure 30 are shown in the exploded view of FIG. 4 , but for purposes of readability these parts are not labeled and all explode lines are not included.
[0055] FIG. 8 shows an exemplary corner of the enclosure 30 , where top panel 42 , side panel 44 , and front panel 48 are joined together via a panel attachment block 60 . In this embodiment, the block 60 is cubic in shape and has internal threading located through the center of all three major axes thereof, with the internal threading terminating at three adjacent faces of the block 60 at fastener holes 61 a - 61 c (fastener hole 61 c labeled in FIG. 3A ). Exterior washer 63 a is placed around panel attachment fastener 62 a , which is used to secure top panel 42 to the fastener hole 61 a of block 60 ; exterior washer 63 b is placed around panel attachment fastener 62 b , which is used to secure side panel 44 to the fastener hole 61 b of block 60 ; and exterior washer 63 c is placed around panel attachment fastener 62 c , which is used to secure front panel 48 to the fastener hole 61 c of block 60 . In alternate embodiments, the panels may be directly connected together without the use of corner blocks.
[0056] In some embodiments, as shown in FIG. 9 , one or more exterior surfaces of a prior art wellhead outlet 1 may be tapped so that these surfaces are outfitted with internally threaded holes 70 for accommodation of the shaft 35 of the spacing fastener 33 therein. In alternate embodiments according to the present invention, the wellhead outlet may be provided with tapped holes already located in the exterior surface(s) thereof for accommodating the spacing fastener(s), and the wellhead outlet provided along with the necessary parts of the enclosure as part of the protective system for the wellhead outlet.
[0057] The embodiment of the enclosure 30 shown in FIGS. 3A-4 fully encloses the wellhead outlet 1 therein, with the exception of the port holes 43 , 51 that permit the atmosphere data port 15 and high pressure data port 14 , respectively, to pass therethrough and exit the enclosure 30 . In embodiments where there is a gap left between one or both of the port holes 43 , 51 and the respective port 14 , 15 , said gap is preferably filled with a flame-retardant material, for example a commercially-available fire blanket. One example of a suitable, commercially-available fire blanket is the Fiberfrax S Durablanket which is produced by Thermal Products Company, Inc. of Norcross, Ga., U.S.A.
[0058] In some applications, it may not be necessary to fully enclose all sides of the wellhead outlet 1 within an enclosure. FIG. 5 shows a partial enclosure 130 for a wellhead outlet that utilizes only some of the parts of the full enclosure 30 . For example, in this embodiment the partial enclosure 130 utilizes only the side 46 , rear 53 , and bottom 55 panels, spacing assemblies 32 b - 32 f (spacing assemblies 32 d - 32 f not shown in FIG. 5 ), and some panel attachment blocks and accompanying panel attachment fasteners.
[0059] One purpose of the enclosure 30 or partial enclosure 130 is that it is designed to enable the wellhead outlet 1 to withstand exposure to fire or other sources of high heat without seal failure. The enclosure 30 is designed to protect the seals of the wellhead outlet 1 —e.g., the high pressure bowl 2 and the fiber optic feedthrough assembly (not labeled), which is located interior to the low pressure bowl 9 —from significant leakage after exposure to fire.
[0060] In order to demonstrate this capability, the wellhead outlet 1 (i.e., the end connection) was fitted with the enclosure 30 and successfully tested using the following test protocol:
An exterior surface of the enclosure 30 is fitted with at least three thermocouples, each thermocouple being located within the center of 1.5-inch (3.8 cm) cubic carbon steel calorimeter blocks, the thermocouples and calorimeter blocks being spaced apart from each other within the plane of the exterior surface of the enclosure 30 by no more than 12 inches (30.5 cm); The wellhead outlet system is completely filled with water; The wellhead outlet system is pressurized to at least 75% of its rated working pressure (for example, if an end connection is rated at 2000 psig (13.8 MPa), the system should be pressurized to at least 1500 psig (10.3 MPa)); A fire is established in the vicinity of the end connection to be tested (i.e., the exterior surface of the enclosure) and the flame temperature is monitored during the “burn period,” which is no less than 30 minutes in duration from the time that the fire is first established:
The average temperature reading of the thermocouples must reach 1400 degrees F. (761 degrees C.) within 2 minutes from the time that the fire is established; The average temperature reading of the thermocouples must be maintained between 1400 and 1800 degrees F. (761 and 980 degrees C.), with no reading less than 1300 degrees F. (704 degrees C.), until the average calorimeter temperature reaches 1200 degrees F. (650 degrees C.). The average calorimeter temperature shall reach 1200 degrees F. (650 degrees C.) within 15 minutes from the time that the fire is established. After those average calorimeter temperatures are reached, for the remainder of the duration of the burn period, the calorimeters shall maintain a minimum average temperature of 1200 degrees F. (650 degrees C.), and no calorimeter reading shall be below 1050 degrees F. (565 degrees C.);
The wellhead outlet system is then cooled to no more than 212 degrees F. (100 degrees C.), and the system is depressurized; The pressure in the wellhead outlet system is then increased to no less than 75% of its rated working pressure, and this test pressure is held for a minimum of 5 minutes; The water leakage rate from the end connection is measured during the burn and cooldown periods and during the 5 minute period after depressurization and repressurization, with a “pass” result for this test being an end connection leakage rate of no greater than 1 ml/in. per minute of mean primary gasket circumference (i.e., the mean circumference of the primary gasket of the tested end connection).
[0070] It should be appreciated that the foregoing is presented by way of illustration only, and not by way of any limitation, and that various alternatives and modifications may be made to the illustrated embodiments without departing from the spirit and scope of the present invention.
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The present application teaches fire-resistant structures and methods for wellhead outlets, and methods of using same. In one embodiment, the fire-resistant structure includes a plurality of spacing assemblies ( 32 a - f ) that space a plurality of fire-resistant panels ( 42, 44, 46, 48, 49, 50, 53, 55 ) away from the exterior surface of a wellhead outlet ( 1 ), such that a space or volume is created between the fire-resistant panels ( 42, 44, 46, 48, 49, 50, 53, 55 ) and the exterior surface of the wellhead outlet ( 1 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 60/650,471, filed Feb. 7, 2005, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to concrete curb forming machines. More particularly, the present invention relates to an improved method and apparatus for forming concrete curbs wherein a motorized, preferably tracked excavator supports a frame with an improved interface at a lateral “outrigger” position, the frame having a vertically extended hollowed hopper that receives wet concrete at an upper opening and discharges the wet concrete to a curb shaping portion at a lower opening, a special optional guide arrangement aiding an operator to track a desired path during formation of the curb.
2. General Background of the Invention
Devices that form concrete curbs or curbing are known. Examples of such devices are seen in the patents listed in the following table, each patent listed being incorporated herein by reference.
TABLE
PATENT
NUMBER
TITLE
ISSUE DATE
1,334,483
Tool for Shaping or Forming Cement Curbs
Mar. 23, 1920
and Gutters
3,108,518
Curb and Gutter Formers
Oct. 29, 1963
3,749,505
Concrete Curb Laying Machine
Jul. 31, 1973
3,779,662
Curb Slip Form Apparatus
Dec. 18, 1973
3,954,359
Apparatus for the Continuous Casting of
May 4, 1976
Concrete
4,391,549
Expansion Joint Inserter for Continuous Curb
Jul. 5, 1983
Laying Machines
5,173,005
Prime Mover Actuated Concrete Curb
Dec. 22, 1992
Extruder
5,662,431
Self-Propelled Slip-Form Paving Apparatus
Sep. 2, 1997
BRIEF SUMMARY OF THE INVENTION
The present invention provides an apparatus for forming elongated concrete curbs. The apparatus includes a frame having front and rear portions, the frame supporting a hopper having upper and lower end portions. The hopper provides a hollowed interior that includes upper and lower openings.
The frame has an curb shaping portion that extends from the lower end of the hopper next to the lower opening. A motor driven vehicle (e.g. tractor) is provided for moving the frame along the selected path, the tractor can have a liftable portion (e.g. hydraulically operated) that is movable between lowered and elevated positions.
The liftable portion of the vehicle can thus elevate and lower the frame.
An interface connects the frame to the vehicle in a manner that supports the hopper wall in a proper attitude during curb forming operations.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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:
FIG. 1 is a perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 2 is a rear view of the preferred embodiment of the apparatus of the present invention;
FIG. 3 is a front view of the preferred embodiment of the apparatus of the present invention;
FIG. 4 is a top view of the preferred embodiment of the apparatus of the present invention;
FIG. 5 is a front view of the preferred embodiment of the apparatus of the present invention;
FIG. 6 is a fragmentary perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 7 is a fragmentary perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 8 is a rear perspective view of the preferred embodiment of the apparatus of the present invention; and
FIG. 9 is a fragmentary view of the preferred embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1-9 of the drawings, curb forming machine or curbing machine 10 utilizes a self propelled vehicle (e.g. tracked) such as an excavator or tractor 11 that can have a motor driven frame 12 and a ground engaging interface provided for example by endless tracks such as the left track 13 and right track 14 shown. Tractor 11 can for example be a Bobcat® model 325 mini-excavator or the like.
Vehicle 11 has front end portion 15 , rear end portion 16 and a mounting plate 17 that releasably attaches to frame 12 at a position next to left track 13 .
The mounting plate 17 provides a T-shaped socket 18 that forms a connection with correspondingly shaped hanger 19 . Hanger 19 can be comprised of horizontal flange 19 A and vertical flange 19 B. Vertical flange 19 C joins horizontal flange 19 A to bushing 56 . In order to disconnect, a user simply lowers blade 34 and moves vehicle 11 until plate 17 and socket 18 receives hanger 19 (see arrow). To engage, this procedure is reversed. Set screws 67 can be used to secure hanger 19 to plate 17 (see FIG. 6 ). The hanger 19 connects to frame 20 at bushing 56 and rod 33 . Frame 20 is a frame that receives wet concrete via hopper 23 and shapes that wet concrete into a curb shape in continuous fashion as tractor 11 advances along a selected path, continuously forming a curb C.
Frame 20 has front end portion 21 , rear end portion 22 and hopper 23 . Hopper 23 has upper end portion 24 , lower end portion 25 and a hollowed interior 26 for receiving wet concrete that can for example be transferred to the hopper 23 upper end portion 24 using a cement mixer vehicle or truck 62 (see FIG. 8 ) having a delivery chute 63 . Hopper 23 provides upper opening 27 and lower opening 28 . The upper opening 27 is at upper end portion 24 and receives wet concrete. The lower opening 28 communicates with curb forming section 29 .
In FIG. 2 , the curb forming section 29 includes a shaped plate 30 that is shaped to produce a curb having a substantially uniform cross section. The curb transverse cross sectional shape is defined by the shape of the plate 30 as vehicle 11 moves forward, as best seen in FIGS. 2 and 8 . The shaped plate 30 is comprised of plate sections 31 a , 31 b , 31 c , 31 d.
At the front end portion 21 of frame 20 , a cylindrical bushing 32 extends transversely, being generally perpendicular to left track 13 , right track 14 and the central longitudinal axis of tractor 11 . Bushing 32 carries rod 35 . Transverse rod 35 connects to a hydraulic lifting device on tractor 11 such as for example blade 34 . Rod 32 attaches to blade 34 at sleeve 65 , secured with bolt 66 or a bolted or welded connection. Transverse bushing 32 is connected to and a part of frame 20 , being attached to forward, diagonally extending strut 52 .
When blade 34 is elevated, transverse rod 35 and transverse bushing 32 are also elevated. In order to insure that frame 20 maintains a desired attitude with respect to an underlying support surface 55 , longitudinal rod 33 connects to the front end portion 21 and rear end portion 22 of frame 20 using front arm 37 , front bushing 38 , rear arm 41 , and rear bushing 42 . The front arm 37 and bushing 38 are attached to bushing 32 . Rear arm 41 and bushing 42 attach to rear end portion 22 of frame 20 . Cylindrical, longitudinal bushing 56 is at a fixed elevation, being rigidly attached to hanger 19 of tractor 11 (see FIGS. 6-7 ).
When blade 34 and rod 35 are elevated (see arrow 52 , FIG. 5 ), front and rear arms 37 , 41 rotate with respect to cylindrical bushing 32 as each of the arms 37 , 41 is attached to longitudinal rod 33 (see FIGS. 2-3 ). The transverse rod 35 lifts bushing 36 , rod 33 , and rotates front arm 37 while also rotating longitudinal rod 33 to which front arm 37 is connected. This rotation of front arm 37 and longitudinal rod 33 also rotates rear arm 41 .
Because rear arm 41 is attached to rear end portion 22 of frame 20 at rear bushing 42 , frame 20 is elevated (see arrow 54 ) while maintaining its attitude with respect to an underlying support surface (e.g. road) 55 . The front and rear arms 37 , 41 lift front 21 and rear 22 end portions of frame 20 simultaneously and at substantially equal elevational positions.
Forward threaded rods 44 , 45 are each provided with adjustment nuts 46 , 47 respectively. Similarly, rear threaded rods 48 , 49 are provided with adjustment nuts 50 , 51 respectively. The threaded rods 44 , 45 , 48 , 49 provide a fine adjustment for finely adjusting the position of shaped plate 30 and forward plate 53 to thus fine tune the shape of a curb C that is produced as the apparatus 10 moves in the direction of arrow 40 in FIG. 8 .
Guide rod 60 is an optional, elongated substantially horizontally extending rod having transverse sections 61 . An operator can rotate the transverse section 61 until is tracking the edge of an area (for example street, driveway, parking lot) to be curbed. The operator of the tractor 11 ensures that transverse section 61 travels along a selected path so that by definition, the curb C formed by apparatus 10 will also track a selected path.
During use, a cement mixer vehicle 62 having a delivery chute 63 can travel in front of the apparatus 10 of the present invention continuously adding wet concrete to the hopper 20 as needed while ensuring that it does not empty nor overflow.
FIG. 9 shows an alternate construction for a curb forming section, designated by the numeral 64 .
The following is a list of parts and materials suitable for use in the present invention.
PARTS LIST
Part Number
Description
10
curbing machine
11
excavator
12
motor driven frame
13
left track
14
right track
15
front end portion
16
rear end portion
17
mounting plate
18
T-shaped socket
19
hanger
19A
horizontal flange
19B
vertical flange
19C
vertical flange
20
frame
21
front end portion
22
rear end portion
23
hopper
24
upper end portion
25
lower end portion
26
hollowed interior
27
upper opening
28
lower opening
29
curb forming section
30
shaped plate
31a
section
31b
section
31c
section
31d
section
32
cylindrical bushing
33
longitudinal rod
34
blade
35
transverse rod
36
transverse bushing
37
front arm
38
front bushing
39
rod
40
arrow
41
rear arm
42
rear bushing
43
rod
44
forward threaded rod
45
forward threaded rod
46
adjustment nut
47
adjustment nut
48
rear threaded rod
49
rear threaded rod
50
adjustment nut
51
adjustment nut
52
arrow
53
forward plate
54
arrow
55
underlying support surface
56
longitudinal bushing
60
guide rod
61
transverse section
62
cement mixer vehicle
63
chute
64
curb forming section
65
sleeve
66
set bolt
67
set screw
c
curb
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.
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 method and apparatus for laying a curb is disclosed. The apparatus features a preferably tracked vehicle (tractor) that connects to a frame having a hopper. A hydraulic lifting arrangement enables hydraulic controls on the vehicle to elevate/lower the frame. The frame has a hopper for receiving wet concrete and a curb shaping portion that shapes the wet concrete into a curb shape. A specially configured interface maintains attitude of the frame during use.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] The present disclosure generally relates to a device and method for monitoring the water level in a fire hydrant. More specifically, the present disclosure relates to a detector connected to a fire hydrant that communicates signals indicative of water present in the fire hydrant, as well as the status of the detector, to a central computing/network system.
[0002] Presently, several devices are available in the commercial marketplace for determining whether or not water is being discharged from the hydrant due to theft, leaks, and/or removal of the hydrant itself. Present detectors sense the presence of water by detecting flow across sensors, voltage drop across sensors, and the like. Additionally, present detectors are not remotely monitored.
SUMMARY
[0003] The present disclosure relates to a detector that senses the presence of water in a fire hydrant barrel. The detector includes a communication device to send a radio, cellular or other wireless signal to a central computing/network system or signal collection station.
[0004] The detector includes a pair of electrodes that form a portion of an open electrical circuit. During a low water level event, the electrical circuit remains open and no signal is produced by the detector. In contrast, at a high water mark, water closes the electrical circuit and allows electrical current to flow from one electrode to another causing a controller to produce a signal.
[0005] The conductivity of the water is linked to the total dissolved solids in the water. The water in a fire hydrant barrel contains a percentage of total dissolved solids that allows the current to flow through the water. The inventors of the present invention has recognized that using these inherent conductive properties of the water flowing through the barrel is an reliable and inexpensive way to determine if water is present at the location when the detector is installed on the barrel.
[0006] In some examples, a fire hydrant monitoring system for a fire hydrant includes a housing and an inlet. The housing is connected to the exterior surface of the barrel. The system also includes a controller and a pair of electrodes. The controller is located in the housing and the pair of electrodes are connected to the controller. The controller and the electrodes form an open circuit. When water enters the housing and flows between the electrodes, the open circuit is closed and the controller processes a signal.
[0007] In other examples, a detector for monitoring the presence of water in a fire hydrant includes a housing, an inlet, and a sensing chamber. The housing is connected to the fire hydrant, and the inlet is connected to the sensing chamber. The detector also includes a pair of electrodes, a sensor interface, a processing device, a communication device, an antenna controller, and an antenna. Each electrode includes a first end and second end. The first ends positioned in the sensing chamber and the second ends connected to the sensor interface. The sensor interface and electrodes form an open circuit. The sensor interface is connected to the processing device. When water is located between the two electrodes the open circuit is closed and the processing device processes a signal. The processing device is connected to the communication device, the antenna controller, and antenna which transmits the signal.
[0008] Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:
[0010] FIG. 1 is a side view a fire hydrant above grade including the water detector device of the present disclosure.
[0011] FIG. 2 is a cross sectional view of the fire hydrant of FIG. 1 and includes portions of the fire hydrant that are below grade.
[0012] FIGS. 3A-3D are enlarged section views of the valve assembly of the fire hydrant in the present disclosure.
[0013] FIG. 4 is an enlarged section view of the device of the present disclosure.
[0014] FIG. 5 is a block diagram illustrating the device circuitry.
[0015] FIG. 6 is a block diagram illustrating the processing device shown in FIG. 6 of the present disclosure.
DETAILED DESCRIPTION
[0016] FIGS. 1-2 illustrate a fire hydrant water detector 50 in accordance with the present disclosure. The detector 50 is shown connected to a fire hydrant 4 . In one example, the detector 50 is connected to a conventional dry barrel fire hydrant 4 which includes a barrel 18 connected to the water main 14 by a pipe fitting 12 , such as a tee or elbow. In most applications, the water main 14 is buried below grade 10 . The barrel 18 is substantially perpendicular to the water main 14 and rises upwardly from the pipe fitting 12 .
[0017] Referring to FIG. 2 , the fire hydrant 4 includes a valve assembly 35 , an operating mechanism 30 , and a nozzle assembly 23 .
[0018] The barrel 18 includes an upper barrel 19 and a lower barrel 20 . The lower barrel 20 is connected to the upper barrel 19 , and the upper barrel 19 extends above grade 10 such that a portion of the fire hydrant 4 is accessible to fire departments and/or utilities. The operating mechanism 30 and a nozzle assembly 23 are connected to the upper barrel 19 .
[0019] The nozzle assembly 23 includes at least one nozzle outlet 24 , which extends substantially lateral from the upper barrel 19 . A nozzle cap 25 is removably connected to the nozzle outlet 24 and prevents water from flowing out of the fire hydrant 4 and/or prevents contaminates from entering the upper barrel 19 . Fire fighting hoses or other apparatus to be removably connected to the nozzle outlet 24 .
[0020] The operating mechanism 30 is connected to the valve assembly 35 by an operating rod 31 . The operating rod 31 is an elongated shaft (one or two piece) extending through the lower barrel 20 and upper barrel 19 . In one example, the operating mechanism 30 includes an operating nut 32 that is accessible from the top of the upper barrel 19 . The size and shape of the operating nut 32 is the same as the nozzle nut 26 on the nozzle cap 25 . In operation, the operating nut 32 is rotated counterclockwise by an operator causing the operating rod 31 to also rotate in a counterclockwise direction. Under the rotation, the valve assembly 35 moves between a closed position ( FIG. 3A ) to a partially open position ( FIG. 3B ) and further to a fully open position ( FIG. 3C ). Alternatively, if the operating nut 32 is rotated in a clockwise direction, the valve assembly 35 moves in the opposite direction from the fully open position ( FIG. 3C ) to a closing position ( FIG. 3D ) and further to a closed position ( FIG. 3A ).
[0021] Referring to FIG. 3A-3D , the valve assembly 35 controls the flow of water moving into the barrel 18 . The valve assembly 35 includes a series of plates, seats, flanges, gaskets, and other elements. As depicted in FIG. 3A , the valve assembly 35 is in a fully closed position. In this closed position, pressurized water from the water main 14 does not enter the barrel 18 . Turning to FIG. 3B , as the operating rod 31 rotates counterclockwise, the valve assembly 35 is depicted in a partially open position. In the partially open position, a space between the valve assembly 35 and the pipe fitting 12 allows water to enter the barrel 18 . As water continues to enter the barrel 18 , the water level in the barrel moves upward through the lower barrel 20 and into the upper barrel 19 . With further rotation of the operating rod 31 , the valve assembly 35 moves to the fully open position, as depicted in FIG. 3C . Once the water level reaches an open nozzle outlet 24 , the water may exit the barrel 18 .
[0022] To close the valve assembly 35 and prevent water from flowing out of the nozzle outlet 24 , the operator applies a clockwise rotation to the operating nut 22 . Under this rotation, the valve assembly 35 moves to the closing position, as depicted FIG. 3D . Further clockwise rotation moves the valve assembly 35 back to a fully closed position, as depicted in FIG. 3A . Once closed, any water remaining in the barrel 18 below the level of the open nozzle outlet drains from the barrel 18 through weep holes or drain valves 16 located at the bottom of lower barrel 20 , as shown by arrow 36 in FIGS. 3B and 3D . In some examples, the drain valves 16 may be connected to the pipe fitting 12 .
[0023] If the weep holes or drain valves 16 become clogged with debris or any other foreign matter, the water in the barrel 18 will not properly drain. In climates where the temperature drops below freezing, if the water does not properly drain and freezes, the expansion of the frozen water can create problems and damage the operating components of the fire hydrant.
[0024] Now referring to FIG. 4 , an enlarged view of the detector 50 is depicted. The detector 50 is connected to the upper barrel 19 . In one example, the detector 50 is connected to the upper barrel 19 below the nozzle assembly 23 , as shown in FIG. 1 . The detector 50 includes a housing 52 and an inlet fitting 53 . In one example, the inlet fitting 53 is generally cylindrical and includes screw threads 54 on an attachment portion 55 and drain surfaces (not shown). In operation, the inlet fitting 53 is connected to the upper barrel 19 at a threaded receiver hole 58 in the upper barrel 19 . However, one of ordinary skill in the art will recognize that the inlet fitting 53 may be connected to the upper barrel 19 in any suitable way including screw threads, adhesives, snap fittings, and the like. In other examples the detector 50 may be connected to the nozzle outlet 24 . It will also be recognized that additional components, such as gaskets, fittings, and the like, may be used to connect the detector 50 to the barrel 18 . When connected to the upper barrel 19 , the housing 52 is adjacent to or in contact with the outer surface of the upper barrel 19 . Gaskets and/or O-rings may be included between the inlet fitting 53 and the upper barrel 19 to create a fluid tight seal.
[0025] The drain surfaces of the inlet fitting 53 may be connected to the inlet fitting 53 and/or the housing 52 . In some examples, the drain surfaces are integral with the housing 52 . The inlet fitting 53 includes an open sensing chamber 56 . The sensing chamber 56 is an open space defined by the outer wall of the inlet fitting 53 and is open to the open interior 65 of the upper barrel 19 . The sensing chamber 56 is independent and sealed from the other portions of the detector 50 to prevent water damage to other components.
[0026] When the detector 50 is in operation and connected to the barrel 18 , as described above, the detector 50 determines whether or not water is present in the barrel 18 at the elevation where the detector 50 is installed. Water may sensed by the detector 50 when the hydrant 4 is being operated by an authorized or unauthorized user, when water is being stolen from the hydrant 4 , when there is a leak in the valve assembly 35 that causes water to continuously fill the barrel 18 , and/or when the drain valves 16 are blocked.
[0027] Water in the barrel 18 flows into the sensing chamber 56 of the inlet fitting 53 of the detector 50 . The inlet fitting 53 includes a cap 66 that includes at least one sensing hole 57 to provide access to the sensing chamber 56 . The sensing holes 57 may be sealed with a gasket, glue, caulk, O-rings, and the like to prevent water from moving into other portions of the housing 52 . The sensing holes 57 allow at least one electrode 59 , 62 to extend into the sensing chamber 56 , and each electrode 59 , 62 includes a first end 60 , 63 and a second end 61 , 64 . The first ends 60 , 63 of the electrodes 59 , 62 protrude through the sensing holes 57 and are positioned in the sensing chamber 56 . The second ends 61 , 64 of the electrodes 59 , 62 are connected to a controller 70 , to be discussed further herein. The first ends 60 , 63 of the electrodes 59 , 62 are separated by a distance D such that the controller 70 and electrodes 59 , 62 form an open electrical circuit.
[0028] As mentioned above, the electrodes 59 , 62 are positioned in the sensing chamber 56 such that they from an open electrical circuit with the controller 70 . However, when water is present between the electrodes 59 , 62 , such as when the water level reaches a high water mark 6 , the electrical circuit is closed and an electrical current can flow through the water due to the electrical conductivity of the water. When the circuit is closed, the controller 70 is placed into an alert mode and is capable of producing a water-present signal. When the circuit is open, the controller 70 may remain in a sleep mode and produces a no-water-present signal or no signal at all. It will be recognized that the high water mark 6 may be any water level that allows water to flow between the two electrodes 59 , 62 .
[0029] Now referring to FIG. 5 , the controller portion of the detector is depicted in greater detail. As mentioned above, the second ends 61 , 64 of the electrodes 59 , 62 are connected to a controller 70 located inside the housing 52 . The controller 70 includes a sensor interface 71 , a processing device 72 , power supply 73 , and a communication device 74 . In some examples the controller 70 may also include an antenna connector 75 and an antenna 76 . The processing device 72 controls the sensor interface 71 and the communication device 74 . The processing device 72 may continually or periodically monitor the status of the sensor interface 71 .
[0030] In some examples, the second ends 61 , 64 of the electrodes 59 , 62 are connected to the sensor interface 71 . When water between the electrodes 59 , 62 forms a closed circuit, the processing device 72 will generate and alarm or warning signal to the communication device 74 , to be described further herein. The processing device 72 may also aggregate and store multiple alarm or warning signals from the sensor interface 71 on a memory (not shown). For instance, the processing device 72 may monitor the status of the sensor interface 71 for several hours before relaying signal data to the communication device 73 . In this example, each water-present signal or no-water-present signal is held in the memory with an appropriate time stamp until the processing device 72 is scheduled to relay the signal data to the communication device 74 . The aggregation of data and sending periodic signal data helps to minimize power consumption. It is also contemplated that the processing device 72 may encrypt and/or transform signal data from the sensor interface and/or data from the communication device 74 into different data formats.
[0031] Since the processing device 72 will generate an alarm or warning signal every time water is present between the pair of electrodes 59 , 62 , such signal will also be generated during authorized testing of the fire hydrant. In order to prevent alarm signals from being generated during authorized testing, the detector 50 can be configured to include some type of override device. Such an override device may include a unique password or code that is entered into the controller 70 using a user interface (not shown) on the housing 52 or some type of wireless communication. When authorized personnel, such as a fire department or utility, wishes to test the hydrant, the authorized personnel can enter the unique code or override signal to temporarily suspend generation of the alarm or warning signal from the controller 70 . During the authorized testing, water present between the pair of electrodes 59 , 62 would not generate an alert or alarm condition, which would avoid nuisance alarms being received at the utility. Once the authorized testing is complete, the override would be disabled and the detector 50 would continue operating in a normal manner.
[0032] The communication device 74 is connected to an antenna connector 75 and an antenna 76 . The communication device 74 processes the data from the processing device 72 and transmits the data via the antenna connector 75 and the antenna 76 . The communication device 74 may use various types of communication networks and protocols, such as FlexNet®, Wi-Fi, low-energy Bluetooth®, and the like. The communication device 74 may communicate with a router, a modem, handheld remote receiver unit, and/or cloud services for retrieval and analysis including internet accessibility. One of ordinary skill in the art may also recognize that the communication device 74 may be a wired connection. The communication device 74 may also act as a transceiver, and thus receive data from external sources. The antenna 76 is connected to the antenna connector 75 , and the antenna 76 may be positioned inside the housing 52 , attached to the outside the housing 52 , or partially inside the housing 52 . It is also contemplated that an intermediate base station may be provided between the detector 50 and the utility. The base station may collect signals from multiple detectors 50 before communicating the signals to the utility via the internet.
[0033] The power supply 73 is connected to the processing device 72 and the communication device 74 . It should also be known to those having ordinary skill in the art that the power supply 73 may provide power to other components of the detector 50 . It is also contemplated that the power supply 73 may be any type of power component such as a battery, rechargeable battery, and the like. It is further contemplated that the power supply 73 may include thermal couples, photovoltaic cells, vibration kinetic motion converters, and the like. The power supply 73 may also be a wired connection via AC source, DC source, Ethernet connection, and the like. In one example, the power supply 73 in a battery that contains enough electrical power to power the detector 50 for at least ten years under normal operation.
[0034] Turning now to FIG. 6 , a block diagram showing an example of the processing device 72 is shown. The processing device 72 depicted in FIG. 6 may include the devices and interfaces discussed above as well as a power assembly 82 , a communication module 83 , a water detection module 84 , a heartbeat module 85 , and a timer/sleep module 86 .
[0035] The power assembly 82 may be connected to the power supply 73 , and the power assembly 82 may control the voltage and current levels provided to the processing device 72 and/or the communication device 74 . The communication module 83 connects to the communication device 74 and receives and/or sends signals for communication through the communication device 74 . The water detection module 84 may be configured to analyze the status of the circuit formed by electrodes 59 , 62 and the sensor interface 71 , as described above. Besides the presence of water between the electrodes 59 , 62 to complete the circuit and detect the presence of water, the water detection module 84 may determine the probability and/or likelihood that signals are indicative of a water-present situation or some other situation, such as damaged electrodes 59 , 62 and a blocked inlet 53 . The water detection module 84 may create alarm signals when the detector 50 is tampered with, broken, or moved to a non-standard orientation.
[0036] The heartbeat module 85 is connected to the processing device 72 and communicates the status of the detector 50 to the utility through the communication device 74 . In one example, the heartbeat module 85 processes a heartbeat signal every two to eight hours essentially broadcasting that the detector 50 is operational and operating normally.
[0037] The timer/sleep module 86 controls the sleep modes in order to minimize power supply 73 usage when the detector 50 is not in use. The timer/sleep module 86 is configured to wake different components discussed herein at set pre-programmed times. The timer/sleep module 86 may also be configured to wake up different components when specific circumstances are sensed by the detector 50 such as a large flow of water or damage to the detector 50 .
[0038] It is also contemplated that the detector 50 may include other sensors such as pressure sensors, tilt sensors, and the like. One of ordinary skill in the art will recognize that additional sensors added to the detector will include corresponding circuitry similar to those components and/or modules described above and tailored to the additional sensors.
[0039] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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A fire hydrant water leak and theft detection system is connected to a dry barrel fire hydrant. The detector is connected to the upper barrel portion of the fire hydrant below the nozzle assembly and includes a pair of electrodes. A signal is generated when water in the upper barrel portion closes an electrical circuit between the two electrodes due to the conductivity of the water between the electrodes. The detection system sends a signal to a network system upon detection of water in the barrel portion and relays to remote monitoring locations.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 61/545,970, filed Oct. 11, 2011, which is hereby incorporated by reference.
FIELD
The present disclosure concerns embodiments of a construction technique that can be used for modifying existing walls.
BACKGROUND
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. One method that has been used to accomplish some of these aims is building a masonry veneer that is structurally tied to an existing wall. In the past, these have been anchored to the existing wall using mechanical fasteners and required the provision of an open space behind the masonry veneer to allow penetrating moisture to drain and exit at weep holes. The provision of an open space and weep holes and the use of mechanical fasteners make the structure unnecessarily complex and increase its total cost.
Accordingly, it would be desirable to provide methods of building masonry veneers that do not require the provision of an open space or weep holes, and that can be completed without the use of mechanical fasteners for structurally tying the veneer to the existing wall. It would also be desirable to provide methods of constructing masonry veneers that have greater strength, insulation, waterproofing, vapor-proofing, and aesthetic properties, and to do so at a lower total cost.
SUMMARY
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 certain embodiments, a masonry wall is constructed near an existing wall, and the cavity between the two walls is filled with a foamable, adhesive material. The foamable, adhesive material adheres to both walls, creating an adhesive connection between them. Certain embodiments create multiple layers of the foamable, adhesive material, allowing each layer to expand before the next is introduced. Certain embodiments utilize a brush device to reduce the amount of mortar left between the two walls. Certain embodiments utilize clips for temporarily securing the masonry wall to the existing wall while the adhesive material is introduced into the cavity.
In one embodiment, a plurality of vertically stacked courses of masonry units are formed a desired distance from an existing wall, creating a cavity between the masonry and the existing wall. The uppermost course of masonry units can be secured to the existing wall using removable clips, and the cavity can be filled with a foamable, adhesive material, which is allowed to cure. Thereafter, the clips can be removed.
In another embodiment, a brush can be positioned along the bottom of an existing wall and can be attached to a tether connected to a fixed location above the intended top of a masonry wall. A plurality of vertically stacked courses of masonry units are formed a desired distance from the existing wall, creating a cavity between the masonry and the existing wall, with the brush at the bottom of the cavity. The tether can be used to raise the brush, removing excess mortar from the cavity. The uppermost course of masonry units can be temporarily secured to the existing wall using removable clips and the cavity can be filled with a foamable, adhesive material, which is allowed to cure. Thereafter, the clips can be removed.
In yet another embodiment, a bottom portion of a masonry wall can be constructed a desired distance from an existing wall. The masonry wall can be temporarily secured to the existing wall using mechanical fasteners, and a foamable, adhesive material can be introduced between the masonry and the existing wall and allowed to cure. The mechanical fasteners can then be removed, and an additional portion of masonry wall can be constructed on top of the masonry wall already adhesively secured to the existing wall. The additional portion of the masonry wall can be temporarily secured to the existing wall using mechanical fasteners and the foamable, adhesive material can be introduced between the additional portion of the masonry wall and the existing wall and allowed to cure. Thereafter, the mechanical fasteners can be removed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 illustrate a construction technique for constructing a veneer masonry wall adjacent an existing wall.
FIG. 5 is an enlarged side elevation view of one embodiment of a wall clip shown mounted on the uppermost course of a partially constructed masonry wall.
FIG. 6 is a top plan view of the clip shown in FIG. 5 .
FIG. 7 is a front elevation view of the clip shown in FIG. 5 .
FIG. 8 is an enlarged side elevation view of another embodiment of a wall clip shown mounted on the uppermost course of a partially constructed masonry wall.
FIG. 9 is a front elevation view of the clip shown in FIG. 8 .
FIG. 10 is a top plan view of the clip shown in FIG. 8 .
FIG. 11 is an enlarged view of a portion of the clip shown in FIG. 8 .
DETAILED DESCRIPTION
FIGS. 1-4 illustrate a method for constructing a first masonry wall (e.g., wall 10 ) adjacent a second wall (e.g., wall 12 ). The method involves the use of a foamable, adhesive material to secure the first wall to the second wall. The foamable, adhesive material also serves as a vapor barrier and a waterproofing layer for the wall structure, and insulates the structure. The method has particular applicability for constructing a veneer masonry wall 10 adjacent an existing wall 12 . The existing wall 12 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.
Referring to FIG. 1 , the masonry wall 10 is constructed relative to the existing wall 12 to create a cavity C having a spacing S equal to a desired distance between the two walls. In particular embodiments, the spacing S between the walls (the width of the cavity) is at least 2 inches and can be varied as needed depending upon the particular application. The masonry wall 10 itself can constructed by laying masonry units 14 (e.g., bricks, stones, or concrete blocks) in vertically stacked courses and using mortar or grout to form the joints between adjacent units 14 , as known in the art. Each course of masonry units can comprise a plurality of masonry units placed end-to-end in a row. In other embodiments, each course of masonry units can be formed by placing the masonry units in various orientations, as known in the art.
As the wall 10 is constructed, a brush or gasket device 16 is placed at the very bottom of the cavity between the existing wall 12 and the first course of masonry units. The brush device 16 is connected to the lower end of a tether 18 , which can be, for example, a length of wire, rope, or string. The upper end of the tether 18 is secured at a convenient position above the wall 10 under construction, such as at a location on the existing wall 12 adjacent the upper end of the wall 12 . The brush device 16 desirably extends the length of the cavity between the two walls. The purpose of the brush device is to catch excess mortar that falls into the cavity as the mason forms the courses of the wall 10 . Additionally, after a predetermined number of courses have been formed, using the tether 18 , the mason can drag or pull the brush device 16 upwardly against the inner surface of the wall 10 , causing the brush device to brush or otherwise scrape off mortar fins (excess mortar) that extends outwardly from the joints between the masonry units 14 . The brush device collects the excess mortar and keeps the cavity substantially free of mortar fins and droppings, which can otherwise create flow paths for air or water once the adhesive material is introduced into the cavity.
In particular embodiments, the brush device 16 comprises a roll of fibrous material, such as felt, fiberglass netting, or polymeric fiber. The brush device 16 can comprise an internal stiffening member, such as a wooden 2×4, which is wrapped in the fibrous material. Desirably, the width of the brush device is slightly less than the width of the cavity C. As noted above, the brush device 16 desirably extends the entire length of the cavity to prevent any excess mortar from accumulating in the cavity. If the cavity is relatively long, a plurality of tethers 18 can be used to support the brush device. Each tether 18 can be spaced apart from each other along the length of the cavity C and can have a lower end secured to the brush device 16 and an upper end secured at a respective fixed location above the intended top of the masonry wall 10 . In an alternative embodiment, a plurality of brush devices 16 can be placed end-to-end along the length of the cavity, in which case each brush device can be supported by one or more respective tethers 18 . The brush device 16 eliminates the need for providing clean outs, or access openings, at the bottom of the wall to remove excess mortar. By removing mortar fins, the brush device allows for a better insulated cavity.
Referring to FIG. 2 , after the predetermined number of courses have been formed, the uppermost course can be secured to the existing wall 12 using one or more fasteners, such as the illustrated clips 20 . Although only one clip 20 is shown in the drawings, a plurality of clips can be spaced along the length of the uppermost course. In particular embodiments, the clips 20 are temporary in that they are removed (and desirably can be re-used) just prior to forming the next course of masonry units 14 . The clips 20 hold the partially constructed wall 10 in place relative to the existing wall 12 as the foamable, adhesive material is introduced into the cavity, as further described below. FIG. 2 also shows the brush device outside of the cavity after it has been used to scrape off the mortar fins on the inner surface of the partially constructed wall 10 . Typically, it is desirable to remove the brush device from the cavity before the clips 20 are installed. In a specific implementation, the wall is constructed to a height of about 6 feet to about 10 feet, with about 8 feet being a specific example, before the clips are installed.
Referring to FIG. 3 , after installation of the clips 20 , the cavity can be filled with a foamable, adhesive material 22 to bond the partially constructed wall 10 to the existing wall 12 . In particular embodiments, the cavity is filled with a plurality of layers 24 of the foamable, adhesive material 22 . Desirably, the adhesive material 22 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 22 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 22 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 22 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 .
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 22 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.
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 26 to a spray gun, or nozzle, 28 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 28 , the activating agent triggers an exothermic chemical reaction, the product of which is the adhesive foam material 22 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 nozzle 28 is moved longitudinally along the bottom of the cavity to form an even layer 24 of material of a height H. After the adhesive material is sprayed into the cavity to form the bottommost layer 24 , the end of the nozzle 28 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 24 . 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 and temperature of the foam. 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. Also, curing time increases as the temperature of the foam decreases. Once the adhesive material has substantially cured, the end of the nozzle 28 is positioned at a point just above the previously formed, bottommost layer 24 and adhesive material is sprayed on top of the bottommost layer as the nozzle is moved longitudinally of 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. 3 ). In particular embodiments, the height H of each layer 24 is about 6 inches to about 48 inches, with about 16 inches being a specific example. Additional details regarding the foamable material 22 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.
As shown in FIG. 4 , a small section of the cavity adjacent the upper portion of the partially constructed wall 10 can be left empty (without any material 22 ). After forming the uppermost layer 24 of material 22 , the clips 20 can be removed from the wall and the brush device 16 can be reinserted into the cavity so as to rest on top of the uppermost layer of material 22 . The clips 20 desirably are configured to be reusable. Thereafter, additional courses of masonry units 14 can be formed to a predetermined height, the top of the partially constructed wall can be secured to the existing wall with clips 20 , and the cavity can be filled with layers of materials 22 , as previously described. This process can be repeated as needed until the wall 10 is fully formed.
As noted above, the material 22 bonds the masonry wall 10 to the existing wall 12 , thereby eliminating the need for conventional ties for securing the masonry wall to the existing wall. The layers of material 22 also function as a water and air barrier for the wall structure such that traditional wall waterproofing is not required. Additionally, conventional weep holes in the masonry wall are not required. Furthermore, the layers of material 22 also insulate the building.
FIG. 5 is an enlarged view of a clip 20 shown mounted on the uppermost course of a partially constructed wall 10 . FIGS. 6 and 7 are top plan and elevation views, respectively, of the clip. The clip 20 in the illustrated embodiment comprises a vertical portion 40 , a horizontal portion 42 , and two leg portions 44 extending downwardly from the horizontal portion 42 . The lateral spacing between the leg portions 44 is selected to be equal to or slightly greater than the width of masonry units 14 so that the clip can be easily placed over a masonry unit and firmly engage the rear and front faces of the masonry unit. As shown in FIG. 7 , the vertical portion 40 can be formed with a vertical slot 46 that receives one or more screws 48 that can be tightened into the existing wall 12 .
FIGS. 8-11 illustrate an adjustable clip 60 that can be used in the construction of the wall 10 . The clip 60 is configured to be adjustable in length to accommodate different cavity widths. The clip 60 in the illustrated embodiment includes a first wall engaging component 62 coupled to a second wall engaging component 64 by a clamping device 66 . The first wall engaging component 62 comprises a horizontal portion 68 and two leg portions 70 that engage the front and rear faces of a masonry unit 14 . The second wall engaging component 64 comprises a horizontal portion 72 and a vertical portion 74 , which is formed with a slot 76 for receiving one or more screws 48 that are screwed into the existing wall 12 . The horizontal portion 68 of the first wall engaging component can be formed with a slot 78 that receives a shaft 80 of the clamping device 66 .
The clamping device 66 is configured to tightly clamp and release the respective horizontal portions 68 , 72 of the first and second wall engaging components to permit adjustment of the overall length L of the clip. When the clamping device 66 is loosened, the first and second wall engaging components can be moved relative to each other to adjust the overall length L of the clip to accommodate the width of the cavity being formed. When the clamping device is tightened, the respective horizontal portions 68 , 72 of the first and second wall engaging components are tightly secured to each other. In this state, the overall length L of the clip 60 is fixed and the clip is effective to retain the partially constructed wall in place as the foamable material is introduced into the cavity. As best shown in FIG. 11 , the contacting faces of the horizontal portions 68 , 72 can be formed with teeth 82 (or similar surface features) that intermesh with each other and prevent slippage between the first and second wall engaging components.
As best shown in FIG. 11 , the clamping device 66 can include a fixed nut 84 that is fixedly secured (e.g., welded) to the lower end portion of the shaft 80 and a rotatable knob 86 received on the upper portion of the shaft 80 (the knob can have internal threads that engage external threads of the shaft). An o-ring or washer 88 can be disposed on the shaft 80 between the knob 86 and the fixed nut 84 . Rotating the knob 86 in a first direction (e.g., clockwise) is effective to secure the wall engaging components to each other while rotating the knob 86 in the opposite direction (e.g., counterclockwise) is effective to loosen the clamping device and allow for adjustment of the clip's length.
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 certain embodiments, a masonry wall is constructed near an existing wall, and the cavity between the two walls is filled with a foamable, adhesive material. The foamable, adhesive material adheres to both walls, creating an adhesive connection between them. Certain embodiments create multiple layers of the foamable, adhesive material, allowing each layer to expand before the next is introduced. Certain embodiments utilize a brush device to reduce the amount of mortar left between the two walls. Certain embodiments utilize clips for temporarily securing the masonry wall to the existing wall.
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BRIEF DESCRIPTION OF THE PRIOR ART, IMPROVEMENTS OVER THE PRIOR ART AND DRAWINGS
The present invention relates to a new and improved sinker bar for use with sucker rods and a string for the production of fluids with a sinker bar and sucker rods comprising a string as that term is known for the production of fluids at the bottom of a well bore with a mechanical downhole pump. It is known to use, for example, 60% fiberglass sucker rods and 40% steel rods positioned on the bottom of such fiberglass sucker rods to cause the fiberglass sucker rod string to stretch at the end of the downstroke from the surface such that 100 inches of stroke at the surface of the well bore might well be 150 inches at the bottom of the hole. The invention is not limited to this example, however. On the return upstroke the fiberglass rods on the bottom and the mechanical pump attached to the end thereof might travel an additional 50 inches to produce a substantially increased amount of fluid because of the added length of the stroke.
While this method has advantages with respect to increased production of fluid, its disadvantages are many because the over-all total length of the string is continually under compression on the downstroke and continually under tension on the upstroke. Further, it is to be understood that while such a combination of a sucker rod string of steel and fiberglass or something lighter than steel creates overall less weight on the string and thus less energy requirements at the surface to move the string upwardly and downwardly to produce fluids, that the ultimate efficient combination would be to concentrate all the weight immediately above the downhole mechanical pump. Thus the ultimate objective for the most efficient use of fiberglass rods or steel rods or rods lighter than steel for the production of fluids downhole (rather than the objective of attempting to obtain greater fluid production) is to provide the minimum weight to overcome forces in the well bore system so that the maximum weight of the combination sucker rod string and sinker bars is immediately above the mechanical pump and the minimum weight is at the well bore surface. In this way, frictional losses are minimized and the center of gravity is concentrated over the downhole mechanical pump so that a substantial amount of rubbing of the sucker rod string against the tubing is eliminated. In the prior art, the following patents are considered relevant:
U.S. Pat. Nos. 901,282; 1,064,764; 1,689,281; 2,244,104; 2,266,357; 2,652,231; 2,825,752; 2,863,704; 2,874,927; 2,874,938; 2,948,231; 3,018,140; 3,461,539; 3,534,989; 3,549,791; 3,661,388; 3,737,556; 4,024,913; 4,127,741; 4,195,691; 4,198,538; 4,205,926; 4,315,699: Canada No. 1072191: Fed. Rep. of Germany No. 2511809: France No. 1210779: United Kingdom No. 681550.
Further, your Applicant has found that the use of a square sinker bar has several advantages. It is known that sinker bars are used to attempt to concentrate the weight down near the bottom of the sucker rod string to eliminate the friction or rubbing of sucker rods up and down against the well bore. In the prior art, such sinker bars were round and it was desired to always keep the sucker rod string in tension. To accomplish that a heavier circular bar was used or a greater number of smaller circular bars was used. The bar was notched for a wrench flat to enable making up and disassambling of the sinker bar with the steel sucker rod string, but obviously such cutting into the bar created a stress area.
Applicant's design is a square sinker bar with radiused corners producing increased rigidity downhole and additional weight per foot. Additionally there is an area provided for a wrench flat for assembly and disassembly of the sinker bars from the sucker rod string, but the area for the wrench flat does not produce any substantial loss of rigidity in such suker bar. In addition, connections for the sinker bar are female to female or male to male connections which when assembled with a coupling provide four pressure interlocking faces for box to box connection.
While some of the advantages of the present invention over the prior art have been described, and while the specifications set forth hereinbelow are designed to set forth Applicant's preferred embodiment, it is to be understood that other embodiments of Applicant's invention may be encompassed by the claims appended hereto, and that such specifications set forth hereinbelow sets forth Applicant's best mode of his invention at the present time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a detailed view of the sinker bar of the present invention;
FIG. 2 is a perspective view of Applicant's sinker bar of the present invention; and,
FIG. 3 is an overall perspective view of Applicant's bar used in a well bore with other sucker rods for purposes of illustration of the use of Applicant's invention.
DETAILED DESCRIPTION OF THE INVENTION
As illustrated in FIGS. 1 and 2, the sinker bar of the present invention is generally designated by the numeral 10 and normally has an overall length L of 24 feet. The bar 10 has a square cross section for a substantial portion of its length. Lengths L1, L2 and L3 as illustrated in FIGS. 1 and 2 have a square cross section. Normally length L1 will be inserted first into a well bore.
As illustrated in FIGS. 1 and 2, only the square surface areas 15, 16 and 17 associated with L1, L2 and L3 respectively are illustrated, it being understood that such surfaces represent flat surfaces of those portions of the bar having a square cross section. As further illustrated in FIG. 1, adjacent each end 20 and 21 are machined female threads 22 which extend inwardly, as shown by the dotted lines, into the ends 20 and 21 respectively with each end 20 and 21 being a flat surface. A bevelled area 23 is provided around the outer periphery of such flat surfaces 20 and 21. The bevel or scallop area 23 of the surfaces 20 and 21 permits a pressure interlocking of surfaces on adjacent bars when bars are mated end to end with suitable pin to pin connection (not shown). A pin-pin assembly technique can also be used with standard couplings. It is to be understood that the square cross sectional configuration of lengths L1, L2 and L3 renders the sinker bar more rigid than the typical circular prior art bars. Because of the square corners, there is less contact area if rubbing of the bars against the tubing string occurs, thus reducing normally encountered drag and friction.
As further illustrated in FIGS. 1 and 2, lengths L4 and L5 are machined with a substantially circular cross section. The exterior areas of the bar 10 between L1 and L4; L4 and L2; L2 and L5; and L5 and L3 are tapered toward the immediately adjacent portions of the bar with circular cross sections. The surfaces 42 and 44 are sufficiently separated so that the square area 16 can serve as a "flat" for wrenching and disconnecting or connecting the sucker rods. The areas 42 and 44 also provide suitable elevator neck and transfer slot areas as for enabling manipulation of the bars 10.
As illustrated in FIG. 3 the sinker bars are used with sucker rods 12; the rods 12 may be of steel, iron or of any material lighter than steel or iron. The object is to determine the minimum weight necessary to overcome forces such as friction created by the rubbing of the rod string up against the side of the well bore 15. A typical installation is illustrated with a power source PS positioned on or adjacent the ground G for moving a walking beam WB upwardly and downwardly in the direction of the arrows 60, 61. The downhole pump 64 moves upwardly or downwardly in the direction of the arrow 66, 68. The downhole pump 64 moves fluid upwardly in the well bore in the direction of the arrow 66 when the walking beam WB moves upwardly. Simultaneously the bar 10 and sucker rod 12 also move upwardly. The tubing string 70 is usually perforated so that the well bore can communicate with the surrounding formation. The arrows 72 indicate perforating through suitable ports 74 to enable fluid to enter into the tubing string.
For a sucker rod string constructed of 60% fiberglass rods and 40% steel rods, 4,000 feet of steel rods would be required in a 10,000 foot string. The energy requirements at the surface to overcome the downhole friction forces of such a string are enormous. Less energy is required when only two to four bars 10 are used according to the present invention. In a sucker rod string for a 10,000 foot well only five to fifteen percent of the total sucker rod string must be sinker bars according to the present invention. By placing the sinker bars 10 immediately above the mechanical pump the center of gravity of the complete string is immediately above the pump. This positioning of the bars prevents deviation, curling, rubbing and wobbling of the string. Further, concentration of the weight immediately above the pump reduces friction pull.
Another type of friction encountered in the well bore is the viscous friction of the hydrostatic head or fluid that is desired to be lifted. The depth of the well determines the amount of bars used. As an additional safety factor more bars can be used. The pump must move upwardly and downwardly throuh wall to wall contact against the weight of the hydrostatic head and the like. Thus, it has been found that the sinker bar weight calculation is a function of the rod size, the hydrostatic head, the well depth, the safety factor and the friction force from the pump. A multiple of such factors determines the minimum sinker bar weight to overcome forces in the pump, but yet maximum efficiency to move fluid up the well bore while at the same time reducing torque and drag immediately above the pump. With the use of Applicant's rigid square sinker bars positioned directly above the pump a substantial amount of rub and friction against the side of the well bore is eliminated and the rod string's center of gravity is located immediately above the pump.
While the invention and specific embodiment have been disclosed in Applicant's invention in FIGS. 1-3, it is to be understood that Applicant's invention is not limited to the embodiment disclosed and may contain and relate to other embodiments; however, the appended claims are intended to cover the full scope of Applicant's invention including, but not limited to, the specific embodiments illustrated in FIGS. 1-3.
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A new and improved sinker bar has a substantial portion of its body square in cross section which increases rigidity and decreases wall to wall contact downhole in the production of fluids utilizing a sucker rod string. In addition, when the bars are used with a certain percentage of sucker rods, a greater efficiency and thus reduction of friction is accomplished in production of the fluids downhole.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This Non-Provisional Application claims benefit to U.S. Provisional Application Ser. No. 60/964,299 filed Aug. 10, 2007, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a drawer manipulation system to facilitate opening and, more particularly, to a system incorporating a biasing drawer actuator mountable in supported relation relative to projecting edge portions of a cabinet frame structure.
BACKGROUND OF THE INVENTION
[0003] Drawer manipulation systems using biasing actuators and cooperating latch structures are generally known. Such drawer actuators operatively engage a rear portion of the drawer when the drawer is in a closed position so as to urge the drawer towards an open position to permit access to the interior by a user. When the drawer is in the closed position, a latch assembly is engaged to resist the biasing opening force provided by the actuator. Upon disengagement of the latch assembly, the biasing force of the actuator urges the drawer forward towards the open position.
[0004] So-called “push-push” latch assemblies are generally known. Such latch assemblies typically lockingly engage a striker element when the striker element is pushed into an acceptance opening within the latch assembly. When a second pushing force is subsequently applied to the striker the locking relation is released and the striker is urged outwardly from the latch assembly by an internal spring or other biasing element.
[0005] In a number of drawer environments the mounting of actuators has proven to be difficult due to the need to secure the actuators in a fixed and stable position so as to promote consistency of the applied biasing force to the rear of the drawer over an extended life of the system. By way of example only, and not limitation, drawers located in appliances or other structures incorporating metal or plastic cabinet structures with adjustable legs may require particular skill and effort to provide a consistent mounting arrangement.
SUMMARY OF THE INVENTION
[0006] The present invention provides advantages and alternatives over the prior art by providing a drawer manipulation system incorporating a biasing actuator which may be used in combination with a cooperating push-push latch wherein the actuator is adapted for mounting in supported relation at edge portions of a support frame structure within a cabinet housing the drawer.
[0007] According to one exemplary feature, a biasing actuator adapted for mounting within a drawer cabinet at a position behind a sling drawer is provided. The biasing actuator includes a rearwardly projecting slot adapted to slidingly engage a support frame rib member extending at least partially across the width of the drawer cabinet and projecting away from the rear wall of the cabinet. The biasing actuator further includes a downwardly projecting bracket structure adapted to engage a support structure projecting away from a bottom surface of the cabinet.
[0008] Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic of an appliance system incorporating drawers housed within appliance cabinet structures.
[0010] FIG. 2 is a cut-away schematic drawing illustrating components of a drawer system.
[0011] FIG. 3 is a partial cut-away perspective view illustrating an arrangement of biasing actuators within a drawer system.
[0012] FIG. 4 is a perspective view illustrating an exemplary mounting arrangement for a biasing actuator at a frame member of a drawer cabinet.
[0013] FIG. 5 is a partial cut-away view of the actuator illustrated in FIG. 4 .
[0014] FIG. 6 is a rear perspective view of the actuator illustrated in FIG. 4 .
[0015] FIG. 7 is a schematic view illustrating another embodiment of a biasing actuator.
[0016] FIG. 8 illustrates the actuator of FIG. 7 in mounted relation at a support frame of a drawer cabinet.
[0017] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Turning now to the drawings, in FIG. 1 there is illustrated an appliance system 10 such as a clothes washer and dryer or the like. In the illustrated arrangement, each of the appliances in the appliance system 10 includes a user manipulated drawer system 12 including a cabinet structure 14 and a user manipulated sliding drawer 16 . Of course, it is to be understood that the drawer system 12 is in no way limited to use within an appliance system. Rather, a drawer system 12 consistent with the present disclosure may be utilized in any suitable environment where storage is required.
[0019] As best illustrated through joint reference to FIGS. 2 and 3 , the illustrated exemplary drawer system 12 incorporates a latch assembly 20 mounted adjacent an edge of a drawer acceptance opening within the cabinet structure 14 . The latch structure 20 is preferably a so called “push-push” latch assembly of a type well known to those of skill in the art adapted to matedly engage a strike element 22 extending away from an inwardly projecting shoulder surface of a drawer fascia structure 24 .
[0020] In operation, when the drawer 16 is pushed to a closed position the strike element 22 is inserted into the latch assembly and becomes locked against outward withdrawal. Applying a subsequent pushing force causes the strike element 22 to be released from locking engagement within the latch assembly 20 . The latch assembly 20 typically includes a spring biasing element to urge the strike element 22 outwardly when the strike element is disengaged.
[0021] In order to promote the outward opening movement of the drawer 16 , the drawer system 12 includes one or more biasing actuators 30 adapted to apply an opening biasing force against a rearwardly projecting surface of the drawer 16 . By way of example only, and not limitation, according to the arrangement illustrated in FIG. 3 , a pair of such actuators 30 may be disposed adjacent rear corners of the cabinet structure 14 . Of course, any other suitable positioning arrangement may likewise be utilized if desired.
[0022] As best illustrated in FIG. 5 , according to one contemplated arrangement the actuators 30 may include a biasing piston element 32 including an outwardly projecting distal end adapted to engage a rear surface of the drawer 16 and a proximal end disposed within a cylinder 34 . As illustrated, the cylinder 34 may include a biasing spring element 36 which is compressed as the piston element 32 moves into the cylinder 34 along the cylinder axis. Thus, the spring element 36 applies a constant biasing force urging the piston element 32 towards an outward projecting position thereby applying force against a rear surface of the drawer 16 .
[0023] In operation, when the drawer 16 is moved to a closed position, the piston element 32 moves along a plane and is forced into the cylinder 34 thereby compressing the spring element 36 . While the strike element 22 is held in locked relation within the latch assembly 20 , the spring element 36 is retained in a state of compression. However, upon the release of the strike element 22 from locked relation within the latch assembly 20 , the spring element 36 urges the piston element 32 to an outward position thereby causing the drawer 16 to also move. Thus, the actuators 30 may operate in concert with the latch assembly 20 to permit controlled outward movement of the drawer 16 .
[0024] As best illustrated through joint reference to FIGS. 4 and 6 , the actuators 30 may be adapted for positional mounting using projecting edges of a supporting channel frame structure 40 disposed adjacent a rear wall of the cabinet structure 14 . As illustrated, according to one contemplated arrangement, the actuator 30 may include a downwardly projecting tongue 42 disposed adjacent to the base of the actuator and including a rearwardly projecting slot 44 . As shown, the depth dimension of the slot 44 resides in a plane substantially parallel to the axis of the cylinder 34 with the width dimension being in a substantially transverse horizontal orientation relative to the axis of the cylinder 34 such that portions of the rearwardly projecting engagement slot are disposed outboard of opposing sides of the cylinder axis.
[0025] According to the illustrated exemplary configuration, the actuator 30 further includes a downwardly projecting bracket structure 46 disposed at a position forward of the tongue 42 . In the illustrated arrangement the bracket structure includes a first leg 48 and a second leg 50 defining boundary surfaces for a substantially “U” shaped channel 52 . As shown, the channel 52 projects downwardly in a plane oriented at a substantially right angle to the plane defined by the slot 44 .
[0026] As best illustrated in FIG. 4 , the arrangement of the slot 44 and the channel 52 facilitates a secure placement of the actuators 30 utilizing slotted engagement with protruding edge portions of the channel frame structure 40 . In particular, the slot 44 is adapted to engage a rib member 56 extending across at least a portion of the width of the drawer cabinet structure. By way of example only, and not limitation, the rib member 56 may be an inwardly projecting lip of the channel frame structure 40 . As shown, the rib member projects generally away from a rear wall of the cabinet structure 14 and towards a back surface of the drawer 16 . The engagement between the slot 44 and the rib member 56 is preferably a substantially sliding engagement so as to permit a sliding motion of the actuator 30 during installation.
[0027] As shown in phantom lines in FIG. 4 , during installation the actuator 30 may first be arranged in engaged relation to the rib member 56 to establish the proper vertical placement. The actuator 30 may then be moved to the proper position along the width of the cabinet structure 14 by sliding along the rib member 56 as shown by the directional arrow until the channel 52 engages an upstanding support plate member 60 . Upon reaching this position, the upstanding support plate member 60 is held between the first leg 48 and the second leg 50 . The actuator 30 may then be secured in place by a screw 62 or other fastening structure as may be desired. The actuator 30 is thus restrained against both horizontal and vertical displacement. As shown, the upstanding support plate member 60 may have a slightly reduced thickness relative to the channel frame structure 40 thereby defining a step 64 which engages the lower terminal surface of the first leg 48 of the bracket structure 46 to further assist in positioning of the actuator 30 . Such an arrangement may provide additional support against tilting.
[0028] As illustrated, the edge structures engaging the actuator 30 may be portions of a channel frame structure 40 disposed at an interior portion of the cabinet structure 14 . However, the invention is in no way limited to the use of such a separate channel frame structure. To the contrary, it is contemplated that virtually any arrangement of corresponding edge elements may be utilized if desired. By way of example only, and not limitation, the rib member 56 and/or the upstanding support member 60 may be integral with the cabinet structure 14 if desired.
[0029] Of course, the present invention is susceptible to a number of different embodiments. By way of example only, and not limitation, FIGS. 7 and 8 illustrate an alternative embodiment of an actuator 130 wherein elements corresponding to those previously described are designated by like reference numerals increased by 100 . As illustrated, the actuator 130 incorporates a modified bracket structure 146 having a first leg 148 and a substantially shorter second leg 150 opposing the first leg 148 so as to define a generally inverted “J” shaped profile with a shallow channel 152 between the first leg 148 and the second leg 150 .
[0030] FIG. 8 illustrates an exemplary orientation of the actuator 130 relative to a rib member 156 and upstanding support plate 160 as previously described in relation to FIG. 4 . As will be noted, in this arrangement, the second leg 150 extends only a portion of the distance from the upper edge of the support plate 160 . However, the actuator 130 is nonetheless provided with full support.
[0031] Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.
[0032] Various features of the invention are set forth in the following claims.
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A drawer manipulation system adapted to facilitate opening of a drawer supported within a cabinet. The system includes at least one biasing actuator adapted for mounting in supported relation at projecting edge elements within the cabinet housing the drawer. The actuator incorporates an arrangement of slotted engagement surfaces adapted to accept supporting edge structures. The actuator may be used in conjunction with a push-push latch assembly.
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This is a division of application Ser. No. 597,203 filed Oct. 11, 1990, now U.S. Pat. No. 5,062,480.
BACKGROUND OF THE INVENTION
The present invention is drawn to an improved inlet valve assembly for use in subsurface sucker rod operated reciprocating piston pumps used in the petroleum industry for pumping oil from a downhole well to the surface.
Typically, subsurface sucker rod operated reciprocating piston pumps comprise a pump barrel having any inlet check valve and an outlet check valve and a pump plunger which is reciprocated within the barrel via a sucker rod. The intake valve is generally located at the entrance to the pump barrel and allows for the flow of well fluids into the pump barrel. The discharge valve is commonly located in the plunger and permits the flow of well fluids out of the pump barrel and up to the surface. Upon reciprocation of the pump plunger by the sucker rod, the coordinated action of both the intake valve and the discharge valve results in fluid flow from the well to the surface.
In order for the reciprocating piston pumps to operate properly they must be anchored within the production tube of the deep well. Thus, during normal pumping operations from the well the reciprocating piston pump is anchored within the production tube. However, during well maintenance, repair and stimulation operations, such as, steam injection or diluent injection, it is necessary to stop the normal pumping operation and to remove the subsurface reciprocating pump from its anchored position in the production tube as no fluids could flow down through the pump when in its anchored position. While the pump must be unanchored in order to carry out fluid injection and the like as aforesaid, it is highly desirable that the reciprocating piston pump remain within the production tube in order to avoid the cost and lost time associated with bringing the subsurface reciprocating pump and sucker rod string to the surface during the aforesaid operations. Accordingly, it is common practice in the prior art to unanchor the subsurface reciprocating pump by pulling the sucker rod string from the surface and move the pump a short distance from its anchored position to an enlarged section of the production tube. In this position, specific fluids from the surface can be injected downhole into the well for maintenance, repair and recovery stimulation.
During the injection of the aforesaid fluids into the well it is extremely important not allow any flow through the pump barrel of the subsurface reciprocating pump as the fluids being injected generally carry particles which are known to damage the pump plunger and pump barrel surfaces. Accordingly, in existing systems one must choose between removing the reciprocating pump entirely from the production tube or suffer the consequences of passing a portion of the aforesaid injected fluid through the pump barrel of the pump thus resulting in the aforesaid damage to same.
Naturally, it would be highly desirable to provide a system wherein the reciprocating piston pump may be maintained in the production tube of a downhole well and at the same time insure that no fluids which would damage the pump will pass through the pump during the maintenance, repair and stimulation operations as set forth above.
Accordingly, it is the principal object of the present invention to provide an improved inlet valve assembly for use in subsurface sucker rod operated reciprocating piston pumps.
It is a particular object of the present invention to provide an intake valve assembly as aforesaid wherein the inlet valve to the reciprocating piston pump is locked in its closed position when the pump is in its unanchored, non-pumping position within the production tube of a deep well.
It is a further object of the present invention to provide an inlet valve assembly as aforesaid wherein the inlet valve is freely moveable between its open and closed position when anchored within the production tube of the deep well for pumping fluid from the well to the surface. It is a further object of the present invention to provide an inlet valve assembly as aforesaid which is effective in service and relatively inexpensive to manufacture.
Further objects and advantages of the present invention will appear hereinbelow.
SUMMARY OF THE INVENTION
In accordance with the present invention the foregoing objects and advantages readily obtained.
The present invention is drawn to an improved inlet valve assembly for use in combination with a sucker rod operated reciprocating subsurface pump which is disposed within the production tube of a deep well for pumping oil from the well to the surface. In accordance with the present invention the sucker rod operated reciprocating subsurface pump is selectively positioned between a first position wherein the pump is anchored in the production tube for pumping fluid from the well and a second position wherein said pump is unanchored in said production tube for non-pumping operations such as maintenance, repair and recovery stimulation operations. The reciprocating subsurface pump comprises a pump barrel having a first valve seat defining an inlet to the pump barrel and a second valve seat defining an outlet port from the valve barrel. An inlet valve is provided for selectively sealing the inlet port by seating on a surface of the first valve seat. Likewise, an outlet valve is provided for selectively sealing the outlet port from the valve barrel. A pump plunger is mounted for reciprocal movement via a sucker rod within the pump barrel for pumping fluid from the inlet port to the outlet port when the pump is anchored in the production tube. In accordance with the present invention the inlet valve of the present invention includes means for locking the inlet valve against the inlet port for sealing same against pressure downhole in the well when the pump is in its second unanchored position so as to prohibit passage of fluid into the pump barrel. The inlet valve further includes means for unlocking the inlet valve so as to allow for selective sealing and unsealing of the inlet port to the pump barrel when the pump is in its first anchored position for pumping fluid from the well.
In one preferred embodiment of the present invention the mechanism for locking the inlet valve includes a mechanical biasing mechanism which biases the inlet valve against the inlet port. In a further embodiment the mechanism for locking the inlet valve against the inlet port includes a flow control mechanism for sealing off the flow of fluid to the inlet port and accordingly the inlet valve of the subsurface pump.
By providing an arrangement as aforesaid the sucker rod operated reciprocating subsurface pump may be maintained within the production tube when in its unanchored position without fear of fluid passing through the inlet valve and through the pump barrel and damaging same.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view of a deep well pump assembly in its unanchored position in the production tube and illustrating an inlet valve of the present invention in its locked position.
FIG. 2 is a partial cross sectional view similar to FIG. 1 showing the subsurface pump in its anchored positioned within the production tube wherein the inlet valve is free to move between its open and closed positions.
FIG. 3 is a partial cross sectional view similar to FIG. 2 showing the position of the inlet valve of the present invention on the upstroke of the plunger.
FIG. 4 is a partial cross sectional view similar to FIG. 3 showing the position of the inlet valve of the present invention on the downward stroke of the pump plunger.
FIG. 5 is a cross sectional view of a second embodiment of an inlet valve in accordance with the present invention showing the valve in its locked position.
FIG. 6 is a further cross sectional view of the valve of FIG. 5 showing the inlet valve in its unlocked position.
FIG. 7 is a cross sectional view of a third embodiment of an inlet valve in accordance with the present invention shown in its locked position.
FIG. 8 is a cross sectional view of the inlet valve of FIG. 7 shown in its unlocked position.
DETAILED DESCRIPTION
With reference to the drawings and, more particularly, FIGS. 1 through 4 there is illustrated a sucker rod operated reciprocating subsurface pump located within the production tube of a deep well. The reciprocating subsurface pump 10 comprises a pump barrel 12 having a piston 14 mounted therein for reciprocal movement via sucker rod 16. As can be seen in FIG. 3, the pump barrel 12 is provided with an inlet valve assembly 18 for drawing fluid into the pump barrel during the upward stroke of the pump piston 14 via the sucker rod 12. The pump piston 14 carries a discharge valve 20 which, as can best be seen in FIG. 4, opens for passing fluid from the pump barrel and up the well production tube 22 on the downward stroke of the pump piston 14.
In accordance with the present invention a first embodiment of inlet valve assembly 18 is illustrated in FIGS. 1 through 4. The inlet valve assembly includes a valve seat 24 formed within the pump barrel and defining a sealing surface 26 upon which valve sealing element 28 seals when the valve 18 is in its closed position. The assembly further includes an extension portion 30 which extends from the valve seat 24 upstream of valve sealing element 28. Portion 30 has either integrally therewith or secured thereto a sealing portion 32 provided with a seal or friction ring 34 for sealing the extension and therefor the pump barrel in seating nipple 36 in a manner to be described in more detail hereinbelow. In accordance with the embodiment of inlet valve of the present invention as illustrated in FIGS. 1 through 4, a connection portion 38 extends from the sealing element 28 and connects to a vane guide member 40 which consists of, for example, four vane members 42 located 90 degrees apart with respect to the axis of the connecting element 38.
As can be seen most clearly in FIG. 1, a locking member 44 in the form of a hollow substantially cylindrical tube is mounted within extension portion 30 and 32. The locking member includes a bore 46 defined by radial flange 48. The connecting portion 38 of the valve 18 penetrates the bore 46. The vanes 42 of valve portion 40 abut radial flange 48 as shown in FIG. 1. The locking mechanism 44 has an annular rib 50 located intermediate the ends of the locking mechanism. The end of the locking mechanism 44 opposite radial flange 48 is provided with a flange 52 which abuts the locking nipple 36 when the pump is in its anchored position within the production tube 22 in a manner to be discussed in greater detail hereinbelow. A coil spring 54 is provided in an annular chamber 56 defined by extension portion 30 and locking mechanism 44. The coil spring contacts the underside of valve seat 24 and biases against annular rib 50 on locking mechanism 44 for biasing the locking mechanism downward. As can be seen in FIG. 1, the coil spring 54 biases the locking mechanism 44 downward so that radial flange 48 abuts the vanes 42 of vane guide portion 40 of valve 18. In turn, the valve sealing element 28 is likewised carried by the locking mechanism 44 downward so as to lock the valve sealing element 28 against the sealing surface 26 of valve seat 24.
With further reference to FIGS. 1 through 4 the operation of the inlet valve assembly and sucker rod operated reciprocating subsurface pump will be described in detail. As noted above, when the well is being serviced and no pumping is being carried out by the reciprocating subsurface pump, it is desirable to maintain the pump within the well tube in an unanchored position. The unanchored position of the pump within the well tube 22 is illustrated in FIG. 1. As illustrated in FIG. 1 the pump barrel 12 is held in this position by the sucker rod 16 which is connected to piston 14. The piston 14 abuts an annular abutment 60 provided on the pump barrel. In this manner the pump 10 is suspended within the well tube. In order to prohibit the flow of fluid into the pump barrel 12 when in its unanchored suspended position, valve sealing element 28 is held against the sealing surface 26 of the valve seat 24 by locking member 44 which is biased downwardly by coil spring 54. The locking mechanism 44 abuts valve portion 40 and assures that the valve sealing element 28 seals on the valve seat 24. In this manner fluids are prohibited from flowing into the valve barrel. The biasing force of the coil spring 54 is selected in order to insure that the valve remains in its sealed position against the pressures which will be created downhole in the well during servicing, maintenance and the injection of fluids for well stimulation.
When maintenance of the well is complete and pumping from the well is again desired the pump 10 is lowered via the suction rod 16 into seating nipple 36 wherein friction ring or sealing means 34 seals on the annular wall 62 of the seating nipple 36. Upon anchoring the pump within the seating nipple 36 flange 52 of the locking member 44 abuts the bottom surface 64 of the annular chamber defined in seating nipple 36. As can be seen in FIG. 2, as the pump is lowered the locking means 44 is pressed upward against the force of spring 54 and frees valve portion 40 thereby allowing the valve to act as a conventional check valve. As can be seen in FIGS. 3 and 4 on the upward stroke of the pump piston 14 the valve is moved upward so that element 28 unseals from valve seat 24 so as to draw fluid into the pump barrel 12. On the downward stroke (FIG. 4) the fluid is compressed in the pump barrel 12, the valve is closed as a result of compression of fluid in the barrel and outlet valve 20 provided in pump piston 14 opens allowing the fluid to pass from the pump barrel up the production tube 22.
FIGS. 5 and 6 illustrate a second embodiment inlet valve assembly in accordance with the present invention. With reference to FIG. 5, the pump barrel 12' has secured thereto by means of threads 70 an extension 30' which carries friction ring or seals 34' in a manner similar to the embodiment discussed above with regard to FIGS. 1 through 4. The pump barrel 12' is provided with a rib extension 72 on which a valve seat 24' rests. The valve seat 24' is held against rib 72 by cage member 74 which includes ports 76 for communicating fluid to the interior of pump barrel 12' via valve sealing element 28'. Cage member 74 is held against valve seat 24' by extension member 30' which is screwed to the valve barrel 12' by threads 70 as noted above. The cage member 74 is provided with a receptacle 78 which receives spring element, 54'. Locking member 44' is mounted within bore 79 of extension element 30'. Locking member 44' includes on one end thereof a piston element 80 provided with annular recess 82 in which seal 84 seats. Piston 80 is contacted by spring 54' for biasing the locking member 44' in the downward direction where intermediate rib portion 86 abuts annular ridge 88. In this position the piston 80 is sealed within passage 78 thereby prohibiting flow of fluid up hollow conduit 92 in locking elements 44' and radial passages 94 to valve sealing element 28'. Thus, in the position shown in FIG. 5 locking element 44' insures that no fluid from the well bore reaches the valve element 28' and thereby insures no fluid flows into the pump barrel 12'. The position of the valve in FIG. 5 is that position which the valve will assume when the pump is suspended in the production tube as discussed above with reference to FIG. 1.
Upon seating of the pump in seating nipple 36' the valve of FIG. 5 assumes the position illustrated in FIG. 6. As discussed above with regard to FIG. 2, element 52' on locking member 44' abuts the seating nipple and accordingly compresses spring 54' upon anchoring of the valve pump within the seating nipple as shown in FIG. 6. The compression of the spring element 54 allows the ports 94 to communicate with annular chamber 96 and thereby allows fluid to pass up through conduit 92 into annular chamber 96 through ports 76 to the valve sealing element 28'. In this position the valve now functions as a conventional check valve and will open and close in the same manner as discussed above with regard to FIGS. 3 and 4.
FIGS. 7 and 8 illustrate a third embodiment of inlet valve in accordance with the present invention. The inlet valve of FIGS. 7 and 8 is similar construction to that of the inlet valve assembly FIGS. 5 and 6 discussed above. In the embodiment of FIGS. 7 and 8, the locking mechanism is provided with a piston portion 80' which has a sealing radial peripheral surface 100 adapted to seal on sealing surface 102 provided in extension portion 30". Accordingly, as can be seen in FIG. 7, when the pump is in its unanchored position within the production tube the spring element 54" biases piston portion 80' downwards so that it seals on sealing surface 102 thereby preventing flow of fluid up through conduit 92' and into annular space 96'. In this manner it is insured that fluid cannot pass through inlet valve seating element 28" and into the pump barrel 12". When the pump is anchored within seating nipple 36" of the production tube, element 54" of the locking mechanism 44" abuts the seating nipple and thereby compresses spring 54" so as to establish communication between conduit 92' and annular chamber 96' via ports 94' provided in locking element 44". Thus, as was the case with the embodiments discussed above, when the pump is anchored within the seating nipple the valve assembly of the present invention acts as a normal check valve for pumping fluid from the deep well in the manner previously discussed with regard to FIGS. 3 and 4.
It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
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The present invention is drawn to an inlet valve assembly for a subsurface sucker rod operated reciprocating piston pump and, more particularly an inlet valve assembly which is locked in its closed position when the pump is in its unanchored, non-pumping position within the production tube of a deep well. When the subsurface piston pump is anchored within the production tube of the deep well of the inlet valve assembly is freely movable between open and close positions upon reciprocation of the piston.
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This is a continuation of copending application Ser. No. 07/642,358 filed on Jan. 17, 1991 now abandoned.
TECHNICAL FIELD
The present invention deals broadly with doors providing access to a building such as a residential dwelling. More specifically, however, the invention deals with sills for sliding doors such as doors to patios, decks, etc. The specific focus of the invention is the overall composition of a sill for such a door.
BACKGROUND OF THE INVENTION
Sliding doors such as ones providing egress, for example, from a residential dwelling to a patio or deck are well-known in the prior art. Such prior art is fairly well developed. Sliding doors having been in existence for a considerable period of time. Typically, such doors, which are known as French doors, are utilized to provide access, as indicated above, to patios, decks, etc. from residences with which such patios, decks, etc. are associated.
Of serious concern in the manufacture of doors in general and, particularly, sliding doors, is the sill structure. The sill is the portion which provides the threshhold over which one passes when passing through the door closure.
In the case of sliding doors, sills provide unique problems. They must be resistent to chemical action which might result from exposure to ultraviolet light. Additionally, they must be strong and durable, since traffic across them can be quite significant.
In the prior art, various materials have been employed in the manufacture of sliding door sills. Wood is one particular composition which has been employed. Wood, however, decays over a period of time, since wood absorbs moisture. Even when decay is slow so that the useful life of a sill is obtained, warping can occur. Warping, if significant enough, can create a safety hazard. At a minimum, however, it gives rise to an unsightly condition.
Aluminum has been deemed to be a logical choice for a sliding door sill application. Aluminum has been thought to have the most significant strength for this application. Stronger materials would, of course, be more desirable.
Even aside from the strength issue, however, aluminum does have certain drawbacks. Because of its inherent metallic properties, aluminum has a relatively high coefficient of thermal conductivity. When used in a sliding door sill application, aluminum can conduct heat within the building in which the door is installed to the outside. This is a particularly acute problem in geographic locations where winters are very cold. In extreme temperature conditions, the temperature gradient between the inside and outside of a building is quite extreme.
The solution proposed when aluminum is used has been to provide a thermal break in order to inhibit thermal conduction. Doing this, however, has translated to high manufacturing costs.
It is to these dictates of the prior art and the problems discussed above that the present invention is directed. It is a composition for a sliding door sill which overcomes the problems of the prior art, taking into account the desirable dictates for such a product.
SUMMARY OF THE INVENTION
The present invention is a door sill having a particular composition. The sill includes a core which defines a form. The form is made from spun glass fibers which are treated with a polyester resin. The form thus formed is, in turn, coated with an ultraviolet stable cladding.
In one embodiment of the invention, the core form includes a plurality of vertically-oriented spun glass fiber panels. The vertically-oriented panels are, in turn, integrated by a plurality of interconnecting panels.
In certain embodiments of the invention, the form can include an unsupported cantilevered portion. Such a portion, it would be intended, would extend outwardly from a building in which the sill is installed. Because of the strength properties afforded to the sill, the cantilevered portion could, in fact, be unsupported.
In the preferred embodiment, the core form would include glass fibers oriented both in lineal rows and random mats. The form thus constructed would provide flexing strength during vertical load over the length of the sill. The random mat would contribute strength against bending in the vertical plane. As a result, the need for a sill nose support would be eliminated.
The preferred embodiment also envisions employment of an ultraviolet stable sheathing. It is felt that a sheathing made of a material such as LEXAN would be optimum since such a material is not only ultraviolet stable, but it is also resistent to impact and abrasion. LEXAN® is a registered trademark of the General Electric Corporation.
Other claddings are, however, contemplated. Other appropriate claddings would, further, include the characteristics of a polycarbonate.
The present invention is thus an improved sill composition and construction. More specific features and advantages obtained in view of those features will become apparent with reference to the DETAILED DESCRIPTION OF THE INVENTION, appended claims, and accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is an end perspective view of a door sill constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawing wherein like reference numerals denote like elements throughout the several views, the FIGURE illustrates a door sill 10 composed in accordance with the present invention. While the overall sill 10 will be described in order to provide the general background and environment in which the present invention functions, it will be understood that the specific focus of the invention is the sill structure itself.
The FIGURE illustrates a sill 10 in position on a block 12 of a building in which a sliding door assembly, of which the sill is a part, is installed. The sill assembly 14 is seated on the block 12 with a cantilevered portion 16 of the sill 10 extending outwardly from the block 12. A baseboard 18 is in engagement with a generally vertically-extending inner panel 20 of the sill 10.
The overall sill 10 supports an extrusion 22 which mounts a fixed door panel 24. The door panel 24 is secured to the extrusion 22 by means of a block 26 which is received within a channel 28 formed within the lower edge 20 of the fixed door panel 24.
A sliding door panel 32 is mounted to a track 34 for longitudinal movement therealong, between open and closed dispositions. A pile seal is 36 engaged by the bottom edge 38 of the sliding door panel 32 to insulate, when the door panel 32 is in a closed disposition, the inside of the building in which the door 14 is mounted, from the exterior. Additionally, a weather seal strip 40 is mounted to the track 34 along which the sliding door panel 32 moves to seal along the bottom edge 38 of the sliding door panel 32 when that panel 32 is in its closed disposition.
The FIGURE also illustrates a sliding screen door 42 mounted to a track 44 extending upwardly from a cantilevered portion 16 of the sill structure 10. In fact, the screen door 42 is, typically, suspended by an upper rail thereof (not shown) from an upper track (not shown). The lower rail 46 of the screen door panel 42 interfaces with the lower track 34 merely for alignment purposes and to inhibit the passage of mud, snow, ice, etc.
As seen in the FIGURE, the sill structure 10 comprises two components, a core 48 and a cladding 50. The core 48 primarily functions to provide structural integrity, rigidity, and strength to the sill 10. The cladding 50 functions primarily to present a surface 52 exposed to the elements and which is protective against those elements. Typically, the cladding 50 is impact and abrasion resistant. Further, it is ultra-violet stable in view of the fact that the sill 10 is usually exposed to solar radiation.
The core 48 in accordance with the present invention is formed from spun glass fibers. Those fibers are treated with a resin binder. Shape is given to the core 48 by manufacturing it through a process known as "pultrusion". The process is similar to extrusion, but the thrust of the force is applied to draw the item through the die from a side of the die after the item has been formed. This is a corollary to a standard extrusion process.
The core 48 comprises a form which includes a plurality of generally vertically-oriented panels 54 which provide support in a vertical plane. The generally vertically-oriented panels 54 are interconnected by a series of transverse panels 56, the core 48 thereby being provided with form and shape.
The core 48 includes a generally horizontally-disposed cantilever portion 58. The core 48 cantilever portion 58 serves as a foundation for the overall cantilver portion 16 of the sill 10.
In the preferred embodiment of the invention, the core 48 includes glass fibers which are oriented both in lineal rows and random mats. A core so constructed provides flexing strength during vertical load over the length of the sill 10. The fibers formed into a random mat function to contribute strength against bending in the vertical plane. That is, they provide strength against torque forces applied, for example, to the cantilever portion 16 of the sill 10. Because of the random fiber matting, the cantilever portion 16 of the sill 10 need not be supported.
The sill further includes a cladding 50 which coats the core 48. It is important that the cladding 50 provide ultraviolet stability so that chemical breakdown does not occur. Further, the cladding 50 should be resistant to both impact and abrasion. Typically, any material having characteristics of a polycarbonate could appropriately function as the material for the cladding 50. It has been found, however, that LEXAN® is particularly appropriate to function for this purpose. It will be understood, however, that metals can, additionally, be appropriately used as the cladding material. Metals, however, because of their high thermal conductivity, are less desirable.
As seen in the FIGURE, the inner surface 60 of the cladding 50 generally conforms to a shape defined by various panels 56 of the core 48. The cladding 50 can, thereby, be fitted closely over the core 48 and be made substantially an integral structure.
Numerous characteristics and advantages of the invention have been set forth in the foregoing description. It will be understood, of course, that this disclosure is, in many respects, only illustrative. Changes can be made in details, particularly in matters of shape, size, and arrangement of parts without exceeding the scope of the invention. The invention's scope is defined in the language in which the appended claims are expressed.
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An improved door sill construction. The sill includes a core including a form made from spun class fibers treated with a polyester resin. The spun glass fibers are oriented in both lineal rows and random mats in order to maximize strength. The sill further includes a cladding coating the form which is stable to ultraviolet radiation.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] This Application claims the benefit of U.S. Provisional Application No. 62/240,643 titled “Coated Concrete Form,” to Bryan White, filed Oct. 13, 2015, the entire disclosure of which is expressly incorporated by reference herein.
TECHNICAL FIELD
[0002] The present disclosure relates generally to concrete forms and related concrete construction technology, and relates more particularly to a concrete form system having an outer form with a structural foam material and an outer protective skin material.
BACKGROUND
[0003] Construction technology related to the pouring, forming, and curing of concrete to build foundation slabs, footers, and basement walls has advanced significantly over the years. While some of the basic materials and procedures for creating a concrete structure have been little changed for literally more than a thousand years, more recently highly sophisticated materials, science, and construction engineering have been applied to certain apparatuses, notably forms, used in pouring concrete.
[0004] One known technique relates to the use of foam panels to contain concrete in its uncured, flowable state in a particular shape so that the concrete can retain that shape once cured. Foam panels have the advantage of being relatively lightweight and easy to handle, and can provide insulation about the periphery of the structure to be formed. Foam panels of known design have various shortcomings relative to certain applications. For instance, foam panels are typically removed once curing of the poured concrete is complete, leaving an unsightly and unfinished exterior surface that must be painted, obscured, or otherwise treated to produce a suitably aesthetically pleasing finish.
SUMMARY
[0005] In one aspect, a concrete form system includes inner and outer forms coupled together via a plurality of connecting webs. The outer form includes a structural foam material forming an inner surface, facing the inner form, and structured to contact concrete poured into a space between the inner form and the outer form. The outer form further includes a protective skin material in contact with the structural foam material and forming an exposed outer surface of the outer form.
[0006] In another aspect, a method of making a concrete form is disclosed. The method includes production of a substantially rectangular body having a plurality of peripheral edges extending about a first and a second body side of an outer concrete form from a structural foam material, applying a protective skin material in liquid form to the first body side such that the skin material adheres to the structural foam material on the first body side, and packaging the substantial rectangular body for shipping with the protective material adhered to the structural foam material located upon only the first body side.
[0007] In still another aspect, a method of constructing a foundation is disclosed, the method including assembling a concrete form system such that an inner form and an outer form are supported in parallel spaced apart relation, positioning the concrete form system upon a footing, pouring uncured concrete into a space extending between the inner and outer forms such that upon curing the concrete forms a solid wall extending upwardly from the footing, and orienting the outer form during assembly and positioning such that an inner surface formed from a structural foam material of the outer form faces the space and is contacted by the poured concrete, and an opposite surface formed from a protective skin material of the outer form is exposed and faces outwardly of the foundation.
BRIEF DESCRIPTION OF THE FIGURES
[0008] FIG. 1 is a top diagrammatic view of a concrete form system and a foundation system at one stage of construction, according to one embodiment;
[0009] FIG. 2 is a sectioned side diagrammatic view of a concrete form system at one stage of construction, according to one embodiment;
[0010] FIG. 3 is a detailed enlargement of a rectangular body, according to one embodiment; and
[0011] FIG. 4 is a diagrammatic view of stages of making a form for use in a concrete form system, according to one embodiment.
DETAILED DESCRIPTION
[0012] Referring to FIG. 1 , there is shown a concrete form system 20 according to one embodiment. Form system 20 may be part of a foundation system 10 including a footer 12 of poured and cured concrete within a trench in the ground. An aggregate 14 of any suitable kind can be placed adjacent to footer 12 to form a subgrade, upon which a poured concrete foundation 13 , typically in the form of a slab is to be poured. A cutout 19 of foundation 13 illustrates aggregate 14 underneath and adjacent to foundation 13 . It should be appreciated that foundation system 10 could be used for supporting a residential living structure, a light industrial installation, or even a bare concrete slab to serve as a parking lot, or for any other conceivable purpose. In a practical implementation strategy, plumbing pipes 18 , electrical service wires, or other installations may be located within or upon aggregate 14 and thus covered by concrete foundation 13 once formed.
[0013] Referring now also to FIG. 2 , there is shown a sectioned diagrammatic view of foundation system 10 and form system 20 along line 2 - 2 of FIG. 1 . System 20 may include an inner form 22 having a first substantially rectangular body 24 with a top peripheral edge 26 and a bottom peripheral edge 28 . System 20 may also include an outer form 30 having a second substantially rectangular body 32 with a top peripheral edge 34 and a bottom peripheral edge 36 . A plurality of connecting webs 38 couple together inner form 22 and outer form 30 in spaced apart relation, with a space 48 extending therebetween. The coupling together of inner form 22 and outer form 30 is also such that rectangular bodies 24 and 32 are oriented parallel to one another at least in a practical implementation, and bottom peripheral edges 28 and 36 are positioned in a common plane or only modestly out of plane, for positioning system 20 upon footer 12 . In one implementation, the components of form system 20 can be assembled prior to placement upon footer 12 , either at a job site or even at a remote assembly facility. An alignment channel 40 extends along bottom peripheral edge 36 , and can be fastened by any suitable means such as an adhesive or fasteners to the concrete forming footer 12 . A fastening bolt 41 is shown as an illustrative example. In a practical implementation strategy, form system 20 may have the general shape of a polygon, extending about a plurality of sides of the foundation system 10 . Form system 20 can therefore contain and direct the flow of concrete 16 not yet in a cured state, filling space 48 to form a stem wall or the like that is positioned upon footer 12 .
[0014] In FIG. 2 , space 48 is shown filled part way with concrete 16 , which will typically be poured to fill space 48 , and flow or extend over the top of inner form 22 to make contact with aggregate 14 . Contact between portions of the poured concrete forming the stem wall and forming the slab is not visible in FIG. 2 due to the section planes chosen. In some instances a gap or intervening layer of a different material could be positioned between the stem wall and slab portions. Inner form 22 may have a shorter height 27 , height 27 being the distance from footer 12 to top peripheral edge 26 , than height 35 of outer form 30 , height 35 the distance from footer 12 to top peripheral edge 34 . It can thus be appreciated that a horizontally extending foundation 13 once cured will be supported upon aggregate 14 , while a downwardly extending stem wall may be formed integrally with the foundation 13 and at least in certain instances extends peripherally about aggregate 14 at an outer edge of foundation system 10 , to contact footer 12 in between inner form 22 and outer form 30 . The relative height 27 of inner form 22 to height 35 of outer form 30 may facilitate the general shaping of the stem wall so as to allow concrete 16 to flow over inner form 22 and come into contact with aggregate 14 when poured into space 48 , or flow over inner form 22 in an opposite direction to fill space 48 . The difference between height 27 and height 35 may depend on a desired thickness of foundation 13 . As concrete 16 may flow over inner form 22 but not outer form 30 , height 35 may be at least the total of height 27 and the desired thickness of foundation 13 . For example, if the height 35 of outer form 30 is 4 feet and the desired thickness of foundation is 6 inches, the height 27 of inner form 30 may not be greater than 42 inches. Outer form 30 may be shaped so a kicker brace or the like 42 may receive top peripheral edge 34 and support the same during pouring of concrete into space 48 . An additional channel piece 52 may be provided as shown end-on in FIG. 1 for positioning at a corner where adjacent panels of outer form 30 are adjoining, extending vertically from footer 12 . It can be seen that channel piece 52 can include channels generally extending in a parallel configuration but opening so as to define approximately a right angle to receive the rectangular bodies 32 of outer form 30 at the corner. An analogous channel can be provided for inner form 22 and is shown in FIG. 1 via reference numeral 54 .
[0015] Outer form 30 may include a structural foam material 50 that forms an inner surface 44 of substantially rectangular body 32 , faces inner form 22 and is thus structured to contact concrete 16 poured into space 48 . Structural foam material 50 may be a one-piece body and is to be understood as structural in that it does not collapse under its own weight, at least when shaped and dimensioned according to generally analogous building products. For instance, outer form 30 might be from about 3 feet wide or tall to about 6 feet wide or tall, from about 2 feet long to about 16 feet long, and from about ½ inch thick to about 12 inches thick. It will be appreciated that the width and length and thickness of body 32 will typically be chosen based upon the intended service application, and accordingly relatively shorter or narrower forms constructed according to the present disclosure might be relatively thinner, whereas relatively taller or wider forms might be relatively thicker. Specific examples of suitable materials for constructing outer form 30 are further discussed herein.
[0016] Referring also to FIG. 3 , there is shown a detailed enlargement of a portion of outer form 30 in greater detail. Outer form 30 further includes a protective skin material 56 in contact with structural foam material 50 . In FIG. 2 , protective skin material 56 is peeled back from structural foam material 50 to illustrate the relatively greater flexibility of material 56 versus material 50 . In the present embodiment, protective skin material 56 may be in contact with only one side of structural foam material 50 , with inner surface 44 remaining free of protective skin material 56 allowing inner surface 44 to contact concrete 16 freely. Inner surface 44 may therefore be in fluid contact with uncured concrete 16 allowing concrete 16 to flow into any voids or pores 60 in structural foam material 50 . The ability of uncured concrete 16 to fluidly contact inner surface 44 without any barrier such as a polymeric coating or other material allows concrete 16 to form a relatively stronger mechanical bond with structural foam material 50 when curing, providing structural rigidity to form system 20 , and may increase durability and longevity of system 20 . In some embodiments, there may additionally be a chemical bond between concrete 16 and structural foam material 50 . A strong bond between outer form 30 and concrete 16 , especially where an outer surface 46 may be textured to have visual or stylistic characteristics as will be discussed further herein, may have certain advantages as will be appreciated by those with skill in the art.
[0017] Protective skin material 56 forms the exposed outer surface 46 of outer form 30 located opposite inner surface 44 . In a practical implementation strategy, rectangular body 32 may consist essentially of structural foam material 50 and protective skin material 56 , although certain additives such as fire retardants, anti-fungals, colorants, pesticides, or still other materials might be part of rectangular body 32 . The outer surface 46 formed by protective skin material 56 may be substantially smooth in many instances, and smoother than inner surface 44 , but can also be roughened or textured in others. In FIG. 3 , indentations or slots 59 are shown in a regular and alternating arrangement with protrusions 57 , a structure that might be seen where a faux brick or stone finish is formed on skin 56 . It is contemplated that material 56 might be applied, as further discussed herein, and textured via mechanical indentation means or another technique prior to completing curing, although the present disclosure is not thereby limited. Thus, embodiments are contemplated where a wood grain, a stone grain, a brick pattern, or still other visually and aesthetically observable properties are present. Top peripheral edge 34 and bottom peripheral edge 36 may be formed of structural foam material 50 . Since surface 44 will typically be formed of the structural foam material, the only protective skin material used may be the protective skin material that is applied to one side only of body 32 .
[0018] It is also contemplated that structural foam material 50 may include a foamed polymeric material, and protective skin material 56 may include a continuous polymeric material adhered to the foamed polymeric material. Further still, the continuous polymeric material may be chemically bonded to the foamed polymeric material. Examples of suitable continuous polymeric materials are certain materials commonly applied by plural component spray, and including a polyurethane, a polyurea, an epoxy, or a hybrid of any of these. Foamed polymeric material comprising material 50 may include a polyisocyanate, polyurethane, or polystyrene, for example. Inner form 22 may be any suitable material desirably but not necessarily having some resistance to degradation over time. The material of which inner form 22 is made will typically be different than the material of which outer form 30 is made, and could include any polymeric material suitable for permanent installation in ground contact conditions.
[0019] It can also be seen from FIG. 3 that an interface 58 resides between material 50 and material 56 . Material 50 may contain voids or pores 60 , commonly associated with a cellular foam material. It will be seen at interface 58 that certain of the voids or pores 60 may be open such that material 56 intrudes therein. It will thus be appreciated that some degree of mechanical interlocking between material 50 and material 56 may occur. As will be further discussed herein, material 56 is applied in the form of a liquid or liquids, thus imparting the tendency for flow of the liquid into any voids or pores in material 50 and interlocking with the same upon curing. Depending upon the materials selected which will typically and by necessity be chemically compatible, polymer crosslinking between material 56 and material 50 may occur. Those skilled in the art will appreciate the cure time and/or hardening time of foamed polymeric materials, and in particular extruded foam polymeric materials, can be such that application of material 56 in plural component liquid form can be timed to enable some chemical bonding between the materials 50 and 56 , and even making available some flexibility in the extent to which chemical bonding is sought. In other words, while it is contemplated that prefabricated and fully cured and/or hardened foamed polymeric materials can be sprayed with plural component coatings according to the present disclosure, in many instances the plural component polymeric material coatings can be sprayed onto the foamed polymeric material prior to completion of curing and/or hardening, in some instances substantially prior to completion of curing and/or hardening and in others when curing and/or hardening of the foamed polymeric material is substantially completed. Desirable properties relating to the manner in which materials 50 and 56 interact and stick together can be empirically determined.
[0020] Referring now to FIG. 4 , there is shown an example a production assembly 100 for producing rectangular bodies 24 , 32 having a protective skin material 56 that can be used in constructing foundation system 10 or form system 20 according to the present disclosure. Process flow in the production assembly generally flows from an extruder 64 to a sprayer 72 and then to a cutter 68 as demonstrated by process flow arrows in FIG. 4 . A texturing device (not shown) could also be part of production assembly 100 , and positioned so as to form texturing as contemplated herein on skin 56 , potentially while soft and/or prior to completing curing. Raw material of conventional type can be fed into a hopper 62 , and then heated and processed to a foamed or foamy state in extruder 64 . Extruder 64 will generate an extrusion in the form of a foam body 66 that can be cut via cutter 68 to a desired dimension, foam body 66 having a first body side 67 and a second body side 69 . For example, according to the present disclosure, cutter 68 may be configured to cut foam body 66 for use as rectangular body 24 and/or rectangular body 32 . In some embodiments, foam body 66 may be formed of structural foam material 50 . It can be seen from the process flow of FIG. 4 that cutter 68 will typically be employed after application of plural component spray 70 . In other words, given a relatively fast cure time commonly on the order of no more than several minutes for many plural component sprays, cutting of the extruded foam body with adhered skin material will typically occur after the skin material has been applied. Plural component spray 70 includes relatively fast-curing liquids, which, when applied to foam body 66 will cure rapidly, forming protective skin material 56 . As discussed herein, plural component spray 70 may chemically bond to foam body 66 when curing. Sprayer 72 may be structured so as to spray plural component spray 70 on first body side 67 of foam body 66 while leaving second body side 69 free of plural component spray 70 . An optional cutter 74 is shown, however, that might be additionally or alternatively used to cut foam body 66 prior to application of the plural component spray 70 . With the plural component spray 70 applied only upon first body side 67 of the extruded foam body 66 , resulting in a coated foam body 76 . Once cut to length coated foam body 76 can be packaged for shipping. While embodiments are contemplated where a number of packaged panels will be strapped to a pallet or the like 78 , it will be appreciated that no limitation to the manner of packaging is contemplated herein, and in some instances no packaging at all could be used without departing from the full and fair scope of the present disclosure. From the foregoing description and that to follow, it will be apparent the present disclosure provides solutions to various shortcomings in known systems. On the one hand, the present disclosure provides for a finished exterior and protective surface of the form system. Physical damage, soiling and UV damage to the insulating foam is avoided. Those skilled in the art will be familiar with the relatively long periods of time that can occur between various stages of construction. Seasonal breaks and long periods of bad weather can leave insulating concrete forms exposed and likely to deteriorate if some protection is not provided. A separate crew in addition to the concrete contractor is often retained to install some sort of protective shielding exterior to the concrete forms. In some housing developments, some homes may be finished and ready for showing to prospective buyers while others are in various states of construction. Exposed foam board and the like can be considered unsightly, especially where splashed with mud, torn, dented, or otherwise degraded. The present disclosure overcomes these and other shortcomings of standard approaches.
[0021] The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the full and fair scope and spirit of the present disclosure. For instance, while certain practical implementation strategies are disclosed herein relative to specific material compositions, it will be appreciated that the present disclosure is not strictly limited as such and other possible combinations and mixtures of materials will be apparent to those skilled in the art. Other aspects, features and advantages will be apparent upon an examination of the attached drawings and appended claims.
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A concrete form system includes an outer form composed of a structural foam material and a protective skin material. The protective skin material is in contact with the structural foam material and may be chemically bonded such as by crosslinking with the structural foam material. Each of the structural foam material and protective skin material may include a polymeric material. The protective skin material forms an exposed outer surface of the outer form, obviating any need for additional protection from the elements or to be applied during the construction process. The outer form thermally insulates around the periphery of a poured concrete slab, and can be coupled with an inner form, each of the outer form and inner form being assembled in a predetermined relationship and sized so as to control the vertical elevation and thickness of a concrete slab and a foundation stem wall cast between the inner and outer forms. The concrete form system can be pre-assembled in accordance with appropriate dimensions in a workshop in preparation for pouring a concrete slab on a remote job site.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] This application claims priority to U.S. Provisional Application No. 60/626,912, filed on Nov. 12, 2004, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field Of The Invention
[0003] This invention generally relates to structural supports. In particular, this invention relates to structural supports for, for example, wind turbines, or the like.
[0004] 2. Description Of Related Art
[0005] Conventional offshore platforms have deck legs that are vertical or are battered outward as they extend downwards. The conventional arrangement provides structurally efficient support for the deck but the associated dimensions of the platform at the water surface result in increased expense for the platform.
[0006] Wind turbines have traditionally been supported on mono-piles when placed offshore. However, recently, efforts have taken place to position wind turbines in deeper water (approximately six to seven or more miles offshore) in part to increase the aesthetics of the view from the shoreline. However, with the movement of wind turbines further offshore, the employment of mono-piles as the base on which wind turbines are placed has become less cost effective.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention is directed to a wind turbine in combination with a structure support that provides a sturdy and cost effective support even in deep waters. This combination includes a wind turbine comprising a base and a blade mechanism. The structure support further includes at least three elements configured in a substantially teepee shaped configuration, where the at least three elements encompassing a substantially vertical member. A first end of the at least three elements is capable of being affixed to a structure and a second end of the at least three elements adapted to be in contact with a surface. The at least three elements intersect between the first end and the second end. The combination also includes a mounting flange connecting the structure support to the wind turbine.
[0008] In accordance with a further embodiment of the present invention the at least three elements intersect above a waterline or at a waterline.
[0009] In accordance with another exemplary aspect of the present invention, a method of constructing a wind turbine on a structure support is disclosed. At least three legs are provided in a teepee configuration. A first end of the first three legs are placed on a mounting surface and a deck is affixed to a second end of the at least three legs. A wind turbine mounting flange is affixed to the structure and a base is affixed to the mounting frame and turbine element is affixed to the base. A blade mechanism affixed to the turbine element.
[0010] These and other features and advantages of this invention are described in or are apparent from the following detailed description of the embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The embodiments of the invention will be described in detail, with reference to the following figures, wherein:
[0012] FIG. 1 is a view in side elevation of an offshore platform according to the present invention;
[0013] FIG. 2 is a view in front elevation of the offshore platform according to the present invention;
[0014] FIG. 3 is a perspective view of the offshore platform with a wind turbine placed on a deck of the platform according to the present invention;
[0015] FIG. 4 is a side perspective view of the offshore platform with a wind turbine placed on the deck of the platform according to the present invention;
[0016] FIGS. 5-18 illustrate an exemplary method of assembling the offshore structure and wind turbine according to this invention;
[0017] FIGS. 19-21 illustrate nnother exemplary method of assembling the offshore structure and wind turbine according to this invention;
[0018] FIGS. 22 and 23 illustrate another exemplary offshore structure support foundation according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The exemplary embodiments of this invention will be described in relation to a support structure, such as an oil and gas platform or a platform for the placement of additional structures, supported by three piles and a central vertical member, such as drill pipe. However, to avoid unnecessarily obscuring the present invention, the following description omits well-known structures and devices that may be shown in block diagram form or otherwise summarized. For the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It should be appreciated that the present invention may be practiced in a variety of ways beyond these specific details. For example, the systems and methods of this invention can be generally expanded and applied to support any type of structure. Furthermore, while exemplary distances and scales are shown in the figures, it is to be appreciated the systems and methods of this invention can be varied to fit any particular implementation.
[0020] FIGS. 1 and 2 show an inward battered guide offshore platform indicated generally at 10 in which battered bracing piles 12 a, 12 c and 12 e are arranged so as to minimize platform dimensions at the water surface 14 while maximizing the spacing of the piles as they extend upward from the water surface so that loads from a deck 16 at the top of the piles are transferred directly to the piling. For example, if three or more piles are employed to create the structure, they could be spaced apart 120 degrees. Piles 12 b and 12 d are conductor piles used in oil and gas platforms.
[0021] The platform includes a pile guide structure 18 which fits over and is connected to a central vertical member 20 to receive the piles 12 a, 12 c and 12 e at the water surface. The piles extend angularly through guides 22 of the pile guide structure in such a manner that the distance between piles is minimized at the water surface, but the distances between angled piles is maximized both at the ends supporting the deck 16 as well as at the opposed end buried below the mudline 24 . The pile guide connects the piles to act in unison to restrain lateral movement of the entire offshore platform 10 including the central vertical member 20 .
[0022] The pile guide 18 also supports appurtenances such as ladders, boat landings, stairs, or the like, so that they can be installed in the field as a unit, thereby, for example, reducing installation expense for the platform. The legs 26 of the deck structure are connected to the tops of the piles. The increased pile spacing at the pile tops provides, for example, more structurally efficient support for the deck, reduced structural vibration periods for the platform and increased resistance to the rotation that results if the deck mass is eccentric to the central vertical member 20 than if the deck is supported by the central member. All field connections can be made above the water surface where structural integrity of the connections can be more easily verified than if the connections were made below the water surface.
[0023] Once the piles 12 a, 12 c and 12 e are in place, and the legs 26 and deck 16 are placed on the piles then, as shown in FIGS. 3 and 4 , a wind turbine 100 can be installed. FIGS. 3 and 4 show two different perspective views of the wind turbine 100 when installed on the deck 16 of platform 10 . The wind turbine 100 comprises: a base 125 including a lower section 110 and an upper section 120 ; a turbine element 130 ; and a blade mechanism 150 that comprises a rotor star 152 and individual blades 154 . While the wind turbine described herein comprises a base 125 and three individual blades 154 , other types of wind turbines can also be employed with the structure of FIG. 1 , for example, in the manner described above. For example, a wind turbine with a single base part or having a multitude of parts that make up the base can be employed. Moreover, the wind turbine can also include more or a lesser number of blades as well as different types of blade mechanisms.
[0024] FIGS. 5-19 illustrate an exemplary method for assembling a the platform 10 and wind turbine 100 in accordance with an exemplary embodiment of this invention with, for example, a barge boat, around a substantially vertical member 20 such as SSC 50 (Self Sustaining Caisson). In this exemplary embodiment, the SSC 50 has been installed by an oil and gas drilling rig, such as a rig drilling an exploration well. The vertical member 20 (SSC 50 ) can either be installed when the platform is assembled or alternately, the remaining parts of the platform can be assembled around a previously erected vertical member. This enables the platform to be advantageously built on existing already used oil drill caissons or mono-piles to support oil and gas wells.
[0025] In FIG. 5 , the position and orientation of the legs are determined and a lift boat 55 anchored and jacked-up relative to the installation point of the SSC 50 . Next, as illustrated in FIG. 6 , the guide structure 18 is unloaded from the barge 60 . Then, as illustrated in FIG. 7 , the piles 12 a, 12 c and 12 e, are unloaded, placed in the guide structure, and in FIG. 8 , installed via the guide structure into, for example, the ocean floor with the aid of a pile driving hammer (e.g., a hydraulic hammer). As can be seen from this illustration, the piles 12 a, 12 c and 12 e intersect at a point just above the water line. This allows, for example, the piles and all associated connections to be made above water. However, one would also understand that the intersection point could also reside at or below the waterline.
[0026] In FIG. 9 , the barge 60 is relocated and the deck 16 is unloaded. In FIG. 10 the deck 16 including legs 26 are installed on the piles. In accordance with an exemplary embodiment of the invention, the deck can be modified to employ and support a wind turbine 100 . Specifically to support the turbine a mounted flange can be built on the deck 16 . The flange can be attached to the deck via bolting, grouting or welding. Although as illustrated in FIG. 10 , the mounting flange 200 is shown being attached to the deck prior to placement on the legs 26 , the mounting flange 200 could be installed after the deck has been installed. FIGS. 11 and 12 provide a side view and top view of the deck 16 and mounting flange 200 when installed.
[0027] As illustrated in FIG. 13 , once the mounting flange 200 is placed and set onto the deck 16 , the tower lower section 110 is unloaded from the lift boat 55 and installed onto the mounting frame 200 . Next, as illustrated in FIG. 14 , the upper section 120 of the tower is unloaded and installed onto the tower lower section 110 . Once the upper section 120 of the base has been installed, as illustrated in FIGS. 15 and 16 , the turbine 130 is removed from the lift boat and attached to the upper section 120 of the tower.
[0028] As the tower lower section 110 , tower upper section 120 and turbine 130 are installed, the blade mechanism 150 is readied for installation. The installation of this part of the wind turbine 100 can be performed in a plurality of different ways, in accordance with the present invention, as discussed below.
[0029] In accordance with one exemplary embodiment of the present invention, as illustrated in FIGS. 17 and 18 , the complete, blade mechanism already fully assembled is unloaded from the lift boat 55 and attached to the turbine 130 .
[0030] Alternatively, as illustrated in FIGS. 19-21 , the blade mechanism does not need to be fully assembled prior to attachment to the turbine 130 . This is advantageous for several different reasons. The blade mechanism, if fully assembled would require extra stowage area for transport to the assembly area. If, for example, only two of the blades were assembled, then to the rotor star, then the required space needed to transport the blade mechanism is reduced. Furthermore, if the remaining blade is not attached to the rotor star until it is already attached to the turbine, additional monetary savings can be achieved since the crane employed to attach the blade can be smaller. In FIG. 19 , the blade mechanism having the two blades attached to the rotor star is raised (via a crane) and attached to the turbine (as illustrated in FIG. 20 ). Finally, in FIG. 21 , the remaining blade 158 is attached to the rotor star. Again, FIGS. 3 and 4 provide a side views of the assembled wind turbine on the offshore structure support 10 .
[0031] In accordance with another exemplary aspect of the present invention, a deck and associated mounting flange 300 is provided to receive a wind turbine, as illustrated in FIGS. 22 and 23 . Specifically, the mounting flange 300 includes a body 310 and an elliptical (or spherical) head 320 extending below deck 16 . The body 310 is circular and includes a deck end 312 and a head end 314 portion. A wind turbine 100 is able to be attached to the foundation body 310 at the deck end 312 of the foundation body, via bolting, for example. The foundation body 310 is also able to receive legs 26 that are connected to the batter bracing piles 12 a, 12 c and 12 e. Note that four piles are illustrated in FIG. 22 .
[0032] The elliptical (or spherical) head 320 is attached to the foundation body 310 at its deck leg connection end and enables the turbine foundation 300 a more fatigue resistant connection at the deck leg. For this same reason, as illustrated in FIG. 22 , the ends of the legs 26 also employ a curved surface. By making the intersection between the foundation body 310 and the elliptical (or spherical) head 320 as well as foundation body 310 and the elliptical shape of the legs 26 , a continuously curved intersection is provide and a sharp corner is avoided. As a result, hot spot stresses are reduced on the joints.
[0033] Additionally in accordance with the present embodiment discussed with regard to FIGS. 22 and 23 , the deck 16 includes structural support elements extending from the deck end of the turbine foundation to the edge of the deck 16 . While the deck 16 in the embodiment shown in FIG. 23 is illustrated as octagonal, one could understand that the deck could be made to be other shapes also, (e.g., hexagonal, rectangular, circular, or the like).
[0034] In accordance with another aspect of the present invention, the natural period of the offshore support structure can be adjusted to avoid the excessive vibration of the wind turbine while operating that would result if the natural period of the support structure was too close to matching the rotational period of the turbine. This tuning of the natural period can be accomplished by changing the size of the components of the support structure, by increasing or decreasing the batter of the piles, adjusting the spacing of the piles and/or by raising or lowering the elevations where the piles are laterally supported. The extent and combination of tuning measures required vary depending on the design and operational characteristics of the wind turbine and the water depth, meteorological and oceanographic conditions and soil characteristics at the location.
[0035] For example, a typical three blade wind turbine is controlled by adjusting blade pitch to make one rotation about every 4.5 seconds in most wind conditions. Therefore, for a typical wind turbine one of the three blades would than pass the wind turbine support tower every 1.5 seconds. To avoid the wind turbine rotational periods and limit potential for destructive resonance, frequency forbidden zones are established for the natural frequency of the entire support structure. For a typical wind turbine the forbidden natural frequency zones could be 0.18 Hz to 0.28 Hz and 0.50 Hz to 0.80 Hz. Likewise, the target natural frequency would be 0.30 Hz to 0.33 Hz and higher order natural frequencies should be above 0.80 Hz. If computed eignfrequencies are in a forbidden zone tuning will be necessary. Tuning can then be accomplished in the manner discussed above.
[0036] It is, therefore, apparent that there has been provided, in accordance with the present invention, a support and method for assembling a wind turbine for placement on an offshore support structure. While this invention has been described in conjunction with a number of illustrative embodiments, it is evident that many alternatives, modifications, and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, the disclosure is intended to embrace all such alternatives, modifications, equivalents and variations that are within in the spirit and scope of this invention.
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A pile based braced caisson structural support device includes a number of legs in is used to support a wind turbine. The wind turbine includes a base, a turbine generator and a blade mechanism. The legs are configured in a teepee type configuration such that the footprint of the base is larger than the footprint of the opposing end. This structural support can be used as a base for an offshore platform in that the support reduces the lateral forces on the support caused by wave action.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present disclosure is related to the application titled APPARATUS AND METHOD FOR INCREASING MONOPOLE CAPACITY USING EXTERNAL STRENGTHENING filed concurrently herewith by the same inventive entity. The disclosure of such related patent application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Antennas for over-the-air communications, such as cellular telephone systems, are usually supported on hollow tubular steel monopoles. Monopoles are located throughout most metropolitan and suburban areas. The location and density of monopoles in any particular area depend on the density of users, the elevation of the monopole sites, the height of each monopole and the coverage required. The height of each monopole can vary from only a few feet up to hundreds of feet.
[0003] As areas have more and more over-the-air communication demands, monopoles are becoming more and more ubiquitous. Many neighborhoods are resisting the installation of monopoles with great vigor. In addition to the resistance to installation of new monopoles, many of the prime sites for monopoles have already been acquired and are thus not available for new entrants into the field, or for upgrading of an existing system. Many remaining sites are less desirable for companies seeking to enter or expand in the field of over-the-air communication. Reacting to pressure from constituents, many local governments are reluctant to grant permits for new monopoles.
[0004] Therefore, there is a need for a means for increasing over-the-air coverage while meeting the requirements placed on locating monopoles.
[0005] One way of increasing the over-the-air coverage is to increase the number of antennas available for such coverage. In view of the restrictions placed on adding new monopoles, this will require adding antennas to existing monopoles. It is possible to achieve this end using new antenna technology whereby new antennas do not need to be located as high as antennas embodying older technology. Thus, new antennas could be simply mounted onto existing monopoles and this will achieve the goal of increasing antenna coverage for an over-the-air system without requiring the placement of more monopoles.
[0006] However, this approach is not as simple as it appears at first blush. The problem with adding more antennas to an existing monopole is that such addition of antennas increases the loading on the monopole. Loading on the monopole is increased both from a dead load standpoint and from a live load standpoint.
[0007] Thus, simply adding more antennas to a monopole will increase the load on the monopole by the addition of the weight associated with the additional antennas. This weight is manifested in added compression stresses placed on the monopole.
[0008] Another problem associated with adding antennas to an existing monopole is that live loads on the monopole associated with wind loading on the antennas (both the existing antennas and the newly added antennas) will be increased by a factor determined by the wind area added to the monopole.
[0009] It is also noted that wind forces on the antennas can also cause a twisting stress on the monopole, and this stress will also be increased by the addition of antennas to the existing monopole.
[0010] The wind forces on the antennas creates both live loading on the monopole and may create a possibility of misaligning antennas. Misalignment of one antenna can be created by wind loading on other antennas on the same monopole due to the twisting or deflection of the monopole associated with such wind forces on the monopole and other antennas.
[0011] Yet another problem with simply adding antennas to an existing monopole arises because many existing monopoles have been designed for loads associated with a certain number of antennas. Thus, adding antennas and the forces associated with those additional antennas may create a situation for some existing monopoles in which the loading on the monopole is not within design parameters.
[0012] Therefore, there is a need for apparatus and methods for increasing the number of antennas that can be supported on an existing monopole whereby advantage can be taken of new antenna technology without exceeding the design limits of existing monopoles.
[0013] It may also not be possible to simply re-enforce existing monopoles by purchasing additional land to accommodate the guy wires or the like. Many municipalities have aesthetic requirements that will be violated by such guys, and some monopole sites are not large enough to include such guys. Still further, adding guys may be so expensive that it overwhelms the cost savings associated with the addition of antennas.
[0014] Therefore, there is a need for an apparatus and methods for increasing the number of antennas that can be supported on an existing monopole without requiring guy re-enforcement of the monopole.
[0015] Of course, one approach to accommodating additional antennas would be to simply replace existing monopoles with new and stronger monopoles. However, this approach may prove to be too costly to be feasible.
[0016] Therefore, there is a need for a means and a method for modifying existing monopoles to accommodate additional antennas without requiring replacement of such existing monopoles.
SUMMARY OF THE INVENTION
[0017] The inventive entity of the present invention has observed that existing monopoles are generally hollow tubular structures. These structures have been designed according to deflection limitations or to allowable stress placed on the wall of the tubular structure. The inventive entity has also observed that design calculations indicate that design stresses are well under allowable stresses when the design is based on deflection. Therefore, there will be strength available if the monopole can be stiffened to reduce deflection when antennas are added to the structure.
[0018] When design limits associated with hollow tubular structures such as monopoles are based on stress, the allowable stress is based on compression failure rather than tension failure. When antennas supported on a monopole are subject to wind forces, the forces transferred to the monopole are manifested in tension forces on some parts of the structure wall and in compression forces on other parts of the structure wall. It has also been observed that the forces associated with the weight of the antennas and the monopole are compression forces and thus added to the compression forces associated with wind loading on the antennas and the monopole. This will exacerbate any problems that may be associated with compression forces applied to the monopole. Still further exacerbating the problem is the observed fact that allowable stress associated with compression is generally less than the yield point stress which is associated with allowable stress using tension as a design criterion. It is also noted that adding guys generally does not increase the structure's ability to accommodate compressive loading.
[0019] The steel used in monopoles is high strength steel. When the design of such monopoles is based on deflection, the steel is often stressed to less than seventy per cent of the yield point stress of the steel. Plate used for bent plate structures commonly has a yield point of sixty-five thousand pounds per square inch (psi). However, the allowable stress, when compression governs, is often about fifty-two thousand psi. Thus, if it is possible to retrofit an existing monopole that has been designed using limits associated with compression to actually be limited by tension instead, an additional percentage (in the case presented above, an additional twenty-five per cent) in design limits could be gained. Further, if mill tests for plates in a particular structure are available, it may be possible to determine that the yield point stress exceeds the minimum specified value thereby creating an opportunity to further increase the design limits associated with an existing monopole. As can be understood from the teaching of the above discussion, increasing the design limits of an existing monopole will permit that monopole to support additional antennas without requiring guys or the like or without requiring replacement of existing monopoles.
[0020] The present inventive entity has discovered that the design limits of an existing monopole can be increased by strengthening the monopole in its ability to accommodate compressive loading. This increase of strength in compression thus permits the design limits to be based on tension rather than compression. As discussed above, the allowable stress associated with compression is generally less than the yield point stress which would be the allowable stress if tension governs the design. This thus increases the load carrying capacity of a monopole.
[0021] Thus, the present invention overcomes the above-discussed problems and drawbacks by increasing the compression limits of an existing monopole by supporting the compression faces and by increasing its section modulus which allows more load-carrying capacity. One form of the invention achieves this goal by placing filler material that is strong in compression inside the monopole.
[0022] This takes advantage of the fact that most existing monopoles are hollow. By increasing the compression design limits of a monopole, expense and effort are directed to the most efficient use of resources and are not wasted on increasing design limits that are not as efficiently utilized for increasing compression limits.
[0023] Still further, increasing the compression limits of an existing monopole by filling the monopole with material that is strong in compression takes advantage of the fact that most existing monopoles are already hollow and the filler material can be installed in an economical manner. Still further, using the hollow nature of existing monopoles to add strengthening material internally to the monopole permits strengthening the monopole without endangering the aesthetics of such poles that have already been approved. Thus, the inventive means and method of the present invention is a way of increasing the design limits of an existing monopole in a manner that is both efficient and economical thereby increasing the strength of a monopole to accommodate additional antennas becomes economically feasible.
[0024] The present invention also includes strengthened base plates and foundations supporting monopoles.
TECHNICAL FIELD OF THE INVENTION
[0025] The present invention relates to the general art of static structures, and to the particular field of monopoles.
OBJECTS AND ADVANTAGES OF THE INVENTION
[0026] It is a main object of the present invention to provide a means for increasing over-the-air coverage while meeting the requirements placed on locating monopoles.
[0027] It is another object of the present invention to provide an apparatus and methods for increasing the number of antennas that can be supported on an existing monopole without requiring guy re-enforcement of the monopole.
[0028] It is another object of the present invention to strengthen an existing monopole without changing the aesthetics of the existing monopole.
[0029] It is another object of the present invention to strengthen an existing monopole by adding strengthening material internally of the monopole.
[0030] It is another object of the present invention to strengthen an existing monopole in the most efficient and cost effective manner.
[0031] It is another object of the present invention to provide a means and a method for modifying existing monopoles to accommodate additional antennas without requiring replacement of such existing monopoles.
[0032] It is a more specific object of the present invention to strengthen an existing monopole by increasing the design limit that is most effective in providing the overall increase in design limits that will be most effective and efficient to increase the load carrying capacity of the monopole.
[0033] Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
[0034] The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1 is an elevational view of one form of a monopole.
[0036] [0036]FIG. 2 is an elevational view of another form of a monopole.
[0037] [0037]FIG. 3 is a sketch that illustrates loading on a monopole subject to wind forces.
[0038] [0038]FIG. 4 is an elevational view of one form of a monopole that has been modified and strengthened according to the teaching of the present invention.
[0039] [0039]FIG. 5 is an elevational view of another form of a monopole that has been modified and strengthened according to the teaching of the present invention.
[0040] [0040]FIG. 6 is a top plan view of a base of a monopole.
[0041] [0041]FIG. 7 is an elevational view of a base of a monopole.
[0042] [0042]FIG. 8 is a top plan view of a template used in a base of a monopole.
[0043] [0043]FIG. 9 is a partial view of a multi-sided monopole which has been strengthened by affixing strengthening elements to the outside surface, or surfaces, of the monopole.
[0044] [0044]FIG. 10 is an enlarged view of a portion of the monopole shown in FIG. 9.
[0045] [0045]FIG. 11 is a cross-section of a twelve-sided pole.
[0046] [0046]FIG. 12 is an enlarged view of FIG. 10.
[0047] [0047]FIG. 13 is similar to FIG. 12 but with an access flange through which internal cables pass into a pole.
[0048] FIGS. 14 - 16 are similar to FIGS. 11 - 13 respectively, showing a monopole that is circular in perimetric shape.
DETAILED DESCRIPTION OF THE INVENTION
[0049] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0050] It is noted that the present disclosure will refer to antennas or antenna structures. It is intended that the term “antenna” will cover any element used in over-the-air communication systems, including microwave dishes, supporting platforms and the like and it is not intended to limit the scope of this invention to antennas per se. It is also intended that the broad term “over-the-air communication system” covers cellular telephone systems as well as any other such system.
[0051] Two types of existing monopoles are shown in FIGS. 1 and 2. Both monopoles are tubular and hollow and are formed of steel to have a hollow interior and are anchored at the base thereof in the ground. One type of existing monopole is unitary and is shown in FIG. 1 as monopole 10 . Monopole 10 has a base 12 that is cast in ground G and a base assembly 14 . Monopole 10 extends upward from ground G and tapers to a top area 15 . As indicated, monopole supports a variety of elements that are associated with over-the-air communication systems, such as antennas 16 , dishes 18 and the like. These elements are positioned on monopole 10 at levels above the ground, indicated by level 20 which corresponds to the lowest level of the elements existing on the monopole. One form of existing monopole is one hundred fifty feet tall, has a fourteen inch top diameter and a sixty inch base diameter. Antennas are located at the one hundred fifty foot level and at the one hundred thirty foot level, with the one hundred thirty foot level being indicated as level 20 .
[0052] Monopole 10 is hollow as indicated by dotted lines 22 to define an inner bore 24 and has been designed to safely support the communications elements in position to effectively carry out the functions associated with such elements in over-the-air communications systems. Thus, design stresses, yield points, and the like have been selected to achieve this goal.
[0053] An alternative form of monopole 10 ′ is shown in FIG. 2 as including a plurality of sections, such as sections 30 and 32 , that have outside diameters differing from each other to produce a stepped shape with a shoulder 34 between adjacent sections. Otherwise, monopole 10 ′ is identical to monopole 10 and includes a hollow bore 24 ′ and supports elements such as an antenna dish 18 at a first level, with the lowest level element being at a level 20 above the ground. Other forms of monopoles may occur to those skilled in the art based on the disclosure herein and these additional types of monopoles are also intended to be included in the scope of this disclosure and invention.
[0054] For convenience, the elements on the monopoles as these monopoles exist prior to being modified according to the teaching of the present invention to support additional elements will be referred to as first elements. Elements added to the existing monopoles to accommodate additional traffic in over-the-air communications systems will be referred to as second elements.
[0055] Referring to FIG. 3, the various forces of interest to this disclosure are identified. Thus, the wall W of monopole M is subject to a force associated with the weight W t which manifests itself as a compressive force C on the wall of the hollow monopole. As the structure is exposed to wind D, the pole deflects in direction X from vertical. Due to this deflection, various portions of the monopole wall are subjected to forces. Thus, one portion T 1 of wall W is subject to tension T due to the deflection of the monopole, while another portion C 1 of wall W is subject to compression force C 2 . This compression force is added to the compression force C associated with the weight of the monopole and the elements supported thereon.
[0056] As discussed above, the inventive entity of the present invention has discovered that if the design of an existing monopole can be controlled by tension, there is additional bending capacity that can be utilized so more antennas can be installed on an existing monopole that has been thus modified. This is achieved by adding elements to the existing monopole that adds to the strength of the monopole in regard to compression.
[0057] Accordingly, the best mode of the present invention includes placing a filler element that is strong for compression forces inside the hollow bore of the existing monopole. Specifically, the best mode of the present invention includes placing expanding foam and aggregate, lightweight aggregate concrete normal aggregate concrete or the like in the bore of the hollow existing monopole. The concrete is the most efficient and economical element that can be used to achieve the purposes of this invention. One form of the aggregate used for this concrete is manufactured under the trademark HADITE. Other types of concrete, including that which uses standard weight aggregate, can also be used as will occur to those skilled in the art based on the teaching of the present disclosure. These additional types of fills and concrete are intended to be included in the scope of this invention as well.
[0058] Referring to FIGS. 4 and 5, it can be seen that monopole 10 is modified to monopole 10 R, or retrofit, by locating filler material 50 into the hollow bore 24 as by flowing the filler into the bore via a hole defined through the wall of the pole, or the like. The filler material is filled in the bore to a level 52 . While this level can vary according to the factors associated with each monopole, the best mode of the present invention includes level 52 being essentially co-level with the level of the lowest element of the first elements existing on the monopole before the monopole is modified to include the filler material. That is, level 52 is essentially co-level with level 20 .
[0059] Once filler material 50 is in place, additional elements, 16 ′ and/or 18 ′ can be added to the monopole. These additional, or second, elements can be located at levels that are lower than levels 20 and/or 52 because they are manufactured using technology that is newer than the technology used for first elements 16 and/or 18 . However, it may be possible to add antennas above the first elements.
[0060] Referring to FIG. 5, it is seen that monopole 10 ′ is modified, or retrofit, as monopole by locating filler material 50 in bore 24 of monopole 10 ′ to level 52 ′ that is co-level with antennas 16 ′. Antennas 16 ′ are located at a level that is above level 20 ; however, this is illustrated to emphasize that the actual level of the filler material is dictated by the particular conditions associated with the particular monopole being modified. The level of the concrete will depend on the added antennas and the specific pole and any other appropriate design criteria as will be understood by those skilled in the art based on the teaching of this disclosure.
[0061] As will be understood by those skilled in the art based on the teaching of this disclosure, the steel monopole is not the only area of concern. Foundation structure 60 shown in FIGS. 6, 7 and 8 includes a central section 62 to which plates 64 and 66 are attached and on which anchor bolts 68 are mounted by nuts 70 . Central section 62 is pre-existing and is placed when the pre-existing monopole is erected. In order to accommodate the extra weight and forces associated with the modified monopole, foundation 60 is modified to include a collar 70 of concrete or the like to add further stability to the foundation structure. One form of the modified foundation includes an outside diameter of eighty-four inches and a thirty foot depth, with a collar 70 of twelve inches in width and a depth of seven and one-half inches.
[0062] The base plates can be replaced or stiffened to accommodate the added forces and anchor bolts can be replaced or added to accommodate the added forces as well.
[0063] If suitable, guys, such as guy 80 indicated in FIGS. 4 and 5, can be added. The guys can be colored or the like to accommodate aesthetic considerations. Additionally, seismic considerations can be addressed in a manner that is common to such considerations, as by adding material, or special elements that can accommodate seismic events.
[0064] Additionally, the filler material includes sufficient internal as well as external passages to accommodate water as from rain, snow, or the like. Additives can also be used to meet these considerations as well as to address shrinkage, adherence and the like as will be understood by those skilled in the art based on the teaching of this disclosure.
[0065] Design criteria can be implemented in a software program so filler height, filler density, foundation structure design, economics and the like can be analyzed before a monopole is modified.
[0066] It is noted that any coaxial communication cables that are located inside an existing monopole should be removed and either moved to the outside of the monopole or be replaced by new coaxial cables on the outside of the monopole before filler material is added.
[0067] It is noted that, in the embodiments disclosed hereinbelow, the strengthening of the monopole is achieved by affixing strengthening elements, such as plates, to the external surface, or surfaces, of the monopole; whereas, the strengthening of an existing monopole discussed above has been achieved by adding strengthening material internally of the monopole.
[0068] The foregoing discussion has been directed to a monopole which will be strengthened by adding filler material internally; however, some monopoles have one or more external surfaces that are amenable to accommodating strengthening elements. In fact, some monopoles can have as many as eight or twelve sides. The present invention takes advantage of this feature to increase the strength of an existing monopole. This approach is illustrated in FIGS. 9 - 13 in which a polygonal monopole 10 P is supported by an anchor assembly 60 P and has an antenna structure 16 P supported thereon. As discussed above, additional antenna structures 16 ′P are to be added for the reasons discussed above. In order to achieve this goal, monopole 10 P should be strengthened. This is achieved by fixing strengthening plates 100 to one or more faces of the polygonal monopole 10 P. In one form of the invention, plates 100 are affixed to each face of the polygonal monopole. As shown in FIG. 9, a bridge structure 102 is included to support cables as they enter the monopole. As those skilled in the art will understand based on the teaching of this disclosure, such a bridge structure can be used in connection with any of the monopoles disclosed herein.
[0069] As is best shown in FIG. 9, plates 100 are formed to conform to the shape of the faces on the monopole to which they are attached. Thus, as can be seen in FIG. 9, the plates taper outwardly near the bottom of the in-place plate. That is, the width of a base plate as measured between sides 104 and 106 near the bottom 108 of the plate is greater than the width of the plate near the top 110 of the plate.
[0070] As is best indicated in FIG. 12, one method of fixing the plates to the outer surface of the monopole wall is by adhesive 112 . The surface preparation required will be known to those skilled in the art based on the conditions and materials used in the monopole, the adhesive and the plates. For example, a monopole that is galvanized metal having steel plates fixed thereto will have one form of surface preparation while a painted monopole may have another form of surface preparation as well as another adhesive. A cable or band 114 can be used to encircle the plates mounted on the monopole and support those plates in position while adhesive 112 is setting up. Only a portion of the cable is shown for simplicity of illustration, but it is understood that the cable will encircle the plates and several cables can be used if necessary. The plates preferably are formed of steel, but other shapes and materials can also be used based on the requirements of a particular application. In one form of the plates, the plates are one-eighth inch thick but other thicknesses can be used without departing from the scope of the present invention.
[0071] As indicated in FIG. 13, one of the strengthening plates, plate 100 ′, can have a bore 122 defined therethrough to accommodate an access collar 124 . Cables, such as cable 126 extend into interior 128 of the monopole via collar 124 . Collar 124 can be located in conjunction with bridge 102 if desired and suitable.
[0072] As discussed above, the strengthening plates can extend from adjacent to the ground in which the monopole is supported to adjacent to the level of the lowest antenna structure to be added. Thus, as illustrated in FIG. 9, a future antenna structure 16 ′ P will be added beneath the lowest level of existing antenna structures 16 P. However, it may be possible to add antennas above the first elements. The level of the lowest existing antenna structure 16 P is indicated at 20 ′ and the level and the level of the highest proposed antenna structure is indicated as 20 P. Strengthening plates 100 are fixed to the monopole to adjacent to level 20 P. That is, for example, the length of each plate 100 in the installed condition as measured from top end 100 T to bottom end 100 B, is essentially equal to, but can be slightly less than, distance 20 P. A bottom plate 130 can encircle the bottom of the monopole if desired. The level of the top of the strengthening elements will depend on the added antennas and the specific pole and any other appropriate design criteria as will be understood by those skilled in the art based on the teaching of this disclosure.
[0073] The technique in which strengthening plates are fixed to the outer surface of a wall of a monopole can be used to strengthen a monopole having a circular outer perimetric shape as well. This provides an option for strengthening a circular monopole that is in addition to the method discussed above in which concrete is placed in the hollow bore of the monopole. This second option is illustrated in FIGS. 14 - 16 . Strengthening plates 100 C are fixed to outer surface 140 of circular monopole 10 C using suitable fixing means 142 to strengthen monopole 10 C in the manner discussed hereinabove. Plates 100 C can be steel and the fixing means can be any of the above-discussed means. Thus, suitable adhesive, or chemical bonds, or metallurgical bonds or the like can be used depending on the conditions and requirements. Plates 100 C can also taper if necessary to match the shape of the existing monopole to be strengthened as discussed above with regard to monopole 10 P shown in FIG. 9. A cable or band 114 ′ or a plurality of cables and/or bands, can also be used to secure the plates in place while the bonds between the plates and the monopole are formed and set up. The cable or band is shown spaced from the plates in FIGS. 12 and 14, but will contact those plates as necessary to hold them in place during the formation of the bond between the plates and the monopole.
[0074] As discussed above, plates 100 C will extend from adjacent to the ground supporting a monopole to be strengthened, to a level adjacent to the level of the highest added antenna structure. As the case with the foregoing forms of the invention, antenna structures can be added to the monopole at levels below the level of the highest added strengthening structure. Such antenna structures will be mounted on the strengthening plates in the embodiments using strengthening plates fixed to the outer surface of the monopole. Alternatively, the level of the top ends of the plates added in either monopole 10 P or 10 C can be essentially equal to the level of the lowest existing antenna structure, such as level 20 ′ in FIG. 9. Also, the top end of internally added strengthening material in the forms of the monopole discussed in relation to FIGS. 4 and 5 can reach the level of the lowest level existing antenna structure, such as level 20 in FIGS. 1 and 2. The level of the strengthening elements in this embodiment, like that of the other embodiments, will depend on the added antennas and the specific pole and any other appropriate design criteria as will be understood by those skilled in the art based on the teaching of this disclosure.
[0075] As is the case with the polygonal monopole, one of the plates fixed to a circular monopole, plate 100 ′C can have a bore 122 ′ defined therethrough to accommodate a collar 124 ′ through which cables 126 extend into bore 128 C of monopole 10 C having a circular perimeter.
[0076] It is also noted that the external strengthening that has been discussed hereinabove can be used in conjunction with the internal strengthening discussed in association with FIGS. 4 and 5. That is, strengthening material 50 can be located inside a monopole, and strengthening plates, such as plates 100 and/or 100 C can be applied to the outside of the monopole as well, depending on whether the monopole is circular or polygonal in outer perimetric shape. Thus, in appropriate circumstances, a monopole can be strengthened both internally and externally. This is indicated in FIGS. 4 and 5. While only one strengthening element is shown on each monopole, it is understood that as many as necessary can be used, and the showing of only one strengthening element is merely for the ease of illustration and is not intended to be limiting.
[0077] It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
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An existing monopole is strengthened to accommodate loading associated with additional elements included in over-the-air communications systems by placing expanding foam and aggregate, light weight aggregate concrete, normal weight aggregate concrete or other types of fill material into the hollow bore in the interior of the monopole. Monopole strengthening may equire base plate strengthening, adding anchor bolts and/or foundation strenghtening. This permits an existing monopole to accommodate more elements than were initially envisioned when the monopole was initially erected.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates generally to recreational ramps and, more particularly, to recreational ramps for use with wheeled vehicles such as skateboards and the like.
BACKGROUND OF THE INVENTION
Skateboard ramps provide an ideal way for allowing skateboarding enthusiasts to practice their sport away from the hazards of traffic. Such ramps are typically installed by municipalities in skate parks, which are usually located in residential areas. To ensure maximum usage of these parks by skateboarding enthusiasts, the skateboard ramps must provide a smooth ride. At the same time, by virtue of the fact that skateboard ramps are outdoor installations, these must be made resistant to severe changes in the weather, particularly as occur in northern latitudes. In addition, municipalities must be conscious of the effects of noise pollution on nearby residences and hence the surface of the ramp must be designed with a quiet ride in mind.
It is therefore not surprising that skateboard ramps have undergone a considerable evolution from a time when the ride surface was made of wood. Such wooden ramps, although simple to construct and capable of providing riders with a pleasant “feel”, require a high degree of maintenance as they tend to decay rather quickly, especially in areas where rain or snow are prevalent. Moreover, as they perish, wooden ramps subject skaters to the risk of injury from splinters and exposed screw heads.
By moving from a wooden ramp to one made of painted steel, one reduces the maintenance requirements of the ramp and thus significantly increases its safety and durability, although rust now becomes a significant impediment to the commercial success of this type of ramp. This is especially problematic in humid climates or in the presence of salt used to melt snow in some regions. Moreover, the rolling of wheels on a steel surface causes a much greater amount of noise than on a wooden ramp. Thus, even with the advent of the stainless or galvanized steel ramp, noise remains a critical issue, along with the added cost of treating the large amounts of metal necessary to create stainless steel skateboard ramps.
Another material that has been used in the construction of skateboard ramps is aluminum. Such a ramp offers the advantage of being more durable than one made of stainless steel. However, aluminum is afflicted by an even greater cost than stainless steel and retains the poor noise performance usually associated with metal surfaces. As a result, aluminum is often not the choice of a cash-strapped municipality in search of skateboard ramps to populate a skate park.
Thus, in search of the ideal skateboarding surface, manufacturers of skateboard ramps have turned to concrete. A concrete surface provides quiet, long-lasting skating pleasure with a superior ride “feel”. However, as can be readily imagined, the extreme weight of a concrete structure of the size necessary to provide appropriate elevations and radii of curvature is the most serious drawback of this type of ramp. In particular, the weight of such a structure renders it virtually impossible to account for shifts in the level of the earth that may occur after the ramp is placed, not to mention the disadvantage of requiring special heavy equipment to position the structure in the first place. Moreover, a conventional concrete structure is typically unattractive, not only because of its natural discoloration and liability to graffiti, but also because it curtails the field of view of individuals in its vicinity.
Against this background, it is apparent that the need exists for a skateboard ramp that is capable of providing the durability, safety, noise absorption and “feel” of a conventional concrete ramp, while benefiting from a greatly reduced weight and reduced physical volume.
SUMMARY OF THE INVENTION
The present invention recognizes that the durability, safety, noise absorption and “feel” of the surface provided by a skateboard ramp need not be compromised by excessive weight and/or expense. Accordingly, the present invention may be broadly summarized as providing a recreational ramp suitable for use with wheeled vehicles, including a support structure and a molded concrete layer mounted on the support structure. The molded concrete layer includes a sloping region that extends from a ground level to an above-ground level.
The present invention may also be broadly summarized as a process for the fabrication of a molded concrete layer for use in construction of a recreational ramp suitable for use with wheeled vehicles. The process includes preparing a mold from complementary parts, closing the parts onto one another, thus defining an interior space representative of a concrete layer, pouring concrete mixture into the mold, allowing the concrete to settle and separating the complementary parts of the mold to expose the molded concrete layer. The concrete layer is then mounted onto a support structure.
Embodiments of the invention offer the advantages of conventional concrete, i.e., a smooth, quiet and durable surface for riding, while the ramp as a whole is lighter and less bulky than a conventional concrete ramp. A particularly advantageous embodiment is one in which the concrete is self-leveling concrete, allowing the production of a thin, yet strong molded concrete layer.
These and other aspects and features of the present invention will now become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIGS. 1A , 1 B and 1 C are perspective views of three example ramps in accordance with respective embodiments of the present invention;
FIG. 2 is a perspective view of a support structure forming part of the ramp of FIG. 1A ;
FIG. 3 is a perspective view of the underside of the molded concrete layer forming part of the ramp of FIG. 1B ; and
FIG. 4 is a flowchart showing an example sequence of steps in the process of manufacturing a ramp in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1A , 1 B and 1 C, there are shown three example embodiments of a recreational ramp 100 for use with wheeled vehicles such as skateboards, in-line skates, roller skates, roller-skis, bicycles (e.g., BMX), and so on. In each case, the ramp 100 includes a support structure 110 and a molded concrete layer 120 mounted on the support structure 110 . The molded concrete layer 120 includes a sloping region 130 that extends from a ground level to an above-ground level. The molded concrete layer 120 also includes a platform 140 which acts as a braking surface. The dimensions of the platform 140 depend on the design parameters of the ramp 100 , such as the elevation of the platform 140 with respect to the ground level.
The platform 140 may be integral with the sloping region 130 . Alternatively, the platform 140 may be molded separately from the sloping region 130 and these two portions of the molded concrete layer 120 may be independently attached to the support structure 110 in a manner to be described later in further detail. A similar protective band 165 made of steel or other suitable material may protect a juncture 125 (best seen in FIG. 3 ) where the sloping region 130 and the platform 140 meet.
Likewise, an optional protective band 160 may surround a portion of the periphery 170 of the molded concrete layer 120 . The protective band 160 may be made of steel treated against rust and may be affixed to the periphery 170 in any conventional way. A suitable thickness for the protective band is 1.5 inches, although other thicknesses are within the scope of the invention.
The sloping region 130 and the platform 140 can be said to define a top surface 150 of the molded concrete layer 120 . Due to the texture of concrete, this top surface 150 is quiet when subjected to a rolling motion of wheeled vehicles such as skateboards. This makes the ramp 100 suitable for installation in residential areas. In addition, due to the fact that the concrete supported by the support structure 110 is in the form of a thin slab, the ramp 100 of the present invention will be considerably lighter in weight than conventional solid concrete ramps of the same size, and will not obstruct the field of view of a user proximate the ramp 100 .
Moreover, by making the molded concrete layer 120 out of high-performance (high-compressive-strength) self-leveling concrete, it is possible to obtain a smoother and thinner surface than with traditional concrete, which is of particular advantage when vehicles with small wheels, such as skateboards, are used.
Additionally, as shown in FIG. 1A , a barrier 180 can surround the platform 140 . The barrier 180 is not essential, although it may be advantageous, for example, in order to provide a sense of security to skateboarding enthusiasts who are coming out of a maneuver or waiting to use the ramp 100 . The barrier 180 may take the form of a solid wall or, as illustrated in FIG. 1A , the barrier 180 may take the form of a grille, which has the advantage of being less dense, and thus lighter, than a solid wall.
Also, in some designs, the ramp 100 may include various additional features, such as boxes (see box 190 in FIG. 1 C), islands, gaps, rails (see rail 195 in FIG. 1 C), and so on. Such features are fastenable to the molded concrete layer and/or to the support structure 110 in any known way.
In some embodiments of the ramp 100 , such as the one shown in FIG. 1A , the sloping region 130 will present a straight surface (i.e., at a constant gradient), while in other embodiments, such as the one shown in FIG. 1B , the sloping region 130 will present a curved surface. When a curved surface is presented, the radius of curvature may be constant or variable. Several particularly popular ramp designs include sloping regions 130 with a constant radius of curvature, in which the curved surface presents an arc of substantially 90 degrees (known as a “quarter-pipe” and shown in FIG. 1B ) or 180 degrees (known as a “half-pipe”). Alternatively, a half-pipe may be constructed by placing two quarter-pipes adjacent one another, with the ground-level portions of the respective sloping regions in contact with one another.
As shown in greater detail in FIG. 2 , the support structure 110 may typically include an arrangement of vertical legs 210 and diagonal cross-braces 220 joining the legs 210 . The legs 210 may have a rectangular tube-like structure with dimensions of three inches by three inches, although solid legs and legs having other dimensions are within the scope of the invention. The legs 210 have feet 230 which are adjustable in height. Such height adjustment may be achieved by providing multiple possible levels defined by buttons or by screwing the feet 230 in one direction to increase the leg height and in another to reduce the leg height. The adjustment of the feet 230 can also serve to level the support structure 110 where the ground on which it is placed is not level.
In a non-limiting example embodiment of the ramp 100 in FIG. 1A , known as a “six-foot bank”, the length of the platform 140 is about four feet, the height of the platform 140 is about six feet, the length of the sloped region 130 of the ramp 100 is about fourteen to fifteen feet and the thickness of the molded concrete layer 120 varies between 1.5 and 6.5 inches. In a non-limiting example embodiment of the ramp 100 in FIG. 1B , known as a three-foot quarter pipe”, the length of the platform 140 is about 30 inches, the height of the platform 140 is about three feet, the radius of curvature of the sloped region 130 is about six feet and the thickness of the molded concrete layer 120 varies between 1.5 and 6.5 inches. Other dimensions are of course possible, and the above examples merely serve to illustrate two of the myriad designs that will appeal to today's skateboard enthusiast and which are within the scope of the present invention.
The support structure 110 can be made of steel treated against rust (e.g., stainless or galvanized steel) or any other suitably rigid material that is resistant to corrosion. In order to attach the molded concrete layer 120 to the support structure 110 , any suitable fastening mechanism can be used. For example, the legs may have holes 240 through which tamper-proof masonry fasteners can be inserted. An example of a suitable tamper-proof masonry fastener is the Torx® Tamper-Resistant TapCon® Concrete Screw available from Tanner Bolt & Nut Corp., Brooklyn, N.Y.
Because the molded concrete layer 120 has a finite thickness, the portion of the molded concrete layer 120 which meets the ground level would ordinarily present a step that is not always easy to overcome by a vehicle with small wheels, such as a skateboard. To this end, the portion of the molded concrete layer 120 at the ground level may be gradually thinned out so as to present a much smaller step to the user of the ramp. However, the reduction in thickness of the molded concrete layer 120 at an edge thereof increases the fragility of the layer 120 and may lead to erosion or damage of the concrete layer at its thinnest point around the periphery 170 . Accordingly, a more desirable solution is to provide a transition plate 105 in order to bridge the step presented by the thickness of the molded concrete layer 120 .
Thus, with continued reference to FIGS. 1A , 1 B and 1 C, the molded concrete layer 120 is recessed around a portion of its periphery 170 . The depth of the recessed portion may be about ⅛ of an inch deep, although other depths are within the scope of the present invention, as long as the molded concrete layer 120 remains sufficiently thick in the recessed portion. The transition plate 105 is secured to the recessed portion of the molded concrete layer 120 . The transition plate 105 could be secured to the recessed portion of the molded concrete layer 120 by any suitable masonry fastener or in any other suitable way known to those of ordinary skill in the art. The transition plate 105 may be made of neoprene, metal or plastic, although other materials are within the scope of the present invention.
In the most interior area of the recessed portion, the transition plate 105 has a thickness substantially equal to the thickness of the recess, so that there is a smooth transition between the top surface 150 of the molded concrete layer 120 and a top surface of the transition plate 105 . The transition plate 105 can be curved so that there is also a smooth transition between the top surface of the transition plate 105 and the ground level. It should be noted that it is not necessary to affix the transition plate 105 to the ground, although to do so would not depart from the spirit of the present invention.
Reference is now made to FIG. 3 of the drawings, in which there is shown a perspective view of the underside of the molded concrete layer 120 in accordance with the embodiment shown in FIG. 1 B. To provide additional support where necessary, an armature (shown in dotted outline at 135 ) may be provided within the molded concrete layer 120 around its periphery 170 and also through one or more cross-paths. In a non-limiting embodiment, the armature 135 may be composed of steel wires. Accordingly, the underside of the molded concrete layer 120 may include a plurality of ribs 310 , 320 and a border 330 which occupy the volume in the neighbourhood of the armature 135 .
The molded concrete layer 120 should have a thickness which allows sufficient rigidity to support the weight of multiple users as well as the pressure resulting from skateboard maneuvers. It has been found that a 1.5 inch thick molded concrete layer 120 with a thickness of 6.5 inches in the neighbourhood of the armature 135 and having a compressive strength of at least 40 MPa (Megapascals) provides a suitable degree of rigidity. Other combinations of thickness and compressive strength are of course within the scope of the invention. Generally speaking, higher compressive strength is preferred in order to afford an increased resistance to shock and allow for a reduction in thickness of the molded concrete layer 120 .
One example of concrete having a suitable compressive strength and capable of being molded into a thin layer (on the order of a few inches) is self-leveling concrete. In particular, it has been found that a self-leveling concrete compound having a slump flow of at least 20 inches and a considerable degree of homogeneity is advantageous. Greater slump flow is preferred in order to afford a layer that fits the mold more accurately and has a smoother surface with fewer air pockets. However, it has been observed that too high a slump flow may lead to an inherent weakness in the compound once it solidifies. Therefore, if a self-leveling concrete is used, it is desirable although not essential that such concrete have a slump flow of between 20 and 28 inches.
A non-limiting example process for manufacturing the molded concrete layer 120 is now described with reference to FIG. 4 . Specifically, a mold having several complementary parts is prepared at step 410 . The mold is the negative of the intended shape of the molded concrete layer 120 . Thus, of importance is the shape of the inside surface of each part of the mold. The inside surface of the mold can also be provided with recesses in the positions where it is desired to place the optional armature 135 , around which will appear the reinforcement ribs 310 /beams 320 /border 330 . To avoid the onset of rust, the armature 135 may undergo a pre-processing step, e.g., one which involves pre-coating the armature 135 with epoxy and bathing it in an electrolytic solution. At step 420 , the complementary parts are closed onto one another, defining an interior space that has the desired shape of the concrete layer being manufactured.
A mixture of concrete is poured into the mold at step 430 . Due to the relatively small amount of the space between the parts of the mold (providing a thickness of the ensuing concrete layer that ranges from about 1.5 inches to about 6.5 inches in an example embodiment), suitable rigidity is provided through the use of a high-performance concrete compound having a compressive strength of preferably at least 40 MPa (Megapascals) and, even more preferably, greater than 60 MPa. To this end, it is advantageous to use a self-leveling concrete compound, which typically exhibits a higher compressive strength than ordinary concrete for a given thickness. Also, the use of self-leveling concrete is advantageous because it will have a relatively high degree of fluidity compared to ordinary concrete, allowing it to enter various areas of the mold that occupy a space that is too small to accommodate a slurry of ordinary poured concrete. Moreover, self-leveling concrete has a tendency to produce a mirror-like surface having a desirable smoothness. A non-limiting example of a self-leveling concrete compound that is suitable for use with the present invention is Domflex™, which has been developed by Tessier Récréo-Parc Inc., Nicolet, Quebec, Canada.
Next, a curing period 440 ensues, during which the concrete settles and acquires a smoothness and a rigidity. During this phase the mold and its contents are heat-treated and kept at a high humidity level. A temperature of 60 degrees Celsius and a humidity level of greater than 90% have been found to be suitable, although other combinations are within the scope of the present invention. At step 450 , the parts of the mold are removed and the remaining molded concrete layer 120 is allowed to cool down at step 460 . At this point, the molded concrete layer 120 is ready to be mounted onto a support structure 110 using the fastening techniques described previously.
While specific embodiments of the present invention have been described and illustrated, it will be apparent to those skilled in the art that numerous modifications and variations can be made without departing from the scope of the invention as defined in the appended claims.
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A recreational ramp suitable for use with wheeled vehicles, including a support structure and a molded concrete layer mounted on the support structure. The layer includes a sloping region that extends from a ground level to an above-ground level. Also, a process for the fabrication of a molded concrete layer for such a recreational ramp. The process includes preparing a mold from complementary parts, closing the parts onto one another, thus defining an interior space representative of a concrete layer, pouring concrete mixture into the mold; allowing the concrete to settle and separating the complementary parts of the mold to expose the molded concrete layer. Embodiments of the invention offer the advantages of conventional concrete, i.e., a smooth, quiet and durable surface for riding, while the ramp as a whole remains lightweight and less bulky as compared with conventional concrete ramps. A particularly advantageous embodiment uses self-leveling concrete.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to a rock drill for rotary and/or percussion stress, in particular for percussion or hammer drilling machines.
The production of feed spirals on rock drills usually takes place by milling or whirling. Special forging processes for the production of the drill have also become known. In the case of all processes, the single or double thread feed spiral runs uniformly around the drill shank to the drill head, the spiral pitch being variable, if appropriate, over the length of the feed spiral.
It has become known from German Patent Specification 2,013,327 to design the feed spiral not smooth but staircase-shaped in order to prevent the drilling dust present in the feed spiral slipping due to feed sections with a slight pitch on the feed spiral. In this case, during percussion drilling, the combined rotary and axial movement of the drilling tool is utilised, the drilling tool spinning underneath the drilling dust after axial movement and the associated raising of the said dust, and the raised particles dropping onto the next higher staircase section. The intention of this is to achieve an improved feed without a tendency to clog, it being possible to increase the pitch angle and thus the feed rate.
SUMMARY OF THE INVENTION
The invention is based on the object of creating a drilling tool, in particular a rock drill for use in percussion or hammer drilling machines, in which the feed spiral can be produced easily due to its design and which produces better results in its feed rate than conventionally designed drilling tools.
Starting from a rock drill of the type referred to at the beginning, this object is achieved according to the invention by the provision of a drill spiral having first and second sections offset by 90° in the direction of rotation of the drill, the first sections having a pitch of zero degrees and the second sections having a pitch which is greater than zero degrees.
The rock drill according to the invention is based on the realisation that it is not necessary for a satisfactory drilling dust feed to design the complete feed spiral staircase-shaped or step-shaped with feed sections of flatter pitch. Rather, it suffices if the drilling dust is loosened from time to time along its path over the feed spiral by a rather stronger axial percussive component, in order that a caking of the drilling dust and thus a tendency to clog is avoided. For this purpose, the invention proposes that the feed spiral includes alternately following horizontal feed sections with a 0° pitch and lead sections, the sections in each case encompassing a 90° angle of rotation. Along a lead or pitch, therefore, a first horizontal feed section is followed by a first rising feed section, which is adjoined by a second horizontal feed section and this in turn is adjoined by a second rising feed section. Therefore, with an angle of rotation of 360°, two horizontal and two rising feed sections are provided with one pitch of the spiral. In this arrangement, the horizontal feed sections serve for the loosening brought about by an axial acceleration and the rising feed sections serve for the drilling dust feed itself.
If a feed spiral is divided up into feed sections alternating in this way, this gives rise to a further feature essential for the invention that the feed spiral does not have any undercuts in side view on the horizontal feed sections. This makes it possible to produce the feed spiral in a simple procedure by forging, in particular drop forging with a two-part forging die. The two-part forging die is designed as a ram-shaped die and the forging operation can take place without a rotational movement of the feed spiral. This is preferably achieved whenever the surface tangents of the horizontal feed section run perpendicular to the vertical plane through the horizontal feed section, i.e. whenever there are no undercuts in this feed section. As a result, an extremely inexpensive production process is obtained, even for heavy, solid drilling tools for use in heavy-duty hammer drilling machines.
Consequently, what is decisive for easy production of the feed spiral from a forged base material is the geometrical shape with straight feed sections without undercuts.
The design of the rock drill according to the invention with a double thread feed spiral is particularly advantageous, the horizontal feed sections which are opposite in each case, being formed by horizontal ring segments. The ring segments themselves serve for good guidance of the drilling tool in the drilling hole, since an optimum lateral support of the drill is ensured by the ring segments over the entire drilling length. The ring segments are interrupted by the flanks, in each case obliquely rising, of the rising feed sections.
It goes without saying that the invention may also take the form of a single thread feed spiral. A double threaded feed spiral is advantageous in the case of a drilling tool with a step drill head with center point (holing-through drill), due to the double drilling dust discharge at the drill head.
In an advantageous embodiment as a holing-through drill, the rock drill according to the invention is therefore equipped with a double thread feed spiral with a correspondingly designed drill head. Since such a drill head is itself generally designed as circular-cylindrical with a center point on top and metal carbide cutting elements arranged at the sides, this drill head is joined by two semicircular incisions to the double thread feed spiral.
In a special embodiment of the invention, the rising feed sections may be provided additionally with staircase-shaped flanks, as described in the patent referred to at the beginning.
Further details essential for the invention are described in the following description with reference to an exemplary embodiment.
BRIEF DESCRIPTION OF
THE DRAWINGS
FIG. 1 shows a perspective view of a rock drill according to the invention,
FIG. 2 shows a side view of the ring segment-like horizontal feed sections with rising feed sections in between,
FIG. 3 shows a side view of the representation according to FIG. 2, and
FIG. 4 shows a diagrammatic representation of the feed sections.
DETAILED DESCRIPTION
OF THE PREFERRED EMBODIMENT
The rock drill 1 represented in FIG. 1 is designed as a holing-through drill with a correspondingly designed drill head 2 with a center point 3 and metal carbide cutting elements 4. The double thread feed spiral 5 is joined by semicircular incisions 6 as drilling dust groove to the drill head 2. The drill shank 7 adjoins in the lower region of the drill spiral 5.
As revealed by FIG. 1 in perspective view and by FIGS. 2 and 3 in the respective side view, the feed spiral 5 consists of alternating horizontal feed sections 8,8' with a 0° pitch and feed sections 9,9' which are designed as rising feed sections, individual feed sections adjoining one another at an angle of rotation of 90°. The pitch α of the rising feed sections is denoted by α, where α=20°-60°, and is preferably 45°. In this arrangement, the first spiral has the feed sections 8,9 and the second feed spiral has the feed sections 8',9'. Each helical feed spiral consequently has within a pitch h two horizontally running feed sections 8 and 8' and two rising feed sections 9 and 9' in between.
The feed spiral of the drill according to the invention is also characterised by the feed spiral having no undercuts in the horizontal feed sections 8. To describe this situation, the first vertical plane 11 running parallel to the plane of the page in FIG. 2 and through the longitudinal axis 10 of the drill, or a second vertical plane 12 perpendicular to the first and likewise running through the longitudinal axis 10 of the drill is used. The first vertical plane 11 is perpendicular to the plane of the page in FIG. 3, passes through the longitudinal axis 10 of the drill and halves the horizontal feed section 8,8'. These two vertical planes 11, 12 are likewise drawn in diagrammatically in FIG. 1.
Each horizontal feed section 8 or 8' is halved by the first vertical plane 11 (see FIG. 3) and each surface tangent in the drilling dust groove of the horizontal feed section 8 or 8' is in each case perpendicular to the first vertical plane 11 and to the second vertical plane 12. In the representation of the feed spiral according to FIG. 2, consequently the horizontal feed sections 8,8' can be produced with a two-part forging die which runs perpendicular to the plane of the page. This is a consequence of the horizontal feed section 8,8', including the arcuate transitions 13 between the individual feed sections 8,8' having no undercuts.
As indicated in FIG. 2 in the upper region, in the case of a double thread feed spiral, two laterally opposite horizontal feed sections 8,8' are in each case formed by horizontal ring disk-shaped segments 14, which are interrupted in each case by a rising feed section 9,9'.
In the case of the rising feed sections 9,9' as well, all surface tangents may run parallel to the first vertical plane 11; however, in terms of tool engineering, this is not absolutely necessary in forging, i.e. these feed sections may also be of profiled design. With respect to the second vertical plane 12, the surface tangents run at the angle of rise of the rising feed spiral section 9 and 9'.
In a preferred embodiment, the rising feed sections 9 and 9' may have a staircase-shaped course 15, as mentioned in the patent described at the beginning. As a result, the loosening of the drilling dust is brought about by a vertical impact component also on the rising feed section in addition to the horizontal feed section.
In FIG. 4, the operating principle of the rock drill according to the invention is represented diagrammatically.
The drilling dust generated in the drilling hole passes via the two incisions 6 and 6' via the first rising feed section 9 (9' concealed in FIG. 1) to the first horizontal feed sections 8 and 8', respectively. In these horizontal feed sections 8, 8', as represented in FIG. 4 as a vertical line 16, no feed takes place during an angle of rotation of 90° but only a loosening of the drilling dust due to the vertical percussive movements of the drill. Once the drilling dust has covered an angle of rotation of 90°, it comes to rest in the rising feed sections 9 or 9' and is transported along this feed flank in the direction of the drill shank 7. This axial feeding operation is identified in FIG. 4 by reference numeral 17. After a further transport of the drilling dust over an angle of rotation of 90°, the rising feed section 9,9' is followed in turn by a horizontal feed section 8,8' with a 0° pitch for the loosening of the drilling dust over a transport angle of 90°. Thereafter there finally follows a rising feed section 9,9' with a corresponding feeding operation. The diagrammatic course represented in FIG. 4 over the feed sections 8, 8' is consequently followed over a lead or pitch h. In FIG. 4, the pitch h is represented on an enlarged scale in comparison with the representation in FIGS. 1 to 3. The angles of 90° indicated in FIG. 4 relate to a rotational movement or a transporting movement of the drilling dust along the feed sections by an angle of rotation of 90°.
The invention is not restricted to the exemplary embodiment described and represented. Rather, it also comprises all further developments and refinements accomplished by a person skilled in the art without inventive content of their own.
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A rock drill for rotary and/or percussive stress, in particular for use in percussion or hammer drilling machines, is proposed, which by its geometrical design makes improved efficiency and simplified production possible. For this purpose, the feed spiral 5 is designed alternately with horizontal feed sections 8,8' with a 0° pitch, and adjoining lead sections 9,9', the respective feed sections assuming an angle of rotation of 90° on the drilling tool.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to remote monitoring of flow conduits, such as pipelines and wellbores, and more particularly to a system of self-contained measurement stations for measuring parameters of interest of the flow conduit and transmitting the measurements to a mobile interrogation device.
2. Description of the Related Art
Fluid conduits such as pipelines and aqueducts extend for tens, hundreds, or thousands of kilometers and may be used to transport liquids, gases, slurries or combinations thereof. Such conduits may have multiple sections that run above or below ground. Sections may be run underground to avoid natural obstacles such as rivers or simply as a safety precaution. Other sections may be run above ground depending on the topography and underlying strata. Sensing stations are commonly located at major features, such as pumping station that may be separated by tens or hundreds of kilometers. Sensors are used to determine any of a number of parameters of interest related to the operation and safety of the conduit and/or related to the fluid transported therein. However, due to the relatively large separation of these stations, conditions that may be indicative of potential problems or failures may go undetected until they become so great as to cause a catastrophic event, such as for example a substantial leak that may be a serious environmental problem. It would be highly desirable to be able to determine various parameters relating to the physical condition of the conduit including, but not limited to, mechanical strain and stress, crack initiation and propagation, temperature, acceleration and vibration, seismic events, corrosion, pressure integrity, and flowing fluid properties, such as chemical species, radiation, and chemical contamination. The very nature of the length and location of such conduits, however, make the distribution of power and signal lines to multiple measurement stations substantially impractical and cost prohibitive.
There is a demonstrated need for a system for providing more measurements along fluid conduits without the need for additional power and signal lines.
SUMMARY OF THE INVENTION
The present invention contemplates a system for monitoring a flow conduit using remotely interrogated measurement stations disposed along the conduit.
In one preferred embodiment, a system for monitoring at least one parameter of interest relating to a flow conduit having a through passage and a fluid flow therein comprises at least one measurement station coupled to the flow conduit for taking a measurement relating to the parameter of interest. An interrogation device is adapted to move proximate the measurement station and to transmit a first signal to the measurement station, and to receive a second signal from the measurement station relating to the parameter of interest.
In one aspect, a method for monitoring at least one parameter of interest relating to a flow conduit having a fluid flow therein, comprises coupling at least one measurement station to the flow conduit at a predetermined location. The measurement station is adapted to measure the at least one parameter of interest. An interrogation device is passed proximate the at least one measurement station. A first signal is transmitted from the interrogation device to the measurement station, and the measurement station measures the at least one parameter of interest in response thereto. A second signal related to the parameter of interest and transmitted by the measurement station is received at the interrogation device.
In another aspect, a system for determining at least one parameter of interest relating to a flow conduit having a fluid flowing therein, comprises making the flow conduit from a composite material. At least one electrical conductor is embedded along the flow conduit in the composite material, and is adapted to transmit and receive radio frequency signals. A plurality of measurement stations are disposed, spaced apart, along the flow conduit at predetermined locations. Each of the plurality of measurement stations is adapted to receive a first signal transmitted from the at least one electrical conductor and to transmit a second signal in response thereto related to a measurement of the at least one parameter of interest.
BRIEF DESCRIPTION OF THE DRAWINGS
For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
FIG. 1 is a schematic drawing of a fluid conduit traversing an uneven terrain;
FIG. 2 is a schematic drawing of a self contained measurement and information station according to one embodiment of the present invention;
FIG. 3 is a schematic drawing of a measurement module of a self contained measurement and information station according to one embodiment of the present invention;
FIG. 4 is a schematic drawing of an articulated conduit inspection pig for use as a mobile interrogation device according to one embodiment of the present invention;
FIG. 5 is a schematic drawing showing an automotive device and an aircraft device for use as mobile interrogation devices according to one embodiment of the present invention;
FIG. 6 is a schematic drawing of a composite conduit with embedded conductors for transmitting command signals and/or power to multiple measurement stations according to one embodiment of the present invention;
FIG. 7 is a schematic drawing of a coiled composite tubing having embedded conductors and a plurality of self contained measurement and information stations disposed along the tubing according to one embodiment of the present invention; and
FIG. 8 is a schematic drawing of a casing with a plurality of self contained measurement and information stations disposed along the tubing and an interrogation device deployed on a tubular member according to one embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In one preferred embodiment, see FIG. 1 , a fluid conduit 1 extends across terrain 10 . Note that the term fluid conduit as used herein, means a closed conduit, such as a pipeline or other substantially tubular member, and an open conduit such as an aqueduct for transporting liquids such as water. Such conduits may extend for tens, hundreds, or thousands of kilometers and may be used to transport liquids, gases, slurries or other fluids. The conduit 1 , for example may be a pipeline having multiple sections 5 , 6 , 7 that run above or below ground. Sections may be run underground to avoid natural obstacles such as river 8 or simply as a safety precaution. Other sections may be run above ground depending on the topography and underlying strata. Self contained measurement and information stations 20 , called measurement stations for simplicity, are disposed along conduit 1 at predetermined locations, to determine any of a number of parameters of interest related to the operation and safety of the conduit and/or related to the fluid transported therein. The greater the number of measurement stations 20 , the better will be the confidence that the conduit is operating properly. Various parameters may be measured relating to various physical conditions including, but not limited to, mechanical strain and stress, crack initiation and propagation, temperature, acceleration and vibration, seismic events, corrosion, pressure integrity, and flowing fluid properties, such as flow rate and chemical species, radiation, and chemical contamination. For an open channel, such as an aqueduct, measurement stations 20 may be mounted to determine parameters related to the flow channel such as, for example, seismic events, and/or for determining parameters related to the flowing fluid. Such fluid related parameters, for a water supply flow for example, may relate to chemical analysis and water purity or to contamination by chemical and/or biological agents. The very nature of the length and location of such conduits make the distribution of power and signal lines to multiple measurement stations 20 physically impractical and cost prohibitive.
FIG. 2 shows one preferred embodiment of measurement station 20 having measurement module 30 , radio frequency (RF) transmitting and receiving antenna 22 , and flexible adhesive base 21 for attaching measurement module 30 to flow conduit 1 . In one embodiment, see FIG. 3 , measurement module 30 includes at least one sensor 27 for detecting the parameter of interest. Alternatively, sensor 27 may be external to measurement module 30 and suitably electrically connected using techniques known in the art. Interface module 24 conditions the output signal from sensor 27 , if necessary, and transfers the signal to data memory in controller module 23 . Controller module 23 has a processor with sufficient memory for storing program instructions and for storing acquired sensor measurement data. The controller module may contain a unique identification, such as a digital identifier, for uniquely identifying each measurement station 20 that may be used for correlating the measurements with location on the conduit 1 . Also included is RF transceiver 26 for receiving command and power signals and for transmitting data signals in response to the received command signals.
In one preferred embodiment, the measurement module 30 has no internal power source, but receives power via the received RF signal. This power is converted to usable power by power module 28 . Sensor 27 is chosen as a low power sensor such that the RF link transmits sufficient power to power measurement module 30 including sensor 27 and to transmit the resulting data signal using RF transceiver 26 . The components of measurement module 30 are encapsulated in a suitable compound 29 to protect the components from the environment.
The RF command signal and RF power are transmitted from, and the data signals received by, a mobile interrogation device (see FIGS. 4 and 5 ) such as an internal inspection pig 40 , an automotive device 45 , and an aircraft device 50 . Inspection pigs are commonly self-powered for movement in the conduit or, alternatively, may be pumped through flow conduit 1 . Any type of inspection pig is suitable for this invention The automotive device 45 may be any common vehicle including, but not limited to an automobile, a truck, and an all-terrain vehicle. The automotive device, is adapted to carry an RF transceiver (not shown) and a controller (not shown) transmitting command signals and power to measurement stations 20 and receiving and storing data signals from measurement stations 20 . The aircraft device 50 may be an airplane, helicopter, or any suitable aircraft and may be manned or a remotely controlled, unpiloted aircraft. Remotely controlled aircraft device 50 may be preprogrammed to follow a predetermined flight pattern along the known path of flow conduit 1 , using, for example, preprogrammed way points and GPS signals to guide aircraft device 50 along the predetermined flight pattern. Relatively small remotely controlled vehicles are commercially available.
The placement of a particular measurement station 20 at a predetermined location and the type of flow conduit 1 will be used to determine the type of interrogation device used for that particular measurement station 20 . For example, the flow conduit 1 may be (i) a tubular conduit of metallic material such as steel, (ii) a tubular conduit out of a non-metallic material such as a composite material, or (iii) an open-channel conduit. For a metallic conduit, the RF energy will not penetrate the conduit. Therefore, a measurement station 20 mounted inside the metallic conduit 1 (see FIG. 4 ) requires an internal interrogation device such as a pipeline pig 40 . A measurement station 20 mounted outside of a metallic conduit 1 (see FIG. 5 ) requires an external interrogation device such as automotive device 45 and/or aircraft device 50 . For a composite material, the conduit 1 is substantially transparent to RF energy and allows the measurement stations 20 to be mounted internally, externally, and/or embedded within the conduit and be able to operate with an internal and/or external interrogation device.
The sensors 27 used to detect the parameters of interest include, but are not limited to, (i) mechanical strain gages, (ii) fiber optic strain gages, (iii) ultrasonic detectors for detecting micro-crack initiation and propagation, (iv) accelerometers, (v) temperature sensors, including distributed fiber optic temperature sensors known in the art, (vi) pressure sensors, (vii) corrosion detectors, (viii) radiation detectors, (ix) spectroscopic chemical detectors, and (x) ultrasonic detectors for measuring the wall thickness of the flow conduit for detecting erosion and/or corrosion of the conduit. The sensors 27 may detect characteristics associated with the conduit and/or the fluid flowing therein. One skilled in the art will recognize that many of the sensors, for example accelerometers and seismic detectors, are currently achievable using Micro Electromechanical Systems (MEMS) fabrication techniques for providing low power consumption devices. Other sensors are available using piezoelectric crystal technology or resonant crystal technology that require very low power consumption. Thermocouple temperature sensors, for example, generate their own electrical signal and do not require external power to operate.
In operation, the measurement stations 20 are disposed along the flow conduit 1 . The measurement stations 20 may be both above and below ground along the length of flow conduit 1 depending on the path of conduit 1 . An interrogation device is caused to pass in relative proximity to the measurement stations 20 . The interrogation device has an RF transceiver for transmitting command signals and power to the measurement stations 20 and for receiving data signals from the measurement stations 20 . The data collected is downloaded from the interrogation device, using techniques known in the art, to a central control station (not shown) for monitoring the various parameter data collected.
In another preferred embodiment, measurement module 30 includes an internal power source (not shown) for powering the electronic devices and sensors as required. The internal power source may include, but is not limited to, (i) a commercially packaged battery, (ii) a thick film battery integrally attached to the measurement module, (iii) a piezoelectric power source deriving power from shock and vibration in the proximity of the measurement module, (iv) a solar cell integrated into an external surface of the measurement module, and (v) a thermoelectric generator integrated into the measurement module. All of these power sources are known in the art. Any combination of these sources may be used and their selection is application specific, and may be determined without undue experimentation, by considering such factors as (i) power required for the type of sensors, (ii) transmission strength required of data signals, and (iii) location of measurement station and flow conduit (for example, above ground or below ground).
In another preferred embodiment, the power sources described above are mounted external to the measurement module 30 and connected to the measurement module via connectors and/or cables using techniques known in the art.
In one preferred embodiment, measurement module 30 contains a real time clock for time stamping measurements. A low power seismic detector, for example, may be continuously measuring seismic activity, but the data is only stored and time stamped if the sensed event exceeds a predetermined threshold or alarm criterion. The data is retrieved by the interrogation device and may be used to indicate that more extensive inspection is needed in the area where the seismic event was detected.
In one preferred embodiment, shown in FIG. 6 , composite fluid conduit 60 has electrical conductors 61 embedded in the wall 63 of fluid conduit 60 during the manufacturing process for forming the conduit. Measurement stations 20 are disposed along the conduit at at least one of (i) on an internal walls of conduit 60 , (ii) on an external wall of conduit 60 , and (iii) embedded in a wall 63 of conduit 60 . The electrical conductors 61 may be disposed substantially longitudinally in the wall of conduit 60 . Alternatively, the electrical conductors 61 may be spirally wrapped in the wall of conduit 60 . Electrical conductors 60 are connected to RF transceiver (not shown) in a controller 62 . Power and command signals are transmitted through the conductors which act as RF antennas. The signals are detected by the measurement modules 30 along the conduit. The measurement stations 20 receive and convert the RF signals to power and command instructions for taking data from sensors in the measurement modules 30 . The data are then transmitted via an RF signal that is received by the electrical conductors 61 and decoded by controller 62 , according to programmed instructions. The signals from measurement stations 20 are suitably encoded and identified, using techniques known in the art, so as to be able to determine the measurement stations 20 associated with each data signal.
In one preferred embodiment, see FIG. 7 , a composite conduit, as described previously having embedded electrical conductors and internal, external, and/or embedded measurement stations 20 , may be formed as a coiled tubing 71 , contained on reel 70 , for use in drilling and/or completing a wellbore 72 . Measurements from measurement modules 30 , embedded in the coiled tubing 71 , may be used to determine parameters of interest regarding the condition of the tubing string and/or parameters related to the drilling process. Such parameters of interest include, but are not limited to, (i) directional parameters, (ii) drilling induce vibration, including axial and torsional, (iii) weight on bit, (iv) downhole pressure, (v) downhole temperature, and (vi) formation parameters including natural gamma ray emission.
In one preferred embodiment, see FIG. 8 , metallic casing 83 is fixed in place in production wellbore 80 . Measurement modules 30 are fixed to an internal surface of casing 83 and measure parameters of interest including, but not limited to, (i) fluid pressure, (ii) fluid temperature, (iii) fluid flow rate, (iv) corrosion, and (v) casing stress. An interrogation device 82 is deployed on wireline 81 and is passed in proximity to measurement modules 30 and has an RF transceiver that transmits RF power and command signals to measurement modules 30 , which in turn, make measurements and transmit that data via RF transmission to interrogation device 82 . Interrogation device 82 has internal memory for storing the received data and is downloaded at the surface. Alternatively, wireline 81 has electrical conductors and received data is transmitted directly to the surface. The interrogation device 82 may alternatively be deployed on a coiled tubing (not shown) using techniques known in the art.
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A system for monitoring at least one parameter of interest relating to a flow conduit having a through passage and a fluid flow therein comprises at least one measurement station coupled to the flow conduit for taking a measurement relating to the parameter of interest. An interrogation device is adapted to move proximate the measurement station and to transmit a first signal to the measurement station, and to receive a second signal from the measurement station relating to the parameter of interest. The measurement station receives power from the first signal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention is related to the field of the invention disclosed and claimed in copending U.S. patent application Ser. No. 584,581, now U.S. Pat. No. 4,512,405, entitled "Pneumatic Transfer of Solids Into Wells" filed concurrently herewith.
BACKGROUND OF THE INVENTION
The present invention relates generally to a method and apparatus for treating a subsurface earth formation penetrated by a well bore and, specifically, to a method and apparatus for pneumatically adding additional proppant to a pressurized fluid being injected into a well bore to stimulate a well.
Various methods are known for stimulating the production of crude oil and natural gas from wells drilled in reservoirs of low permeability. Certain prior art techniques have involved the hydraulic fracturing of such formations with various liquids such as crude oil, with or without proppants such as sand, glass beads, or the like. Hydraulic pressure was applied to the permeable formation to fracture the rock surrounding the well bore. The initially formed fractures were then extended by the injection of fluids containing a proppant to be deposited in the fractures. The hydraulic pressure was then released and the proppant which was deposited in the fractures served to hold the fractures open so that channels were created for flow of reservoir fluids to the well annulus. It has been recognized for some time that the concentration of proppant in the stimulation fluid is significant since it determines the final thickness of the fractures.
Another prior art technique for stimulating reservoirs of low permeability is the use of hydraulic fracturing with foam. Typical foam fracturing operations involve making a foam by blending sand with a jelled water solution and treating the solution thus formed with a surfactant. The fluid pressure is increased with a conventional pump after which a gas, such as nitrogen, is injected into the fluid to create a high pressure foam. The foam containing the sand proppant is then injected into the well. Foam fracturing has several advantages over fracturing techniques using conventional liquids. Foam has a low fluid loss and has the ability to create larger area fractures with equivalent volumes of treatment fluid. Since fluid loss to the formation is minimized, the chances of damaging sensitive formations is lessened. The foam is also thought to have a higher sand carrying and sand suspending capability to suspend a greater amount of sand in the foam until the fracture starts to heal. Since the foam has a high effective viscosity, sand does not settle out of the carrier fluid as quickly as it would settle from a traditional fluid such as crude oil. The foam creates wider vertical fractures as well as horizontal fractures of greater area.
In spite of the many advantages of using foam, some of which have been described, one disadvantage of such prior art techniques is that the maximum concentration of proppant obtainable is quite low. Conventional hydraulic fluids can achieve sand concentrations of 6 to 8 lbs. per gallon of carrying fluid. However, with foamed fluids, the gas expands the liquid to about four times the original volume of the gelled liquid. The net result is that the sand foam concentration is reduced to about 11/2 to 2 lbs. per gallon of carrying fluid.
In order to provide a foam fracturing fluid that was a high concentration of sand or other proppant, various schemes have been suggested which involve introducing the pressurized foamable fluid and sand slurry into a centrifugal separator or concentrator for separating some of the carrier fluid to concentrate the amount of proppant per volume of carrier fluid. The equipment necessary to effect such a separation is expensive and the separated fluid is usually wasted. Such schemes have generally been effective only to increase the proppant concentration from about 6 to 8 lbs. per gallon of carrying fluid to about 12 to 15 lbs. per gallon of carrying fluid. This results in a sand concentration of about 3 to 4 lbs. of proppant per gallon of carrying foam.
There exists a need, therefore, for a method and apparatus for treating a subsurface earth formation with pressurized foam which allows an increased proppant concentration to provide a greater fracture thickness.
There exists a need for such a method and apparatus which is simple in design and operation and which does not add greatly in the overall cost of the fracturing job.
There exists a need for such a method and apparatus which provides a proppant concentration in the foam carrier in excess of 4 lbs. per gallon of proppant carrier foam.
There exists a need for such a method and apparatus which provides a proppant concentration in a fluid in excess of 6 to 8 lbs. per gallon of carrying fluid without the wasted fluid and expense of separators or concentrators.
There exists a need for such a method and apparatus which reduces or eliminates the need for abrasive proppant passing thru and wearing very expensive conventional sand/fluid blending and high pressure pump equipment, and which reduces or eliminates the use of conventional sand/fluid blending and high pressure pump equipment.
SUMMARY OF THE INVENTION
In the method of treating a subsurface earth formation of the invention, a proppant is blended with a foamable carrier to form a carrier slurry. The slurry is then pressurized and a pressurized gas is added to the slurry to form a pressurized foam. Additional proppant is then added pneumatically by using a bypass or secondary flow of gas pressure to blow proppant into the main pressurized gas flow to increase the proppant concentration in the pressurized foam. The pressurized foam is then injected into the well bore.
Preferably, the additional proppant is fed to a manifold which is connected to a source of pressurized gas whereby the application of gas to the manifold serves to blow the additional proppant into the pressurized foam. The proppant can be supplied from tube truck proppant containers connected to the manifold. A source of gas pressure is connected by an inlet line to one side of the manifold and an outlet line is connected to the opposite side of the manifold for receiving a flow of pressurized gas and entrained proppant exiting the manifold. A coupling connects the manifold outlet line to a conduit carrying the carrier fluid to the well.
The proppant containers are preferably cylindrical tubes having loading ends for receiving a quantity of proppant and discharge ends for dispensing proppant to a common manifold. The proppant containers can be mounted on the bed of a truck for transportation to the well site. A pivoting mechanism on the truck bed can be provided for inclining the longitudinal axis of the cylindrical proppant container with respect to the horizontal plane of the truck bed whereby proppant is supplied from the containers discharge ends to the common manifold by gravity feed.
An alternative or enhancement to gravity feed is to force proppant out of the tubes by gas flow into one end of the tubes thru a common inlet manifold and the proppant and gas mixture out of the opposite end of the tubes into a common discharge manifold. The common inlet manifold may be mounted on the opposite end of the tubes from the discharge manifold and may be used for loading proppant into the tubes. The inlet manifold may also be placed at any point between the ends of the tubes when enhancing gravity feed. Each tube may also have a valve to control the discharge rate.
Additional objects, feature and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the process of the invention showing the pneumatic addition of proppant to a liquid, gelled carrier fluid.
FIG. 2 is a schematic diagram of another process of the invention for adding proppant to a foam carrier with all of the proppant being added after formation of the foam carrier.
FIG. 3 is a schematic diagram of another process of the invention for adding additional proppant to a conventional proppant carrying foam being injected into a well.
FIG. 4 is a side perspective view of a truck for transporting the proppant containers used in practicing the method of the present invention.
FIG. 5 is a partial close-up perspective view of the proppant containers and manifold used in practicing the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic diagram illustrating one form of the present method of treating a subsurface earth formation penetrated by a well bore. As shown in FIG. 1, one or more fracturing tanks or tank trucks 11, 13, 15, and 17 store a fluid carrier which can be a liquid, a gel, a colloidal suspension, or the like. The term "carrier fluid" or "fluid carrier" is meant to include ungelled water, hydrocarbon liquids, acids and liquified gases such as carbon dioxide. In the preferred embodiment, the carrier can comprise water thickened with a guar gum at a concentration in the range of about 1 to 5 lbs. per 100 gallons of water. The water-guar gum solution forms a gel, the viscosity of which depends on the rate of shear. The gel is a non-neutonian fluid with a plastic viscosity in the range from about 10 to 30 centipoise. The carrier fluid passes out conduits 19, 21, 23, 25 to one or more high pressure injection pumps, preferably located on pump trucks 27, 29. The pump trucks 27, 29 are conventional equipment used to raise the pressure of the carrier liquid to at least the required wellhead pressure, usually less than about 5000 psig. The gelled water slurry flows out a connecting fluid conduit 31 to the well head 33.
A nitrogen storage tank and pump 35 are provided for adding a pressurized gas to the gelled water slurry in the conduit 31. A low rate meter 37, such as a differential orifice meter, is provided in the line 39 from the nitrogen pump 35 to provide a flow rate in the range of about 400 to 2500 SCF/MIN of nitrogen. The low rate nitrogen flow passes through one or more inlet lines 41, 43 and 45 to the sand truck tube manifolds 47, 49 and 51. It should be understood that while three tube trucks are illustrated in FIG. 1, that a greater or lesser number can be utilized depending on the size of the job. The use of a plurality of tube trucks allows one truck to be taken off line and refilled while another truck is connected to the source of pressurized gas.
The tube truck, proppant containers, and manifold used in the method of the invention are shown in greater detail in FIGS. 4 and 5. The tube truck includes one or more proppant containers 53, 55 which are connected to a common manifold 57 for receiving a gradual flow of particulate proppant from the containers 53, 55. The preferred proppant is 40 to 60 screen sand. However, other proppants can be used including glass, plastics, or metal particles. The proppant containers 53, 55 are preferably generally cylindrical tubes having closed ends. Each tube has a loading end or cap 59 for receiving a quantity of proppant from a holding tank or bin (not shown) and a discharge cap or end 61 for dispensing proppant to the common manifold 57. The discharge pipes 63 extending from the discharge caps 61 of the tubes 53 are connected, as by a T-connection 65 into the manifold 57. Flow valves 62 can be provided for controlling the flow of proppant from the discharge ends 61.
The tube design allows for lower cost construction than heavy wall relatively short height or length pressure vessel designs with inside length to inside diameter ratios of less than about 5 to 1. Preferably the tubes used for the proppant containers 53, 55 have ratios in the range from about 5 to 1 to upwards of 500 to 1. The tubes 53, 55 are mounted by any convenient means on a pivoting bed 67 of a transport truck 69 whereby the longitudinal axis of the proppant carrier tubes 53 can be pivoted with respect to the bed 67 of the truck to allow the proppant in the containers 53, 55 to flow by gravity feed to the manifold 57. A hydraulic lift 64 pivots the truck bed 67 between a horizontal position and selected vertically inclined angles (shown in dotted lines in FIG. 4). An alternative pneumatic force feed through the tubes can enhance the gravity feed method when well conditions require very high proppant discharge rates or where conditions require the tubes to discharge proppant with the tubes in the horizontal position.
The nitrogen inlet line 41 is connected to one end of the manifold 57 for supplying gas pressure through a valve 66 to the manifold and the manifold has an outlet line 71 which is connected through a T-connection 79 (FIG. 1) to the fluid conduit 31. T-connection 79 can be placed on the wellhead 33 when required by job design. By adding the proppant pneumatically to the pressurized slurry in the fluid conduit 31, a gelled fluid and sand slurry can be provided with 1 to 2% nitrogen by volume and sand concentrations of up to about 16 lbs. per gallon of carrier slurry. A nuclear densimeter 80 can be provided in the fluid conduit 31 for monitoring the sand rate going to the wellhead 33. The monitor van 82 also contains conventional monitoring equipment for checking pressure sensors at various points in the fluid conduits and monitoring the volume of sand passing into the well with time.
In the method of FIG. 1, sand is added downstream pneumatically to the gelled fluid after the high pressure pumps, thus lessening pump wear. The sand is added to the fluid conduit 31 in a low rate nitrogen flow carrying a high rate of sand. Liquefied gases such as carbon dioxide can be used in the method of FIG. 1 when fracturing water sensitive formations.
FIG. 2 illustrates another embodiment of the method of the invention. Once again, fracturing tanks 81, 83 provide a water-gel slurry through outlet conduits 85, 87 to a high pressure pump 89. A foaming agent, such as a conventional surfactant, is supplied through an inlet line 91 to the water-gel slurry on the way to the pump truck 89. The gelled slurry and surfactant pass out a fluid conduit 93 toward a foam generation tee 95. Nitrogen is supplied from a transport truck 97 to a nitrogen pump truck 99 and passes out an outlet line 101 where the fluid flow splits between a high rate nitrogen line 103 carrying nitrogen at a rate in the range of about 10,000 to 50,000 SCF/min. and a low rate line 105. A low rate meter 107 in the low rate line 105 provides a nitrogen flow rate in the range of about 400 to 2500 SCF/MIN through the fluid line 109 leading to the manifold on the sand tube truck 111.
The low rate nitrogen passes through the tube truck manifold and pneumatically blows sand being fed from the proppant containers 53 into the manifold 57 out the outlet line 113 to a connecting tee 115 on the fluid conduit 93.
The resulting foam contains sand in a concentration up to about 16 pounds per gallon of foam. The foam passes through a nuclear densimeter 117 and through a fluid conduit 119 to the wellhead 121 as previously described.
The method shown in FIG. 2 adds nitrogen at a high rate through the high rate line 103 to form foam in the fluid conduit 93 prior to the addition of sand in the low rate stream passing through outlet line 113 to the connecting tee 115. Conventional sand/water blender trucks and sand storage tanks are not needed in this method where tube trucks are used to pneumatically add sand to the foam. Once again, the sand is being added downstream of the high pressure pump to save wear on the pump.
FIG. 3 shows another embodiment of the invention in which fracturing tanks 123, 125, 127, 129 supply a water-gel carrier fluid through outlet lines, e.g. line 124, to a water and sand blender truck 131. The conventional water and sand blender truck 131 is connected to a sand storage tank 133 and a foaming agent, such as a surfactant can be supplied from a tank 135 to the outlet lines 137 from the blender 131 to the pump truck pumps 139, 140. The outlet lines, e.g. line 137, from the water and sand blender 131 pass to one or more high pressure pumps 139, 140 to provide a pressurized gel-water slurry containing sand in a concentration of about 6 to 8 lbs. per gallon in the fluid conduit 141.
Nitrogen from a nitrogen transport 143 is supplied to a nitrogen pump 145. High rate nitrogen passes through a gas line 147 and fluid tee 149 to the fluid conduit 141 to form a foam containing sand in a concentration of about 11/2 to 2 lbs. per gallon of foam. Another nitrogen transport 151 supplies nitrogen to a nitrogen pump 153 which is connected by a gas line 155 to a gas tee 156. High rate nitrogen flows through line 158 back into line 147. The remainder of the nitrogen flow from line 155 passes down line 160 to a low rate meter 157 which supplies low rate nitrogen, i.e., 400-2500 SCF/min., through an inlet line 159 to the tube truck manifold 161. The tube truck outlet line 163 is connected by a fluid tee 165 to conduit 141 whereby sand is pneumatically added to the foam in conduit 141. In this way, sand concentrations upwards of 16 pounds per gallon of carrying foam can be achieved.
An invention has been provided with significant advantages. The present method allows foamed carriers to contain proppant concentrations upwards of 16 pounds per gallon of carrier without the use of expensive centrifugal separation schemes or complicated equipment. The increased proppant concentrations can be added downstream of the high pressure pumps to lessen pump wear.
While the invention has been shown in only three of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
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A method and apparatus are shown for treating a subsurface earth formation penetrated by a well bore. A proppant is blended with a foamable carrier to form a slurry and the slurry is pressurized to a desired pressure. A gas is added to the pressurized slurry to form a foam. Proppant is then added pneumatically to the pressurized slurry after foaming the slurry and the pressurized fluid is injected into the well bore. The proppant is fed to a manifold which is connected to a source of pressurized gas whereby the application of gas pressure to the manifold serves to blow the proppant into the pressurized foam stream. The foam containing the proppant is then injected into the well in the conventional manner to prop open the fracture.
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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 an anti-theft device and, more particularly, to a collapsible barrier which is used to prevent a car being stolen. Alternately or additionally, the device may be employed to reserve a parking place for a vehicle.
[0002] The need for flexible barrier systems to control vehicular access has led to a number of different kinds of barriers. Locked gates have long been used for obstructing vehicles of all types. Gates, however, also obstruct pedestrian traffic, and locks securing the gates are often exposed to the elements and become inoperable over time. The use of keys or combinations further encumbers emergency access, which at best slows down emergency personnel, and at worst bars their access.
[0003] U.S. Pat. No. 5,018,902, to Miller et al., describes a bollard which is hinged so that it can fold into a collapsed position. Inside the bollard, a latch bar mates with a protruding locking section rigidly connected to a base, to lock the bollard in an upright, obstructing position. A fireplug wrench is used to actuate the latch bar to disengage it from the locking section, by swinging it about an axis perpendicular to the hinge axis. For automatic reengagement, a hinge is provided in the latch bar, and the portion of the latch bar below the hinge is spring-urged so that it snaps into engagement with the locking section when the bollard housing is brought to its upright, obstructing position. The latch bar needs to be quite large so that a relatively small amount of rotation of the fireplug wrench produces enough movement of a remote portion of the latch base to clear the protruding locking section connected to the base. Consequently, a large movement is required to disengage the latch bar from the locking section. The force needed to disengage the latch bar from the locking section increases over time as a result of corrosion. Therefore release of the bollard becomes increasingly difficult and failure eventually occurs.
[0004] U.S. Pat. Nos. 4,576,508 and 4,715,742 to Dickinson, describe bollards which are vertically depressible into underground mounting frames. The locking mechanisms of these bollards may, however, become exposed to the elements, causing them to freeze in position. These bollards are also expensive to install and dependent upon complex actuation mechanisms. The requirement for a hole to receive the retracted bollard is a distinct and inherent disadvantage.
[0005] U.S. Pat. No. to Stice, describes a vertically depressible bollard with a substantially self-contained actuation mechanism. This bollard is exceedingly complex, and is dependent upon an electrical power source, which is supplied either through an enclosed battery, or through wires from an outside power source. Battery life and availability of electric current impose severe limits on the use of this device.
[0006] U.S. Pat. No. 5,711,110, to Williams, teaches a parking barrier permanently installed in vehicle parking surface, which has a base and legs embedded within a surface. This barrier is set into place by mechanical or electromechanical means through a coded radio frequency transmitter and receiver and in turn, energizes the actuator to rotate the barrier into a horizontal position. The electric system operates on low voltage direct current supplied by a D.C. power supply. The disadvantage to this system is that a there is no give for a frontal accidental head on hit which would cause damage to both the vehicle and to the barrier.
[0007] U.S. Pat. No. 6,150,958, to Worsham, teaches a radio-operated parking barrier apparatus including a base housing, a barrier arm including a shaft rotatably mounted in the housing, and a drive assembly disposed within the base housing that includes a pivot arm having a proximal end affixed to the shaft, and a driver having a reciprocally driven plunger movably connected to a distal end of the pivot arm. The back end of the driver is pivotally connected to the floor panel of the base housing to accommodate the vertical movement of the accurate motion that the end of the plunger must necessarily follow in converting the linear movement of the plunger into the rotation movement of the barrier arm around the shaft mounted in the base housing. The driver preferably utilizes a threaded shaft and drive nut to reciprocate the driver in operating the device. The drive assembly provides a simple and reliable linkage between the barrier arm and the base housing. The disadvantage to this system is that a there is no give for a frontal accidental head on hit which would cause damage to both the vehicle and to the barrier.
[0008] There is thus an unmet need for, and it would be advantageous to have, a collapsible barrier which is used to prevent a car being stolen and can also be used to guard a parking place for a vehicle when the car is not in the parking place devoid of the above limitations.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the present invention there is provided a device for guarding a parking space of a vehicle within a parking area. The parking area includes at least one parking space and at least one drive aisle. The device comprises (i) a base member securable onto a surface, the base member capable of engaging and retaining a rotatable barrier pivot axis, (ii) a barrier member integrally formed with or joined to the rotatable pivot axis such that rotation of the barrier pivot axis causes a change in a position of the barrier member from a first position to a second position, (iii) a driving mechanism for reversibly rotating the barrier pivot axis; and (iv) a biasing element for retaining the barrier member in the first position, wherein the first position prevents vehicular access to the parking space and the second position permits vehicular access to the parking space.
[0010] According to one aspect of the present invention there is provided a device for guarding a parking space of a vehicle within a parking area. The parking area includes at least one parking space and at least one drive aisle. The device comprises (i) a base member securable onto a ceiling, the base member capable of engaging and retaining a rotatable barrier pivot axis (ii) a barrier member integrally formed with or joined to the rotatable pivot axis such that rotation of the barrier pivot axis causes a change in a position of the barrier member from a first position to a second position, and a driving mechanism for reversibly rotating the barrier pivot axis, wherein the first position prevents vehicular access to the parking space and the second position permits vehicular access to the parking space.
[0011] According to further features in preferred embodiments of the invention described below the barrier member further includes two arms approximately perpendicular to the pivot axis joined at a proximal end to the pivot axis and joined at a distal end by a bar which is approximately parallel to the barrier pivot axis.
[0012] According to still further features in the described preferred embodiments the barrier member is comprised of one arm approximately perpendicular to the pivot axis joined at a proximal end to the pivot axis.
[0013] According to still further features in the described preferred embodiments the distal end of the barrier member in the second position is pointing away from the approach drive aisle.
[0014] According to still further features in the described preferred embodiments when an external substantially horizontal force is applied in a direction towards the barrier member in the first position, the barrier member moves from the first position towards the second position. When the external horizontal force is discontinued, the biasing element returns the barrier member to the first position.
[0015] According to still further features in the described preferred embodiments rotation of the barrier pivot axis is controllable by a remote control mechanism.
[0016] According to still further features in the described preferred embodiments the driving mechanism comprises (i) a motor, (ii) a plurality of connected shafts and rods; and (iii) an electrical mechanism for powering of the motor.
[0017] According to still further features in the described preferred embodiments the electrical mechanism includes a power source selected from the group consisting of a solar power source, a battery power source or a power source from a vehicle parked in the parking space.
[0018] According to still further features in the described preferred embodiments the device further comprises a detection mechanism, the detection mechanism capable of detecting an approaching vehicle. The detection mechanism further comprises a warning mechanism for warning a driver of the approaching vehicle that the barrier member is in the first position.
[0019] According to still further features in the described preferred embodiments the barrier member is manually operated in case of a malfunction of the driving mechanism.
[0020] According to still further features in the described preferred embodiments wherein resistance of an obstructing object during movement of the barrier member automatically reverses the direction of movement of the barrier member.
[0021] According to still further features in the described preferred embodiments the surface is a surface selected from the group consisting of a floor, a parking lot ground, a ceiling, a wall and a post.
[0022] According to still further features in the described preferred embodiments the electrical mechanism is powered by an electrical source from the ceiling.
[0023] According to still further features in the described preferred embodiments the first position of the barrier member is a vertical position and the second position of the barrier is a horizontal position.
[0024] According to still further features in the described preferred embodiments the electrical mechanism is powered by an item selected from the group consisting of a battery and an AC electrical power source.
[0025] According to still further features in the described preferred embodiments the device further includes a biasing element for retaining the barrier member in the first position
[0026] According to still further features in the described preferred embodiments the AC electric power source is located in the ceiling.
[0027] The present invention successfully addresses the shortcomings of the presently known configurations by providing a collapsible barrier which is used to prevent a car being stolen and can also be used to guard a parking place for a vehicle when the car is not in the parking place.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] 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.
[0029] In the drawings:
[0030] [0030]FIG. 1 a is a schematic representation of a vehicle approaching a parking space with an anti-car-theft device in a vertical position;
[0031] [0031]FIG. 1 b is a schematic representation of a vehicle in a parking space with an anti-car-theft device in a horizontal position;
[0032] [0032]FIG. 1 c is a schematic representation of an anti-car-theft device in a vertical position;
[0033] [0033]FIG. 1 d is a schematic representation of an anti-car-theft device in a vertical position showing it on its way to being in a horizontal position;
[0034] [0034]FIG. 1 e is a schematic representation of an anti-car-theft device in a horizontal position;
[0035] [0035]FIG. 2 is an isometric view of an anti-car-theft device in a vertical position viewed from above with the cover removed allowing view of internal working parts;
[0036] [0036]FIG. 3 is an isometric view of an anti-car-theft device in a horizontal position during exertion of an external horizontal force viewed from above with the cover removed allowing view of internal working parts;
[0037] [0037]FIG. 4 a is a schematic representation of a ceiling mounted anti-car-theft device; and
[0038] [0038]FIG. 4 b is a schematic representation of a covered parking lot with numerous anti-car-theft devices installed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] The present invention is of an anti-theft device. Specifically, the present invention is of a collapsible barrier that can be used to prevent a car from being stolen. The present invention is further of a device which can be used to guard a parking place for a vehicle when the car is not in the parking place.
[0040] The principles and operation of an anti-theft device and parking space saver according to the present invention may be better understood with reference to the drawings and accompanying descriptions.
[0041] 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 drawings. 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.
[0042] For purposes of this specification and the accompanying claims, the term “surface ” includes but is not limited to floor, a parking lot ground, a ceiling, a wall and a post.
[0043] For purposes of this specification and the accompanying claims, the term “first position” generally refers to a perpendicular or vertical position of the barrier member in relationship to the barrier base member and “second position” generally refers to a parallel or horizontal position of the barrier member in relationship to the barrier base member.
[0044] Referring now to the drawings, FIG. 1 a illustrates a device for guarding a parking space 12 of a vehicle 14 within a parking area 16 . Parking area 16 includes at least one parking space 12 and at least one drive aisle 18 . Device 10 can be positioned at the entrance to a parking space 12 as illustrated which would provide protection for both a parked vehicle 14 and a parking space 12 in the absence of a vehicle 14 , or somewhere else inside parking space 12 where it would serve the purpose of reserving a parking space. In the alternative position within parking space 12 , device 10 will remain in the horizontal position and vehicle 14 is parked above device 10 . Device 10 includes a base member 20 secured onto or into a surface. Base member 20 engages and retains a barrier pivot axis 52 (FIG. 2). A barrier member 21 is integrally formed with barrier pivot axis 52 . A driving mechanism 43 reversibly rotates barrier pivot axis 52 from a “first” position to a “second” position. FIG. 1 a depicts a vehicle 14 approaching device 10 , which is in a “first” or vertical position. FIG. 1 b depicts vehicle 14 in parking space 12 after having driven over device 10 with barrier member 21 in a “second” or horizontal position. FIGS. 1 c, 1 d and 1 e depict barrier member 21 moving from a “first” or a vertical to a “second” or a horizontal position. The distal end 25 of barrier member 21 in the horizontal position is pointing away from the approach drive aisle 18 .
[0045] Barrier member 21 may be, for example, comprised of two arms 22 approximately perpendicular to the pivot axis 52 joined at a proximal end 23 to pivot axis 52 and joined at a distal end 25 by a bar 24 which is approximately parallel to barrier pivot axis 52 . In a preferred embodiment bar 24 serves as a sign such as a “reserved” sign. Alternatively, the two arms 22 are integrally formed with both barrier pivot axis 52 and bar 24 .
[0046] In another preferred embodiment, barrier member 21 is comprised of one arm approximately perpendicular to pivot axis joined at a proximal end to the pivot axis 52 .
[0047] In a preferred embodiment of this invention, a biasing element 58 retains barrier member 21 in the first position. When an external substantially horizontal force is applied in a direction towards barrier member 21 in the first position, barrier member 21 rotates about barrier pivot axis 52 at an acute angle from the first position to the second position. FIG. 3 illustrates device 10 in a second position during exertion of an external horizontal force. When the external horizontal force is discontinued, biasing element 58 returns barrier member 21 to the first position.
[0048] In a preferred embodiment of this invention, the movement of barrier member 21 is controlled by a remote control mechanism including a remote control sensor 26 which detects a signal emitted by remote control device 15 . Remote control mechanisms are commercially available and one ordinarily skilled in the art will be capable of selecting a commercially available mechanism and integrating it into the present invention.
[0049] [0049]FIG. 2 illustrates device 10 shown here from above with the lid 27 removed to expose internal working parts. Driving mechanism 43 includes a motor 42 . Operation of motor 42 rotates a threaded rod 44 in one direction in order moves barrier member 21 from a first position to a second position. Rotation of threaded rod 44 in an opposite direction by motor 42 moves barrier member 21 from a second position to a first position. Threaded rod 44 passes through a transfer rod 46 . Transfer rod 46 has a matching female threaded hole 41 through which threaded rod 44 traverses. Transfer rod 46 penetrates a pair of transfer clips 48 . Transfer clips 48 are permanently connected to a pivot axis sheath 50 . Pivot axis sheath 50 functions as a female sheath over the barrier pivot axis 52 . A pivot-connecting pin 66 through matching holes 64 in both pivot axis sheath 50 and pivot axis 52 joins pivot axis sheath 50 and pivot axis 52 . Barrier pivot axis 52 protrudes through base member 20 through exit hole 54 and is connected to the arm 22 of barrier member 21 . Only part of one arm 22 is shown here to expose additional parts.
[0050] In operation, when barrier member 21 is in the first position motor 42 rotates threaded rod 44 . As transfer rod 46 is not free to rotate because it is held in place by transfer clips 48 , threaded rod 44 advances through the female threading 41 of transfer rod 46 thus causing transfer rod 46 to move perpendicularly down threaded rod 44 toward motor 42 . This in turn causes transfer clips 48 to rotate perpendicularly to threaded rod 44 , which causes pivot axis sheath 50 and pivot axis 52 to rotate in the same direction. Pivot axis 52 being integrally connected to barrier arm 22 causes barrier arm 22 to descend into a second position as in FIG. 1 e.
[0051] On the other hand, when barrier member 21 is in the second position motor 42 rotates threaded rod 44 in the opposite direction. As transfer rod 46 is not free to rotate because it is held in place by transfer clips 48 , threaded rod 44 moves through the female threading of transfer rod 46 in the opposite direction thus actually causing transfer rod 46 to move perpendicularly up threaded rod 44 away from motor 42 . This in turn causes transfer clips 48 to rotate (in the opposite direction to the above mentioned descending of barrier arm 22 ), which as a result cause pivot axis sheath 50 and pivot axis 52 to rotate. Pivot axis 52 being integrally connected to barrier arm 22 causes barrier arm 22 to ascend into a first position.
[0052] The purpose of pivot connecting pin 66 and of having both pivot axis sheath 50 and pivot axis 52 is in case of a malfunction preventing driving mechanism 43 from moving the barrier member on the barrier pivot axis from the first position to the second position or vice-versa. In case of a malfunction a person removes the base member lid 27 by opening base member lid lock 28 and removing pivot connecting pin 66 . Barrier member 22 can then be manually pulled up or pushed down as needed.
[0053] A device in another preferred embodiment without the abovementioned malfunctioning function would not need pivot connecting pin 66 or pivot axis sheath 50 or matching holes 64 and in such a case, pivot axis 52 is connected directly to transfer clips 48 .
[0054] When there is resistance of an obstructing object during its movement, barrier member 22 automatically reverses the direction of movement by motor 42 .
[0055] Electrical mechanism 45 can be solar-powered or battery 40 powered (rechargeable or disposable), and in one preferred embodiment is recharged from vehicle 14 , parked in parking space 12 . In another preferred embodiment (FIG. 4 a ) ceiling mounted device 10 is powered by an alternating current source in the ceiling of the parking area. Electric switch-box 38 (FIG. 3) governs the entire electric operations of device 10 . Electric wiring 38 relays electricity to motor 42 and from sensor 26 .
[0056] Remote control sensor 26 in another embodiment of this invention detects approaching vehicle 14 . When vehicle 14 comes in close proximity to device 10 from either side and barrier member 21 is in a first position an audible alarm warning of a collision between vehicle 14 and barrier member 21 is sounded emanating either from an alarm in device 10 or from the remote control device 15 in vehicle 14 .
[0057] In a preferred embodiment remote control device 15 in vehicle 12 or alternatively a unit carried by a person constantly emits a signal. When vehicle 14 approaches device 10 remote control sensor 26 detects approaching vehicle 14 and automatically lowers barrier member 21 from a first position to a second position, thus avoiding any accidental collision by vehicle 14 with remote control device 15 . Sensors capable of detecting approaching objects are commonplace in many alarms and are well known to those skilled in the art of moving object detection.
[0058] In a preferred embodiment, there is a built-in mechanism for protecting both device 10 and cars inadvertently colliding with barrier member 21 while in the first position. Threaded rod 44 passes through a moveable transfer block 56 through which at least one biasing spring rod 60 (shown here in FIG. 2 as two rods) also pass. The distal ends of biasing spring rod 60 are permanently attached to a stationary end block 62 . A biasing element such as a spring 58 connects the back of moveable transfer block 56 to the front of stationary end block 62 . When an external horizontal force is applied to barrier member 21 , for example by a car backing up into barrier member 21 from the approach drive aisle 18 , barrier member 21 rotates in an acute angle towards the second position. It does this as barrier arm 22 rotates, barrier arm 22 also rotates pivot axis 52 , pivot axis sheath 50 and transfer clips 48 . Transfer clips 48 then is physically push transfer rod 46 back towards stationary end block 62 , causing moveable transfer block 56 to move closer to stationary end block 62 along biasing spring rod 60 . This in turn tensions spring 58 as illustrated in FIG. 3. Spring 58 is configured to be able to give only to strong forces such as vehicles and not to give way for a person pushing barrier member 21 down.
[0059] When the external horizontal force is discontinued, biasing element 58 returns barrier member 21 to a first position by pushing moveable transfer block 56 away from stationary end block 62 along biasing spring rod 60 back into its original position before the external force was applied. This in turn pushes transfer rod 48 which causes transfer clips 48 to rotate, which in turn rotates pivot axis sheath 50 and barrier pivot axis 52 causing barrier arm 22 to return to its first position.
[0060] In a preferred embodiment brake 70 physically prevents barrier member 21 from descending into a second position pointing away from parking space 12 . When a vehicle 14 enters the parking space by forcing device 10 into its second position, the vehicle will be stuck in the parking space until the device owner will release him.
[0061] Another preferred embodiment is FIG. 5 illustrates device 10 installed onto a ceiling 78 in a covered structure. In this embodiment device 10 is either mounted onto a ceiling or roof assembly 78 or suspended from a ceiling or a roof assembly to allow for ceiling obstructions such as conduit or pluming lines. Device 10 is suspended with the aid of a threaded rod assembly with base plates 80 . This embodiment has many advantages. Device 10 can be connected to the electric wiring 82 which runs through the ceiling anyway for example for lighting purposes without having to alter parking surface 12 . When the barrier members 21 are in a horizontal position, then mechanical sweeping of surfaces is much easier.
[0062] Numerous devices 10 can also be operated through a centralized control panel with audible alarm sounding in a parking office.
[0063] The present invention proposes some innovative design improvements making the barrier a stronger and safer barrier. In addition the present invention teaches a device for protecting a parking place within a covered parking lot, whereby a barrier is attached to a ceiling where it would be convenient to obtain an electric power source within the ceiling as well as making parking lot parking surface easy to clean.
[0064] 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.
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A device for prevention of theft of a vehicle and for keeping a parking space for a vehicle when the vehicle is not parked in the space. The device is a collapsible barrier controlled by a remote control. It has a novel mechanism of protecting accidental damage to cars and to the barrier itself. Protection is afforded by means of a biasing element built into the device which gives way when accidentally hit by an approaching car and then automatically returns to a vertical position. When the vehicle with the remote control approaches and is about to hit the barrier a warning alarm is sounded, or in another embodiment of this invention, the remote sensor in the device is automatically lowered when it senses the approaching vehicle. In another embodiment of this invention the collapsible barrier is secured onto a ceiling above a parking surface enabling a convenient electric source for the devices and easier maintenance and central control over numerous barriers placed in a large parking facility.
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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 multiple blade curtain, in particular a Venetian blind.
The problems which arise in using a Venetian blind installed on a window are known; among them, the most evident reside in the fact that such blinds require frequent cleaning operations and are often subject to accidental damage.
In order to overcome these problems, two kinds of solutions are mostly used at present: a first solution consists of accomodating the Venetian blind between two separate window-frames; the second entails the use of a single frame with double shutters, inside which the Venetian blind is inserted.
However, both these solutions present some disadvantages and inconveniences, such as a high cost and a considerable weight, as well as the fact that, since the accomodation is not hermetic, dust and condensed fumes can still deposit on the slats, thus requiring frequent cleaning operations which can cause damage to the blades. Conversely, since very frequent cleaning (or washing) cannot be performed, the aesthetical aspect of the blind is obviously compromised.
It should be furthermore noted that such known solutions also entail large dimensions and restrict the use of the product.
SUMMARY OF THE INVENTION
The main aim of the present invention is to eliminate the above described disadvantages of known Venetian blinds, by devising a blind which, by virtue of its peculiar characteristics, after being installed is not subject either to becoming dirty or to the possibility of accidental damage, so as to completely eliminate the need for cleaning or maintenance operations.
Within this aim, a particular object of the invention is to provide a Venetian blind which can be accommodated in a hermetical seat and nevertheless is provided with an operation system which allows a rapid and functional adjustment of packing and inclination of the blades, without jeopardizing tighteness of the accomodation.
Not least object is to devise a Venetian blind or the like having an accomodation with a very simplified structure, which can be easily obtained starting from commonly available elements, furthermore the Venetian blind should be able to have very small dimensions to allow a wide utilization.
The above aim and objects as well as others which will become apparent hereinafter, are achieved, according to the invention, by a Venetian blind characterized in that it is accommodated in the sealed interspace defined between two glass surfaces of a glass-box, said blind being provided with first control means for the adjustment of the inclination of the slats and second control means for the adjustment of the accumulator of the slats, said first and said second control means comprising first magnet which is movable inside said interspace and can be operated, by means of a magnetic coupling through one of said glass surfaces, by a second magnet, located outside said glass-box, said second control means comprising automatically variable counterwight means for maintaining the force required for accumulation of the slats at a constant minimum value.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will become apparent from the description of a preferred, but not exclusive, embodiment of a Venetian blind, according to the invention, illustrated only by way of non-limitative example in the accompanying drawing, where:
FIG. 1 is a front view of the entire Venetian blind;
FIG. 2 is a view of a peripheral portion of the blind of FIG. 1, illustrating the blade inclination control means;
FIG. 3 is a side view, in enlarged scale, of a detail of the control means shown in FIG. 2;
FIG. 4 is a view of a peripheral portion, opposite to the portion of FIG. 2, illustrating the blade packing control means;
FIG. 5 is a side view, in enlarged scale, of a detail illustrating the magnetic coupling for blade packing adjusting; and
FIG. 6 is a cross section view, in enlarged scale, along line VI--VI of FIG. 4, where the position of the upright of the window-frame has been indicated schematically by a broken line.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the figures, a Venetian blind according to the invention, generally indicated at 1, comprises a plurality of blades 2 forming blind slats and connected to the upper side 3 of a perimetral frame 4, suitably formed, as is better illustrated in FIG. 6, of a C-shaped profile having a thickness which is approximately the same as the inner interspace 5 of a glass-box 6 accomodating the frame 4.
This glass-box 6, as is known, essentially comprises of a pair of glass surfaces, respectively outer 7 and inner 8, kept spaced apart from one another by an aluminum framework 9 which contains a molecular sieve 10 and is sealingly connected to the glass surfaces by means of sealing elements 11.
The Venetian blind 1 is provided with slats inclination adjustment means which, as is better illustrated in FIG. 2, comprise a shaft 12, of a usual kind, extending inside the upper side 3 and bearing, rigidly connected thereto, supports 13 for winding thereon small cables 14 which, through their vertical motion, rotate all the blades 2 in a synchronized manner about a blade longitudinal axis.
According to the invention, the shaft 12 receives its motion from a second rotating shaft 15, which extends within a first side portion 16 of the frame 4, through an angular return transmission suitably comprising a toothed wheel 17 keyed onto the shaft 12 and meshing with an endless screw 18 provided in the upper end 19 of the second shaft 15. The second shaft 15 is internally threaded and, at its lower end 20, is engaged by a complementarily shaped helical rod-like element 21, with a suitable pitch, which bears, downwardly rigidly connected therewith, a first inner magnet 22.
This inner magnet 22 is associated with a second outer magnet 23, which is separated therefrom by the inner glass surface 8, so that by means of the magnetic connection therebetween it is possible to control rotation of the slats 2 from the outside.
Indeed, when the first external magnet 23 is moved vertically, it causes an equal movement of the inner magnet 22, and thus of the helical rod-like element 21, so that the second shaft 15 and therefore the first shaft 12 are caused to rotate in the desired direction.
It is thus evident that by moving the outer magnet 23 the desired orientation of the Venetian blind is achieved between a maximum darkening, at the two ends of the stroke, and a partial darkening at an intermediate level.
The Venetian blind 1 furthermore comprises control means which allow packing of the blinds 2 and therefore vertical extension of the blind to be varied from a total extension thereof, which corresponds to a complete darkening, up to the complete lifting, which corresponds to a full view.
Now with particular reference to FIGS. 4 and 5, the packing control means comprises a pair of cables 24 and 25 which are connected on one side to a rigid rod 26 which is located at the base of the blades 2 and which, after being wound on the respective guide or return pulleys 27 and 28, and on an idle roller 29, extend inside a second side portion 30 of the perimetral frame 4, connecting at the other end to an inner slider 31, suitably composed of two magnets 32 rigidly fixed to a metallic plate 33.
According to the invention, the inner slider 31 is magnetically connected, through the inner glass surface 8, to an outer slider 34 which is also advantageously formed by a pair of outer magnets 35 joined to a metallic bracket 36.
The stroke of the sliders 31 and 34 must be equal to the maximum extension of the blind 1, so that the motion of the inner slider 31, imparted from outside the glass-box 6 by means of a corresponding vertical motion of the outer slider 34, acting by means of the pair of cables 24 and 25, causes lifting or lowering of the rigid rod 26, accordingly varying the extension of the blind 1.
It should be pointed out that, for example during lifting of the rigid rod 26, more and more blades 2 gradually rest on it, starting from the lower ones; for this reason, the weight which must be lifted by means of the cables 24 and 25 depends on the extension of the blind 1 and, precisely, increases as the rigid rod 26 rises.
In other words, when the rod 26 is completely lowered the lifting force is mininal, while when the rod 26 is almost completely raised the force required for a further ascending motion is much greater.
To solve this problem, a counterweight is used, the action whereof depends on the position of the rigid rod 26, so as to keep constant the effort required to raise the Venetian blind 1.
According to the invention, the counterweight suitably comprises a track 37 which, connected at one first end 38 thereof to the inner slider 31, winds around the upper idle roller 29 and has the opposite end 39 connected to a return cable 40 which, by winding on a lower idle roller 41, is in turn connected to the inner slider 31.
For the sake of descriptive completeness, it should be furthermore observed that, in order to achieve optimum system balancing, it is appropriate for the weight of the inner slider 31 to be equal to the sum of the weight of the rigid rod 26 and of half the weight of all the blades 2, reaching this value with a possible addition of ballast; in this case the track 37 will have a length equal to the entire extension of the blind 1 and a weight equal to half the weight of all the blades 2.
In this manner, the system is exactly balanced in every position, and the sliders 31 and 34 may be placed at any intermediate level, with the blind 1 keeping the corresponding thus set extension.
In practice, it has been observed that a Venetian blind according to the invention presents remarkable advantages with respect to other known solutions, since dust is absolutely prevented from entering the interspace 5, due to the latter remaining perfectly sealed, and the blades 2 are permanent clean, thus eliminating the need for any subsequent cleaning operation.
The installation inside the glass-box 6 furthermore avoids that accidental deformations or breakages of the blades 2 may occur, and this, together with the foregoing, ensures a perfect unalterability of the Venetian blind 1 in time.
It should be furthermore observed that with a blind according to the invention the overall dimensions are reduced to a minimum and the weight is also consequently smaller, thus increasing the possible utilizations of the Venetian blind according to the invention.
A further advantage is determined by a low cost of installation, since with a single operation for fitting the glass-box, a Venetian blind is also simultaneously installed, thus eliminating the cost of a subsequent second fitting.
The costs can be reduced further by taking into account the fact that the use of a window-frame with a glass-box accommodating therein a Venetian blind according to the invention allows elimination of the outer blinds of the windows.
The invention thus conceived is susceptible to numerous modifications and variations, all of which are within the scope of the inventive concept.
Thus, for example, the shape of the perimetral frame 4 may vary; the helical rod-like element 21 may be replaced by a helical thin plate; the outer face of the glass surface 8 may be provided with any guiding elements slidably engaged by the outer magnet 23 and/or the outer slider 34; the structure of the track 37 may be any, so long as the indispensable balance relationships are respected, and moreover, the motion transmission between the magnets may be non-linear, but also, for example, of a rotary type, so long as the internal control means for adjusting the Venetian blind may be operated without direct physical contact.
Furthermore, in practice, the materials employed, so long as compatible with the contingent use, as well as the dimensions, may be any according to the requirements and to the state of the art.
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A Venetian blind is accommodated within the sealed interspace defined by the two glass surfaces of a glass-box including two or more glass surfaces spaced apart by an aluminum frame which contains the molecular sieve. The Venetian blind is provided with control members which allow adjustment of packing and/or inclination of its blades from outside the glass-box without altering the seal, and therefore the functionality, of the same. Operation from the outside of the control members inside the glass-box is achieved, for each adjustment, by magnetic coupling, through one of the glass surfaces of the glass-box, between a first magnet, positioned inside the glass-box and directly connected to the respective control system, and a second external magnet.
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TECHNICAL FIELD
One possible embodiment of the present disclosure relates, generally, to the field of producing hydrocarbons from subsurface formations. Further, one possible embodiment of the present disclosure relates, generally, to the field of making a well ready for production or injection. More particularly, one possible embodiment of the present disclosure relates to completion systems and methods adapted for use in wells having long lateral boreholes.
BACKGROUND
In petroleum production, completion is the process of making a well ready for production or injection. This principally involves preparing the bottom of the hole to the required specifications, running the production tubing and associated down hole tools, as well as perforating and/or stimulating the well as required. Sometimes, the process of running and cementing the casing is also included.
Lower completion refers to the portion of the well across the production or injection zone, beneath the production tubing. A well designer has many tools and options available to design the lower completion according to the conditions of the reservoir. Typically, the lower completion is set across the production zone using a liner hanger system, which anchors the lower completion equipment to the production casing string.
Upper completion refers to all components positioned above the bottom of the production tubing. Proper design of this “completion string” is essential to ensure the well can flow properly given the reservoir conditions and to permit any operations deemed necessary for enhancing production and safety.
In cased hole completions, which are performed in the majority of wells, once the completion string is in place, the final stage includes making a flow path or connection between the wellbore and the formation. The flow path or connection is created by running perforation guns into the casing or liner and actuating the perforation guns to create holes through the casing or liner to access the formation. Modern perforations can be made using shaped explosive charges.
Sometimes, further stimulation is necessary to achieve viable productivity after a well is fully completed. There are a number of stimulation techniques which can be employed at such a time.
Fracturing is a common stimulation technique that includes creating and extending fractures from the perforation tunnels deeper into the formation, thereby increasing the surface area available for formation fluids to flow into the well and avoiding damage near the wellbore. This may be done by injecting fluids at high pressure (hydraulic fracturing), injecting fluids laced with round granular material (proppant fracturing), or using explosives to generate a high pressure and high speed gas flow (TNT or PETN, and propellant stimulation).
Hydraulic fracturing, often called fracking, fracing or hydrofracking, is the process of initiating and subsequently propagating a fracture in a rock layer, by means of a pressurized fluid, in order to release petroleum, natural gas, coal steam gas or other substances for extraction. The fracturing, known colloquially as a frack job or frac job, is performed from a wellbore drilled into reservoir rock formations. The energy from the injection of a highly pressurized fluid, such as water, creates new channels in the rock that can increase the extraction rates and recovery of fossil fuels.
The technique of fracturing is used to increase or restore the rate at which fluids, such as oil or water, or natural gas can be produced from subterranean natural reservoirs, including unconventional reservoirs such as shale rock or coal beds. Fracturing enables the production of natural gas and oil from rock formations deep below the earth's surface, generally 5,000-20,000 feet or 1,500-6,100 meters. At such depths, there may not be sufficient porosity and permeability to allow natural gas and oil to flow from the rock into the wellbore at economic rates. Thus, creating conductive fractures in the rock is essential to extract gas from shale reservoirs due to the extremely low natural permeability of shale. Fractures provide a conductive path connecting a larger area of the reservoir to the well, thereby increasing the area from which natural gas and liquids can be recovered from the targeted formation.
Pumping the fracturing fluid into the wellbore, at a rate sufficient to increase pressure downhole, until the pressure exceeds the fracture gradient of the rock and forms a fracture. As the rock cracks, the fracture fluid continues to flow farther into the rock, extending the crack farther. To prevent the fracture(s) from closing after the injection process has stopped, a solid proppant, such as a sieved round sand, can be added to the fluid. The propped fracture remains sufficiently permeable to allow the flow of formation fluids to the well.
The location of fracturing along the length of the borehole can be controlled by inserting composite plugs, also known as bridge plugs, above and below the region to be fractured. This allows a borehole to be progressively fractured along the length of the bore while preventing leakage of fluid through previously fractured regions. Fluid and proppant are introduced to the working region through piping in the upper plug. This method is commonly referred to as “plug and perf.”
Typically, hydraulic fracturing is performed in cased wellbores, and the zones to be fractured are accessed by perforating the casing at those locations.
While hydraulic fracturing can be performed in vertical wells, today it is more often performed in horizontal wells. Horizontal drilling involves wellbores where the terminal borehole is completed as a “lateral” that extends parallel with the rock layer containing the substance to be extracted. For example, laterals extend 1,500 to 5,000 feet in the Barnett Shale basin. In contrast, a vertical well only accesses the thickness of the rock layer, typically 50-300 feet. Horizontal drilling also reduces surface disruptions, as fewer wells are required. Drilling a wellbore produces rock chips and fine rock particles that may enter cracks and pore space at the wellbore wall, reducing the porosity and/or permeability at and near the wellbore. The production of rock chips, fine rock particles and the like reduces flow into the borehole from the surrounding rock formation, and partially seals off the borehole from the surrounding rock. Hydraulic fracturing can be used to restore porosity and/or permeability.
Conventional lateral wells are completed by inserting coiled tubing or a similar, generally flexible conduit therein, until the flexible nature of the tubing prevents further insertion. While coil tubing does not require making up and/or breaking out each pipe joint, coiled tubing cannot be rotated, which increases the likelihood of sticking and significantly reduces the ability to extend the pipe laterally. Once a certain depth is reached in a highly angled and/or horizontal well, the pipe essentially acts like soft spaghetti and can no longer be pushed into the hole. Coiled tubing is also more limited in terms of pipe wall thickness to provide flexibility thereby limiting the weight of the string.
Conventional completion rigs include a mast, which extends upward and slightly outward typically at approximately a 3 degree angle from a carrier or similar base structure. The angled mast provides that cables and/or other features that support a top drive and/or other equipment can hang downward from the mast, directly over a wellbore, without contacting the mast. For example, most top drives and/or power swivels require a “torque arm” to be attached thereto, the torque arm including a cable that is secured to the ground or another fixed structure to counteract excess torque and/or rotation applied to the top drive/power swivel. Additionally, a blowout preventer stack, having sufficient components and a height that complies with required regulations, must be positioned directly above the wellbore. A mast having a slight angle accommodates for these and other features common to completion rigs. As a result, a rig must often be positioned at least four feet, or more, away from the wellbore depending on the height of the mast. A need exists for systems and methods having a reduced footprint, especially in lucrative regions where closer spacing of wells can significantly affect production and economic gain, and in marginal regions, where closer spacing of wells would be necessary to enable economically viable production.
Prior to common use of coiled tubing, completion operations often involved the use of workover/production rigs for insertion of successive joints of pipe, which must be threaded together and torqued, often by hand, creating a significant potential for injury or death of laborers involved in the completion operation, and requiring significant time to engage (e.g., “make up”) each pipe joint Drilling rigs could also be utilized to run production tubing but are more expensive although the individual joints of pipes result in the same types of problems.
A significant problem with prior art production/workover rigs or drilling rigs as opposed to coiled tubing units is that individual production tubing pipe connections are often considerably more difficult to make up and/or break out than the drilling pipe connections. Drilling pipe connections are enlarged and are designed for quick make up and break out many times with very little concern about exact alignment of the connectors. Drill pipe is designed to be frequently and quickly made up and broken out without being damaged even if the alignment is not particularly precise. On the other hand, production tubing is normally intended for long term use in the well and requires much more accurate alignment of the connectors to avoid damaging the threads. Production tubing does not typically utilize the expensive enlarged connectors like drill pipe and, in some completions, enlarged connectors simply are not feasible due to clearance problems within the wellbore. Thus, especially for production tubing, prior art workover/production rigs are much slower for inserting and/or removing production tubing pipe into or out of the well than coiled tubing units and are more likely to result in operator injuries and errors during pipe connection make up and break out than coiled tubing. There are also problems with human error in aligning the individual production tubing connectors whereby cross-threading could result in a damaged or leaking connection.
Prior art insertion techniques of completion tubing into a lateral well therefore suffers from significant limitations including but not limited to: 1) the longer time required to run tubing into a well; 2) operator safety; and 3) the maximum horizontal distance across which the tubing can be inserted is limited by the nature of the tubing used and/or the force able to be applied from the surface. Generally, once the frictional forces between the lateral portion of the well and the length of tubing therein exceed the downward force applied by the weight of the tubing in the vertical portion of the well, further insertion becomes extremely difficult, if not impossible, thus limiting the maximum length of a lateral.
Due to the significant day rates and rental costs when performing oilfield operations, a need exists for systems and methods capable of faster, yet safer insertion of pipe and/or tubing into a well. Additionally, due to the costs associated with the drilling, completion, and production of a well, a need exists for systems and methods capable of extending the maximum length of a lateral, thereby increasing the productivity of the well.
Hydraulic fracturing is commonly applied to wells drilled in low permeability reservoir rock. An estimated 90 percent of the natural gas wells in the United States use hydraulic fracturing to produce gas at economic rates.
The fluid injected into the rock is typically a slurry of water, proppants, and chemical additives. Additionally, gels, foams, and/or compressed gases, including nitrogen, carbon dioxide and air can be injected. Various types of proppant include silica sand, resin-coated sand, and man-made ceramics. The type of proppant used may vary depending on the type of permeability or grain strength needed. Sand containing naturally radioactive minerals is sometimes used so that the fracture trace along the wellbore can be measured. Chemical additives can be applied to tailor the injected material to the specific geological situation, protect the well, and improve its operation, though the injected fluid is approximately 99 percent water and 1 percent proppant, this composition varying slightly based on the type of well. The composition of injected fluid can be changed during the operation of a well over time. Typically, acid is initially used to increase permeability, then proppants are used with a gradual increase in size and/or density, and finally, the well is flushed with water under pressure. At least a portion of the injected fluid can be recovered and stored in pits or containers; the fluid can be toxic due to the chemical additives and material washed out from the ground. The recovered fluid is sometimes processed so that at least a portion thereof can be reused in fracking operations, released into the environment after treatment, and/or left in the geologic formation.
Advances in completion technology have led to the emergence of open hole multi-stage fracturing systems. These systems effectively place fractures in specific places in the wellbore, thus increasing the cumulative production in a shorter time frame.
Those of skill in the art will appreciate the present system which addresses the above and other problems.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of apparatus consistent with one possible embodiment of the present disclosure and, together with the detailed description, serve to explain advantages and principles consistent with the disclosure. In the drawings,
FIG. 1 illustrates an embodiment of a long lateral completion system usable within the scope of one possible embodiment of the present disclosure.
FIG. 2 is a perspective view of the mast assembly, pipe arm, pipe tubs, and the carrier of the long lateral completion system of FIG. 1 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 3 is a plan view of the carrier, mast assembly, pipe arm, and pipe tub of the long lateral completion system of FIG. 1 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 4 is an illustration of the carrier of the long lateral completion system of FIG. 1 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 4A-A is a cross sectional view of the carrier of FIG. 4 taken along the section line A-A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 4B-B is a cross sectional view of the carrier of FIG. 4 taken along the section line B-B in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 5 is an elevation view of the carrier, the mast assembly, the pipe arm and the pipe tubs of the long lateral completion system of FIG. 1 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 5A is an enlarged or detailed view of the section identified in FIG. 5 as “A” of the rear portion of the carrier engaged with a skid of the depicted long lateral completion system in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 6 illustrates an elevation view of the completion system of FIG. 1 with the mast assembly extended in a perpendicular relationship with the carrier and the pipe tubs in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 6A is an enlarged or detailed view of the portion of FIG. 6 indicated as section “A” illustrating the relationship of the mast assembly, the deck and the base beam in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 7 is an elevation view of the carrier, the mast assembly, the pipe arm, and the pipe tub of FIG. 1 , with the mast assembly shown in a perpendicular relationship with the carrier, and the pipe arm engaged with the mast in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 7A-A is a cross sectional view of FIG. 7 taken along the section line A-A showing the mast assembly and top drive of the depicted long lateral completion system in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 7B is a perspective view of the portion of the mast assembly and pipe arm illustrated in FIG. 7A-A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 8 is an elevation view of the completion system of FIG. 1 illustrating the mast assembly in a perpendicular relationship with the carrier, including the use of a hydraulic pipe tong in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 8A-A is a cross sectional view of the system of FIG. 8 taken along the section line A-A, showing the pipe tong with respect to the mast assembly in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 8B-B is a cross sectional view of the system of FIG. 8 taken along the section line B-B, showing the mast assembly and top drive in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 8C is a perspective view of the portion of the system shown in FIG. 8B in accord with one possible embodiment of the completion system of the present disclosure. FIG. 9 is an illustration of the long lateral completion system of FIG. 1 , depicting the relationship between the carrier, the mast assembly, the pipe arm, the pipe tubs and a blowout preventer in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 9A-A is a cross sectional view of the system of FIG. 9 taken along the section line A-A, illustrating the upper portion of the mast assembly in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 9B-B is a perspective view of the upper portion of the mast assembly as illustrated in FIG. 9A-A , showing the top drive and the pipe clamp in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 9C-C is a cross sectional view of the system of FIG. 9 taken along the section line C-C, illustrating the relationship of the blowout preventer to the completion system in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 10A is an illustration of an embodiment of a pipe tong fixture usable in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 10B is a perspective view of the pipe tong fixture of FIG. 10A .
FIG. 11A , FIG. 11B , FIG. 11C , and FIG. 11D illustrate an embodiment of a compact snubbing unit usable in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 12A is a schematic view of an embodiment of a control cabin usable in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 12B is an elevation view of the control cabin of FIG. 12A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 12C is a first end view (e.g., a left side view) of the control cabin of FIG. 12A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 12D is an opposing end view (e.g., a right side view) of the control cabin of FIG. 12A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 13 is an illustration of an embodiment of a carrier adapted for use in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 14 is an illustration of an embodiment of a pipe arm usable in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 14A depicts a detail view of an engagement between the pipe arm of FIG. 14 and an associated skid in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 15A is an elevation view of the pipe arm of FIG. 14 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 15B is an exploded view of a portion of the pipe arm of FIG. 15A , indicated as section “B” in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 15C is an enlarged or detailed view of a portion of the pipe arm of FIG. 15A , indicated as section “C” in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 15D is an enlarged or detailed view of a portion of the pipe arm of FIG. 15A , indicated as section “D” in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 15E is a plan view of the pipe arm of FIG. 14 in accord with one possible embodiment of the completion system of the present disclosure.
FIGS. 15F and 15G are end views of the pipe arm of FIG. 14 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 16A is an elevation view of the pipe arm of FIG. 14 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 16B is a plan view of the pipe arm of FIG. 14 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 16C is an enlarged or detailed view of a portion of the pipe arm of FIG. 16 A, indicated as section “C” in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 16D is an end view of the pipe arm of FIG. 14 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 17 is a perspective view of an embodiment of a kickout arm usable in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 17A is an enlarged or detailed view of an embodiment of a clamp of the kickout arm of FIG. 17 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 18A is an elevation view of the kickout arm of FIG. 17 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 18B is a bottom view of the kickout arm of FIG. 17 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 18C is a top view of the kickout arm of FIG. 17 in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 18B-B is a sectional view of the end taken along the section line B-B in FIG. 18B in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 18C-C is a cross sectional view of the kickout arm of FIG. 18C taken along the section line C-C in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 19A is an elevation view of an embodiment of a top drive fixture usable with the mast assembly of embodiments of the completion system in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 19B is a side view of the top drive fixture illustrated in FIG. 19A in accord with one possible embodiment of the completion system of the present invention.
FIG. 19C-C is a cross sectional view of the top drive fixture of FIG. 19B taken along the section line C-C in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 19D is an enlarged or detailed view of a portion of the top drive fixture of FIG. 19B indicated as section “D” in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 19E-E is a cross sectional view of the top drive fixture of FIG. 19A taken along the section line E-E in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 20A is an illustration of a top drive within the top drive fixture of FIG. 19A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 20 A-A is a cross sectional view of the top drive and fixture of FIG. 20A taken along section line A-A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 20B is a top view of the top drive and fixture of FIG. 20A in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 21A is a perspective view of a pivotal pipe arm having a pipe thereon with pipe clamps retracted to allow a pipe to be received into receptacles of the pipe arm in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 21B is a perspective view of a pivotal pipe arm having a pipe thereon with pipe clamps engaged with the pipe whereby the pipe arm can be moved to an upright position in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 22A is an end perspective view of a walkway with pipe moving elements whereby the pipe moving elements are positioned to urge pipe into a pipe arm in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 22B is an end perspective view of a walkway with pipe moving elements whereby a pipe has been urged into a pipe arm by pipe moving elements in accord with one possible embodiment of the completion system of the present disclosure.
FIG. 23A is an end perspective view of a pipe feeding mechanism whereby a pipe is transferred from a pipe tub into a pipe arm in accord with one possible embodiment of the present disclosure.
FIG. 23B is another end perspective view of a pipe feeding mechanism whereby a pipe is transferred from a pipe tub into a pipe arm in accord with one possible embodiment of the present disclosure.
FIG. 23C is a cross sectional view of a pipe feeding mechanism whereby a pipe is transferred from a pipe tub into a pipe arm in accord with one possible embodiment of the present disclosure.
FIG. 23D is a cross sectional view of a pipe feeding mechanism with the pipes removed in accord with one possible embodiment of the present disclosure.
FIG. 23E is a cross sectional view of a pipe feeding mechanism whereby a pipe is transferred from a pipe tub into a pipe arm in accord with one possible embodiment of the present disclosure.
FIG. 24A is a perspective view of an embodiment of a gripping apparatus engageable with a top drive of one possible embodiment of the present disclosure.
FIG. 24B depicts a diagrammatic side view of the gripping apparatus of FIG. 24A .
FIG. 25A is an exploded perspective view of a guide apparatus engageable with a top drive in accord with one possible embodiment of the present disclosure.
FIG. 25B is a diagrammatic side view of the guide apparatus of FIG. 25A .
FIG. 26 is a top view of a roller engaged with a guide rail in accord with one possible embodiment of the present disclosure.
FIG. 27A is a top view of a crown block sheave assembly showing an axis of rotation in accord with one possible embodiment of the present disclosure.
FIG. 27B is a top view of a traveling sheave block showing an axis of rotation in accord with one possible embodiment of the present disclosure.
FIG. 28A is a perspective view of a system for conducting a long lateral well completion system of multiple wellheads in close proximity in accord with one possible embodiment of the present invention.
FIG. 28B is another perspective view of a system for conducting a long lateral well completion system of multiple wellheads in close proximity in accord with one possible embodiment of the present invention.
The above general description and the following detailed description are merely illustrative of the generic invention, and additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention.
DESCRIPTION OF EMBODIMENTS
FIG. 1 illustrates an embodiment of a long lateral completion system 10 usable in accord with one possible embodiment of the completion system of the present disclosure. In this embodiment, the completion system 10 is shown having a mast assembly 100 , which extends in a generally vertical direction (i.e., perpendicular to the rig carrier 600 and/or the earth's surface), a pipe handling mechanism 200 , a catwalk-pipe arm assembly 300 , two pipe tubs 400 , a pump pit combination skid 500 , a rig carrier 600 usable to transport the mast assembly 100 and various hydraulic and/or motorized pumps and power sources for raising and lowering the mast assembly 100 and operating other rig components, and a control van 700 , used to control operation of one or more of the components of long lateral completion system 10 . Other embodiments may comprise the desired completion system 10 components otherwise arranged on skids as desired. For example, in another embodiment, separate pump and pit skids might be utilized. In another embodiment, catwalk pipe tubes with tube handling elements might be combined on one skid with pipe arm assembly 300 provided separately. It will be appreciated that many different embodiments may be utilized. Accordingly, FIG. 1 shows one possible arrangement of various components of the completion system 10 that can be implemented around a well (e.g., an oil, natural gas, or water well). Due to the construction, system 10 can work with wells that are in close proximity to each other, e.g. within ten feet of each other. For example, mast assembly 100 may be located above a first well, as discussed hereinafter, and rig floor 102 (if used) may be elevated above a second capped wellhead (not shown) within ten feet of the first well. Sensors, such as laser sights, guides mounted to the rear of rig carrier 600 , and the like may be utilized, e.g., mounted to and/or guided to the well head, to locate and orient the axis of drilling rig mast 100 precisely with respect to the wellbore, which in one embodiment may be utilized to align a top drive mounted on guide rails with the wellbore, as discussed hereinafter.
Control van 700 and automated features of system 10 can allow a single operator in the van to view and operate the truck mounted production rig by himself, including raising the derrick, picking up pipe, torqueing to the desired torque levels for tubing, going in the hole, coming out of the hole, performing workover functions, drilling out plugs, and/or other steps completing the well, which in the prior art required a rig crew, some problems of which were discussed above. In other embodiments, the control van 700 and/or other features can be configured for use and operation by multiple operators. Control van 700 may comprise a window arrangement with windows at the top, front, sides and rear (See e.g., FIG. 12B ), so that once positioned in a desired position on the well site, all operations to the top of mast 100 are readily visible.
For example, embodiments of the system 10 can be positioned for real time operation, e.g., by a single individual operating the control van 700 and/or a similar control system, and further embodiments can be used to perform various functions automatically, e.g., after calibrating the system 10 for certain movements of the pipe arm assembly 300 , the top drive or a similar type of drive unit along the mast assembly 100 , etc. After providing the system 10 in association with a wellbore, e.g., by erecting the mast assembly 100 vertically thereabove, a tubular segment can be transferred from one or more pipe tubs and/or similar vessels to the pipe arm assembly 300 , and the control van 700 and/or a similar system can be used to engage the tubular segment with a pipe moving arm thereof. For example, as described hereinafter, hydraulic members of the pipe tubs and/or similar vessels can be used to urge a tubular member over a stop into a position for engagement with a pipe moving arm, while hydraulic grippers thereof can be actuated to grip the tubular member. The control system can then be used to raise the pipe moving arm and align the tubular segment with the mast assembly, which can include extension of a kick-out arm from the pipe moving arm, further described below. Alignment of the tubular segment with the mast assembly could further include engagement of the tubular segment by grippers (e.g., hydraulic clamps and/or jaws) positioned along the mast. The control system is further usable to move the top drive along the mast assembly to engage the tubular segment (e.g., through rotation thereof), to disengage the pipe moving arm from the tubular, and to further move the top drive to engage the tubular segment with a tubular string associated with the wellbore. While the system is depicted having a pipe moving arm used to raise gripped segments of pipe into association and/or alignment with the mast, in other embodiments, a catwalk-type pipe handling system in which the front end of each pipe segment is pulled and/or lifted into a desired position, while the remainder of the pipe segment travels along a catwalk, can be used.
In an embodiment, any of the aforementioned operations can be automated. For example, the control system can be used to calibrate movement of the drive unit along the mast assembly, e.g., by determining a suitable vertical distance to travel to engage a top drive with a tubular segment positioned by the pipe moving arm, and a suitable vertical distance to travel to engage a tubular segment engaged by the top drive with a tubular string below, such that movement of a top drive between positions for engagement with tubular members and engagement of tubular members with a tubular string can be performed automatically thereafter. The control system can also be used to calibrate movement of the pipe moving arm between raised and lowered positions, depending on the position of the mast assembly 100 relative to the pipe arm assembly 300 after positioning the system 10 relative to the wellbore. Then, future movements of the pipe moving arm, and the kick-out arm, if used, can be automated. In a similar manner, grippers on the mast assembly 100 , if used, annular blowout preventers and/or ram/snubbing assemblies, and other components of the system 10 can be operated using the control system, and in an embodiment, in an automated fashion. After assembly of a completion string, further operations, such as fracturing, production, and/or other operations that include injection of substances into or removal of substances from the wellbore can be controlled using the control system, and in an embodiment, can be automated. In embodiments where a catwalk-type pipe handling system is used, operations of the catwalk-type pipe handling system can also be highly automated, including engagement of the front end of a pipe segment, lifting and/or otherwise moving the front end of the pipe segment, and the like.
FIG. 2 is a perspective view of the mast assembly 100 , catwalk-pipe arm assembly 300 , pipe tubs 400 , and the carrier 600 of the long lateral completion system 10 in accord with one possible embodiment of the completion system of the present invention. The carrier 600 has the mast assembly 100 extending from the rear portion of the carrier 600 . In one embodiment, the mast assembly 100 is essentially perpendicular to the carrier 600 . In another embodiment, mast assembly 100 is aligned either coaxially, within less than three inches, or two inches, or one inch to an axis of the bore through the wellhead, BOPs, or the like when the top drive is positioned at a lower portion of the mast and/or is parallel to the axis of the borehole adjacent the surface of the well and/or the bore of the wellhead pressure equipment within less than five degrees, or less than three degrees, or less than one degree in another embodiment. For example, in one embodiment, mast rails 104 , which guide top drive 150 , may be aligned to be essentially parallel to the axis of the bore, within less than five degrees in one embodiment, or less than three degrees, or less than one degree in another embodiment, whereby top drive 150 moves coaxially or concentric to the well bore within a desired tolerance. As used herein a well completion system may be essentially synonymous with a workover system or drilling system or rig or drilling rig or the like. The system of the present invention may be utilized for completions, workovers, drilling, general operations, and the like and the term workover rig, completing rig, drilling rig, completion system, intervention system, operating system, and the like are used herein substantially interchangeably for the herein described system. Pipe as used herein may refer interchangeably to a pipe string, a single pipe, a single pipe that is connected to or removed from a pipe string, a stand of pipe for connection or removal from a pipe string, or a pipe utilized to build a pipe string, tubular, tubulars, tubular string, oil country tubulars, or the like.
The carrier 600 is illustrated with a power plant 650 and a winch or drawworks assembly 620 . Winch or drawworks 620 can be utilized for lifting and lowering the top drive 150 in mast 100 utilizing pulley arrangements in crown 190 and blocks associated with top drive 150 . The mast positioning hydraulic actuators 630 provide for lifting the mast assembly 100 into a desired essentially vertical position, with respect to the axis of the borehole at the surface of the well, within a desired accuracy alignment angle. In one embodiment, a laser sight may be mounted to the wellbore with a target positioned at an upper portion of the mast to provide the desired accuracy of alignment. In this embodiment, crown laser alignment target 192 is provided adjacent crown 190 . The mast assembly 100 is affixed to the rear portion of the carrier 600 . Also the mast assembly 100 is illustrated with a top drive 150 and a crown 190 . The top drive allows rotation of the tubing, which results in significant improvement when inserting pipe into high angled and/or horizontal well portions. Further associated with the mast assembly 100 and the carrier 600 is a mast support base beam 120 for providing stability to the carrier 600 and the mast assembly 100 , e.g., by increasing the surface area that contacts the ground.
In one possible embodiment, a catwalk-pipe arm assembly 300 may be located proximate to the mast assembly 100 , which, in one possible embodiment, may be utilized to automatically insert and/or remove pipe from the wellbore. In one embodiment, the pipe is not stacked in the rig but instead is stored in one or more moveable pipe tubs 400 . Catwalk-pipe arm assembly 300 may be configured so that components are provided in different skids, as discussed hereinbefore, and as discussed hereinafter to some extent. In this example, catwalk-pipe arm assembly 300 has associated on either side thereof a pipe tub 400 . However, pipe tubes 400 may be used on only one side, two on one side, or any configuration may be utilized that fits with the well site. While more than two pipe tubes can be utilized, usually not more than four pipe tubs are utilized. However, pipe racks or other means to hold and/or feed pipe may be utilized. It can be appreciated that multiple pipe tubs 400 are provided for supplying multiple pipes to the catwalk-pipe arm assembly 300 . Pipe tubs 400 may or may not comprise feed elements, which guide each pipe as needed to roll across catwalk 302 to pivotal pipe arm 320 . Conceivably, means (not shown) may be provided which allow torqueing two or more pipes from associated pipe tubes for simultaneously handling stands of pipes utilizing pivotal pipe arm 300 for faster insertion into the well bore. However, in the presently shown embodiment, only one pipe at a time is typically handled by pipe arm 300 . When handling stands of pipe, then the correspondingly lengthened mast 100 may be carried in multiple carrier trucks 600 .
The pipe tubs are preferably capable of holding multiple joints of pipe for delivery to the pipe arm. The pipe tubs are further preferably capable of continuously lifting and feeding a section of pipe to the pipe arm. The pipe tubs in some embodiments can be positioned in an orientation substantially parallel to the pipe arm, so that the sections of pipe are in a length-wise orientation parallel to the pipe arm. A pipe tub may further comprise a hydraulic lifting system for raising the floor or bottom shelf of the pipe tub in an upwards direction away from the ground and additionally may be used to tilt the pipe tub, so as to lift and roll one or more sections of pipe into a position to be received by the pipe arm. The pipe tubs could additionally include a series of pins along the edge of the pipe tub closest to the pipe arm, which feeds the sections of pipe to the pipe arm. However, preferably the series of pins are disposed on the pipe arm skid at a location proximate to the adjacent edge of the pipe tubs. These pins serve the purpose of stopping or preventing a joint of pipe from rolling onto the pipe arm or pipe arm skid prematurely. Each pipe tub used in the pipe handling system can further incorporate one or more flipper arms, which are hydraulically actuated arms or plates to push or bump a section of pipe over the above mentioned pins when the pipe handling skid and pipe arm are in a position to receive the said section of pipe. Preferably, the pipe arm skid includes one or more flipper arms which pivotally rotate in an upward direction and which engage the joints of pipe to lift the joints of pipe over the pins retaining the joint(s) of pipe, whether the pins are disposed along the edge of the pipe arm skid or on the edge of the pipe tub. It can be appreciated that as an alternative to the pipe tubs 400 , pipe ramps, saw horses, or tables can be used. The selection of the apparatus (e.g. pipe tubs, ramps, saw horses, or tables) for delivery of pipe joints to the pipe arm depends on the physical layout of the surrounding area and if there are any obstructions or hazards that need to be avoided or overcome.
Various types of scanners such as laser scanners for bar codes, RFIDs, and the like may be utilized to monitor each pipe whereby the amount of usage, the length, torque history and other applied stresses, testing history of wall thickness, wear, and the like may be recorded, retrieved, and viewed. If desired, the pipe tub and/or catwalk may comprise sensors to automatically measure the length of each pipe. Thus, the operator in the van can automatically keep a pipe tally to determine accurate depths/lengths of the pipe string in the well bore. Torque sensors may be utilized and recorded so that the torque record shows that each connection was accurately aligned and properly torqued, and/or immediately detect/warn of any incorrectly made up connection.
FIG. 3 is a plan view of one possible embodiment of carrier 600 , mast assembly 100 , catwalk-pipe arm assembly 300 and pipe tub 400 of the long lateral completion system 10 pursuant to one possible embodiment of the present invention The carrier 600 is illustrated with the power plant 650 and the winch or drawworks assembly 620 The mast assembly 100 is disposed at a rear extremity of the carrier 600 and adjacent to the winch or drawworks assembly 620 In this embodiment, base beam 120 is disposed beneath and/or adjacent to the mast assembly 100 for providing security/stability for the mast assembly 100 Base beam 120 may comprise wide flat mats 122 , (also shown in FIG. 2 ), which are pushed downwardly by base beam hydraulic actuators 612 (shown in FIG. 2 and better shown in FIG. 8A-A ). In one possible embodiment, wide flat mats 122 may be 50 percent to 200 percent as wide as mast 100 Wide flat mats 122 may fold upon each other and/or extend telescopingly or slidingly outwardly from carrier 600 and/or hydraulically Wide flat mats 122 may be slidingly supported on beam runner 124 and may be transported on carrier 600 or provided separately with other trucks
In this embodiment, catwalk-pipe arm assembly 300 is affixed to mast assembly 100 and carrier 600 by rig to arm connectors 305 (also shown in FIG. 2 ) In this embodiment, catwalk-pipe arm assembly 300 is shown with a pipe tub 400 on both sides of the catwalk-pipe arm assembly 300 The pipe tubs 400 are shown with the side supports 402 , the end support 404 and a cavity 420 A plurality of pipes (not illustrated) is placed in the pipe tubs 400 Pipes are displaced on to the catwalk-pipe arm assembly 300 and lifted up to the mast assembly 100 . Catwalk 302 may be somewhat V-shaped or channeled to urge pipes to roll into the center for receipt and clamping, utilizing catwalk-pipe arm assembly 300 Catwalk 302 provides a walkway surface for workers and the like Additional pipe tubs 400 can be slid into place to provide for a continuum of pipe lengths for use by the completion system 10 Acoustic and/or laser and/or sensors or RFID transceivers 408 and 410 may be positioned on ends 404 and sides 402 of pipe tubs 400 , or elsewhere as desired, to measure and/or detect the lengths of the pipes, and to detect RFIDs, bar codes, and/or other indicators which may be mounted to the pipes Alternatively, pipe length sensors 412 , 414 may each comprise one or more sensors, which may be mounted to pipe arm 320 . In one embodiment, sensors 412 , 414 may comprise acoustic, electromagnetic, or light sensors which may be utilized to detect features such as length of the pipe. Pipe connection cleaning/grease injectors 416 , 418 may be provided for wire brushing, grease injecting, thread protector removal and other automated functions, if desired.
In one embodiment, sensors 412 , 414 may comprise thread protector sensors provided to ensure that the thread protectors have been removed from both ends of a pipe. Thread protectors are generally plastic or steel and used during transportation to prevent any damage to the threading of pipe. Damage as a result of faulty or damaged threads could jeopardize a well site and the safety of the workers therein. However, failing to remove a thread protector can cause the same potential dangers if not found before inserted into the pipe string. The pipe will not mate properly with the threads of the pipe string, compromising the integrity of the entire pipe string and well site. The thread protector sensors 412 , 414 may be acoustic sensors or lasers used to determine whether the thread protectors have been removed and communicate this data with the control system. If the thread protectors are present, an acoustic or light signal transmitted by sensor 412 may be reflected rather than received at sensor 414 . Alternatively, sensors 412 and 414 may be transceivers that will not receive a signal unless the thread protector is present. In another embodiment, a light detector will detect a different profile. In another embodiment, sensors 412 and 414 may comprise a camera in addition to other thread protector sensors. If the thread protectors have not been removed, an operator will be informed before attempting to make up the pipe connection so that the problem can be fixed.
In one possible embodiment, inner portion adjacent catwalk 302 and/or catwalk edges 301 and 307 may comprise gated feed compartments whereby pipes are fed into a compartment or funnel large enough for only single pipes or stands of pipes, and then gated to allow individual pipes or stands of pipes to be automatically rolled onto either side of catwalk 302 .
FIG. 4 is an illustration of the carrier 600 of the long lateral completion system 10 in accord with one possible embodiment of the completion system of the present disclosure. The carrier 600 is illustrated with the power plant 650 and the winch or drawworks assembly 620 . Also, the mast assembly 100 is illustrated in a lowered or horizontal position, which is essentially parallel relationship with the carrier 600 . Mast 100 is clamped into the generally horizontal position with carrier front clamp/support 633 above cab 605 . Mast 100 is hinged at mast to carrier pivot 634 so that the mast is secured from any forward/reverse/side-to-side movement with respect to carrier 600 during transport after being clamped at the front and/or elsewhere. In this embodiment, mast positioning hydraulic actuators 630 are pivotally mounted with respect to carrier walkway 602 so that when extended, the hydraulic actuators 630 are angled toward the rear instead of toward the front of carrier 600 as in FIG. 4 (See for example FIG. 2 ). In one embodiment, mast positioning hydraulic actuators 630 may comprise multiple telescopingly connected sections as shown in FIG. 6A . The horizontally disposed mast assembly 100 is illustrated for moving on the highway and for arrangement in the proximate location with respect to a wellbore. It will be noted that hydraulic pipe tongs 170 are mounted to mast 100 so that when the mast 100 is lowered pipe tongs 170 are in a position generally perpendicular to the operational position. Movements and actuation of the pipe tongs can be fully automated, for forming and/or breaking both shoulder connections and collared connections. The mast assembly 100 has the crown 690 extending in front of the carrier 600 . In one embodiment, rig carrier is less than 20 feet high, or less than 15 feet high, while still allowing the rig to work with well head equipment having a height of about 20 feet. This is due to the construction of the mast with the Y-frame connection as discussed herein. The rig floor can be adjusted to a convenient height and is not necessarily fixed in height. In an embodiment, the rig floor could be connected to snubbing jacks.
FIG. 4A-A is a top view taken along the line A-A in FIG. 4 of the mast assembly 100 of the long lateral completion system pursuant to one possible embodiment of the present invention. FIG. 4A-A illustrates a downward view of the mast assembly 100 . The mast assembly 100 shows the top drive assembly or fixture 150 (also shown in FIG. 4 ) affixed to the portion of the mast assembly 100 over the winch or drawworks assembly 620 over the carrier 600 . The top drive assembly or fixture 150 is provided at the location associated with the carrier 600 for distributing the load associated with the carrier 600 for easy transportation on the highway. Top drive or fixture 150 may be clamped or pinned into position with clamps or pins 162 or the like that are inserted into holes within mast 100 at the desired axial position along the length of mast 100 . Angled struts 134 (also shown in FIG. 4 ) on Y-section 132 , which may be utilized in one possible embodiment of mast 100 , are illustrated in the plan view. Top drive 150 is shown with end 163 , which may comprise a threaded connector and/or tubular guide member and/or pipe clamping elements and/or torque sensors and/or alignment sensors.
FIG. 4B-B is an end elevational view taken along the line B-B in FIG. 4 of the carrier 600 and the mast assembly 100 of the long lateral completion system 10 of in accord with one possible embodiment of the completion system of the present disclosure. FIG. 4B-B illustrates the carrier 600 , the winch or drawworks assembly 620 and the top drive 150 . In this view, vertical top drive guide rails 104 are shown, upon which top drive 150 is guided, as discussed hereinafter. In this embodiment, it will also be noted that top drive threaded connector and/or guide member and/or clamp portion 163 is positioned in the plane defined between vertical top drive guide rails 104 . In this embodiment, the view also shows one or more angled struts 134 , which may comprise Y section 132 of one possible embodiment of mast 100 , which is discussed in more detail with respect to FIG. 6A .
FIG. 5 is an elevation view of the carrier 600 , the mast assembly 100 , and the catwalk-pipe arm assembly 300 of the long lateral completion system 10 with respect to one possible embodiment of the present invention. The carrier 600 is illustrated with the power plant 650 and the winch or drawworks assembly 620 . The cable from drawworks 620 to crown 190 is not shown but may remain connected during transportation and raising of mast 100 . The drawworks cable may be pulled from drawworks 620 as mast 100 is raised. The mast assembly is illustrated engaged at the rear extremity of the carrier 600 . The mast assembly 100 is in a vertical arrangement such that it is at an essentially perpendicular relationship with the carrier 600 . The mast assembly 100 is illustrated with the top drive 150 in an upper position near the crown 190 . The pivotal pipe arm 320 is shown in an angled disposition slightly above catwalk 302 for clarity of view. Pivotal pipe arm 320 is shown with pipe 321 clamped thereto. The catwalk-pipe arm assembly 300 is engaged or connected via rig to arm assembly connectors 305 with the carrier 600 and the mast assembly 100 . Rig to arm assembly connectors 305 provide that the spacing arrangement between pivotal pipe arm 320 and mast 100 and/or carrier 600 is affixed so the spacing does not change during operation. Rig to arm assembly connectors 305 may comprise hydraulic operators for precise positioning of the spacing between mast 100 and pivotal pipe arm 320 , if desired.
FIG. 5A is an enlarged or detailed view of a section shown in FIG. 5 as the rear portion of the carrier 600 engaged with a skid or mast support base beam 120 of the long lateral completion system 10 with respect to one possible embodiment of the present invention. Mast positioning hydraulic actuators 630 are provided for lowering and raising the mast assembly 100 with respect to the carrier 600 , about mast to carrier pivot connection 634 . Brace 632 for Y-base or support section 130 provides additional support for mast 100 .
FIG. 6 illustrates the completion system 10 in a side elevational view with the mast assembly 100 extended in a perpendicular relationship with the carrier 600 and the pipe tubs 400 of the long lateral completion system 10 with respect to one possible embodiment of the present invention. The pivotal pipe arm 320 is angularly disposed with respect to the catwalk 302 . The mast assembly 100 is illustrated with the top drive 150 slightly below the crown 190 . Alternately, and not required in practicing the present disclosure, guy wires 101 can be engaged between the crown 190 of the mast assembly 100 and the carrier 600 on one extreme and the remote portion of a pipe tube 400 on the other extreme. However, one or more guy wires could be anchored to the ground and/or may not be utilized. One or more guy wires can also be secured to the ends of base beam 120 . It can be appreciated that the rigidity of the mast assembly 100 with respect to the carrier 600 and the base beam 120 does not require guy wires 101 . However, it may be appropriate in a particular situation or in severe weather conditions to adapt the present disclosure for use with such guy wires 101 . The carrier is illustrated with the power plant 650 and the winch or drawworks assembly 620 on the carrier deck 602 .
FIG. 6A is an enlarged or detailed view of the portion of FIG. 6 illustrating the relationship of the mast assembly 100 , the deck 602 and the base beam 120 of the long lateral completion system 10 with respect to one possible embodiment of the present invention. FIG. 6A shows the relationship of the mast assembly 100 , the deck 602 of the carrier 600 and the base beam 120 . It will be noted that base beam widening sections 121 may extend or slide outwardly from base beam 120 and be pinned into position with pin 123 . Also illustrated is what may comprise multiple segments of mast positioning hydraulic actuators 630 for angularly disposing the mast assembly 100 in a proximately perpendicular relationship with the carrier 600 , and aligned with respect to the well bore, as discussed hereinbefore. Above the deck 602 of the carrier and affixed with the mast assembly 100 is a hydraulic pipe tong 170 . The hydraulic pipe tong 170 is usable for handling the pipe as it is placed into a well, e.g., by receiving joints of pipe from the pipe arm and/or the top drive. The lower extremity of the mast assembly 100 includes a y-base 130 , which defines a recessed region above the wellbore at the base of the mast assembly 100 , for accommodating a blowout preventer stack, snubbing equipment, and/or other wellhead components. The recessed region enables the generally vertical mast assembly 100 to be positioned directly over a wellbore without causing undesirable contact between blowout preventers and/or other wellhead components and the mast assembly 100 .
The lower extremity of the mast assembly 100 is defined by the y-base 130 . The y-base 130 provides a disposed arrangement for making and inserting pipe using the completion system 10 in accord with one possible embodiment of the completion system of the present invention. Y-base 130 supports Y section 132 , which extends angularly with angled strut 134 out to support one side of mast 100 . This construction provides an opening or space 136 for the BOP assembly, such as BOP (see FIG. 9 ), snubbing unit (see FIG. 11A ), Christmas tree, well head, and/or other pressure control equipment. Mast 100 is supported by carrier to mast pivot connection 634 and at the carrier 600 rearmost position by mast support plate 636 (also shown in FIG. 4 ). Mast support plate 636 may be shimmed, if desired. In another embodiment, mast support plate may be mounted to be slightly moveable upwardly or downwardly with hydraulic controls to support the desired angle of mast 100 , which as discussed above may be oriented to a desired angle (e.g. less than five degrees or in another embodiment less than one degree) with respect to the axis of the bore of the well bore and/or bore of BOP 900 , shown in FIG. 9 . In this embodiment, mast support plate 636 does not extend horizontally and rearwardly from carrier 600 , as far as the other mast 100 horizontal supports, e.g., horizontal mast supports or struts 140 . This construction allows the opening or space 136 for the BOP (see FIG. 9 ), snubbing unit (see FIG. 11A ), Christmas tree, well head, and/or other pressure control equipment. However, the mast construction is not intended to be limited to this arrangement.
In other words, Y-base 130 back most rail 138 is horizontally offset closer to carrier 600 than back most vertical mast supports 105 with respect to carrier 600 . Y-base 130 is sufficiently tall to allow BOP stacks to fit within opening or space 136 . However, Y-base 130 is replaceable and may be replaced with a higher or shorter Y-base as desired. to accommodate the desired height of any pressure control and/or well head equipment. In this example, the bottoms of Y-base 130 may be replaceably inserted/removed from Y-base receptacles 142 to allow for easy removal/replacement of Y-base 130 from carrier 600 .
As discussed hereinafter, vertical mast supports 105 support vertical top drive guide rails 104 (see FIG. 4 B-B and FIG. 8 B-B), which guide top drive 150 . An optional raiseable/lowerable rig floor, such as rig floor 102 (See FIG. 1 ) is not shown for viewing convenience.
FIG. 7 is a side elevational view of the carrier 600 , the mast assembly 100 , the catwalk-pipe arm assembly 300 , and the pipe tub 400 with the mast assembly 100 (e.g., transporting a joint of pipe to the mast assembly 100 for engagement by the top drive) in a perpendicular relationship with the carrier 600 , and an arm to mast engagement element 325 of the pivotal pipe arm 320 engaged with optional upper mast fixture 135 on mast assembly 100 of the long lateral completion system 10 with respect to one possible embodiment of the present disclosure. The engagement of elements 325 and 135 may be utilized to provide an initial alignment of the pivotal connection of kick out arm 360 to pivotal pipe arm 320 . Kick out arm 360 is shown pivotally rotated to a vertical position so that pipe 321 is aligned for connection with top drive 150 , as discussed hereinafter. The carrier 600 is illustrated with the winch assembly 620 on the deck 602 . The depicted hydraulic actuator 630 has raised the mast assembly 100 into its vertical position, as discussed hereinbefore. The mast assembly 100 is illustrated with the top drive 150 near the crown 190 . The kickout arm 360 of the catwalk-pipe arm assembly 300 may be more accurately vertically placed in the extended position adjacent to the mast assembly 100 , having a kickout arm 360 in association therewith. As such, when the pipe arm 320 pivots into the position shown in FIG. 7 (e.g., using the hydraulic cylinder 304 ), the pipe arm 320 is not parallel with the mast assembly 100 , thus a joint of pipe engaged with the pipe arm 320 would not be positioned suitably for engagement with the top drive 150 . The kickout arm 360 is extendable from the pipe arm 320 into a position that is generally parallel with the mast assembly 100 , e.g., by use of a hydraulic actuator 362 . Using the kickout arm 360 , the pipe 321 is placed in the position which is essentially parallel with the mast assembly 100 , and in this embodiment is positioned in the plane defined by mast rails 104 (See FIG. 4B-B ), which guide top drive 150 , by use of the hydraulic actuator 362 . The movement of the pivotal pipe arm 320 is provided by the hydraulic actuator 304 .
In one possible embodiment, the upright position of pivotal pipe arm 320 is controlled by angular sensors 325 and/or shaft position sensors 326 (see FIG. 16A ) to account for any variations in hydraulic operator 304 operation.
Alternatively, or in addition, upper mast fixture 135 may comprise a receptacle and guide structure. In this embodiment, which may be provided to guide the top of pivotal pipe arm 320 into contact with mast 100 , whereby the same vertical/side-to-side positioning of kick out arm 360 is assured in the horizontal and vertical directions. The guide elements may, if desired, comprise a funnel structure that guides arm to mast engagement element 325 into a relatively close fitting arrangement. If desired, a clamp and/or moveable pin element (with mating hole in pivotal pipe arm) may be utilized to pin and/or clamp pivotal pipe arm 320 into the same position for each operation. In another embodiment upper mast fixture may comprise a hydraulically operated clamp with moveable elements that clamp the pipe in a desired position for aligned engagement with top drive threaded connector and/or guide member and/or clamp portion 163 . As shown in FIG. 7A-A , upper fixture 135 may also comprise one or more pipe alignment guide members/clamps/supports as indicated at 139 to position pipe 321 and/or kickout arm 360 to thereby align pipe 321 and pipe connector 323 with respect to top drive threaded connector and/or guide member and/or clamp portion 163 . Element 139 may comprise a moveable hydraulic clamp or guide to affix and align the pipe in a particular position. Element 139 may instead comprise a fixed groove or slot or guide and may be hydraulically moveable to a laser aligned position.
As a result, top connector 323 on tubing pipe 321 is aligned to top drive threaded connector and/or guide member and/or clamp portion 163 , as discussed in more detail hereinafter, by consistent positioning of kick out arm 360 . It will be appreciated that rig to arm connectors 305 further aid alignment by insuring that the distance between catwalk-pipe arm assembly 300 and mast 100 remains constant.
FIG. 7A-A is a rear elevational view of FIG. 7 showing the mast assembly 100 and top drive 150 of the long lateral completion system 10 with respect to one possible embodiment of the present disclosure. FIG. 7A-A illustrates the portion of the mast assembly 100 , which includes the top drive 150 , and the upper portion of the pivotal pipe arm 320 . Also illustrated are the lattice structural support elements 112 of the mast assembly 100 . The top drive 150 is shown secured within a top drive fixture/carrier 151 , which can be moved vertically along the mast assembly 100 , e.g., via a rail/track-in-channel engagement using rollers, bearings, etc. Due to the generally vertical orientation of the mast assembly 100 , and the positioning of the mast assembly 100 directly over the wellbore, the top drive 150 can be directly engaged with the mast assembly 100 , via the top drive fixture 151 , as shown, rather than requiring use of conventional cables, traveling blocks, and other features required when an angled mast is used. Engagement between the top drive 150 and the mast assembly 100 via the top drive fixture 151 eliminates the need for a conventional cable-based torque arm. Contact between the top drive 150 and the fixture 151 prevents undesired rotation and/or torqueing of the top drive 150 entirely, using the structure of the mast assembly 100 to resist the torque forces normally imparted to the top drive 150 during operation.
FIG. 7B is a perspective view of the portion of the mast assembly 100 and pivotal pipe arm 320 with clamps 370 B engaged with upper fixture 135 as illustrated in FIG. 7A-A of the long lateral completion system 10 with respect to one possible embodiment of the present invention. The mast assembly 100 is illustrated with the top drive 150 positioned a selected distance the pipe arm 300 .
FIG. 8 is a side elevational view of the completion system 10 in accord with another embodiment of the present disclosure illustrating the mast assembly 100 in a perpendicular relationship with the carrier 600 and/or aligned with an axis of the upper portion of the wellbore. The carrier 600 is shown with the deck 602 and the mast positioning hydraulic actuators 630 providing movement for the mast assembly 100 mast to carrier pivot connection 634 . The mast assembly 100 has the top drive 150 disposed proximate to the crown 190 . As discussed hereinafter, crown 190 may comprise multiple pulleys that are utilized to raise and lower the blocks associated with top drive 150 utilizing drawworks 620 . The pipe arm 320 is extended in an upward position using the pipe arm hydraulic actuator 304 . Further, the kickout arm 360 is disposed in a parallel relationship with the mast assembly 100 using the kick out arm hydraulic alignment actuator 362 to align pipe 321 appropriately with respect to the mast assembly 100 , e.g., in one embodiment the pipe is positioned in the plane defined between mast top drive rails 104 . Mast top drive rails 104 (shown in FIG. 8B-B ) are secured to an inner portion of the two rear most (with respect to carrier 600 ) vertical supports 105 of mast 100 .
FIG. 8A-A shows another view of Y section 132 , which comprises one or more angled struts 134 on each side of mast 100 utilized to support vertical mast supports 105 . Pipe tong 170 is aligned within the plane between guide rails 104 to thereby be aligned with top drive threaded connector and/or guide member and/or clamp portion 163 (see FIG. 8B-B and FIG. 4B-B ) of top drive 150
FIG. 8B-B is a rear elevational view of the mast assembly 100 and top drive 150 of the long lateral completion system 10 (shown in FIG. 8 ) with respect to one possible embodiment of the present invention. FIG. 8B-B illustrates the relationship of pivotal pipe arm 320 , the top drive 150 and the mast assembly 100 . Further, the lattice support structure 112 is illustrated for providing superior rigidity to and for the mast assembly 100 .
FIG. 8C is a perspective view of FIG. 8B-B of the relationship between the pivotal pipe arm 320 and the top drive 150 relative to the mast assembly 100 of the long lateral completion system with respect to one possible embodiment of the present invention. Also illustrated is the pipe clamp 370 associated with the pivotal pipe arm 300 for holding a joint of pipe. In an embodiment, a joint of pipe raised by the pipe arm 300 then extended using the kickout arm 360 may require additional stabilization prior to threading the pipe joint to the top drive. Additional pipe clamps along the mast assembly 100 can be used to receive and engage the joint of pipe while the pipe clamp 370 of the pipe arm 300 is released, and to maintain the pipe directly beneath the top drive 150 for engagement therewith.
Returning again to FIG. 8A-A , the figure depicts a sectional view of FIG. showing the pipe tong 170 with respect to the mast assembly 100 of the long lateral completion system with respect to one possible embodiment of the present invention. FIG. 8A-A illustrates the relationship of the hydraulic pipe tong 170 with respect to the mast assembly 100 and the base beam 120 . The mast assembly 100 is supported by braces 112 . The braces 112 can be at various locations about the system 10 as one skilled in the art would appreciate.
FIG. 9 is an illustration of the long lateral completion system 10 of the present enclosure that depicts an embodied relationship of the carrier 600 , the mast assembly 100 , catwalk-pipe arm assembly 300 , the catwalk 302 and a blowout preventer and snubbing stack 900 of the long lateral completion system 10 with respect to one possible embodiment of the present disclosure. As described previously, the mast assembly 100 is disposed in a generally vertical orientation (e.g., perpendicular to the earth's surface and/or the deck 602 ), such that the mast assembly 100 is directly above the blowout prevent and snubbing stack 900 with the wellbore therebelow. The recessed region at the base of the mast assembly 100 accommodates the blowout preventer and snubbing stack 900 , while the top drive 150 disposed near the crown 190 of the mast assembly 100 can move vertically along the mast assembly 100 while remaining directly over the well.
The mast assembly 100 can be moved and maintained in position by the hydraulic actuators 630 and/or other supports. The pipe arm 300 can be moved and maintained in the depicted raised position via extension of the hydraulic actuator 304 . The kickout arm 360 pivots from the top of pivotal pipe arm using the hydraulic system 362 for aligning a joint of pipe in alignment with the well and BOP and snubbing stack 900 , which may utilize sensors 902 , 904 , 906 , 908 , for example, laser alignment sensors 902 mounted on BOP and snubbing stack 900 , 904 on kickout arm 360 , and/or laser alignment sensors 906 on top drive 150 . It should be appreciated that the kick-out arm can be extended or retracted through the use of hydraulic system 362 and may be connected through manual actuation of hydraulic/pneumatics or through an electronic control system, which maybe be operated through a control van or remotely through an Internet connection. This particular embodiment implements the use of a kick-out arm 360 to provide a substantially vertical joint of pipe for reception by the mast assembly 100 , which may include a top drive of some configuration. It is important that the joint of pipe be substantially vertical so that the threads on each joint are not cross-threaded when the connection to the top drive is made. Cross-threading can lead to catastrophic failure of the connected joints of pipe or damage the threads of the joint of pipe and render the joint of pipe unusable without extensive and costly repair. As mentioned above, the pipe arm 300 can further include a centering guide, which is capable of mating with a centering receiver located on the mast assembly 100 . This centering guide and centering receiver, when used provides an additional point of contact between the pipe arm 300 and the mast assembly 100 providing additional stability to the system and more precise placement and orientation of the pipe arm and joints of pipe.
FIG. 9A-A is a sectional view of FIG. 9 illustrating the upper portion of the mast assembly 100 of the long lateral completion system 10 with respect to one possible embodiment of the present invention. One possible embodiment of the relationship of the pipe arm 300 and the clamp 370 is shown. Also, the lattice support 112 for providing rigidity for the mast assembly 100 is illustrated. The top drive 150 is retained by the fixture 151 , which is moveably disposed along the mast assembly 100 .
FIG. 9B is a perspective view of the upper portion of the mast assembly 100 as illustrated in FIG. 9A-A , showing the top drive 150 and the upper mast fixture 135 of the long lateral completion system with respect to one possible embodiment of the present invention. The pipe arm 300 is shown below the top drive 150 . The pipe clamp 370 enables removable engagement between pipe arm 300 , and a joint of pipe, which said joint of pipe is engaged by the top drive 150 , and alternately one or more clamps or similar means of engagement along the mast assembly 100 , or other engagement systems associated with the mast assembly 100 and/or the top drive 150 , can be used to assist with the transfer of the joint of pipe from the pipe arm 300 to the top drive 150 .
FIG. 9C-C is a sectional view of FIG. 9 illustrating the relationship of the blowout preventer and snubbing stack 900 with respect to the completion system 10 of one possible embodiment of the present invention. The blowout preventer and snubbing stack 900 is shown directly underneath the mast assembly 100 , and thus directly adjacent to the rig carrier, such that the hydraulic pipe tong 170 can be operatively associated with joints of pipe added to or removed from a string within the wellbore. The mast assembly 100 can be secured using the adjustable braces 612 attached to the base plate 120 . As another example, mast top drive guide rails 104 , which guide top drive 150 may be aligned to be essentially parallel to the axis of the bore of BOP, within less than five degrees in one embodiment, or less than three degrees, or less than one degree in another embodiment. Accordingly, top drive threaded connector and/or guide member and/or clamp portion 163 (See FIG. 4B-B ) is also aligned to move up and down mast 100 essentially parallel or coaxial to the axis of the bore of BOP, within less than five degrees in one embodiment, or less than three degrees, or less than one degree in another embodiment. The blowout preventer and/or other pressure equipment may comprise pipe clamps and seals to clamp and/or seal around pipe as is well known in the art. As discussed hereinafter, a snubbing jack may comprise additional clamps and hydraulic arms for moving pipe into and out of a well under pressure, which is especially important when the pipe string in the hole weighs less than the force of the well pressure acting on the pipe, which would otherwise cause the pipe to be blown out of the well.
Specifically, the blowout preventer of the BOP and snubbing stack 900 is shown having a first set of rams 1012 positioned beneath a second set of rams 1014 , the rams 1012 , 1014 usable to shear and/or close about a tubular string, and/or to close the wellbore below, such as during emergent situations (e.g., blowouts or other instances of increased pressure in the wellbore). Above the first and second set of rams 1012 , 1014 , a snubbing assembly can be positioned, which is shown including a lower ram assembly 1016 positioned above the rams 1014 , a spool 1018 positioned above the lower ram assembly 1014 , an upper ram assembly 1020 positioned above the spool 1018 , and an annular blowout preventer 1022 positioned above the upper ram assembly 1018 . In an embodiment, the upper and lower ram assemblies 1020 , 1016 and/or the annular blowout preventer 1022 can be actuated using hydraulic power from the mobile rig, while the first and second set of rams 1012 , 1014 of the blowout preventer can be actuated via a separate hydraulic power source. In further embodiments, multiple controllers for actuating any of the rams 1012 , 1014 , 1016 , 1018 and/or the annular blowout preventer 1022 can be provided, such as a first controller disposed on the blowout preventer and/or snubbing assembly and a second controller disposed at a remote location (e.g., elsewhere on the mobile rig and/or in a control cabin). During snubbing operations, the upper and lower ram assemblies 1020 , 1016 and/or the annular blowout preventer 1022 can be used to prevent upward movement of tubular strings and joints, while during non-snubbing operations, the upper and lower ram assemblies 1020 , 1016 and annular blowout preventer 1022 can permit unimpeded upward and downward movement of tubular strings and joints. Typically, the annular blowout preventer 1022 can be used to limit or eliminate upward movement of tubular strings and/or joints caused by pressure in the wellbore, though if the annular blowout preventer 1022 fails or becomes damaged, or under non-ideal or extremely volatile circumstances, the upper and lower ram assemblies 1020 , 1016 can be used, e.g., in alternating fashion, to prevent upward movement of tubulars. As such, the depicted snubbing assembly (the ram assemblies 1020 , 1018 and annular blowout preventer 1022 ) can remain in place, above the blowout preventer, such that snubbing operations can be performed at any time, as immediately as necessary, without requiring rental and installation of third party snubbing equipment, which can be limited by equipment availability, cost, etc. In an embodiment, the upper and lower ram assemblies 1020 , 1018 can be used as stripping blowout preventers during snubbing operations. Additionally, while the figures depict a single ram-type blowout preventer in the BOP and snubbing stack 900 having two sets of rams 1012 , 1014 , in various embodiments, additional blowout preventers could be used as safety blowout preventers, which can include pipe blowout preventers, blind blowout preventers, or combinations thereof.
Due to the clearance provided in the recessed region defined by the Y-base 132 and support section 130 , the snubbing assembly can remain in place continuously, beneath the vertical mast, without interfering with operations and/or undesirably contacting the top drive or other portions of the mobile rig. Further, the clearance provided in the recessed region can enable a compact snubbing unit (e.g., snubbing jacks and/or jaws) to be positioned above the annular blowout preventer 1022 , such as the embodiment of the compact snubbing unit 800 , described below, and depicted in FIGS. 11A through 11D .
FIG. 9C-C also shows a first hydraulic jack 1024 A positioned at the lower end of the Y-base 132 , on a first side of the rig, and a second hydraulic jack 1024 B positioned at the lower end of the Y-base 132 , on a second side of the rig. The hydraulic jacks 1024 A, 1024 B are usable to raise and/or lower a respective side of the rig to provide the rig with a generally horizontal orientation. For example, while FIG. 1 depicts an embodiment the long lateral completion system 10 having a mast assembly 100 and a pipe handling system (e.g., skid 200 , system 300 , and tubs 400 ) positioned at ground level, each component having a lower surface contacting the upper surface of the well (e.g., the earth's surface), the hydraulic jacks 1024 A, 1024 B can be used to maintain a ground level rig in an operable, horizontal orientation, independent of the grade of the surface upon which the rig is operated.
FIG. 10A and FIG. 10B provide an illustration of one possible embodiment for mounting pipe tong 170 utilizing the pipe tong fixture 172 to support pipe tong 170 at a desired vertical distance in mast 100 from BOPs, such as the blowout preventer 900 shown in FIG. 9C-C , and with respect to a co-axial orientation with respect to the bore of the BOPs. Pipe tongs 170 may be moved in/out and up/down. The pipe tong fixture comprises one or more pipe tong vertical support rails 176 , two pipe tong horizontal movement hydraulic actuators 178 in association with a horizontal pipe support 174 for displacing the pipe tong 170 . It will be appreciated that fewer or more than two pipe tong horizontal movement hydraulic actuators 178 could be utilized. In this embodiment, horizontal support 174 may comprise telescoping and/or sliding portions, which engagingly slide with respect to each other, namely square outer tubular component 175 and square inner tubular component 177 , which move slidingly and/or telescopingly with respect to each other. In this embodiment, components 175 and 177 are concentrically mounted with respect to each other for strength but this does not have to be the case. Accordingly, pipe tong 170 is moved slidingly or telescopically horizontally back and forth as shown by comparison of FIGS. 10A and 10B . In FIG. 10A , pipe tong 170 is shown in a first horizontal position moved laterally away from pipe tong vertical support rails 176 . In FIG. 10B , pipe tong 170 is shown in a second horizontal position moved laterally or horizontally toward pipe tong vertical support rails 176 . In this way, pipe tong 170 can be moved in the desired direction to position pipe tong 170 concentrically around the pipe from the bore through BOP 900 . It will be noted that here as elsewhere in this specification, terms such as horizontal, vertical, and the like are relevant only in the sense that they are shown this way in the drawings and that for other purposes, e.g. transportation purposes as shown in FIG. 4 with the rig collapsed and hydraulic tongs oriented vertically as compared to their normal horizontal operation, hydraulic actuators 178 would then move pipe tong 170 vertically. It will also be understood that multiple tongs may be utilized on such mountings, if desired, in other embodiments of the invention, e.g. where a rotary drilling rig were utilized with the pipe tong mounting on a moveable carrier. If desired, additional centering means may be utilized to move pipe tong horizontally between vertical supports 176 to provide positioning in three dimensions
FIG. 10B is a perspective view of the pipe tong fixture 172 as illustrated in FIG. 10A of the blowout preventer with respect to the completion system of one possible embodiment of the present invention whereby pipe tong 170 is moved vertically downwardly along pipe tong vertical support rails 176 . Vertical sliding supports 179 permit pipe tong frame 181 , which comprise various struts and the like, to be moved upwardly and downwardly. Extensions 183 may be utilized in mounting support rails 176 to mast 100 and/or may be utilized with clamps associated with vertical sliding supports 179 for affixing pipe tong frame 181 to a particular vertical position. Pipe tong frame 181 may be lifted utilizing lifting lines within mast 100 and/or by connection with the blocks and/or top drive 150 and/or by hydraulic actuators (not shown).
FIG. 11A , FIG. 11B , FIG. 11C , and FIG. 11D illustrate one possible embodiment for a compact snubbing unit 800 , usable with the completion system 10 of the present disclosure, e.g., by securing the snubbing unit 800 above the blowout preventer and snubbing stack 900 (shown in FIG. 9 ). However, snubbing unit 800 is simply shown as an example of a snubbing jack and other types of snubbing jacks may be utilized in accord with the present invention. Generally, a snubbing jack will have a movable gripper, which may be mounted on a plate that is movable with respect to a stationary gripper. At least one gripper will hold the pipe at all times. The grippers are alternately released and engaged to move pipe into and out of the wellbore under pressure. If not for this type of arrangement, when the string is lighter than the force applied by the well, the string would shoot uncontrollably out of the well. When the string is lighter than the force applied by the well, this example of snubbing jack 800 can be utilized to move pipe into or out of the well in a highly controlled manner, as is known by those of skill in the art. In another embodiment, an additional set of pulleys (not shown) might be utilized to pull top drive downwardly (while the existing cables remain in tension but slip at the desired tension to prevent the cables from swarming). Once the pipe is heavier than the force of the well, then the normal operation of top drive may be utilized for insertion and removal of pipe so long as the pipe string is preferably significantly heavier than the force acting on the pipe string. In this example, the grippers of snubbing jack 800 also provide a back up in case of a sudden increase in pressure in the well. The compact (but extendable) snubbing unit 800 can be sized to fit within the recessed region of the mast assembly 100 , to prevent undesired contact with the mast assembly 100 even when the snubbing jack is in an extended position. In this example, the depicted snubbing unit 800 includes a first horizontally disposed plate member 802 , which is a vertically moveable plate, and a second horizontally disposed plate member 804 , which is a fixed plate with respect to the wellhead, displaced by vertical columns or stanchions 806 and 808 . The lower and/or possibly upper portion of columns or stanchions 806 and 808 may comprise hydraulic jacks members which can be utilized for hydraulically moving plate member 802 upwardly and downwardly with respect to plate member 804 and may be referred to herein as hydraulic jacks 806 and 808 . Also, in this example, between the first member 802 and the second member 804 is an intermediate member 803 . In this example, between the first member 802 and the intermediate member 803 is a first engaging mechanism 820 for engaging and/or clamping and/or advancing or withdrawing pipe. Between the intermediate member 803 and the second member 804 is a second engaging mechanism 830 for engaging and advancing, or withdrawing pipe. In one embodiment, both plates 802 and 803 are vertically moveable with respect to plate 804 whereby both clamps (i.e., engaging mechanisms) 820 and 830 are used at the same time. Accordingly, in one embodiment, both plates 802 and 803 move together. In another embodiment, grippers (i.e., engaging mechanisms) 820 and 830 may be moveable with respect to each other. In one possible mode of operation, the clamping mechanisms 820 , 830 can be used to grip a joint of pipe and exert a downhole force or upward force thereto, counteracting a force applied to the string due to pressure in the wellbore. Because the force of the snubbing jack unit 800 is selected to exceed the pressure from the wellbore, joints can be added or removed from a completion string even under adverse, high pressure conditions. The BOPs or other control equipment, positioned below the snubbing jack 800 , can seal around the pipe as it is moved into and out of the wellbore by snubbing jack 800 . Thus, grippers 820 and 830 may be engaged and hydraulic jacks within stanchions 806 and 808 may be expanded to remove pipe from the well or force pipe into the well. The hydraulic jacks may be contracted to move pipe into the well or pull pipe out of the well in a controlled manner. Other grippers within the BOPs may be utilized to hold the pipe, when grippers 820 and 830 are released and moveable plates 802 and/or 803 are moved to a new position for grasping the pipe to move the pipe into or out of the borehole as is known to those of skill in the art. In one embodiment of the present invention, the computer control of the control van is utilized to control the grippers 820 , 830 , and the hydraulic jacks 806 and 808 , and other grippers and seals in the BOPs to provide automated movement of the pipe into or out of the wellbore. This movement may be coordinated with that of the top drive and tongs for adding pipe or removing pipe. Thus, the entire process or portions of the process of going into the hole with snubbing units may be automated. However, it will be understood that at least two separate grippers or sets of grippers are required for a snubbing unit. If the top drive is connected to be able to apply a downward force then another stationary set of grippers is required. In addition, multiple sealing mechanisms such as rams, inflatable seals, grease injectors, and the like, may be utilized to open and close around sections of pipes so that larger joints and the like may be moved past the sealing mechanisms in a manner where at least one seal or set of seals is always sealed around the pipe string in a manner than allows sliding movement of the pipe string. The control system of the present invention is programmed to operate the entire system in a coordinated manner. In addition to or in lieu of the snubbing unit 800 and/or the snubbing assembly depicted and described above, various embodiments of the present system can include a full-sized snubbing unit, e.g., similar to a rig assist unit.
FIG. 12A depicts a schematic view of an embodiment of a control cabin 702 of the long lateral completion system 10 with respect to the present disclosure. The control cabin 702 comprises a command station 710 . The command station 710 comprises a seat 712 , control 714 , monitor 716 and related control devices. Further, the control cabin 702 provides for a second seat 715 in association with a monitor, and, optionally, a structure for supporting other related monitoring and/or control activities 722 , 724 , and a third seat 718 in association with yet another monitor. The control cabin 702 has doors for exiting the cabin area and accessing a walkway 720 disposed around the perimeter of the control cabin 702 .
In one embodiment, command station 710 is positioned so that once control van 700 is oriented or positioned with respect to mast 100 (See FIG. 1 ), carrier 600 , catwalk and pipe handling assembly 300 , and/or pump/pit 500 , then all mast operations can be observed through command station front windows 730 as well as command station top windows 732 . Front windows 730 , for example, allow a close view of rig operations at the rig floor. Top windows 732 allow a view all the way to the top of mast 100 . In one embodiment, additional command station side and rear windows 740 , side windows 742 (depicted in FIG. 12C ), 744 (depicted in FIG. 12D ) will allow easy observation of other actions around mast 100 . If desired, control van 700 may be positioned as shown in FIG. 1 and/or adjacent pump/pit combination skid 500 . If desired, additional cameras may be positioned around the rig to allow direct observation of other components of the rig, e.g., pump/pit return line flow or the like.
The control van 700 may include a scissor lift mechanism to lift and adjust the yaw of command station 710 . A scissor lift mechanism is a device used to extend or position a platform by mechanical means. The term “scissor” is derived from the mechanism used, which is configured with linked, folding supports in a crisscrossed “X” pattern. An extension motion or displacement motion is achieved by applying a force to one of the supports resulting in an elongation of the crossing pattern supports. Typically, the force applied to extend the scissor mechanism is hydraulic, pneumatic or mechanical. The force can be applied by various mechanisms such as by way of example and without limitation a lead screw, a rack and pinion system, etc.
For example with loading applied at the bottom, it is readily determined that the force required to lift a scissor mechanism is equal to the sum of the weights of the payload, its support, and the scissor arms themselves divided by twice the tangent of the angle between the scissor arms and the horizontal. This relationship applies to a scissor lift mechanism that has straight, equal-length arms, i.e., the distance from an actuator point to the scissors-joint is the same as the distance from that scissor-joint to the top load platform attachment. The actuator point can be, by way of examples, a horizontal-jack-screw attachment point, a horizontal hydraulic-ram attachment point or the like. For loading applied at the bottom, the equation would be F=(W+Wa)/2 Tan Φ. The terms are F=the force provided by the hydraulic ram or jack-screw, W=the combined weights of the payload and the load platform, Wa=the combined weight of the two scissor arms themselves, and is the angle between the scissor arm and the horizontal.
And for loading applied at the center pin of the crisscross pattern, the equation would be F=W+(Wa/2)/Tan Φ. The terms are F=the force provided by the hydraulic ram or jack-screw, W=the combined weights of the payload and the load platform, Wa=the combined weight of the two scissor arms themselves, and is the angle between the scissor arm and the horizontal.
FIG. 12B is an elevation view of the control cabin 702 of the completion system 10 of one possible embodiment of the present invention. The command station 710 the walkway 720 and exterior controls 726 .
FIG. 12C is an end view of the control cabin 702 of the completion system 10 of one possible embodiment of the present invention. FIG. 12C illustrates the command station 710 in association with the control cabin 702 . The walkway 720 is also illustrated.
FIG. 12D is an end view of the control cabin 702 taken from the alternate perspective as that of FIG. 12C of the completion system of one possible embodiment of the present invention. The outer controls 726 are illustrated.
FIG. 13 is an illustration of the carrier 600 adapted for use with the completion system 10 of one possible embodiment of the present invention. The carrier comprises a cabin 605 , a power plant 650 , and a deck 610 . Foldable walkway 602 folds up for transportation and then when unfolded extends the walkway space laterally to the side of carrier 600 . Winch assembly 620 can be mounted along slot 622 at a desired axial position at any desired axial position along the length of carrier 600 . Winch or drawworks assembly 620 may or may not be mounted to a mounting such as mounting 624 , which is securable to slot 620 . Mounting 624 may be utilized for mounting an electrical power generator or other desired equipment. Recess 626 may be utilized to support mast positioning hydraulic actuators 630 , which are not shown in FIG. 13 . One or more stanchions 614 (e.g., a Y-base) are illustrated for engaging the mast assembly 100 with the carrier 600 , wherein the mast can be supported by carrier to mast pivot connection 634 and at the carrier 600 rearmost position by mast support plate 363 (also shown in FIG. 4 as 636 ).
FIG. 14 is an illustration of the catwalk-pipe arm assembly 300 of the completion system 10 of one possible embodiment of the present invention. The catwalk-pipe arm assembly 300 is illustrated with a ground skid 310 , pipe arm hydraulic actuators 304 for lifting the pivotal pipe arm 320 and the kickout arm 360 attached thereto. The kickout arm 360 can subsequently be extended the central pipe arm 320 using additional hydraulic cylinders disposed therebetween.
In yet another embodiment, a pivotal clamp could be utilized at 312 in place of the entire kick arm 360 whereby orientation of the pipe for connection with top drive 150 may utilize upper mast fixture 135 and/or mast mounted grippers and/or guide elements.
In one embodiment, catwalk 302 may be provided in two elongate catwalk sections 309 and 311 on either side of pivotal pipe arm 320 for guiding pipe to and/or away from pivotal pipe arm 320 . However, only one elongate section 309 or 311 might be utilized. Catwalk 302 provides a walkway and a catwalk is often part of a rig, along with a V-door, for lifting pipes using a cat line. To the extent desired, catwalk 302 may continue provide this typical function although in one possible embodiment of the present invention, pivotal pipe arm 320 is now preferably utilized, perhaps or perhaps not exclusively, for the insertion and removal of tubing from the wellbore.
In one possible embodiment of catwalk 302 , each catwalk section 309 and 311 may comprise multiple catwalk pipe moving elements 314 which move the pipes toward or away from pivotal pipe arm 320 and otherwise are in a stowed position, resulting in a relatively smooth catwalk walkway. Referring to FIG. 15F and F 15 G, FIG. 21A , and FIG. 21B , catwalk pipe moving hydraulic controls 333 may be utilized to independently tilt catwalk pipe moving elements 314 upwardly or downwardly, as indicated. On the left of FIG. 15F , catwalk pipe moving element 314 is in the stowed position flat with catwalk 309 . On the right of FIG. 15F , catwalk pipe moving element 314 is tilted inwardly to urge pipes toward pivotal pipe arm 320 . In FIG. 15G , catwalk pipe moving elements are both tilted away from pipe moving element 314 to urge pipes away from pivotal pipe arm 320 . However, each group of catwalk pipe moving elements 314 on each of catwalks 309 and 311 operate independently. In one embodiment, by tilting pipe moving elements 314 away from pivotal pipe arm 320 , the pipe moving elements 314 operate in synchronized fashion with pipe ejector direction control which directs pipe away from pipe arm 320 in a desired direction as indicated by arrows 377 A and 377 B (see FIG. 17 ), as discussed hereinafter.
In another embodiment, each entire elongate catwalk section 309 and 311 could be pivotally mounted on skid edges 301 and 307 . Accordingly, due to the pivotal mounting discussed previously or in accord with this alternate embodiment, catwalk sections 309 may be selectively utilized to urge pipes toward or away from pivotal pipe arm 320 . However, in yet another embodiment the catwalks may also be fixed structures so as to either slope towards or away from pivotal arm 320 or may simply be relatively flat.
In yet another embodiment, at least one side of catwalk 302 (catwalk sections 309 and/or 311 ) may be slightly sloped inwardly or downwardly toward pivotal pipe arm 320 to urge pipe toward guide pipe for engagement with pivotal pipe arm 320 . In one embodiment, pipe tubs 400 and/or one or both sides of catwalk 302 (and/or catwalk pipe moving elements 314 ) include means for automatically feeding pipes onto catwalk 302 for insertion into the wellbore, which operation may be synchronized for feeding pipe to or ejecting pipe from pivotal pipe arm 320 . In another embodiment, at least one side of catwalk 302 and/or catwalk pipe moving elements 314 , may also be slightly sloped slightly downwardly towards at least one of pipe tubs 400 to urge pipes toward the respective pipe tub when pipe is removed from the well. In one embodiment, one pipe tub may be utilized for receiving pipe while another is used for feeding pipe. In another embodiment, catwalk 302 may simply provide a surface with elements (not shown) built thereon for urging the pipe to or from the desired pipe tub 400 .
In yet another embodiment, catwalk 302 , which may or may not be pivotally mounted and/or comprise catwalk pipe moving elements 314 , may be provided as part of the pipe tub and may not be integral or built onto the same skid as pivotal pipe arm 320 . In yet another embodiment, the pipes may be manually fed to and from the pipe tubs or pipe racks to pivotal pipe arm 320 via catwalk 302 .
FIG. 14A is a blowup view of the lower pipe arm pivot connection 313 upon which the pivotal pipe arm 320 is lifted for the catwalk-pipe arm assembly 300 . The lower pipe arm pivot connection 313 comprises a bearing 306 and a shaft or pin 308 which provides a pivot point for the pivotal pipe arm 320 with respect to the pipe arm ground skid 310 .
FIG. 15A is an elevation view of the catwalk-pipe arm assembly 300 of the completion system 10 of one possible embodiment of the present invention. The catwalk-pipe arm assembly 300 comprises the central arm 320 , a kickout arm 360 and one or more clamps 370 A, 370 B, 370 C for engaging a pipe “P.” The catwalk-pipe arm assembly 300 is rotationally moved or pivoted with respect to lower pipe arm pivot connection 313 using the hydraulic actuators 304 . In this embodiment, pivotal pipe arm 320 comprises a grid comprising plurality of pipe arm struts 364 .
FIG. 15B is an enlarged or detailed view of the section “B” of pivot connection 313 as illustrated in FIG. 15A of the completion system of one possible embodiment of the present invention. The pivotal pipe arm 320 is pivotally moved using a bearing 306 in association with a shaft or pin 308 . Control arm 315 , to which pivot arm struts 317 (See also FIG. 15A ) are affixed, pivots about lower pipe arm pivot connection 313 .
FIG. 15C is an enlarged or detailed view of section “C” illustrated in FIG. 15A of the completion system of one possible embodiment of the present invention, which shows control arm to hydraulic arm pivot connection 319 . Piston 323 of the hydraulic cylinder of hydraulic actuator 304 is pivotally engaged with control arm 315 using the pin 327 .
FIG. 15D is an enlarged or detailed view of the section indicated by “D” in FIG. 15A of the completion system of one possible embodiment of the present invention, which shows the hydraulic cylinder of hydraulic actuator 304 pivotal connection 329 . FIG. 15D shows the engagement of the hydraulic cylinder with the skid using the pin 331 .
FIG. 15E is a plan view of the catwalk-pipe arm assembly 300 of the completion system 10 of one possible embodiment of the present invention. The catwalk-pipe arm assembly 300 comprises the pivotal pipe arm 320 in association with the skid 310 . The arm has engaged with it a kickout arm 360 which is pivotally moved with the hydraulic actuator 362 . The pivotal pipe arm 320 is pivotally moved with the hydraulic actuator 304 . The kickout arm has clamps 370 A, 370 B for engaging a piece of pipe “P.”
FIG. 16A is an elevation view of the pivotal pipe arm 320 of the completion system 10 of one possible embodiment of the present invention, without the catwalk 302 for easier viewing. Pivotal pipe arm 320 comprises an elongate lower pipe arm section 322 which is pivoted using the hydraulic actuators 304 . Lower pipe arm section 322 is secured to y-joint connector 324 , which in turn connects to pivot arm Y arm strut components 326 A and 326 B (depicted in FIG. 16B ). The Y arm strut components 326 A and 326 B are connected to control arms 315 , which are in moveable engagement with the hydraulic actuators 304 . An extension (not shown) may be utilized to engage upper mast fixture 135 , if desired, to provide a preset starting position from which kickout arm 360 pivots outwardly to align with the top drive 150 .
The elongate kickout arm 360 secures a piece of pipe “P” using a plurality of pipe clamps 370 , which are labeled 370 A and 370 B at the bottom and top (when upright) of kickout arm 360 . Pipe ejector direction control 371 acts to eject the pipe from pivotal arm 320 in a desired direction when the pipe is laid down adjacent catwalk 302 , as discussed hereinafter.
FIG. 16B is a plan view of the pivotal pipe arm 320 , as illustrated in FIG. 16A for the completion system 10 of one possible embodiment of the present invention, showing only the pipe arm components for convenience. In one possible embodiment, upper pipe arm section 340 may also incorporate kickout arm 360 . In this embodiment, kickout arm 360 remains generally parallel to pivotal pipe arm 320 except when pivotal pipe arm 320 is moved into the upright position shown in FIG. 7 , FIG. 8 , and FIG. 9 . Upon reaching the upright position, kickout arm 360 is pivoted using the hydraulic actuators 362 , which cause kickout arm 360 to pivot away from pipe arm 360 about kickout arm pivot connection 312 ( FIG. 16C ) at the top of pivotal pipe arm 320 . The kickout arm 360 is shown with the clamps 370 A and 370 B at the bottom and top (when vertically raised) of kickout arm 360 as well as pipe ejector direction control 371 , which may be positioned more centrally, if desired.
FIG. 16C is an enlarged or detailed view of the section “C” as illustrated in FIG. 16A for the completion system 10 of one possible embodiment of the present invention, which shows kick arm pivot connection 312 ( FIG. 16C ) at the top of pivotal pipe arm 360 . FIG. 16C shows the pivotal pipe arm 320 in association with an upper portion of kickout arm 360 (when vertically raised) and the clamp 370 B.
FIG. 16D is an end view of the pivotal pipe arm 320 and kickout arm 360 of the completion system 10 of one possible embodiment of the present invention for the completion system 10 , which shows an end view kickout arm pivot connection 312 ( FIG. 16C ) at the top of pivotal pipe arm 360 320 and clamp 370 B. Pivot beam 366 connects pipe kickout arm 360 to the top of pivotal pipe arm 320 . Kickout arm base 375 may comprise a rectangular cross-section in this embodiment. The pipe is received into pipe reception groove 378 .
FIG. 17 is a perspective view of a portion of the kickout arm 360 of the completion system 10 of in accord with one possible embodiment of the present invention. The kickout arm 360 is illustrated with the components attached to a kick out arm base 375 , which in this embodiment may have a relatively rectangular or square profile. The kick out arm base 375 is used for supporting one possible embodiment of the pipe clamps 370 A and 370 B (See also FIG. 18A ) and pipe ejector directional control 371 . Torsional arms 372 , which are also referred to as torsional arms 372 A and 372 B, are utilized to selectively activate eject arms 374 A and 374 B. The eject arms 374 A connect to torsional arms 372 A. The eject arms 374 B connect to torsional arms 372 B, respectively. When torsional arms 372 A are rotated utilizing hydraulic actuator 382 A, which rotates plates 384 A, (see FIG. 17A and FIG. 18 C-C), then eject arms 374 A will lift the pipe to eject the pipe from kickout arm 360 in the direction shown by pipe ejection direction arrow 377 A to the pipe tub or the like. Similarly, when torsional arms 372 B are rotated, then eject arms 374 B eject the pipe in the direction indicated by pipe ejection direction arrow 377 B to the other side. Prior to ejection or clamping, the pipe will align with the pipe reception grooves 378 in the clamps 370 and ejector mechanism 380 . Plates 375 comprise a relatively square receptacle 385 (see FIG. 17A ) that mates to kick out arm base 375 for secure mounting to resist torsional forces created during pipe ejection and/or pipe clamping.
FIG. 17A and FIG. 18C-C provide an enlarged or detailed view of the pipe ejector direction control 371 illustrated in FIG. 17 for the completion system of one possible embodiment of the present invention. The pipe ejector direction control 371 is illustrated using the plates 376 , which may be connected by a bracket 386 , in association with the torsional ejection rods 372 A and 372 B. The ejection mechanisms 380 A and 380 B (see FIG. 18 C-C) are between the plates 376 and provides for rotational movement of the torsional ejection rods 372 A and 372 B. Ejection mechanism 380 A operates to eject pipe as indicated by pipe ejection direction arrow 377 A (see FIG. 17 ). Ejection mechanism 380 B operates to eject pipe in the direction indicated by arrow 377 B. The pipe reception groove 378 is for accepting the joint of pipe during clamping or prior to ejection. In this embodiment, ejector hydraulic actuators 382 A and 382 B are pivotally connected to pivotal plates 384 A and 384 B, respectively, which are fastened to respective torsional ejection rods 372 A and 372 B for selectively ejecting the pipe from kickout arm 360 in the desired direction as indicated by pipe ejection arrows 377 A and 377 B. As shown in FIG. 17 , torsional ejection rods 372 A and 372 B are rotationally mounted to plates on clamps 370 A and 370 B for support at the ends thereof.
Referring to FIG. 17 , FIG. 18C , FIG. 21A , and FIG. 21B , clamps 370 A and 370 B are similar and in this embodiment each comprises two sets of clamping members, lower clamp set 387 A,B and upper clamp set 389 A,B. Each clamp set is activated by respective pairs of clamp hydraulic actuators, such as 392 A and 392 B, perhaps best shown in FIG. 18A . In this embodiment, after the pipe is rolled into the pipe reception grooves, then the clamp sets 387 A, 389 A and 387 B, 389 B are pivotally mounted on clamp arms 394 A and 394 B to rotate upwardly around pivot connections to clamp the pipes. When not in use clamp sets 387 A, 389 A and 387 B, 389 B are rotated downwardly to be out of the way (as shown in FIGS. 17 and 21A ) as the pipes are rolled into the pipe reception grooves 378 .
It will be appreciated that other types of clamps, arms, ejection mechanisms and the like may be hydraulically operated to clamp and/or eject the pipe onto or away from kickout arm 360 .
FIG. 18A is an elevation view of the kickout arm 360 of the completion system 10 in accord with one possible embodiment of the present invention. The kickout arm 360 is shown with the lower and upper pipe clamps 370 A and 370 B, pipe ejector direction control 371 , base 375 with torsional ejection rod 372 A (depicted in FIG. 18B ), ejector hydraulic actuator 382 A, and pipe clamp hydraulic actuators 392 A.
FIG. 18B is a bottom view of the kickout arm 360 as illustrated in FIG. 18A for the completion system of one possible embodiment of the present invention. FIG. 18B illustrates the base 375 in association with the torsional ejection rods 372 A and 372 B, which in this embodiment are rotationally secured to each of clamps 370 A and 370 B as well as to pipe ejector direction control 371 . The clamps 370 A and 370 B are dispersed at the remote ends of the kickout arm 360 . There may be fewer or more clamps, as desired.
FIG. 18C is a top view of the kickout arm 360 of the completion system 10 of the present invention. The kickout arm 360 is illustrated with the clamps 370 A and 370 B secured with the base 375 and operatively associated with the torsional ejection rods 372 A and 372 B.
FIG. 18B-B is a sectional view FIG. 18B for the completion system of one possible embodiment of the present invention. The end 390 is illustrated is with kick arm pivot connection 312 at the top (when pivotal pipe arm is upright) of pivotal pipe arm 320 .
FIG. 18C-C is a cross section of FIG. 18C illustrating pipe ejector direction control 371 . The ejector mechanism 380 A and 380 B comprise ejector hydraulic actuators 382 A, 382 B and pivotally mounted ejection control arms 384 A and 384 B, which rotate torsional ejection rods 372 A, and 372 B in one possible embodiment of the present invention.
FIG. 19A is an elevation view of the top drive fixture 151 , without the top drive mechanism 160 , used in conjunction with the mast assembly 100 of the completion system 10 of one possible embodiment of the present invention. The top drive fixture 151 is shown with the guide frame 152 , separated designated as 152 A, 152 B. Guide frames 152 A, 152 B are connected at top drive fixture flanges 141 A, 141 B to extensions 143 A, 143 B downwardly projecting from side plates 156 A, 156 B of a traveling block frame 154 . Traveling block fixture 154 is part of a traveling block assembly 153 comprising frame 154 and a cluster of sheaves 155 A, 155 B, 155 C, 155 D supported in such frame. Guide frames 152 A, 152 B slidingly engage mast top drive guide rails 104 , as discussed hereinbefore.
FIG. 19B is a side view of the top drive fixture 151 and frame 154 of the traveling block assembly 153 illustrated in FIG. 19A . FIG. 19B illustrates the guide frame 152 B in relation to the traveling block frame 154 B using the block side plate 156 B.
FIG. 19C-C is a cross sectional view taken along the section line C-C in FIG. 19B illustrating the mechanism associated with the top drive fixture 151 of the completion system of one possible embodiment of the present invention. The mechanism provides for the slide supports 152 having at its extremities a first and second rollers 158 A, 158 B on a respective roller axles 159 A, 159 B of guide frame 152 B, which may be utilized to provide a rolling interaction with mast top drive guide rails 104 maintaining the top drive in a relatively fixed vertical position. FIG. 19C-C also depicts flange 141 B connected to extension 143 B.
FIG. 19D is an enlarged or detailed view of the roller 158 A as illustrated in FIG. 19B .
FIG. 19E-E is a cross sectional view taken along the section line E-E in FIG. 19A . 19 E-E is in the same orientation as FIG. 19B , but is sectional. Referring to FIGS. 19A, 19B and 19E -E, traveling block frame 154 further comprises a front plate 144 A, a rear plate 144 B (depicted in FIG. 19B ), and side plates 156 A, 156 B including the downwardly projecting extensions 143 A, 143 B. A frame cross member spans side plates 156 A, 156 B above traveling block sheaves 155 A, 155 B, 155 C, 155 D sufficiently within parallel planes tangent to peripheries of flanges of such sheaves that a drilling line reeved around the sheaves as described below does not contact cross member. Cross member mounts inferiorly a plurality of rigid spaced apart parallel hangers 146 A, 146 B, 146 C, 146 D and 146 E (depicted in FIG. 19A ), each in a plane perpendicular to an axis of front sheaves of a crown block assembly described below. Hangers 146 A, 146 B support between them an axle 147 A for traveling block sheave 155 A; hangers 146 B, 146 C support between them an axle 147 B for traveling block sheave 155 B; hangers 146 C, 146 D support between them an axle 147 C for traveling block sheave 155 C; and hangers 146 D, 146 E support between them an axle 147 D for traveling block sheave 155 D. Each sheave axle 147 A, 147 B, 147 C and 147 D is parallel to the plane of the axis of the front sheaves of the crown block assembly. Traveling block sheaves 155 A, 155 B, 155 C, 155 D rotate in traveling block frame respectively on axles 147 A, 147 B, 147 C and 147 D.
FIG. 20A is an illustration of the top drive 150 in the top drive fixture 151 of the completion system of one possible embodiment of the present invention. The top drive comprises the top drive fixture 151 in conjunction with the drive mechanism 160 . The drive mechanism 160 is moveably engaged with the guide frames 152 A, 152 B and moves in a vertical direction using traveling block assembly 153 . A top drive shaft 165 provides rotational movement of the pipe using the drive mechanism 160 . Top drive shaft 165 connects to item 163 , which may comprise a top drive threaded connector and/or pipe connection guide member. Item 163 may also be adapted to hold the pipe. A torque sensor may also be included therein.
FIG. 20B is an upper view of traveling block assembly 153 and top drive 150 as illustrated in FIG. 20A . FIG. 20B illustrates the guide frames 152 A, 152 B with the frame 154 there between.
Referring to FIGS. 19A, 19B, 19E -E, 20 A and 20 B, traveling block sheaves 155 are seen to be horizontally canted in frame 154 . The purpose and angle of this canting and the operation of the traveling block assembly to raise and lower top drive 150 is now explained.
Referring now to FIGS. 4, 7B, 9, 27A, and 27B , carrier 600 pivotally mounts mast 100 on the carrier for rotation upward to an erect drilling position, as has been described. Mast 100 comprises front and rear vertical support members 105 , and a mast top or crown 190 supported atop front and rear vertical support members 105 . Drawworks 620 is mounted on carrier 600 to the rear of an erect mast 100 . Drawworks 620 has a drum 621 with a drum rotation axis perpendicular to the drilling axis for winding and unwinding a drilling line on drum 621 . A crown block assembly 191 is mounted in mast top or crown 190 for engaging the drilling line. The crown block assembly comprises a cluster 193 of front sheaves mounted at the front of mast top 190 facing the drilling axis. This cluster 193 comprises first and second outermost sheaves and at least one inboard sheave, all aligned on an axis in a plane perpendicular to the drilling axis and having a predetermined distance between grooves of adjacent front sheaves. A fast line sheave 194 is mounted on the drawworks side of the mast top behind the first outermost front sheave of cluster 193 and on an axis substantially parallel to the axis of the front sheaves of cluster 193 , for reeving the drilling line to the first outermost front sheave of cluster 193 . A deadline sheave 195 (blocked from view by the front sheaves of cluster 193 ) is mounted on the drawworks side of mast top 190 behind a second laterally outermost front sheave (blocked from view by fast line sheave 194 ) and on an axis substantially parallel to the axis of the front sheaves of cluster 193 , for reeving the drilling line from the second outermost front sheave to an anchorage.
Traveling block assembly 153 hangs by the drilling line from the front sheaves of the crown block assembly, and comprising, as has been described, fixture 154 and the cluster of sheaves 155 supported in the fixture. The cluster is one less in number than the number of front sheaves in the crown block assembly and includes at least first and second outermost traveling block sheaves 155 A, 155 D (in the illustrated embodiment there are two traveling block sheaves, 155 B, 155 C inboard of outermost traveling block sheaves 155 A, 155 D. Traveling block sheaves 155 A, 155 B, 155 C, 155 D have a predetermined distance between grooves of adjacent traveling sheaves and rotate on a common horizontal axis in a plane perpendicular to the drilling axis. The axis of the traveling sheaves 155 A, 155 B, 155 C, 155 D is angled in the latter plane relative to the axis of the front sheaves of the crown block assembly such that the drilling line reeves downwardly from the groove in a first front sheave parallel to the drilling axis to engage the groove in a first traveling block sheave and reeves upwardly from the groove in a first traveling block sheave toward the second front sheave next adjacent such first front sheave at an up-going drilling line angle to the drilling axis effective according to the distance between the grooves of the first and second front sheaves to move the drilling line laterally relative to the front sheave axis and engage the groove of the second front sheave, each the traveling block sheaves receiving the drilling line parallel to the drilling axis and reeving the drilling line to each following front sheave at an up-going angle.
Accordingly, first outermost traveling block sheave 155 A receives the drilling line reeved downward from the first laterally outermost front sheave of the crown block assembly parallel to the drilling axis and reeves the drilling line at an up-going angle to a next adjacent inboard front sheave. The latter inboard front sheave reeves the drilling line downward to traveling block sheave 155 B next adjacent first laterally outermost traveling block sheave 155 A parallel to the drilling axis. The latter traveling block sheave 155 B reeves the drilling line at an up-going angle to a front sheave next adjacent the front sheave next adjacent the first laterally outermost front sheave, and so forth, for each successive traveling block sheave (respectively sheaves 155 C, 155 D in the illustrated embodiment of FIGS. 19A, 19B, 19E -E, 20 A and 20 B), until the second outmost traveling block sheave ( 155 D in the illustrated embodiment) reeves the drilling line at an the up-going angle to the second outmost front sheave. The second outmost front sheave reeves the drilling line to the deadline sheave, and the deadline sheave reeves the line to the anchorage.
In an embodiment, an up-going angle from a traveling block sheave to a crown block front sheave is not more than about 15 degrees. In an embodiment, an up-going angle from a traveling block sheave to a crown block front sheave is about 12 degrees.
In an embodiment, the predetermined distances between grooves of the front sheaves are equal from sheave to sheave. In an embodiment in which the front sheaves comprise a plurality of inboard sheaves, the predetermined distance between at least one pair of inboard front sheaves may be the same or different than the distance separating an outermost front sheave from a next adjacent inboard front sheave.
FIG. 20A-A is a cross sectional view taken along the section line A-A in FIG. 20A illustrating the relationship of the drive mechanism 160 in the top drive frame 151 . The guide frames 152 provide structural support for the drive mechanism 160 .
FIG. 21A is a perspective view of the pipe arm assembly with the pipe clamps recessed allowing the pipe arm to receive pipe, as also previously discussed with respect to FIG. 17 , and FIG. 18C . In this embodiment, pipe ejector direction control 371 is omitted for clarity of the other elements in the figure. However, in another possible embodiment, the pipe ejector mechanism may not be utilized or may be replaced by other pipe ejector means. Kickout arm 360 is secured to pivotal pipe arm 320 at kickout arm pivot connection 312 located at the top of pivotal pipe arm 320 . Kickout arm hydraulic actuators 362 provide pivotal movement when pipe arm 320 is in an upright position. In this embodiment, pipe clamps 370 A and 370 B are mounted to kickout arm 360 , although in other embodiments pipe clamps 370 A and 370 B can be mounted directly to pivotal pipe arm 320 . Catwalk segments 309 and 311 contain one possible embodiment of catwalk pipe moving elements 314 to urge pipe onto pipe arm 320 which are guided or rolled into pipe reception grooves 378 along pipe guides 379 (See FIG. 16D ). Pipe clamp sets 387 A, 389 A and 387 B, 389 B are recessed below an outer surface of pipe guides 379 within pipe clamp mechanisms 370 A and 370 B to allow pipe P to be accepted in pipe reception grooves 378 , such as pipe P which is shown in position in the pipe reception grooves. Pipe clamp sets 387 A, 389 A and 387 B, 389 B are mounted to pivotal pipe clamp arms 394 A and 394 B.
FIG. 21B is a perspective view of the pipe arm assembly with the pipe clamps engaged around the pipe, which allows the pipe arm to move the pipe P to an upright position in mast 100 . In this embodiment, pipe clamp 370 A is located at a lower point on kickout arm 360 , while pipe clamp 370 B is located on an upper part of kickout arm 360 . In another embodiment, pipe clamps 370 A and 370 B could be mounted to pipe arm 320 . As discussed hereinbefore, pipe clamp sets 387 A, 389 A and 387 B, 389 B are mounted to pivotal pipe clamp arms 394 A and 394 B. In this embodiment, once pipe P is urged into pipe receptacle grooves 378 by catwalk moving elements 314 on either catwalk section 309 or 311 , pipe clamp hydraulic actuators 392 A and 392 B (See FIG. 18C ) urge pipe clamp sets 387 A, 389 A and 387 B, 389 B around clamp pivots 391 A and 391 B to engage pipe P.
FIG. 22A is a perspective end view of one possible embodiment of walkway 309 and 311 with one possible example moving elements, illustrating how pipe is moved from the walkway to the pipe arm. In FIG. 22A , catwalk segment 311 contains catwalk pipe moving elements 314 in a sloped position for urging pipe P into pipe clamp mechanisms 370 A and 370 B utilizing pipe reception grooves 378 . In another embodiment, catwalk pipe moving elements 314 can move into a second sloped position for moving pipe away from kickout arm 360 towards a pipe tub. In this embodiment, corresponding pipe moving element hydraulic controls 333 can be utilized for selectively operating pipe moving elements 314 on catwalk segments 309 and 311 (See FIG. 15F ). For example, the moving elements can be retracted below the surface of walkway 311 or raised to provide a gradual slope that urges the pipes into pipe reception grooves 378 .
In one possible embodiment, pipe barrier posts 316 may be utilized to prevent additional pipes from entering catwalk segment 311 while pipe is being moved with pipe moving elements 314 towards pipe clamp mechanisms 370 A and 370 B located on kickout arm 360 . Pipe barrier posts 316 may keep the pipe outside of the catwalk segment 311 after pipe moving elements 314 are lowered, whereby an operator may walk along the catwalk without impediments and/or utilize the catwalk for other purposes such as making up tools or the like. Catwalk segment 309 illustrates pipe moving elements 314 in a flat position flush with the surface of catwalk segment 309 . In one possible embodiment, pipe barrier posts 316 may be hydraulically raised and lowered. In another embodiment pipe barrier posts 316 may mechanically inserted, removed, or replaced (such as with sockets in the catwalk). In another embodiment, pipe barrier posts may not be utilized. In another embodiment, other means for separating the pipe may be utilized to urge a single pipe on pipe moving elements whereupon catwalk moving elements 314 are raised to gently urge one or more pipes into pipe reception grooves 378 . Catwalk pipe moving elements may be larger or wider if desired. In another embodiment, catwalk pipe moving elements may comprise a groove that holds the next pipe until raised whereupon the pipes are urged toward pipe guides 379 and pipe reception grooves 379 .
FIG. 22B is a perspective end view of the walkway with movable elements in accord with one possible embodiment of the invention. Catwalk segment 309 contains pipe moving elements 314 in a recessed position with pipe barrier posts 316 to prevent pipe from entering catwalk segment 309 while pipe P is engaged with pivotal pipe arm 320 . In this embodiment, catwalk segment 311 illustrates pipe moving elements 314 in a raised position that work with pipe barrier posts 316 to prevent pipe from entering catwalk segment 311 . In other embodiments, pipe barrier posts 316 may be hydraulically actuated or manually removable. In another embodiment, pipe barrier posts may be omitted and pipe moving elements 314 may contain a groove for holding back pipe from pipe tub 400 . Kickout arm 360 is secured to pivotal pipe arm 320 at kickout arm pivot connection 312 located at the top of pivotal pipe arm 320 . Pipe P has rolled into pipe reception grooves 378 located in pipe clamp mechanisms 370 A and 370 B where pipe clamp sets 387 A, 389 A and 387 B, 389 B will pivot about pivotal pipe clamp arms 394 A and 394 B to engage pipe P.
FIG. 23A is an end perspective view of a pipe feeding mechanism in accord with one possible embodiment of the invention. In this embodiment, pipe tub 400 comprises a rack or support, at least a portion of which is sloped downward towards catwalk segment 311 which urges pipe towards pipe feed receptacle 424 . Pipe feed receptacle 424 is movably mounted to support arms 434 for transporting pipe between pipe tub 400 and catwalk segment 311 . Accordingly, in one embodiment, pipe receptacle 424 lifts pipe one at a time out of pipe tub 400 onto catwalk 311 and/or catwalk moving elements 314 . As used herein pipe tube 400 may comprise a volume in which multiple layers of pipe may be conveniently carried or may simply be a pipe rack with a single layer of pipe.
FIG. 23B is another end perspective view of a pipe feeding mechanism 422 in accord with one possible embodiment of the present invention. Pipe feed mechanism 422 comprises support arms 434 which, if desired, may be fastened to catwalk segment 311 . In one possible embodiment, pipe feed receptacle may comprise a wall, rods, brace 425 at edge 427 of pipe feed receptacle adjacent the incoming pipe that contains the remaining pipe on the rack when pipe feed receptacle 424 moves, in this embodiment, upwardly. Thus, the wall or rods act as a gate. Once pipe receptacle 424 is lowered, then another pipe drops into pipe receptacle 424 . In this embodiment, pipe feed receptacle 424 is slidingly mounted to support arms 434 for movement between pipe tub 400 and catwalk segment 311 . Once pipe P is moved towards catwalk segment 311 , catwalk moving elements 314 urge pipe P towards pipe arm 320 with kickout arm 360 . Pipe feed receptacle 424 could also be pivotally mounted to urge pipe out of pipe tub 400 . In another embodiment, the tub or rack of pipes may be higher than the surface of catwalk 311 and the catwalk moving elements act as the pipe feed to control the flow of pipe from the pipe tub or rack 400 of pipe. Accordingly, the pipe feed may or may not be mounted within pipe tube 400 .
In yet another embodiment, as shown in FIG. 23C pipe tub 400 may comprise means for moving pipe from the bottom to the top of the pipe tub 400 , such as a hydraulic floor or a spring loaded floor. In one embodiment, pipe tub 400 may also contain pipe gate 426 at an upper edge of pipe tub 400 for efficiently moving pipe from pipe tub 400 to pipe feed receptacle 424 .
FIG. 23C is a cross sectional view of another possible embodiment of a pipe feeding mechanism 422 with the pipes present. The embodiment of pipe tub 400 shown in FIG. 23C may also be utilized for receiving pipe as the pipe is removed from the well in conjunction with pipe ejection mechanisms and/or catwalk pipe moving elements discussed hereinbefore. As discussed hereinbefore, pipe tub 400 contains sloped bottom 428 and optional pipe rungs 432 for controlling movement of pipes towards pipe gate 426 . The downward sloped angle of pipe rungs 432 and their placement inside pipe tub cavity 420 continually move pipe as pipe gate 426 opens to allow pipe P to be received by pipe feed receptacle 424 . Pipe feed receptacle 424 lifts pipe P to an upper position adjacent a surface of catwalk segment 311 for movement unto kickout arm 360 . Various types of lifting mechanisms may be utilized for pipe feed receptacle including hydraulic, electric, or the like. Pipe gate 426 controls movement of pipe onto pipe feed receptacle 424 which is supported by vertical support member 430 and support base 440 to prevent movement during operation.
FIG. 23D is a cross sectional view of a pipe feeding mechanism 422 with the pipes removed in accord with one possible embodiment of the present invention. Pipe feed mechanism 422 is positioned between pipe tub 400 and catwalk segment 311 . Pipe tub 400 contains pipe gate 426 at a lower end of pipe tub 400 facing catwalk segment 311 . Pipe rungs 432 may be utilized in connection with sloped bottom 428 within pipe tub 400 for controlling the movement of pipe P towards pipe gate 426 . As discussed hereinbefore, pipe feed receptacle 424 is stabilized by vertical support member 430 and support base 440 while in this position. Pivotal rungs may be removable or pivotal to open for filling the pipe tub more quickly.
FIG. 23E is a cross sectional view of a pipe feeding mechanism 422 in accord with one possible embodiment of the present invention. In this embodiment, pipe rungs 432 are omitted so that pipe tub cavity 420 only contains sloped bottom 428 and pipe gate 426 . This arrangement allows a higher volume of pipe to be stored in pipe tub 400 for drilling operations. Sloped bottom 428 will urge pipe towards pipe gate 426 which remotely opens and closes to allow pipe P to be received by pipe feed receptacle 424 . After pipe P has cleared pipe gate 426 , it will be hoisted along vertical support member 430 via pipe feed receptacle 424 until it reaches catwalk segment 311 . Once at catwalk segment 311 , pipe P will be further urged to pipe arm 320 by catwalk moving elements 314 (See FIG. 23B ). In one embodiment, the pipe feeding mechanism of FIG. 23E may be utilized with the pipe tub 400 of FIG. 23C . When removing pipe from the well, the pipe may be positioned onto the rungs by catwalk moving elements and/or pipe ejection elements discussed hereinbefore.
During operation for insertion of pipes into the wellbore, pipes are moved from pipe tubs 400 to the catwalk (if desired by automatic operation) and in one embodiment catwalk pipe moving elements 314 are activated to urge the pipes into pipe grooves 378 past retracted pipe clamps 387 A, 389 A and/or 387 B, 389 B. Once the pipe is in the grooves, then the pipe clamps are pivoted upwardly 387 A, 389 A and/or 387 A, 389 A to clamp the pipes. During this time, the length and other factors of the pipe is sensed or read by RFID tags. Pivotal pipe arm 320 is then rotated upwardly to the desired position (which may be determined by sensors and/or an upper mast fixture 315 . Kickout arm 360 pivots outwardly to orient the pipe vertically.
Top drive 150 is lowered using drawworks 620 to lower traveling block assembly 153 , and top drive shaft 165 is rotated to threadably connect with the upper pipe connector. The pipe is then lowered utilizing traveling block assembly 153 and top drive 150 so that the lower connection of the pipe is connected to the uppermost connection of the pipe string already in the wellbore and the pipe may be rotated to partially make up the connection. The pipe tongs 170 are moved around the pipe connection to torque the pipe with the desired torque and the torque sensor measures the make-up torque curve to verify the connection is made correctly. The pipe tongs are moved out of the way. The slips are disengaged and the pipe string is lowered so that the pipe upper connection is adjacent the rig floor and the slips are applied again to hold the pipe string. The pipe tongs may be brought back in for breaking the connection of this pipe and may utilize reverse rotation of the top drive to undo the connection. Using drawworks 620 to raise traveling block assembly 153 , top drive 150 is moved back toward the mast top in readiness for the next pipe.
To remove pipe from the well bore, the top drive is raised so that the lower connection of the pipe for removal is available to be broken by pipe tongs. Once broken, the top drive may be used to undo the connection the remainder of the way. The pipe is then raised, kickout arm 360 is pivoted outwardly, and clamps 370 A and 370 B clamp the pipe. The connection to the top drive is then broken by rotation of the top drive shaft 165 , whereupon the top drive is moved out of the way. Kickout arm 360 is then pivoted back to be adjacent pivotal pipe arm 320 . Pivotal pipe arm 320 is lowered. Clamps 370 A and 370 B are released and retracted. Either the eject arms 374 A or 374 B are activated depending on which side the pipe tube is located. Accordingly, a single operator can run pipe into the well, perform services, and remove pipe from the well. Other personnel at the well site may be utilized for other functions such as cleaning pipe threads, removing thread protectors, moving pipe onto pipe tubs, which may also simply comprise racks, checking mud measurements, checking engines, and the like as is well known.
For alignment purposes of the present application, a wellhead, BOP, snubber stack, pressure control equipment or other equipment with the well bore going through is considered equivalent because this equipment is aligned with the path of the top drive.
FIG. 24A depicts a perspective view of an embodiment of a gripping apparatus 1000 engageable with a top drive, such that pipe segments can be gripped by the apparatus 1000 to eliminate the need to thread each individual segment to the top drive itself. FIG. 24B depicts a diagrammatic side view of the apparatus 1000 .
The apparatus 1000 is shown having an upper connector 1002 (e.g., a threaded connection) usable for engagement with the top drive, though other means of engagement can also be used (e.g., bolts or other fasteners, welding, a force or interference fit). Alternatively, the gripping apparatus 1000 could be formed integrally or otherwise fixedly attached to a top drive or similar drive mechanism.
The apparatus 1000 is shown having an upper member 1004 engaged to the connector 1002 , and a lower member 1006 , engaged to the upper member 1004 via a plurality of spacing members 1008 . While FIGS. 24A and 24B depict the upper and lower members 1004 , 1006 as generally circular, disc-shaped members, separated by generally elongate spacing members 1008 , it should be understood that the depicted configuration of the body of the apparatus 1000 is an exemplary embodiment, and that any shape and/or dimensions of the described parts can be used. The lower member 1006 is shown having a bore 1010 therein, through which pipe segments can pass.
During operation, the apparatus 1000 can be threaded and/or otherwise engaged with the top drive, then after positioning of a pipe segment beneath the top drive and apparatus 1000 , e.g., using a pipe handling system, the apparatus 1000 can be lowered by lowering the top drive. And end of the pipe segment thereby passes through the bore 1010 , such that slips or similar gripping members disposed on the lower member 1006 can be actuated (e.g., through use of hydraulic cylinders or similar means) to grip and engage the pipe segment. Continued vertical movement of the top drive along the mast thereby moves the apparatus 1000 , and the pipe segment, due to the engagement of the gripping members thereto. Likewise, rotational movement of the top drive (e.g., to make or unmake a threaded connection in a pipe string) causes rotation of the apparatus 1000 , and thus, rotation of the gripped pipe segment. The apparatus 1000 is thereby usable as an extension of the top drive, such that pipe segments need not be threaded to the top drive itself, but can instead be efficiently gripped and manipulated using the apparatus 1000 .
Other types of attachments for engagement with a top drive or other drive system, and/or for engaging and/or guiding a tubular joint are also usable. For example, FIG. 25A depicts an exploded perspective view of an embodiment of a guide apparatus 1100 engageable with a top drive such that tubular joints brought into contact with the guide apparatus 1100 can be moved toward a position suitable for engagement with the top drive (e.g., in axial alignment therewith). FIG. 25B depicts a diagrammatic side view of the guide apparatus 1100 .
Specifically, the guide apparatus 1100 is shown having an upper member 1102 that includes a connector (e.g., interior threads) configured to engage a top drive and/or other type of drive mechanism, though other means of engagement can also be used (e.g., bolts or other fasteners, welding, a force or interference fit). Alternatively, the guide apparatus 1100 could be formed integrally or otherwise fixedly attached to a top drive or similar drive mechanism.
The upper member 1102 is shown engaged to the remainder of the guide apparatus 1100 via insertion through a central body 1106 having an internal bore, such that a threaded lower portion 1104 of the upper member 1102 protrudes beyond the lower end of the central body 1106 . A collar-type engagement, shown having two pieces 1108 A, 1108 B, connected via bolts 1110 , nuts 1111 , and washers 1113 , can be used to secure the upper member 1102 to the remainder of the apparatus 1100 , though it should be understood that the depicted configuration is exemplary, and that any manner of removable or non-removable engagement can be used, or that the upper member 1102 could be formed as an integral portion of the guide apparatus 1100 .
A lower member 1112 is shown below the upper member 1102 , the lower member 1112 having a generally frustroconical shape with a bore 1114 extending therethrough. The shape of the lower member 1112 defines a sloped and/or angled interior surface 1116 . A plurality of spacing members 1118 are shown extending between the lower member 1112 and the central body 1106 , thus providing a distance between the lower member 1112 and the upper member 1102 and/or a top drive connected thereto. While FIGS. 25A and 25B depict the upper member 1102 and central body 1106 as generally tubular and/or cylindrical structures, it should be understood that any shape and/or configuration could be used. Similarly, while the lower member 1112 is shown as a generally frustroconical member, other shapes (e.g., pyramid, partially spherical, and/or curved shapes) could be used to present an angled and/or curved surface in the direction of a tubular.
During operation, the guide apparatus 1100 can be threaded and/or otherwise engaged with the top drive, then after positioning of a tubular joint beneath the top drive and the guide apparatus 1100 (e.g., using a pipe handling system), the guide apparatus 1100 can be lowered by lowering the top drive. After the end of the tubular joint passes through the lower end of the bore 1114 , the end of the tubular joint contacts the angled interior surface 1116 . Continued movement of the guide apparatus 1100 causes the tubular to move along the angled interior surface 1116 until the end of the tubular exits the upper end of the bore 1114 , where contact between the tubular and the upper portion off the lower member 1112 , and/or between the tubular and the spacing members 1118 prevents further lateral movement of the tubular relative to the guide apparatus 1100 .
The end of the tubular joint can then be connected (e.g., threaded) to the lower portion 1104 of the upper member 1102 . Continued vertical movement of the top drive along the mast thereby moves the guide apparatus 1100 , and the tubular joint, due to the engagement between the joint and the guide apparatus 1100 . Likewise, rotational movement of the top drive (e.g., to make or unmake a threaded connection in a pipe string) causes rotation of the guide apparatus 1100 , and thus, rotation of the engaged tubular joint. The guide apparatus 1100 is thereby usable as an extension of the top drive, such that tubular joints need not be threaded to the top drive itself, where misalignment can occur, but can instead be presented in a misaligned position, contacted against the angled interior surface 1116 , and moved into alignment for engagement with the apparatus 1100 . In alternate embodiments, the upper member 1102 and lower portion 1104 thereof could be omitted, and a tubular joint could be engaged with a portion of the top drive directly.
FIG. 26 is a top view of a roller and a support rail in accord with one possible embodiment of the present invention. Roller 158 is one of several rollers connected to both guide frames 152 A and 152 B (See FIGS. 19, 19B, and 19C -C). Roller 158 is connected to guide frame 152 at roller axle 159 allowing roller 158 to spin freely around roller axle 159 . Support rail 176 is sized to mate with groove 173 of roller 178 to facilitate movement of top drive 150 along support rail 176 . In another embodiment, support rail 176 could contain groove 173 whereby roller 158 is sized to engage groove 173 to facilitate movement of top drive 150 . In this way, rollers 158 may be utilized to prevent rotation of the top drive and to reduce back and forth movement as may occur in prior art systems.
It will be understood that grooves could be provided in the guide frame whereby the rollers fit in the groove of the guide frame rather than the groove being formed in the rollers. The grooves may be of any type including straight line grooves where the grove sides may be angled or perpendicular with respect to the axis of rotation of the rollers. As well, the grooves may be curved. The grooves may also have combination of angled and perpendicular lines or any variation thereof. Mating surfaces in the opposing component, either the guides or the rollers are utilized. There may be some variation in size to reduce friction, e.g., the groove may have a bottom width of two inches and the inserted member may have a maximum width of 1 and three-quarters inches and so forth. As discussed above, the grooves may be V-shaped or partially V-shaped.
Turning to FIGS. 27A and 27B , a top view of a crown block assembly 193 in accord with one possible embodiment of the present invention. Crown block assembly 193 has cluster of sheaves located on top of mast assembly 100 . Sheaves 193 A, 193 B, 193 C, 193 D have an axis of rotation X upon which the sheave cluster 193 A, 193 B, 193 C, 193 D rotates. Traveling sheave block assembly 153 has sheaves 146 A, 146 B, 146 C, 146 D which are fastened to said guide frame 152 of top drive fixture 150 (see FIG. 19 ). Traveling sheave block assembly 153 has axis of rotation Y, which is offset in relation to axis of rotation X upon which sheave cluster 193 A, 193 B, 193 C, 193 D rotates. In one embodiment, the offset is less than ninety degrees. In another embodiment, the offset is less than forty five degrees. In another embodiment, the offset is less than twenty five degrees. It will be understood that these ranges would also apply if any multiple of ninety degrees were added to these ranges, e.g., between ninety and one-hundred eighty degrees. This orientation improves the ability of sheave cluster 193 A, 193 B, 193 C, 193 D and traveling sheave block assembly 153 to reeve a drilling line. When the traveling sheaves move closely to the crown sheaves, the offset aids in providing a smoother transition from one set of sheaves to the other in that sharp bends of the drilling line are avoided.
Generally, sheave wheels have a minimum diameter with respect to the type of drilling line to limit the amount of bending of the drilling line. Generally, the minimum sheave diameter will be between fifteen times and thirty time the diameter of the drilling line. However, this range may vary. Accordingly, in some embodiments, the ratio of sheave wheel diameter to drilling line diameter may be less than twenty.
Turning to FIGS. 28A and 28B , one possible embodiment of long lateral completion system 10 is depicted. A well site with first wellhead 12 and second wellhead 14 is shown. As discussed hereinbefore, long lateral completion system 10 can work well with wellheads in close proximity with each other on a well site, which can be less than a 10 foot distance between first wellhead 12 and second wellhead 14 . Pipe arm assembly 300 occupies a rear portion of skid 16 while rig floor 102 is positioned at a front end of skid 16 closest to second wellhead 14 . In another embodiment, rig floor 102 and pipe arm assembly 300 are operable without skid 16 . Skid 16 is positioned so that rig platform 102 is directly above second wellhead 14 . Rig floor 102 may or may not be part of skid 16 .
FIG. 28B depicts long lateral completion system 10 in accord with one possible embodiment of the present invention. Rig carrier 600 is shown with mast assembly 100 in an upright position. Mast assembly 100 extends past a rear portion of rig carrier 600 so that top drive unit mounted within mast assembly 100 is positioned directly above first wellhead 12 for drilling operations, as discussed hereinbefore. In other embodiments, sensors such as laser sights or guides mounted to the rear of rig carrier 600 , and the like may be utilized, e.g., mounted to and/or guided to the well head, to locate and orient the axis of mast assembly 100 precisely with respect to the wellbore of first wellhead 12 .
Rig floor 102 is shown positioned above second wellhead 14 providing operators access to mast assembly 100 when conducting drilling operations on first wellhead 12 . System 10 is configured so that pivotal pipe arm 320 of pipe handling system 300 can move pipe to and away from mast assembly 100 without contacting rig floor 102 during operation. Pivotal pipe arm 320 uses control arm 315 to pivot about pipe arm pivotal connection 313 creating an angle which avoids rig floor 102 .
In another embodiment of the present invention, pivotal pipe arm 320 may contain kickout arm 360 . In this embodiment, kickout arm 360 remains generally parallel to pivotal pipe arm 30 except when pivotal pipe arm 360 is moved into the upright position shown in FIG. 7 , FIG. 8 , and FIG. 9 . Upon reaching the upright position, kickout arm 360 is pivoted using the hydraulic actuators 362 , which cause kickout arm 360 to pivot away from pipe arm 320 about kickout arm pivot connection 312 (See FIG. 16B ). This preferred configuration of long lateral completion system 10 allows drilling operations on multiple wells in close proximity, which can be less than 10 feet apart in certain embodiments.
While certain exemplary embodiments have been described in details and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not devised without departing from the basic scope thereof, which is determined by the claims that follow. Moreover, it will be appreciated that numerous inventions are disclosed herein which are taught in various embodiments herein and that the inventions may also be utilized within other types of equipment, systems, methods, and machines so that the invention is not intended to be limited to the specifically disclosed embodiments.
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A method and apparatus for inspecting and tallying pipe in a well completion system. In one embodiment, at least one sensor determines the length of a pipe and/or at least one thread protector sensor determines whether the thread protectors are removed from both ends of the pipe. The sensors may be located in a mast assembly, a pipe arm, a walkway adjacent said pipe arm used to urge pipe towards the pipe arm, or various other places as desired. A moveable control van with a control system receives signals from the sensors. The control van comprises a system which also keeps a tally of the total amount of pipe currently in the wellbore. In one embodiment, memory chips may be used on the pipe to store a history of the pipe. The sensors then communicate this information back to the control system.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation in part of prior U.S. application, Ser. No. 08/784,244, Filed Jan. 15, 1997, and entitled Hydraulically Controlled Riding Trowel now U.S. Pat. No. 5,890,833, issued Apr. 6, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to motorized riding trowels for finishing concrete surfaces of the type classified in United States Patent Class 404, Subclass 112. More particularly, our invention relates to multiple-rotor, hydraulically driven and hydraulically controlled riding trowels.
2. Description of the Prior Art
It is well established in the concrete finishing art that freshly placed concrete must be appropriately finished to achieve the desired smoothness and flatness. As freshly poured concrete sets, it soon becomes hard enough to support the weight of motorized riding trowels, that are particularly effective for finishing concrete. Motorized riding trowels are ideal for finishing large areas of plastic concrete quickly and efficiently, and a variety of riding trowels are known in the art.
Typical riding trowels employ multiple, downwardly projecting rotors that contact the concrete surface and support the weight of the trowel. A typical rotor comprises a plurality of radially spaced-apart finishing blades that revolve in frictional contact with the concrete surface. The blades may be coupled to circular finishing pans for treating unhardened, "green" concrete. When the rotors are tilted, steering and propulsion forces are frictionally developed by the blades (or pans) against the concrete surface. Riding trowels finish large surface areas of wet concrete more efficiently than older "walk behind" trowels. Significant savings are experienced by the contractor using such equipment, as time constraints and labor expenses are reduced.
Preferably, the finishing process starts with panning while the concrete is still green, within one to several hours after pouring depending upon the concrete mixture involved. The advent of more stringent concrete surface finish specifications using "F" numbers to specify flatness (ff) and levelness (fl), dictates the use of pans on a widespread basis. Both "super-flat" and "super-smooth" floors can be achieved by panning with motorized trowels.
Pan finishing is normally followed by medium speed blade finishing, after the pans are removed from the rotors. A developing technique is the use of "combo blades" during the intermediate "fuzz stage" as the concrete continues to harden. So-called "combo-blades" are a compromise between pans and normal finishing blades. They present more surface area to the concrete than normal finishing blades, and attack at a less acute angle. The rotors are preferably turned between 100 to 135 RPM at this time. Finishing blades are then used, and they are rotated between 120 to 150 RPM. Finally, the pitch of the blades is changed to a relatively high contact angle, and burnishing begins. Rotor speeds of between 135 and 165 RPM are recommended in the final trowel finishing stage.
Holz, in U.S. Pat. No. 4,046,484 shows a pioneer, twin rotor, selfpropelled riding trowel wherein the rotors are tilted to generate steering forces. U.S. Pat. No. 3,936,212, also issued to Holz, shows a three rotor riding trowel powered by a single motor. Although the designs depicted in the latter two Holz patents were pioneers in the riding trowel arts, the devices were difficult to steer and control.
Prior U.S. Pat. No. 5,108,220 owned by Allen Engineering Corporation, the same assignee as in this case, relates to an improved, fast steering system for riding trowels. Its steering system enhances riding trowel maneuverability and control. The latter fast steering riding trowel is also the subject of U.S. Des. Pat. No. 323,510 owned by Allen Engineering Corporation.
U.S. Pat. No. 5,613,801, issued Mar. 25, 1997 to Allen Engineering Corporation discloses a power-riding trowel equipped with separate motors for each rotor. Steering is accomplished with structure similar to that depicted in U.S. Pat. No. 5,108,220 previously discussed.
Allen Engineering Corporation Pat. No. 5,480,258 discloses a multiple engine riding trowel. The twin rotor design depicted therein associates a separate engine with each rotor. As the engines are disposed directly over each revolving rotor assembly, horsepower is more efficiently transferred to the revolving blades. Besides resulting in a faster and more efficient trowel, the design is easier to steer. Again, manually activated steering linkages are used.
Allen Engineering Corporation Pat. No. No. 5,685,667 discloses a twin engine riding trowel using "contra rotation." Many trowel users prefer the steering characteristics that result when the trowel rotors are forced to rotate in a direction opposite from that normally expected in the art.
While modern, high power riding trowels are noted for their speed and efficiency, extreme demands are placed upon the relatively small, internal combustion motors that power such machines. Adequate horsepower must be available at all times for the rotors, that must operate under varying conditions of speed, drag, rotor tilt-angle, blade pitch, and concrete hardness. Demands upon drive motors can vary widely when switching between panning and blade-finishing modes. Generally speaking, the more powerful the trowel, the faster finishing operations can be completed. However, optimum engine speed (i.e., for rated torque and horsepower) is limited to a relatively small RPM range. On the other hand, a variety of blade speeds are required for modern finishing, and as explained earlier, load conditions vary widely as well.
Engine RPM is usually the essential variable related to output power. Typical riding trowel engines are coupled through belts and pulleys to gear boxes connected to the rotor shafts. The output shaft speed (i.e., rotor speed) is geared down, with a ratio of 20:1 being common. While it is recognized that effective motor output characteristics are RPM related, the use of fixed ratio reduction gearing often results in a mismatch between the desired blade speed, the frictional load, and the available motor horsepower at a given RPM.
If engine speed increases too much, excessive power may be developed, and the finishing mechanism may rotate too fast. For example, the initial panning stage requires relatively high power because of the viscous character of green concrete, but relatively low rotor speeds are desired. Since the rotors are driven through a fixed ratio established by the gearbox, belts and drive pulleys, optimum engine power often cannot be obtained during panning without risking excessive rotor speeds.
It is desirable to provide a riding trowel wherein the engine or engines can operate at ideal speeds over a wide range of finishing conditions. One solution pioneered by Allen Engineering Corporation, is the subject of pending U.S. patent application Ser. No. 09/008,355, filed Jan. 16, 1998, and entitled "Riding Trowel with Variable Ratio Transmission." The object is to vary the overall drive gear ratio during different panning and blade finishing stages so that motors may operate within optimum RPM ranges as much as possible. In the Allen design, the effective drive ratio established between the motor output pulleys and the drive pulleys splined to the gearbox input shaft can be dynamically varied. However, since the rotor gearbox reduction ratio is still fixed, the range of adjustment of the overall drive train gear ratio (i.e., the ratio between motor RPM and rotor RPM) is limited. What appears necessary is a variable ratio "drive gear" for revolving the rotors that allows the motors to maintain a relatively constant speed over a variety of working conditions and loads. Hydraulic drive motors provide the potential to solve this problem.
Many early riding trowels use manually operated levers for steering. The steering levers project upwardly from the frame and are grasped and manipulated by the operator to direct the machine. The steering levers deflect linkages below the trowel frame to tilt the rotors. Often a vigorous physical effort is required. Where separate engines are used with each rotor assembly, additional physical effort is required to tilt the rotors for steering, or to vary blade pitch. It has now been established that modern, state-of-the art riding trowels require power steering for maximum performance. Hydraulic steering systems for multiple engine trowels previously proposed by Allen Engineering Corporation have proven desirable. For example, copending Allen Engineering Corporation patent application Ser. No. 08/784,244, filed Jan. 15, 1997, entitled "Hydraulically Controlled Riding Trowel" discloses a powered steering system for riding trowels. Quick, responsive handling optimizes trowel efficiency, and preserves operator safety and comfort.
At the same time, the use of hydraulic propulsion and hydraulic power steering amplifies the requirement for available horsepower. By using hydraulic motors to drive trowel rotors, the internal combustion motors may operate continuously within ideal RPM ranges. The resultant horsepower increase more than offsets losses caused by hydraulic inefficiencies. However, the added weight from large internal combustion engines, hydraulic drive motors, and the required hydraulic accessories affects trowel handling and response.
The heavier and more powerful the trowel, the more important it is to establish responsive steering and fast, effective handling. However, not all trowel operators are equally experienced. Operators who first learned to drive riding trowels on older, manually steered, lever controlled models gradually became used to the lever "feel" and the handling characteristics of such designs. As hydraulic steering systems evolved, it was thought important to maintain a "feel" that was "backward compatible" with the expectations of more skilled operators. Late model riding trowels have replaced heavy, manual steering levers with lightweight, easily deflected joysticks. It has been preferred that the joysticks be deflectable in the same relative directions as older steering levers, so that required operator hand movements on older and newer trowels are substantially similar. Thus, those hand motions and reflexes previously learned by the driver on older trowels will aid the driver in mastering joystick-equipped trowels. However, many younger workers entering the job market have never driven the older, lever-controlled trowels. As the popularity of riding trowels continues to rise, the desirability of backwards compatibility may be fading. At the same time it remains important that trowels be easy to operate and steer. Especially with the advent of modern, high powered, internal combustion engines for trowel use, it appears practicable to control hydraulically powered riding trowels without levers or joysticks.
Through years of experimentation we have found it possible to control a trowel with a steering system comprising drive pedals and a steering wheel. The ideal system handles similarly to those used on automobiles or tractors. Hence we have designed a multiple-rotor, hydraulically driven trowel that can be steered like an automobile or tractor. In the best mode the hydraulic drive system employs foot pedals and a steering wheel for optimizing steering and control.
SUMMARY OF THE INVENTION
Our new riding trowel preferably comprises a generally triangular frame supporting a separate rotor assembly at each of its three vertices. Each rotor assembly is gimbaled to the frame and tilted by double acting, hydraulic pistons. For propulsion, the left and right rear rotor assemblies are tilted in a plane coincident with the biaxial plane established and occupied by their parallel and coplanar axes of rotation. For steering effects, the front rotor assembly is tilted in a plane perpendicular to said biaxial plane. Each rotor assembly is directly driven by a hydraulic motor. One or more internal combustion motors power suitable hydraulic pumps for energizing hydraulic motors and accessories. Since the rotor assemblies are directly driven hydraulically, mechanical gearboxes are avoided. The preferably gasoline or diesel powered internal combustion motor operates over an optimized RPM range.
The driver is comfortably seated adjacent the trowel controls. A rotatable steering wheel positioned in front of the operator substantially controls steering. It activates a suitable valve coupled to downline hydraulic components, and ultimately tilts the front rotor for steering and maneuvering. Suitable foot pedals can be deflected by the toe or heels of both feet to control propulsion by tilting the rear rotors. Complex maneuvers can be executed by heel and toe movements of the foot pedals in combination with steering wheel actuation. One or more internal combustion motors that power the hydraulic drive circuit run at optimum speeds, making ample horsepower readily available. The extra horsepower adequately powers the energy demands of the entire hydraulic system. The increased weight and horsepower of the system demands an improved steering design. Our preferred hydraulic steering system readily delivers the enhanced functional characteristics that make hydraulic drive practicable.
Thus, a fundamental object of our invention is to provide a hydraulically driven and hydraulically steered riding trowel.
A related object is to provide a hydraulically operated riding trowel that drives and steers somewhat like an automobile.
Another fundamental object is to provide a hydraulic, direct drive riding trowel that handles well and feels comfortable to a relatively new driver who may lack experience with lever-steered or joystick-controlled riding trowels. Another fundamental object of our invention is to provide a hydraulic direct drive system adapted for multiple engine riding trowels.
Another important object is to provide power steering and power blade pitch control for use with hydraulic, direct drive riding trowels.
A further object is to accomplish the above mentioned goals without the use of electrical components characterizing electrical-over-hydraulic steering and control systems.
Another object is to simplify the circuitry needed for effective joystick control of powered riding trowels.
A related object is to make it easier to drive high power, triple rotor riding trowels.
Another related object is to reduce the physical effort required to safely drive a triple-rotor riding trowel.
Another basic object is to provide a hydraulic direct drive system and a complimentary hydraulic power steering system for high power riding trowels characterized by multiple rotor assemblies.
It is also an object to successfully combine hydraulic power steering and direct hydraulic drive for high powered riding trowels.
Similarly, it is an object to provide hydraulic steering and hydraulic direct drive systems that are effective over a wide variety of operating conditions.
A further object is to provide a triple-rotor riding trowel characterized by direct hydraulic drive and hydraulic steering that readily handles conventional blades, combo-blades, or finishing pans.
A still further object is to provide a hydraulic propulsion and steering circuit that functions on a variety of riding trowels, including diesel or gasoline powered trowels having one, two or three internal combustion motors.
Another object is to provide a high power riding trowel that overcomes power-draining vacuum effects that occur when panning wet concrete.
Another basic object is to provide a functional, hydraulic drive system for riding trowels that enables directional and variable speed control, while applying relatively constant torque under varying speed conditions.
A still further object is to provide a direct drive hydraulic system of the character described that enables the trowel internal combustion motor to run constantly within an optimum RPM and horsepower range.
Yet another object is to provide a power steering riding trowel wherein the rotors flatten the concrete surface sufficiently to attain the high "F-numbers" (i.e., flatness characteristics) that are established by ACI regulations.
Another object is to provide a multiple-rotor, high power riding trowel that is inherently stable and easy to maneuver.
A related object is to provide multiple-rotor riding trowels that are ideal for pan finishing and quick curing concrete jobs.
These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings, which form a part of the specification and are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout in the various views wherever possible:
FIG. 1 is a partially fragmentary, front isometric view of our Hydraulically Driven, Multiple Rotor Riding Trowel, with portions thereof omitted or broken away for clarity;
FIG. 2 is a partially fragmentary, rear isometric view thereof;
FIG. 3 is an enlarged, exploded isometric view of a typical, gimbaled rotor assembly;
FIG. 4 is an enlarged, fragmentary, isometric view the steering wheel system;
FIG. 5 is an enlarged, fragmentary, isometric view of a preferred foot pedal control;
FIG. 6 is a schematic diagram of the preferred hydraulic drive motor circuit;
FIG. 7 is a schematic diagram of the preferred hydraulic steering and propulsion control circuit;
FIG. 8 is a schematic diagram of the preferred hydraulic pitch control circuit; and,
FIG. 9 is a pictorial view indicating how to best orient FIGS. 6-8 for viewing.
DETAILED DESCRIPTION
With initial reference now directed to FIGS. 1-2 of the accompanying drawings, a multiple rotor riding trowel 20 is both hydraulically driven and hydraulically steered. Substantial structural details of pertinent riding trowels are set forth in prior U.S. Pat. Nos. 5,108,220, 5,613,801, 5,480,257, and 5,685,667 which, for disclosure purposes, are hereby incorporated by reference herein. Moreover, many details with respect to the preferred triangular frame and the mounting of various rotors is shown in the parent case hereto, which is also incorporated by reference as if fully set forth herein.
Riding trowel 20 comprises a rigid, generally triangular metal frame 25 formed by forwardly converging sides 27 and 28 (FIG. 1), side panels 29, 30 (FIG. 2), and rear strut 32. The spaced-apart, left and right rear rotor assemblies 40 and 41 respectively are gimbaled to the frame rear. Front rotor assembly 44 is gimbaled at the frame front, largely supported by spaced-apart frame sides 27, 28. Each rotor assembly comprises a bladed rotor projecting downwardly into contact with concrete surface 23. As explained in my prior patents, the rear rotor assemblies preferably tilt in a plane parallel with the biaxial plane established by the axes 45 (FIG. 3) of their rotation. The front rotor assembly preferably tilts in a plane perpendicular to the biaxial plane. In the best mode known to us at this time, the rear rotor assemblies of trowel 20 do not contra-rotate. However, it will be appreciated that the hydraulic steering and drive systems of the present invention may be used with riding trowels, with either normal or contra rotation, and with one or more gasoline, diesel powered, or alternative engines.
The left rear rotor assembly 40 (FIGS. 1, 3) is substantially similar to each of the others. As explained previously in Allen Engineering Corporation patents referenced above, each rotor assembly comprises a plurality of radially spaced-apart finishing blades 50 that either directly contact the concrete surface 23 or mount suitable finishing pans (not shown). As best seen in FIG. 3, each blade 50 is mounted by a radial arm 52 that is coupled to a spider 54 with torsional deflectors 56 and a spring 58. As explained in prior patents, the fork 62 is deflected against clutch mechanism 64 that presses down against the deflectors 56 associated with each blade to control pitch. Preferably a hydraulic cylinder 66 (FIGS. 3, 8) coupled to fork 62 controls pitch.
The left rear hydraulic drive motor 68 (FIGS. 1, 3) is secured to plate 70 that is preferably gimbaled to the frame 25 by a gimbal box 72. Drive motor 68 (and the other rotor drive motors) preferably comprises a Ross Model ME210203AAAA motor. The tilt direction is established by fasteners penetrating either gimbal orifices 73 or 74; however, rotor assembly 40 tilts in a plane parallel and/or coincident with the biaxial plane in response to tilting by torque arm 76 that is deflected by the left hydraulic tilting cylinder 78 (FIGS. 3, 7). The double action, rotor tilting cylinders 78, 79, and 112 (FIG. 7) are all hydraulically controlled with tilting circuit 175 (FIG. 7) as discussed hereinafter. Motor 68 drives union 80 whose output driveshaft 82 is splined to spider 54 within orifice 84. Thus, as appreciated from FIG. 3, each rotor assembly is rotated by a hydraulic drive motor, and tilted for propulsion or steering by a hydraulic cylinder. Additionally, the pitch of each rotor assembly may be varied by a hydraulic cylinder. The right side rotor assembly 41 is driven by hydraulic motor 69 and the front rotor assembly is driven by hydraulic motor 71 (FIG. 2).
An operator station 90 mounted at the top of the frame 25 shrouds the internal combustion drive motor 92 (FIG. 6) and supports operator seat 94. Seat 94 is comfortably disposed apart from a steering wheel system 100 best seen in FIG. 4. System 100 is supported upon and between a pair of upwardly projecting panels 103 and 105 that support dashboard 106. A steering column 108 projecting through the dashboard 106 mounts steering wheel 109 that may be grasped by the driver. The steering wheel directly controls a proportional hydraulic valve 110 (FIGS. 4, 7), which controls a tilting cylinder 112 (FIG. 7) associated with the front rotor assembly 44 that is primarily responsible for steering. A suitable lever (not shown) is mounted to one of the panels 103 or 105 for controlling a conventional cable (not shown) that leads to the conventional throttle on the internal combustion motor.
The left and right rear rotor assemblies are preferably tilted by foot pedal assemblies 120, 121 respectively for propulsion and maneuvering (FIGS. 1, 5). Each foot pedal assembly comprises an operator-accessible pedal 123, 124 (FIG. 1) respectively controlling hydraulic steering control valves 126, 128 (FIGS. 2, 5, 7). The foot pedals function as levers and ultimately tilt the rear rotors for propulsion; they are deflected one way with pressure from the operator's toes or the front of the driver's foot, and deflected the opposite way with suitable pressure from the heel of the foot. As the operator gains skill in driving the trowel 20, a variety of complex motions and maneuvers may be accomplished by combinations of steering wheel rotations and heel-and-toe, foot-pedal motions.
The hydraulic rotor drive circuitry is identified by the reference numeral 150 in FIG. 6 (FIGS. 6-8 should be aligned as in FIG. 9 for convenient viewing). Internal combustion engine 92 drives a pair of hydrostatic, bi-directional piston pumps 152, 154 through coupling 156. Rear rotor drive motors 68, 69 are controlled across lines 158, 159 pressured by pump 152. A cross-over relief package 160 is recommended. Front drive motor 71 is controlled across lines 162 and 163 pressured by pump 154. Another cross-over relief package 166 is provided. Pump 170 pressures lines 172-174 that power the rotor tilting circuit 175 (FIG. 7) and the optional pitch control circuit 178 (FIG. 8).
Turning to FIG. 7, incoming high pressure on line 172 traverses relief valve 180 and enters a four-section, geared flow divider 182. The first output line 183 powers the pitch control circuitry 178 (FIG. 8). The other three outputs 186, 187, 188 respectively control the three hydraulic steering control valves 126, 110, and 128. Suitable valve models are model Hgb40-123 TRW Ross Steering Control Valves. These valves respectively control left tilting cylinder 78, front tilting cylinder 112, and right rear tilting cylinder 79. Cylinders 78, 79 are thus controlled by foot pedals 123, 124 previously discussed. Steering wheel 109 ultimately controls front tilting cylinder 112 through valve 110.
Circuit 178 (FIG. 8) controls the left rear pitch control cylinder 66, front pitch control cylinder 66A, and right rear pitch control cylinder 66B through series-connected reversing valves 200-202 respectively. A return is provided at line 204. Alternatively, conventional cables may be employed for pitch control, as preferred by some trowel operators.
Operation
A variety of operator precautions must be observed for proper operation. The hydraulic tanks should be periodically inspected for proper level, and the rotor blades must be changed as necessary after routine inspections for wear. Fuel tank levels must be sufficient for extended periods of use. During the initial finishing of wet concrete, proper pans will first be installed on the rotors by coupling the rotor blades to the radially spaced-apart brackets provided.
If pressure is applied to the toe portion of pedals 123, 124, the left and right rear rotors will be tilted with the double acting cylinders 78, 79 (FIG. 7), and trowel 20 will move forwardly. Using joint heel action, the machine reverses. In either case the steering wheel 109 influences the direction of travel through front tilting cylinder 112. With the rear rotors untilted (i.e., neutral), subsequent tilting of the front rotor by hydraulic cylinder 112 in response to steering wheel movements will cause the trowel to make gentle, sweeping turns. By a combination of heel and toe actions on alternate pedals 123, 124, vigorous turning maneuvers and crabbing actions can be executed.
From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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A high performance, hydraulically-propelled, multiple rotor riding trowel for finishing concrete is controlled with hydraulic circuitry enabling steering wheel and foot pedal control. The rigid trowel frame preferably mounts three separate spaced-apart, downwardly-projecting, bladed rotor assemblies that frictionally engage the concrete surface. The rear rotor assemblies are tilted with double acting, hydraulic cylinders to effectuate steering and control in response to foot pedals. Double acting hydraulic cylinders also control blade pitch. Separate gimbaled, hydraulic motors revolve each rotor assembly. A steering wheel controlling a front, hydraulic steering control valve controls the front tilting cylinder to facilitates steering with minimal physical exertion.
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[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/456,466, which was filed on Mar. 20, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to door locking mechanisms, and in particular to push bar door mechanisms with rapid unlocking features.
[0004] 2. Description of the Related Art
[0005] Doors, particularly in the commercial environment, are commonly provided with a horizontal push bar that can be activated to unlock and/or open the door. Conventional push bar mechanisms generally comprise a frame mounted on the door, usually at an arm level, with a depressible bar that can be engaged by the hands of a user and pushed to unlock the lock mechanism to allow the door to open. The actual mechanism for causing a pushing movement of the push bar, and the unlocking of the door, is known. There has not been, however, any effective locking mechanism of this type which uses an electromagnetic control to either allow or block operation of the depressible bar.
[0006] U.S. Pat. No. 4,826,223, to Geringer et al. discloses an electromagnetic door lock device that comprises an electromagnet, a bracket for holding the electromagnet in a door frame, an electrical conduit for connecting the electromagnet to a power source, an armature magnetically attracted to the electromagnet when the latter is energized, a connector for holding the armature on a door edge in the frame for adjustable movement towards the electromagnet and a lock component for the device. The lock component comprises one or more ledges at the periphery of the electromagnet and/or armature pair projecting towards and engageable with the other(s) of the pair when the armature is magnetically attracted to the energized electromagnet. This occurs when the armature and electromagnetic are in line with each other, and the armature is free to move toward the electromagnet. Unlocking is effected by de-energizing the electromagnet and allowing the armature to retract by gravity or spring action, so that the lock component also moves out of the described engagement. The device is simple, durable and effective.
[0007] One of the disadvantages with electromagnetic door locks generally, is the fact that there is frequently residual magnetism from the electromagnetic element which initially prevents a separation of the door from a door frame. This is almost universally true in the case where a magnetic lock mechanism is mounted on a door or a door frame, and co-acts with an armature located on the opposite side of the door or door frame. In other words, because of the residual magnetism, the door does not immediately open when the electromagnetic element is de-energized.
[0008] U.S. Pat. No. 5,033,779 to Geringer et al. also discloses an electromagnetic door lock device similar to the lock in U.S. Pat. No. 4,826,223. The device itself comprises an electromagnet in a housing adapted to be connected to the top edge of a door frame, above a door in the frame. The device also includes an armature block connected to the top of the door in a position near the electromagnet. The armature moves between a down inoperative position away from the electromagnet, facilitated by gravity, when the electromagnet is de-energized and an up extended operative position against the underside of the electromagnet housing when the electromagnet is energized. A locking plate connected to the housing has a tab which depends therefrom and abuts the armature when the latter is in the up position to lock the door closed in the door frame. The improvement prevents slow separation of the armature and tab and hesitant unlocking of the door when the electromagnet is de-energized. The lock also includes a separation accelerator that allows the armature to spring away from the electromagnet, along with the force of gravity, for improved operation.
SUMMARY OF THE INVENTION
[0009] One embodiment of a push bar locking mechanism according to the present invention for locking and unlocking a door comprising a push bar movably arranged integral to a bar frame. The push bar can be moved relative to the bar frame to move a door locking mechanism between the locked and unlocked position. An electromagnetic locking mechanism is included integral to said push bar with an electrical conductor provided to apply an electrical signal to the electromagnetic locking mechanism to energize said electromagnetic locking mechanism to prevent the push bar from moving the door locking mechanism to the unlocked position.
[0010] Another embodiment of a push bar locking mechanism according to the present invention for locking and unlocking a door also comprises a push bar arranged integral to a bar frame such that the push bar can be moved relative to the bar frame. An elongated link is integral to the push bar and bar frame and is movable in response to the push bar movement relative to the bar frame. The movement of the elongated link causes a door locking mechanism to move between a locked and unlocked position. An electromagnetic locking mechanism is included that can be changed between an energized and de-energized state by an electrical signal, wherein the electrical locking mechanism generates a magnetic field when energized. An armature is also included in proximity to the electromagnetic locking mechanism and the elongated link. The armature prevents movement of the elongated link when the electromagnetic locking mechanism is energized.
[0011] One embodiment of a door system according to the present invention comprises a door mounted within a door frame such that the door is movable between an open and closed position within the door frame. A spring biased bolt is integral to the door and movable between an extended and retracted position. A bolt receiver opening is integral to the door frame and arranged to accept the bolt when it is extended from the door, with the bolt and opening cooperating to hold the door in the closed position when the bolt is extended into the opening. A push bar locking mechanism is mounted to the door and is operable to retract the bolt and comprises a push bar arranged integral to a bar frame such that the push bar can be moved relative to the bar frame to retract the bolt. An electromagnetic locking mechanism is integral to the push bar and an electrical conductor applies an electrical signal to the electromagnetic locking mechanism to prevent the push bar from moving the door locking mechanism to the unlocked position.
[0012] These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a perspective view one embodiment of a door according to the present invention having a push bar locking mechanism, and being opened with respect to a door frame;
[0014] [0014]FIG. 2 is an exploded perspective view of one embodiment of a push bar locking mechanism according to the present invention;
[0015] [0015]FIG. 3 is a top plan view of one embodiment of internal locking and unlocking components according to the present invention that can be used in the push bar locking mechanism shown in FIG. 2;
[0016] [0016]FIG. 4 is a top plan view of internal locking and unlocking components of the push bar locking mechanism shown in FIG. 2, including an electromagnetic element;
[0017] [0017]FIG. 5 is a top plan view of the components shown in FIG. 4, with the electromagnetic element energized;
[0018] [0018]FIG. 6 is a top plan view of the components shown in FIG. 4, with the electromagnetic element de-energized;
[0019] [0019]FIG. 7 is another top plan view of the internal locking and unlocking components shown in FIG. 4, showing the details of the locking mechanism when the electromagnetic element is de-energized;
[0020] [0020]FIG. 8 is a top plan view of the components shown in FIG. 7, showing the details of the locking mechanism when the electromagnetic element is energized; and
[0021] [0021]FIG. 9 is a top plan view of the components shown in FIG. 8, showing the details of the locking mechanism when the electromagnetic element is de-energized.
DETAILED DESCRIPTION OF THE INVENTION
[0022] [0022]FIG. 1 shows one embodiment of push bar locking mechanism 10 according to the present invention, having an internal electromagnetic element and having improved operation to allow the door to be almost immediately opened after the electromagnetic element is de-energized. The push bar mechanism 10 is mounted horizontally on a conventional door 12 that is then mounted within a door frame 14 by hinges 16 along one of the door's vertical edges so that the door can be easily swung open when the lock mechanism is not engaged. The door 12 of FIG. 1 is shown in the opened position with respect to the door frame 14 .
[0023] The push bar locking mechanism 10 can be arranged in many different ways to hold the door 12 within the door frame 14 when the mechanism 10 is not actuated and allow the door 12 to swing open when the mechanism is actuated. In the embodiment shown in FIG. 1, the door 12 also comprises a spring biased bolt 18 that is extendable from the door edge under control of the push bar locking mechanism 10 . When the bolt 18 is extended it is arranged to mate with a bolt receiving opening 20 in the edge of the door frame to hold the door 12 closed. When the push bar locking mechanism 10 is at rest, the spring biased bolt 18 is typically extended into the opening 20 . Actuation of the push bar locking mechanism 10 causes the bolt 18 to retract from the opening to allow the door 12 to open.
[0024] It should be understood that the bolt 18 and bolt receiving opening 20 arrangement is known and is shown merely to illustrate one embodiment of how the push bar locking mechanism 10 can function to hold door 12 closed, or to allow a door 12 to open. The push bar locking mechanism 10 can be used in many other arrangements, such as those having a bolt mounted directly to the push-bar locking mechanism. Accordingly, the present invention should not be limited to the embodiment shown.
[0025] The push bar locking mechanism 10 comprises an electromagnetic element (described below) that can be energized to block the push bar from opening the door. This can allow for a number of doors to be electrically controlled to allow opening of the doors by the push bar. Alternatively, the electromagnetic element can be arranged to not allow opening of the door until a force is applied to the push bar. In this arrangement the force of the push bar causes the electromagnetic element to allow operation of the push bar to open the door. In both embodiments, the push bar locking mechanism is arranged to allow for near immediate opening of the door, overcoming any delay associated with residual magnetism.
[0026] [0026]FIG. 2 shows an exploded view of one embodiment of push bar locking mechanism 30 according to the present invention, which generally comprises a push bar 32 which has a U-shaped cross-section and is mounted within a bar frame 34 . The bar frame also has a U-shaped cross-section and is sized such that the push bar 32 fits closely within it and can be activated/pushed to move in and out of the bar frame 34 . The bar frame is mounted on a door, preferably in the horizontal position and in one embodiment the locking mechanism 30 is coupled to a spring biased bolt as described in FIG. 1.
[0027] The push bar locking mechanism 30 comprises a number of internal components pursuant to the present invention. One internal element comprises an electromagnetic locking mechanism 36 that is disposed longitudinally between the bar frame 34 and the push bar 32 and comprises an internal coil (not shown). As more fully described below, the electromagnetic locking mechanism provides for the push bar locking mechanism 30 to respond to an electrical signal to prevent the push bar locking mechanism from opening its respective door. Coils are generally known in the art and are only briefly discussed herein. An electrical conductor 38 is arranged to apply an electrical signal to energize the coil. When the coil is energized a magnetic field is created around the electromagnetic locking mechanism 36 that draws surrounding metallic objects towards it. When the coil is de-energized the magnetic field around the electromagnetic locking mechanism dissipates.
[0028] Elongated shiftable links 40 are arranged longitudinally and adjacent to the electromagnetic locking mechanism 36 and are operable when the coil is energized and de-energized. An armature 42 is arranged longitudinally and adjacent to the electromagnetic locking mechanism 36 and is movable within the push bar locking mechanism 30 when the electromagnetic locking mechanism is energized and de-energized. When the coil is energized the magnetic field draws the armature toward the electromagnetic locking mechanism 36 and when the coil is de-energized the armature can move toward the base of the bar frame 34 . As more fully described below this action of the armature is such that the push bar locking mechanism 30 is prevented from opening its door when the electromagnetic locking mechanism 36 is energized and conversely, the push bar locking mechanism 30 is allowed to open its door when the electromagnetic locking mechanism 30 is de-energized.
[0029] According to the present invention, the push bar locking mechanism includes a separation mechanism which overcomes the residual magnetism of the electromagnetic locking mechanism 36 when it is de-energized to permit almost immediate opening of the door. The separation mechanism can comprise one or more spring biased elements (described below) that engage an armature 42 and cause separation between the armature 42 and the electromagnetic locking mechanism 36 after it is de-energized. Without the separation force provided by the springs biased elements, the armature 42 can remain in temporary contact with the electromagnetic lock mechanism 36 by residual magnetism. This can temporarily preclude opening of the door, at least until such time as the residual magnetism has dissipated.
[0030] An elongated first lock link 44 , having each of its ends turned up to approximately 90 degrees, is arranged adjacent to the armature 42 and between the base frame 34 and the armature 42 . The armature 42 is arranged between the turned up ends of the link 44 and the ends of link 44 are connected to a respective one of first and second spring type actuators 46 a , 46 b , preferably to a base 48 on each of the actuators 46 a , 46 b . An elongated second lock link 50 , having at least one end that is turned up to approximately 90 degrees, is also arranged longitudinally within the push bar locking mechanism 30 in alignment with the first lock link 44 . The turned up end of the second lock link 50 is connected to the second spring type actuator 46 b , also preferably to the actuator base 48 .
[0031] When a force is applied to the push bar 32 the electromagnetic locking mechanism is de-energized and the armature 42 is pushed away from the electromagnetic locking element 36 by a spring biased element (described below). This action allows the first and second lock links 44 , 50 to slide/shift within the push bar locking mechanism 30 , which can in turn cause the spring biased bolt to disengage from the door frame so the door can be opened. Pursuant to the present invention, however, the first and second lock links cannot move until such time as there as the electromagnetic locking mechanism 36 is de-energized.
[0032] In the embodiment shown in FIG. 2, when the electromagnetic locking mechanism 36 is de-energized, a force applied to the push bar 32 is applied to actuators 46 a , 46 b , against the action of actuator internal springs (not shown). As the push bar 32 is pushed in toward the bar frame 34 , the actuators 46 a , 46 b compress, which in turn causes each actuator base 48 to slide toward the first end 52 of the push bar locking mechanism 30 . This causes the first and second links 44 , 50 to slide within and toward the first end 52 . As this occurs, the armature 42 is also shifted toward the first end 52 .
[0033] [0033]FIG. 3 shows internal components of the push bar locking mechanism 30 in more detail, including the electromagnetic locking mechanism 36 , one of the shiftable links 40 , the armature 42 and the first elongated link 44 . Different biasing elements can be included that can be arranged in many different ways to bias the armature away from the electromagnetic locking mechanism. In one embodiment according to the present invention, and spring biasing element 54 is arranged internal to the electromagnetic locking mechanism 36 , within an opening 56 and applies a spring separation force to the armature 42 .
[0034] As shown in FIG. 3, the electromagnetic locking mechanism 36 is energized such that the armature 42 is drawn against the electromagnetic locking mechanism 36 , which compresses the spring biasing element 40 . The armature further comprises an armature lip 58 and the electromagnetic locking mechanism 36 further comprises a stop 60 , with an indent 62 provided at the end of the electromagnetic locking mechanism 36 adjacent to the stop 60 . When the electromagnetic locking mechanism 36 is energized, the armature lip 58 is drawn into the indent 62 such that movement of the armature 42 , relative to the electromagnetic locking mechanism 36 , is blocked.
[0035] The first elongated link 44 comprises a link lip 64 , with the armature 42 arranged adjacent to the first elongated link 44 , between the link lip 64 and one of the turned up ends of the elongated link 44 . When movement of the armature 42 is blocked, movement of the elongated link 44 is also blocked by the link lip 64 and the turned up end butting against the armature 42 . As more fully described below, when the electromagnetic locking mechanism 36 is de-energized, the spring biased element 54 causes the armature 42 to separate from the electromagnetic locking element which permits movement of the first elongated link 44 .
[0036] [0036]FIGS. 4-6, show movement of the armature 42 relative to the electromagnetic locking element 36 , as the electromagnetic locking element is energized and de-energized. The first elongated link 44 and link lip 64 are shown. The armature lip 58 , stop 60 , and indent 62 are not shown to simplify the description, but are shown in more detail in FIGS. 7-9. It should be understood that many different arrangements can be used to prevent movement of the first elongated link 44 when the electromagnetic locking mechanism 36 is energized, and the link 58 , stop 60 and indent 62 illustrates only one embodiment pursuant to the present invention. In FIG. 4, the electromagnetic locking mechanism 36 is not energized, and the spring biasing element 54 separates the armature from the electromagnetic locking mechanism 36 . In FIG. 5, the electromagnetic locking mechanism 36 is energized, drawing the armature 42 against it and compresses the spring within the opening 56 . In FIG. 6, the electromagnetic locking mechanism 36 is again de-energized and the armature is again separated from the electromagnetic locking mechanism under the bias of the spring biasing element 54 . The spring biasing element is strong enough to overcome residual magnetism of the electromagnetic locking mechanism 36 , allowing for near immediate separation of the armature 42 and electromagnetic locking mechanism 36 , and near immediate operation of the push bar locking mechanism 30 and opening of the door.
[0037] [0037]FIGS. 7-9 show in more detail the movement of the armature 42 relative to the electromagnetic locking element 36 , as the electromagnetic locking element 36 is energized and de-energized. Again the first elongated link 44 and its link lip 64 are shown and in each of FIGS. 7-9, the spring biasing element 54 , opening 56 , armature lip 58 , stop 60 , indent 62 and link lip 64 are shown in more detail. In FIG. 7, the electromagnetic locking mechanism is not energized and the spring biasing element 54 extends from the electromagnetic locking mechanism 36 , causing a separation with the armature 42 . This in turn causes the armature lip 58 to move out of the indent 62 such that the armature 42 can move relative to the electromagnetic locking mechanism 36 . This in turn allows the first elongated link 44 to move in response to the first and second spring type actuators 46 a , 46 b , which operate in response to movement of the push bar 32 (all shown in FIG. 2).
[0038] [0038]FIG. 8 shows the electromagnetic locking mechanism when it is energized with the armature 42 drawn toward it and the spring biasing element 54 compressed within opening 56 . As described above, this causes this armature lip 58 to be drawn into the indent 62 such that the armature is blocked from longitudinal movement, which in turn blocks the first elongated link from longitudinal movement by the first and second actuators 46 a , 46 b . Accordingly, the push bar 32 is blocked from opening the door until the electromagnetic locking mechanism is de-energized.
[0039] [0039]FIG. 9 again shows the electromagnetic locking mechanism 36 when it is de-energized, with the spring biasing element 54 separating the armature 42 and electromagnetic locking mechanism 36 . This in turn forces the link lip 64 out of the indent 62 to allow movement of the armature 42 and the first elongated link 44 . FIG. 9 shows the first elongated link 44 and armature 42 after movement of the first elongated link 44 by the first and second actuators 46 a , 46 . The link lip 64 is out of alignment with the indent 62 and this movement can cause the spring biased bolt 18 to retract from the bolt receiving opening 20 to allow the door 12 to open (see FIG. 1). This present invention thereby provides a unique and novel push bar door mechanism with rapid unlocking.
[0040] It is understood that many different mechanisms can be used for the spring biasing element in push bar locking mechanisms according to the present invention. The spring biasing element 54 shown in FIGS. 4-9 generally comprises a coil spring with a inflexible ball of ceramic, metal, plastic or the like on top of the spring. The diameter of the opening 56 is slightly smaller than the diameter of the inflexible ball, such that the ball protrudes from the opening in response to bias of the coil spring. Another embodiment of a spring biasing element according to the present invention comprises a resilient, flexible, compressible, elastomeric plug of rubber or plastic seated in the opening 56 . A portion of the plug extends from the opening and is compressible back into it. A third embodiment according to the present invention comprises a resilient compressible, elastomeric plug at the end of a coil spring, with the spring extending the plug from the opening. A fourth embodiment according to the present invention comprises a coil spring in the opening 56 that can extend from the opening.
[0041] Although the present invention has been described in considerable detail with references to certain preferred configurations thereof, other versions are possible. Therefore the spirit and scope of the claims should not be limited to the preferred version contained herein.
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A push bar locking mechanism for locking and unlocking a door also comprising a push bar arranged integral to a bar frame such that the push bar can be moved relative to the bar frame. An elongated link is integral to the push bar and bar frame and is movable in response to the push bar movement relative to the bar frame. The movement of the elongated link causes a door locking mechanism to move between a locked and unlocked position. An electromagnetic locking mechanism is included that can be changed between an energized and de-energized state by an electrical signal, wherein the electrical locking mechanism generates a magnetic field when energized. An armature is also included in proximity to the electromagnetic locking mechanism and the elongated link. The armature prevents movement of the elongated link when the electromagnetic locking mechanism is energized.
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CROSS REFERENCE
[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 61/892,166 having a filing date of Oct. 17, 2013, the entire contents of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a system including a set of sensors capable of collecting information on the environment of a vehicle-ground interface, and methods for the use of this information to improve vehicle safety.
BACKGROUND OF THE INVENTION
[0003] Environmental conditions significantly impact vehicle behavior. This is most commonly noted as degradation of vehicle stopping capabilities in inclement weather such as snow or ice. Such degradations mean that driver behavior should ideally adapt to match immediate road conditions, and that in some cases drivers should entirely avoid areas deemed to be too dangerous, for example those with “black ice”.
[0004] Road conditions can be generally estimated based on known weather conditions. However, both weather conditions and road temperatures can vary dramatically over short distances, so that general area weather forecasts are insufficient to provide specific driving advice to a vehicle in a particular area. Thus, more granular data on weather, and specifically on road conditions, would be of value to improve the safety of drivers.
[0005] Stopping distance and general vehicle safety also depends dramatically on the specific vehicle being driven. Vehicle stopping distances may vary based on vehicle model, vehicle weight, brake quality, and tire tread conditions. Thus, in a defined road location two vehicles with different characteristics may experience dramatically different stopping distances. As a result, knowledge of the weather or road conditions themselves are not sufficient to ensure driver safety.
[0006] The interplay between vehicle and road at a given instant is considered as an input in existing anti-lock braking systems (ABS). In such systems, the tangential acceleration of one or more wheels is measured and compared with the acceleration rate of the vehicle. Because the tire has lower mass than the vehicle it can decelerate much more quickly than the vehicle, and as a result the tire can “lock” in a state where it does not rotate. This locking is undesirable, because the co-efficient of friction of a tire in its locked state is substantially lower than the optimal coefficient of friction for that tire.
[0007] ABS uses a closed-loop control process to optimize the amount of rotation in the tire, and thus optimize coefficient of friction. In ABS, the amount of force applied to the brakes is automatically relaxed if lock (or, more generally, slip) is detected in order to allow the tire to rotate again. The braking is re-established once rotation is sensed. Ideally, this system functions so that the optimum coefficient of friction (corresponding to an optimum amount of tire slip) is maintained during braking.
[0008] While the above closed-loop system can provide excellent control over vehicle braking in an emergency situation, it is not capable of making predictions of future vehicle safety performance, or of assessing its performance versus a baseline. While ABS assures “optimum” braking for the particular emergency case, there is no ability to analyze whether this “optimum” is good enough—whether it represents a safety performance level that will be satisfactory in other situations.
[0009] Thus, while it is possible to provide general advice for a generic vehicle during inclement weather, and it is possible to optimize the safety of a specific vehicle after a loss of control has occurred, it is not currently possible to provide targeted advice to a vehicle about how well it can perform in specific weather conditions and/or upcoming road conditions.
SUMMARY OF THE INVENTION
[0010] The presented inventions are directed to a system that includes sensors and sensor systems, and methods for analyzing data from these sensors, in order to measure characteristics of the tire/road interface in varying environmental conditions, as well as to provide information, guidance, and predictions to drivers, fleet managers, traffic managers, safety services, navigation and/or self-driving vehicle systems, models, services and other interested parties that use weather information and predictions.
[0011] One aspect of the invention is the fusion of multiple sensors, sources of information (including databases) along with models to create or provide information that is not available through the individual sensors alone. In effect, many sensors are actually effected through sensor fusion—for example, differential GPS is effected using the outputs of more than one GPS sensor. If the sensors are not conveniently co-located, the communication system(s) become an integral part of the sensor fusion. In many sensor fusion applications, processing power and modelling are also an integral part of the sensor fusion. Data used in the model(s)—say data from a database—may become, in essence, another sensor that is fused. An example here would be the street map database for a Geographic information system (GIS) being fused with GPS information to display a real time position map on a smartphone of a moving cars position.
[0012] In one embodiment, sensor fusion is done before transmission to reduce the use of limited bandwidth, and to reduce the costs associated with using costly bandwidth (e.g. cell connections). In another embodiment, models reside on the sensor or hubs processor to reduce the costs or bandwidth of transmission, and these models may be updated using OTA.
[0013] In some embodiments, the presented inventions includes inertial measurement sensors comprising accelerometer(s), gyroscope(s), and/or magnetometer(s) that are added to a vehicle to measure its motion. In some embodiments, these inertial measurement sensors are added directly to one or more wheels of the vehicle to measure its tangential motion, velocity, and/or acceleration. One or more such sensors may be added to a non-rotating member of the vehicle such as the bumper to measure its linear and angular motion and or position. In some embodiments, the sensors are added at the lug nut of the wheel to capture tangential acceleration at this position. In other embodiments, one or more sensors are added to a tire pressure monitoring system (TPMS), or affixed inside or outside of the tire or axel.
[0014] In one aspect of the presented inventions, sensor data is used to compute coefficients of friction and slip ratios for the vehicle in certain situations. For example, the wheel rotational acceleration and/or velocity are compared with the linear vehicle acceleration and/or velocity and the difference between the two are computed in order to provide an estimate of coefficient of friction and/or slip ratio. Multiple such measurements may be utilized to generate curves, equations and/or tables of coefficient of friction vs. slip ratios. Likewise, such curves, equations and/or tables may be generated for differing environmental and/or road conditions. In another example, the change in velocity and/or acceleration of a vehicle is calculated during a braking situation in order to provide an estimate of coefficient of friction. In some embodiments, this rate of change is measured by using GPS to identify the known distance over which braking has occurred, and measurement of the total time of braking in order to establish the time over which braking has occurred. In some embodiments, the wheel rotational orientation and vehicle speed along a road with a known geometry is measured in order to estimate the weight of the vehicle. In some embodiments, sensors such as radar, lidar, sonar, or (e.g. 3D) computer vision are used to measure/estimate the distance to other objects, which can be combined with stopping distance information to provide safety information. In some embodiment, computer vision is used to determine visibility, weather conditions (e.g. sleet hail, or black ice), road conditions (e.g. potholes and buckling) and roadside hazards and issues (e.g. semi-tractor trailer tires that have been shed, dead animal etc.). In other embodiments, the tire pressure is measured in order to estimate the vehicle's tire radius and/or contact surface with the ground.
[0015] In another aspect of the presented inventions, profiles of coefficients of frictions and slip ratio and plots of coefficient of friction (COF) versus slip ratio for a vehicle are compiled over time, across a variety of road environments. In one embodiment, these profiles are tagged with information about geographic position and/or are tagged with information about time. In one embodiment, these profiles are tagged with information about environmental conditions. Such environmental conditions may be identified from information provided from the National Weather Service or National Center for Atmospheric Research's (NCAR's) Pikalert system, Road Weather Information System (RWIS), Meteorological Terminal Aviation Routine Weather Report (METAR) or Terminal Aerodrome Forecast (TAF), UCAR's Location Data Manager (LDM) Etc. In another embodiment, the environment conditions are derived, at least in part, by sensor(s) on or near a vehicle at the time the measurements relating to coefficient of friction and slip ratio are taken. In one embodiment, local precipitation is measured using a precipitation gauge mounted on the vehicle, for example on the front windshield. In such an embodiment, the type of precipitation (e.g., rain, snow) is measured directly by the precipitation sensor or inferred from a combination of sensor measurements. In one embodiment, local road temperature and conditions are monitored by an infrared camera mounted to the vehicle, for example on the vehicle bumper. Likewise, light or camera sensors may be used to detect/measure cloud cover. Further, motion sensors may be used to detect/measure wind velocity and gusts.
[0016] In one embodiment, at least one of these sensors communicates to a hub device using a wireless communications protocol. In one embodiment, this wireless communications protocol is Bluetooth or Bluetooth Low Energy. In one embodiment, this wireless communication uses a technique other than conventional electromagnetic radiation, such as magnetic or acoustic communication. In one embodiment, the hub device is a cellular phone. In one embodiment, this cellular phone has one or more applicable sensors, such as an Inertial Measurement Unit. In one embodiment, the hub is connected to the On Board Diagnostics (OBD) system of the car, drawing power and/or measurements from the OBD. In one embodiment, the hub is a device capable of running many applications that make use of the systems capabilities (e.g., an Android device).
[0017] In still another aspect of the presented inventions, the COF or COF vs slip ratio curve for a vehicle are predicted for future environmental conditions and/or future road conditions based on the past COF performance of the vehicle. In one embodiment, the future environmental condition is chosen based on a vehicle's expected travel path. In one embodiment, the future environmental condition represents the present environmental condition at a location that the vehicle will soon be in. In one embodiment, the future environmental condition includes a prediction of the environmental state of that location based on a combination of the present environmental condition and a model that predicts environmental changes. In one embodiment, the future environmental condition is derived at least in part from a report from the National Weather Service. In one embodiment, the future environmental condition is derived at least in part from environmental data taken at that location by fixed sensors. In one embodiment, the future environmental condition is derived at least in part from environmental data taken at that location by mobile sensors. In one embodiment the mobile sensors are affixed to other vehicles. In another embodiment, future road conditions are derived at least in part from road condition information taken by mobile sensors. In one particular embodiment, future or upcoming coefficient of friction information and/or environmental information for a travel path of a vehicle are provided to the vehicle. This upcoming road surface information may be utilized with stored profile information of the vehicle to determine vehicle specific safety information and/or to generate warning outputs.
[0018] In yet another aspect of the invention, the future COF is obtained by matching the previously measured COF values and/or curves with environments that resemble the future environment, and selecting COF values that most closely match that environment. In one embodiment, the future COF is obtained by first building a model for COF as a function of environmental conditions for a particular vehicle, and then extrapolating from this model to predict the COF for these future environmental conditions. In one embodiment of the invention, data from one or more sensors, vehicles, etc., is stored in a computer database. In another embodiment, models are constructed using Big Data (data analytics/predictive analytics) methods and/or control theory methods such as system identification.
[0019] In further aspects of the invention, COF and COF versus slip ratio data for a plurality of vehicles are compiled to form a library of COF data. In one embodiment, data from more than one vehicle in this library is combined to form at least one element of an assessment of road conditions in a specific location common to these vehicles. In one embodiment, the future COF of a first vehicle is predicted based on a mathematical model which comprises data from vehicles other than this first vehicle.
[0020] In still yet another aspect of the invention, the driver, owner, insurer, or other interested party of a vehicle are alerted to the potential for poor safety performance at a future time. In one embodiment, the interested party is notified if the vehicle's future path is anticipated to take the vehicle to a location where its predicted COF will be below a threshold level. In another embodiment, the interested party is notified if the COF is predicted to fall below a threshold value in weather conditions that are common to the vehicle location. These alerts may be output in any appropriate manner to a driver of the vehicle and/or to vehicle systems (e.g., traction control).
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows a relationship between COF and slip ratio.
[0022] FIG. 2 shows an illustration of the forces impinging on a block sliding on an inclined plane.
[0023] FIG. 3 shows a perspective view of a vehicle with sensors formed in accordance with embodiments of the invention.
[0024] FIG. 4 shows a block diagram of communication and processing systems formed in accordance with various embodiments of the invention.
[0025] FIG. 5 shows an exploded view of a lug nut sensor formed in accordance with one embodiment of the invention.
[0026] FIG. 6 shows an exploded view of a wheel-mounted sensor at or near the tire pressure measurement system formed in accordance with one embodiment of the invention.
[0027] FIG. 7 shows an exploded view of a bumper sensor suite formed in accordance with one embodiment of the invention.
[0028] FIG. 8 shows an exploded view of a windshield sensor formed in accordance with one embodiment of the invention.
[0029] FIG. 9 shows an exemplary system that forms a COF/slip profile from sensor data.
[0030] FIG. 10 shows an exemplary system that estimates current environmental conditions from sensor data.
[0031] FIG. 11 shows an exemplary system that notifies an interested party in the vehicle if the vehicle is anticipated to encounter a potentially hazardous environment.
[0032] FIG. 12 shows an exemplary system that combines multiple vehicle outputs and/or profiles into a library which can be used to predict vehicle performance in future environments.
[0033] FIG. 13 shows exemplary COF/slip profiles for a vehicle for different environmental/road conditions.
[0034] FIG. 14 shows a travel path of a vehicle with road surface information for different road segments of the travel path.
[0035] FIG. 15 shows an alternate suggested route for the travel path of FIG. 14 .
[0036] FIG. 16 shows a process for generating safety outputs at a vehicle.
[0037] FIG. 17 shows a process for gathering and distributing road surface information.
DESCRIPTION OF THE INVENTION
[0038] The present invention identifies new and surprising methods for improving vehicle safety by enabling prediction of coefficient of friction, slip ratio, and/or stopping distance for a specific vehicle at a time in the future. The present invention includes sensor(s) and components that perform analysis techniques to customize a prediction to a particular vehicle in order to optimize the utility of the information.
[0039] Generally, aspects of the presented inventions use techniques of “information fusion” to create new information. A definition of information fusion is provided by the International Society of Information Fusion: “Information fusion is the study of efficient methods for automatically or semi-automatically transforming information from different sources and different points in time into a representation that provides effective support for human or automated decision making.” These different sources can include at least two elements from the classes comprising sensors, external data sources, mathematical models, algorithms, etc., as well as combinations of these elements that may be generically described as sensors in these descriptions
[0040] Information fusion can be used to combine measurements/data (and information) from more than one source—often in concert with models in ways that allow one to access information and make predictions about quantities and qualities using sensor fusion and/or information fusion that are not present in any raw measurements/data from one source. A model in this context represents a mathematical representation of a physical system, wherein, for example, the physics of one characteristic can be estimated or predicted based on input values from other characteristics, and includes a broad range of techniques such first principle dynamic models, statistical models, system identification, and neural network and deep learning systems. Data generated by such a process can be broadly called “fusion data”, and may be used directly or serve as an input to another model.
[0041] This analysis can result in an estimate of a characteristic of a system that is not directly measured by the sensors. Additionally, one can fuse two measurements of similar quantities into improved information, for example using two measurements—one accurate not precise, and one precise but not accurate—into an estimate of the quantity which is both more accurate and precise.
[0042] Sensors and information sources which have applications to vehicle sensor/information fusion and or safety include: vehicle sensors networked to the On Board Diagnostics (OBD, dashboard cameras (including dual, three-dimensional, and array cameras, and rearview/backup and/or 360 view cameras, as well as driver and passenger facing cameras), spectroscopic sensor systems, visibility sensors (e.g. extinction coefficient backscattering sensors or integrating nephelometer), sensors such as magnetic loops, micro radar, temperature, and magneto-restive wired and wireless sensors (which may or may not be embedded in the pavement), toll-taking sensors (including RFID, DSRC, and other technologies), distrometers, particulate counters, and ceilometers, lightning sensors, linear optical arrays, proximity detectors, magnetic position sensors, gas sensors, color sensors, infrared pyrometers (especially in linear arrays) and cameras (e.g. temperature sensors), RFID and other location tagging, blind spot sensors such as radar, car ahead-behind distance sensors, and pavement sensors optical and spectral analysis sensors, battery “fuel gauges”, infrared pyrometers, and location technologies such as GPS, Galileo, and Glonass, as well as integrated systems such as GNSS, sensors for precipitation type and amounts, wiper sensor, irradiance and UV/IR sensors (useful both for weather measurements and as instrumentation for estimating available Photovoltaic energy), cloud sensors, roadside snow sensors, computer vision (e.g. sensing lane markers, other vehicles, and roadside traffic markers), lightning sensors, barometric pressure, particulate count, and pollution and chemical sensors, sonic sensors and microphones (e.g. sensors for use in creating sonic profiles of road and tier noise and/or doing FFT analysis of sounds, for the purposes of sensing road surface type, road surface conditions, and precipitation-tire interaction), range finding sensors (e.g. distance to vehicle in front/back), mems sensors, etc. Sensors may also be in the form of information from vehicles and vehicle management systems, such as traffic jam auto drive, auto park, parking space management, and GIS systems with mutli-layer data sets about vehicles, conditions, weather, predictive analytics, etc. Sensors may be the outputs of smart phone and/or car sensor sets—connected to internet via cell, wifi, Bluetooth, etc. Smart phones themselves make excellent information fusion devices, containing a growing number of sensors and communications methods, as well as ever-increasing processing power and access to algorithms and databases via the internet.
[0043] These sensors can, as is appropriate, be connected sensors on vehicles, infrastructure, or persons, be part of connected technologies such as smart phones, smart watches, personal computers, vehicle instrumentation, be part of safety systems such as National Weather Service warning systems, police and fire response, traffic accident reports and lane closure warnings, General Motors OnStar system, etc. Sensors may also be in the form of crowd-sourced information, databases information, broadcasts, etc.
[0044] Sensors, information databases, models, processing power (including cloud technologies), and other elements of information fusion are now often distributed, and thus communications between these elements may be critical. Cell communications have become ubiquitous methods of communication, and have become well integrated in vehicle applications—standards include GSM (Global System for Mobile Communications, a de facto global standard for mobile communications that has expanded over time to include data communications. Other standards include third generation (3G) UMTS standards and fourth generation (4G) LTE Advanced standards. Additional communication methods applicable for the invention include: Satellite internet and telephony, Bluetooth and Bluetooth low energy, wifi, using regulated and unregulated frequency's (such as ISM), whitespace, DSRC (Dedicated Short Range Communications) including but not limited to vehicle to vehicle (including ad hoc networking for passing info such as braking, swerving, GPS position and velocities for avoidance, or in our case COF-Slip) and vehicle to infrastructure (such as traffic signals and signs), radio, repeaters, VHS (such as aircraft bands), infrared, spread spectrum, mobile ad hoc networks (MANETs) and mesh networks, public information systems such as the 5-1-1 telephone car information system (road weather information, ans transportation and traffic information telephone hotline) and National Weather Service Emergency Broadcast systems, and police, fire, ambulance, and rescue bands and systems. This list (and others in this specification) are to be considered illustrative and in no way limiting.
[0045] In one embodiment, input to a model takes the form of a specific measurement (e.g., a value). Input to a model can also take the form of a relationship between two variables, which together define a curve. An example value is the instantaneously measured wheel slip ratio of a vehicle. An example curve is a plot of a relationship between wheel slip ratio and COF for a specific environmental condition. A curve includes measured data and/or data extrapolated from models.
[0046] In one embodiment, input to a model takes the form a more complex “profile”, which includes an array of data associated with a given vehicle. An example profile in this invention is an array of COF versus slip ratio curves for a single vehicle in a number of different environmental conditions. In one embodiment, a profile includes measured data as well as data extrapolated from models. In one embodiment, this profile(s) is stored at the vehicle in a memory unit. In another embodiment, this profile(s) is stored remotely from the vehicle and is accessible by the vehicle and/or similar vehicles via a communications module. In the latter regard, vehicles that have not yet calculated a profile(s) or dot not have adequate sensors to calculate such a profile(s) can access pertinent profile information.
[0047] In one embodiment, input to a model takes the form of a “library”. A library includes a set of multiple profiles. For example, such a library may include COF data from all vehicles that have passed by a particular location and/or includes COF data from a set of similar vehicles, or vehicles with similar tires, or of similar ages, etc. A library is used for inferring the anticipated characteristics of a specific vehicle by comparison with other, similar vehicles. A library includes measured data as well as data extrapolated from models.
[0048] Output from the model is termed a “prediction”, and represents an estimate of the current or future state of a variable that is not directly measured by the sensors. An example prediction from a model is the maximum COF of a vehicle in environmental conditions in a region beyond the exact region of the vehicle at a particular moment. A “vehicle” in this invention can refer to one or more commonly used transportation systems, including a car, a self-driving car or drone, truck, etc.
[0049] One metric of the safety of a vehicle is the vehicle stopping distances. The stopping distance is determined by several factors, including the speed of the vehicle, the mass of the vehicle, and the coefficient of friction between the vehicle and the road. While the vehicle mass can be reasonably estimated by the driver, and its speed is constantly measured by the speedometer, the coefficient of friction is usually not known to the driver, as it is not measured or reported by vehicle systems. The coefficient of friction represents the most significant uncontrolled variable in vehicle safety. Worse, the coefficient of friction can change suddenly on a road, for example as a vehicle moves from dry road to a puddle, or from snowpack to black ice. As a result, road safety is best quantified through coefficient of friction, and means to both measure and predict coefficient of friction produce valuable safety improvements.
[0050] The coefficient of friction at the tire/road interface varies as a function of the “slip ratio” of the wheel, where a slip ratio of zero indicates a freely rolling tire, and a slip ratio of one indicates a completely locked tire. Without being bound by theory, it is believed that the coefficient of friction between tire and road has a maximum at a specific slip ratio. FIG. 1 shows a typical relationship between coefficient of friction and slip ratio. A relationship such as this is referred to as a “COF curve” for a specific road condition. Anti-lock brakes attempt to maintain the COF as close as possible to the maximum value of this curve during aggressive braking. A locked wheel has significantly lower COF than the maximum achievable COF, and is therefore to be avoided if possible. The exact details of this curve, including the COF maximum value, depend on the specifics of the tire, vehicle velocity, and the environmental conditions of the road (e.g., clean dry asphalt, dirt road, packed snow on concrete, etc.).
[0051] In one embodiment, the present invention produces one or more profiles of COF values and COF curves associated with a particular vehicle. See, for example, FIG. 13 . The profiles are created by measuring COF and/or slip ratio using at least one sensor under at least two environmental conditions, and storing the values of COF and/or slip ratio in a database. Such profiles may be stored alongside descriptive information about the environment. The descriptive information may include time, location (e.g., as determined by GPS), other sensor information, local weather conditions, etc. The descriptive information may also include pointers to other information sets, such as weather databases, which are not locally included in the database. Further, such profiles may be periodically updated. This allows changing of a vehicle specific profile as conditions of the vehicle change. This may allow, for example, altering profiles as the tires of the vehicle wear.
[0052] The instantaneous ratio of the tangential velocity of the tire where it meets the road and the velocity of the vehicle to which it is attached is defined as the “Slip ratio”. When braking (or accelerating) in a moderate manner, the tangential velocity of the tire where it meets the road is a little slower (or faster) than the relative velocity of the vehicle vs. the road itself, and the tire “slips”.
[0053] A vehicle safety system is most concerned with the sliding coefficient of friction, which will determine braking distance for a vehicle at a given mass and speed. The sliding (kinetic) COF is defined as μ k =F f /N where F f is the friction force between the vehicle and ground, N is the normal force (gravity) pushing the vehicle and ground together, and μ k is the COF. This is conceptually the same formulation as for a block sliding along a plane, as illustrated in FIG. 2 . A very slick surface will have μ k <<1, as the friction forces are very low. A tire on a high quality asphalt road will have a maximum COF of about 0.85.
[0054] When a vehicle is on a flat (non-inclined) surface, the force N=mg, where m is mass and g is gravitational acceleration. In some embodiments of the invention g=9.81 m/s, and in some embodiments of the invention g can be modeled or derived from a look-up table based on the exact location of the vehicle. The force N represents the force normal to the ground, and will change with the inclination of the vehicle. In some embodiments of the invention, inclination of the vehicle is measured or estimated using an inertial measurement system, which itself may include accelerometer(s), gyroscope(s), inclinometer(s), and/or magnetometer(s), where the information from the inertial measurement system is input into a model to calculate inclination. In some embodiments of the invention, inclination of the vehicle is further measured using global positioning system (GPS) data, which can infer inclination based on known topography of the roads, and can infer orientation based on known direction of travel and/or based on magnetometer measurements. In one embodiment, the inertial sensors are placed on a non-rotating member of the vehicle, such as on the front bumper. In some embodiments of the invention, inclination of the vehicle is measured using a bubble sensor. In any of these embodiments, the inclination is used to further inform the calculation of N and/or the calculation of COF.
[0055] In some embodiments of the invention the mass of the vehicle is estimated. In one embodiment, the mass is estimated based on a look-up table for the vehicle or is estimated using an optical imaging sensor which captures the size of the tire/ground interface for one or more tires. Based on the interface information and the known tire pressure as measured with the tire pressure measurement system, vehicle mass is calculated.
[0056] In some embodiments of the invention, COF is approximated using a formula that includes an input value a f , defined as the difference between the instantaneous tangential acceleration of the tire where it meets the road and the acceleration of the vehicle to which it is attached. Because the mass of the vehicle is a component of both the friction force and the normal force, these cancel each other and the value μ k =a f /g is directly measurable. In one embodiment, μ k =q*a f /g, where q is a fitting factor which may depend on factors such as vehicle inclination or other sensor measurements as discussed above.
[0057] In the above embodiments, forces are calculated using a “grey box” approach that relies on some first principles calculations. In another embodiment, COF itself or the component q are calculated using a “black box” approach that correlates COF with data derived from inertial and other sensors using a multivariable calibration fit approach without reliance on a specific physical model.
[0058] Measurements of slip are also useful for characterizing vehicle performance. Such measurements are performed in the vehicle using a device such as a hall sensor that is built into the wheel for this purpose as part of an ABS system. In one embodiment, the invention tracks GPS position over time to establish vehicle velocity as an input to model slip. In this embodiment, the tangential velocity of the wheel(s) is measured using a gyro or set of gyros attached to the wheel(s), and this is input into a model for the calculation of slip. In some embodiments, data from the accelerometer(s) is used as an input to improve the estimation of the velocity of the vehicle and/or wheel(s), where a velocity at time t n may be estimated based on knowledge of the velocity at a time t m and the acceleration a n-m during this time.
[0059] In one embodiment, measurements of both COF and slip are made using the same or overlapping sets of sensors. In another embodiment, slip may be inferred or calculated based on COF information. In one embodiment, data is received from inertial measurement sensors disposed on at least one rotating member, and on at least one non-rotating member. FIG. 3 shows an exemplary arrangement of sensors on a vehicle 300 , with a sensor or set of sensors 301 disposed on a wheel lug nut, and a sensor or set of sensors 302 disposed at the front bumper. FIG. 3 also shows an optional sensor or set of sensors 303 disposed on the windshield, which can be used for at least detecting precipitation. These locations represent one set of possible placement of sensors, and are not meant to be limiting.
[0060] The sensors are in wired or wireless communication with each other and/or with a central communications node (device), which may be inside or outside the vehicle, and which provides communication with the outside world. In one embodiment, communication between the sensors and the communications node is accomplished through Bluetooth LE. In one embodiment, a sensor may connect to a second sensor but not have a direct connection to the communications node, and in so doing, the sensors form a mesh network. Wireless communications systems may require antennas, and antenna placement, polarization, and directionality may be important for the application. In one embodiment, a sensor or communications hub is placed inside the vehicles windshield, where the signals satellite communications, GPS, infrastructure, and other sensors are unimpeded, or where the signal path to other sensors has the least obstruction (e.g., metal shielding). In another embodiment, the directionality, polarity, placement, and signal output timing of a wheel mounted sensor is chosen so as to improve the reception strength at another sensor, communications hub, or device (e.g. transmission occurs during periods when the hub of the wheel is not obstructing the signal as the sensor rotates with it).
[0061] FIG. 4 shows an exemplary system 400 that includes a wheel sensor 401 and a fixed sensor 402 , which are in data communication with a communications node 404 . To illustrate the potential use of a mesh network, the communications system 400 also includes an additional sensor(s) 403 which communicates to the fixed sensor(s) 402 , but not directly to the communications node 404 . The sensor 402 or 401 relays data from the sensor 403 back to the communications node using a wired or wireless connection. This may favorably save power in some configurations, depending on factors such as the distance of the sensors 401 - 403 from each other and from the communications node 404 . Note that this configuration is not meant to be limiting, merely illustrative. In one embodiment, a communications network might be established up from the individual sensors via BLE to the hub on one vehicle, via a cell network from that vehicle to the cloud, then through the internet and out via wifi connections of passing homes or businesses to a second vehicle, then between that vehicle and a third vehicle using Bluetooth or DSRC. In another embodiment, the houses or businesses might have sensor suites themselves, and pass information via wifi to the cloud, or via wifi or Bluetooth to passing vehicles. In yet another embodiment, roadside infrastructure (e.g. stop signs or streetlights) might be outfitted with sensors and/or communications hubs powered by photovoltaics, and communicate to the cloud via satellite internet, and to passing vehicles using DSRC or wifi.
[0062] The communications node 404 passes sensor data to an on-board processing module 405 which aggregates data from each sensor 401 - 403 . The communications node 404 may also be in contact with an external network such as a cellular network 407 , and may pass data via the cellular network 407 to a cloud database 408 and a cloud computing module 409 . The system of this invention may either use cloud computing module 409 or the on-board processing module 405 to process data from the sensors 401 - 403 and from the cloud components 408 , 409 . The on-board processing module 405 sends an alert to the driver via an output device(s) 406 if a threshold danger probability is reached. The output device(s) 406 includes audio, visual and/or tactile systems in the vehicle. In some embodiments, the on-board processing module 405 is configured with system memory, which may store the one or more profiles of the vehicle. In some embodiments, this stored profile(s) includes a family of COF vs slip ratio curves. FIG. 13 shows exemplary COF/slip profile curves for a vehicle for different road environmental conditions (e.g., dry pavement, wet pavement, compacted snow, smooth ice (i.e., black ice)). In some embodiments, the on-board processing module 405 is configured to retrieve profile information as an input into a model and/or for use with one or more inputs to, for example, make predictions about vehicle performance or estimations of environmental conditions.
[0063] In some embodiments of this configuration, the sensors 401 - 403 may send raw data to the communications node 404 or to each other. In some embodiments of this configuration, the sensors 401 - 403 further include onboard processing to reduce the data set and/or fuse information from one or more sensors, and thereby reduce the total communications overhead. The decision of whether to process the data on an on-board processor or send raw data to the communication node 404 depends on the relative power and bandwidth requirements of each mode of operation, and may differ for different sensors and/or locations of the sensors. Bluetooth Low Energy communication represents an exemplary communications operational mode, as it supports a star architecture, with the central device able to connect many peripheral devices, and supports over-the-air updates. In one embodiment, devices coordinate to “sleep” between short transmissions, significantly reducing power use. Alternatively, information may be stored and transmitted in bursts on higher-bandwidth, higher power-use devices such as standard Bluetooth or wifi. In that case, these devices may be powered down between bursts of transmission to save power.
[0064] In one embodiment, communications are accomplished through means other than radio frequency transmission, including wired transmission, optical transmission, acoustic transmission, magnetic induction, or transmission of electrical signals through the body of the vehicle, or through the vehicles on-board diagnostics (OBD), etc.
[0065] In one embodiment, one or more of the sensors 401 - 403 , on-board processing module 405 , and communications systems 404 are powered by scavenged power (also known as power harvesting or energy scavenging). Energy is derived from external sources constantly during use, or is derived intermittently and stored on battery, capacitor, super capacitor, etc. Example power sources include solar cells, kinetic energy devices that derive power from vibrational, rotational, linear, or other motion of the vehicle, or a harvesting ambient radiation source device (e.g., antenna collection of energy from radio waves, such as in a Powercast system, or via wifi or DSRC power scavenging). In one embodiment, a radio source is provided in the vehicle to create radio waves which are harvested by the sensors. In one embodiment, the sensors are equipped with Piezoelectric, Pyroelectric, Thermoelectrics, Electrostatic (capacitive), Magnetic induction, Mechanical, or Micro wind turbine energy harvesting capability. In one embodiment, a magnetic induction or piezo element is included in a sensor pack to harvest vibrational energy. In one embodiment, the rotation of the tire causes a magnet to move due to changing gravitational field and/or centripetal forces, inducing power in a coil for use in the system.
[0066] The system 400 may optionally include a memory device (or devices) 410 that stores information (wheelbase, tire types, deceleration/acceleration capabilities, etc.) pertaining to the host vehicle, or stores data when communications are interrupted or non-existent The processing module 405 uses stored information to generate profile information (described later). The memory 410 may also store raw and/or processed sensor information, road type/condition information and weather information. The road type/condition information and weather information as well as other information are received at the system 400 from an external source via the communications node 404 .
[0067] FIG. 5 shows a lug nut sensor 500 that is to be attached to a vehicle wheel. In this embodiment, the lug nut sensor 500 includes a screw 501 which threads through a tire package cover 502 to unite with a sensor package housing 506 and the lug nut 507 . The housing 506 includes two lithium polymer batteries 503 , an inertial measurement unit 504 having an accelerometer and gyroscope, and a microprocessor 505 with Bluetooth communications capability. In one embodiment, the accelerometer includes one 6 g 3-axis accelerometer with axes pointing radially, laterally, and tangentially with regard to the tire. In one embodiment, the sensor system 500 includes one additional 120 g one-axis accelerometer for direct measurement of radial accelerations at high speeds. In one embodiment, the microprocessor 505 calibrates the sensor, samples data, and filters it to produce measurements in radial, tangential, lateral axes of the tire. Such calibration is a typical sensor fusion application—e.g. gyros are prone to drift, but this can be compensated for in a full inertial measurement unit. Velocity measurements made using gyros on the tires can be undrifted GPS or accelerometers, etc. This sensor may of course alternatively be affixed to the outside of the vehicle wheel (e.g. using two-sided tape) or to the inside of the vehicle (e.g. attached to a band running along the inside of the hub).
[0068] To calibrate the tangential acceleration (y) measurement, in one embodiment the following approach is used:
1. At constant speed and perfect alignment, tangential acceleration (y) is 0; 2. Define calibrated x as positive to the “east” and calibrated y as positive to the “north”; and 3. At constant speed with misalignment angle θ, defined as a rotation of the system counterclockwise from x and y to x u and y u , the calibrated x and y are
[0000] x=x u cos(θ)+ y u sin(θ)
[0000] y=y u cos(θ)− x u sin(θ).
[0072] In one embodiment, the effects of gravity are averaged out by taking hundreds or thousands of measurements of x u /y u to obtain average measurements x u — avg and y u — avg . At constant velocity, y=0, and thus y u — avg ≅x u — avg tan(θ), such that it is possible to calculate θ=atan(y u — avg /x u — avg ).
[0073] In one embodiment, tangential acceleration is determined by sampling acceleration data at >30 Hz, with a predefined rate of sampling (e.g., 250 Hz). In this embodiment, over a (for example) time of measurement, the max and min values of (calibrated) y are identified, which will roughly correspond to acceleration up and acceleration down, and which will vary by +1 g and −1 g from true acceleration. These measurements are averaged to cancel out the effects of gravity to obtain a tangential acceleration estimate. This value is updated to the processor node, and the measurement process is repeated.
[0074] In another embodiment, tangential acceleration is calculated using a Kalman filter algorithm. In an exemplary process, lug nut tangential acceleration is defined as being proportional to tire/road contact point tangential acceleration—if R eff is the effective radius of the tire (measured from tire axel to road), and R hub is radius of hub to lug, then wheel tan — acc =R eff /R lug lug tan — acc +k, where k is a cyclical component due to gravity. The constants R eff and R lug are set using system identification or a calibration scheme. A Kalman filter which estimates the tire position and velocity—and thus the direction of gravity—is used to filter out the cyclical acceleration components due to gravity and to noise.
[0075] In another embodiment, a commercially available 6-axis sensor (x, y, and z axis accelerometer and x, y, z axis gyroscope on the same silicon chip), is used to directly measure the orientation and angular velocity of the tire. Most such chips are (presently) limited to perhaps 16 g accelerations and 2000 degrees per second. Mounted even a few centimeters from the hub of the wheel (example near a lug nut), a vehicle traveling at highway speeds would saturate an accelerometer channel pointed along the radial axis, and a gyro revolving around the lateral one. This limits the ability to determine the angular velocity of the tire (and thus linear velocity of the vehicle). However, in one embodiment the axis of measurement is offset to reduce the magnitude of both the acceleration and angular velocity measured. This creates a very straightforward linear reduction in the measurement of the angular velocity if the vehicle is going straight, but creates a complex relationship between the angular velocities of the other axes when the auto is turning. Similarly, this can create a very straightforward linear reduction in the measurement radial acceleration (which can be used to estimate the angular velocity) if the vehicle is going straight, but creates a complicated relationship between the angular acceleration of the tire and the estimated angular velocity, and changes the relationship between the position components of the acceleration in the offset radial and tangential measurements. In some embodiments, these complexities are resolved through further processing in a grey box or black box model.
[0076] FIG. 6 shows one embodiment of a wheel assembly 600 where a wheel inertial measurement sensor pack 605 is mounted at or near a tire pressure measurement sensor 601 in proximity to a valve stem 602 on a wheel 604 . The sensor pack 605 is connected by a valve stem retainer screw 603 , or alternatively is fixed in position by an adhesive.
[0077] In an alternate embodiment, the sensor set is affixed to the back of the wheel using an adhesive—the specific location can vary in implementation. In some embodiments, an antenna is added to the sensor system in order to improve communication capability with the communication node. In some embodiments, the tire stem is used as the antenna.
[0078] FIG. 7 shows a suite of sensors system 700 disposed on the front bumper. The system 700 includes a bumper sensor suite housing 701 , a power switch 702 , and a charge controller and voltage regulator 703 which controls charging of a battery pack 705 by a solar panel 704 . The solar panel 704 provides power to the system, and may also usefully measure insolation power levels in real time, and therefore may also be used as a sensor. Other embodiments may utilize other power sources. The system 700 further includes a Bluetooth modem 706 and a microcontroller 707 , which may be housed in the same package (e.g., a system on a chip) or in different packages. The system 700 may optionally include an infrared thermometer 708 and/or a microphone 709 , as well as an inertial measurement unit (IMU) 710 . A cover 711 protects the components of the system 700 .
[0079] In one embodiment, the sensors of the system 700 identify road surface type (e.g., concrete, asphalt, gravel, dirt), condition (e.g., worn, cracked, potholed), and covering (e.g., black ice, lose or packed snow, slush, rain, dirt, etc.). In one embodiment, the sensor(s) measure ambient temperature and/or relative humidity. In one embodiment, the IR sensor(s) 708 measure temperatures in front of the front tires. The microphone sensor 709 measures sound that is analyzed by a processor to quantify road noise, which may be correlated to weather conditions. The IMU 710 includes accelerometers, gyroscopes, inclinometers, and/or magnetometers. In one embodiment, the sensors additionally include optical image sensor (not shown) that provides imaging data that is used by a processor to quantify visibility, particulate counts, cloud cover, etc. In one embodiment, this status of the headlights is determined using sensors.
[0080] FIG. 8 shows an embodiment of a sensor that is attached to or near a windshield of the vehicle. The system 800 includes a housing 801 , a charge controller and voltage regulator 802 , sensor circuitry 803 , a sensor battery pack 804 , and a solar panel 805 . The solar panel 805 provides power to the components, and may also usefully measure insolation power levels in real time, and therefore may be used as a sensor as well. The system 800 further includes a Bluetooth modem 807 and a microcontroller 806 , which may be housed in the same package (e.g., a system on a chip) or in different packages. The system 800 may also include a capacitive sensor 808 and/or a swept frequency sensor 809 , as well as an optional ambient light sensor 810 . The system components are protected from the environment by a bottom level decal 811 . Attaching sensors inside the vehicle (e.g. inside the passenger compartment, tire, or engine housing) may serve to protect the sensors from extremes of temperature, UV, humidity etc. The sensors may alternatively/additionally be protected using superominphobic coatings for lenses, cases etc.
[0081] Information gathered by the system 800 includes precipitation detection, fog, rain, snow, ice, visibility and cloud cover, and/or windshield wiper frequency. The system 800 can be mounted inside or outside of windshield glass. Mounting the system 800 inside will increase the package's life.
[0082] In one embodiment, the swept frequency sensor 809 includes a Swept Frequency Inductive Precipitation Sensor, such as that previously described in U.S. Pat. No. 6,388,453 B1. While '453 describes the use of sine wave sweeping to obtain a response, signals besides sine waves are used—for example, a complex frequency chirp is sent, and a controls theory/signal processing method called an empirical transfer function estimator (ETFE) is applied to determine transfer function. The empirical transfer function estimate is computed as the ratio of an output Fourier transform to an input Fourier transform, using a fast Fourier transform (FFT). The periodogram is computed as the normalized absolute square of the Fourier transform of the time series. Smoothed versions can be obtained by applying a Hamming window to the output FFT times the conjugate of the input FFT, and to the absolute square of the input FFT, respectively, and subsequently forming the ratio of the results.
[0083] In an alternative embodiment for sensing of wiper frequency or precipitation, a light source such as a laser is shone onto the windshield at an angle below (or above) the Brewster's angle of the glass while dry. Precipitation causes a change in the optical index system such that the light now is above (or below) the Brewster's angle. Then when the wiper blade cleans the glass, the system briefly reverts, allowing detection of both the precipitation and the wiper activation via this optical sensor.
[0084] In one embodiment of the invention, the precipitation sensor measures amount or rate of precipitation. In another embodiment of the invention, the precipitation sensor measures type of precipitation, for example by changes in light scattering associated with snow. In another embodiment of the invention, precipitation type is inferred based on a combination of sensor measurements and/or information from weather sensors external to the vehicle.
[0085] When the vehicle is operating, both slip and COF are calculated continuously as the vehicle runs based on a data set including at least data from the wheel-mounted IMU and the fixed IMU. If the environment were always constant, this information could be used to define a curve showing the relationship between COF and slip. However, because road conditions change as the vehicle moves, there is no single curve defining the performance of the vehicle, and a profile of curves is built.
[0086] In one embodiment, vehicle environmental conditions are separated by separating COF vs slip ratio data into different clusters of performance, using a technique such as K-means.
[0087] In a further embodiment, this data on COF vs slip ratio is added to a database alongside further information including time, location, traffic, road type, and/or environmental conditions local to the data capture event. Road conditions are quantified based on an estimated risk associated with the known road type, for example scoring 1=dirt road, 5=highway, etc. In one embodiment, road conditions are quantified based on a score derived from COF measurements made by multiple vehicles. Environmental conditions are quantified on one or more axis to enhance mathematical processing of the data. For example, environmental conditions may be scored in terms of ambient temperature (for example, in ° C.), road temperature (for example, in ° C.), insolation power (for example, in W/m 2 ), precipitation intensity (for example, in cm/hr), etc. In some embodiments, an aggregate environmental score is compiled based on the hazard implied by different environmental elements. In one embodiment, an aggregate environment score is compiled with information about known road type and known environmental conditions. For example, a bridge may receive a high composite score under warm, sunny conditions, but may receive a dramatically lower score under cold, snowy conditions.
[0088] Elements of the database which are measured in high confidence may be usefully employed to identify more accurate values for elements of the database which have lower confidence. In one embodiment, a measured COF or slip value may be used to estimate an environmental condition, or a known environmental condition may be used to estimate a COF or slip value.
[0089] In one embodiment, measurements of COF and slip in known good environmental conditions (e.g., warm and sunny) is combined to create a curve for the vehicle that is generally accurate for good environmental conditions, thus eliminating the previously stated difficulty of clustering data automatically. FIG. 9 shows a system that builds a profile, where information from wheel inertial sensors 901 , the fixed inertial sensor 902 , and optionally the GPS 903 are transferred to a COF/slip computational module 904 , which calculates the local COF and slip ratio associated with this set of sensor data. This information is transferred to a vehicle profile calculator 906 , which fuses the COF and slip ratio information with information from an environmental database 905 and/or GPS data to create a profile for the vehicle. This information may optionally be transferred to an on-board vehicle profile database 907 and/or a vehicle profile database 908 in the cloud.
[0090] In another embodiment, measurements of COF for a vehicle is used to successfully identify adverse environmental conditions such as black ice. In this way, hyper-local environmental changes such as icing are easily identified by examining the COF performance of the vehicle after a profile has been created. FIG. 10 shows a system that estimates environmental conditions, where information from wheel inertial sensors 1001 , the fixed inertial sensor 1002 , and optionally a GPS 1003 are transferred to a COF/slip computational module 1004 , which calculates the local COF and slip associated with this set of sensor data. This information is transferred to an environmental conditions computation module 1005 , which fuses the COF and slip information with information from the vehicle profile 1006 and/or GPS data to estimate environmental conditions for the vehicle. This information may optionally be transferred to an environmental profile database 908 in the cloud, where it may be usefully applied to warn other drivers of adverse weather conditions in the GPS location where the measurement was taken.
[0091] Such a warning system is described in FIG. 11 . In this embodiment, information on the vehicle location from a GPS 1102 and optionally from a trip path module 1101 is fed into a vehicle location prediction module 1103 , which predicts the future locations of the vehicles during the trip. This information is fed into an environmental prediction model 1105 alongside environmental profile information from a database 1104 from the cloud. The environmental profile information includes data from the national weather service, local sensors, and/or data collected by other vehicles using the system described in FIG. 10 above, as well as other mobile vehicle weather collection processes. The environmental prediction information is passed to a vehicle warning module 1107 , which compares the environmental prediction with the vehicle COF/slip profile to identify whether the predicted environment will be outside the suggested operating specification for a vehicle with that profile. If a threshold is passed, this information is sent as a warning to an interested party 1108 . An interested party includes a driver, or a fleet owner, or an insurance operator, etc.
[0092] Information, guidance, and warnings may be provided in many ways, including via smart phone or watch (e.g. alarm bells, vibration, texts, phone calls, via traffic apps, text to speech, satellite communications system such as OnStar, and visual cues), as well as visually or auditorially through the vehicle's OBD display, navigation display or text to speech system, radio/entertainment console, vehicle or aftermarket heads up display, DSRC warning system, and many other means. In one embodiment, the information, guidance, and warnings are delivered via text to speech or heads up display to preserve driver concentration the road, In another embodiment, the warnings are integrated with the vehicles safety system to take action if the driver does not. In another embodiment, the information, guidance and warnings are delivered to a self-driving vehicle, so that the vehicle or driver may take appropriate action. In another embodiment, the guidance takes the form of a safe or advised driving speed, or warning to slow down. In another embodiment, the driver or navigator uses voice commands to request information, guidance, or warnings. In another embodiment, the warnings take the form of an escalating series of warnings with regard to weather, safe driving speed, safe stopping distance, or road conditions.
[0093] One novel thing element is that, before the weather moved and the (often sparsely located) sensors stayed still, the presented system uses moving mobile sensors that can send information machine-to-machine (M2M). The combination of mobility and M2M creates a “crowd-sourced” mobile sensor “fabric”, and the fabric is constructed such that most information is both generated and consumed where there are the most users and sensors. Individual people may perceive changing clouds and precipitation in one area, but networked and fused sensors see changes in pressure, irradiance, humidity, and precipitation rates over large areas, as well as have access to historical weather and data patterns, and thus the whole system is able to do analysis and prediction different in kind rather than degree.
[0094] In one embodiment, a plurality of sensors send to a smartphone acting as a hub, which aggregates, organizes, fuses and/or prepares information; a plurality of smartphones, posts that information to a collection system, where it is quality control checked; a buffering system stores and prioritizes and organizes the data in queues; the data are then fused with existing data such as weather, road, GIS, databases, to create a current situational picture; these situational pictures are made available using (for example) geofencing techniques, both to alert and organize data about motorists and geographic areas; geofencing implies that now we can follow up with a set of triggers, these triggers being assigned to mobile entities, based on fused criteria, indicating desired alerts based on individual preferences.
[0095] Additionally, such a machine-to-machine system is able to return information back quickly and per user preferences—the system can have “smart triggers”. A simple temperature gauge may alert a user with a red light when the temperature goes below a set value, but a smart trigger seeks information and makes warnings that are context sensitive—such as warning as user about how the confluence of the rate of decrease in pavement temperature and predicted precipitation may generate frozen pavement. Using modern software technologies like Pagerank or Twitter that look for important signals using eigenvectors, these signals can result in information, guidance, or warnings routed to a unique user by indexes to the most important links in the eigenvector in a very fast manner. In such a system, metadata is fused together, an eigenvector analysis is run, then indexed the most important events, making it lightning fast to both find the smart triggers and/or users. This can provide fast M to M alerts—in one embodiment, machines automatically spraying salt on a road that will soon require it, or lower barricades on roads that may soon experience white out conditions, or trigger road signals warning of black ice, all in a very fast and automated manner, scalable to huge numbers of users and triggers.
[0096] Use cases for the user criteria of such a system include: soccer mom's criteria is whether she can drive 3 miles safely in the small geofenced area between home and practice; a medium-haul limo service will look at a larger geofenced area, and want fused information about traffic, weather, known pick up sites, and historical patterns in order to make the most efficient run; maintenance and logistics organizations will want to watch vehicles roll over road segments to see what needs repair or where slowdown may be predicted to occur—their user criteria may be real-time analysis, or it may be a forecast about the desirability of salting an iced road in the next four hours, paving a bumpy road in the next four months, or allocating a budget for the next four years; long hall trucking businesses may wish to add weather and road condition forecasts to the fleet management and fleet routing services that are commonly employed by such concerns.
[0097] The availability of the various information available to such a system may be used in novel ways. For instance, unique signals can be created which may be analyzed using advanced mathematical and analytical techniques, identifying conditions, and forecasting conditions in ways that were previously unavailable (e.g., machine learning algorithms with novel features for weather knowledge and actionable information, and neural networks provide logistic regression outputs not previously available do to the scarcity of information about road weather conditions).
[0098] A method of using this data may for example include receiving tire slip information and/or COF information from vehicle sensors; receiving one or more external environmental conditions information from a database; receiving a route request having at least route information and time of departure information; generating safety values for a plurality of portions of the requested route based on the received environmental conditions information and previously stored vehicle performance information associated with the route request; determining if the generated safety values meet at least one of a predefined safety threshold or a time of travel threshold; if the determination indicates that one of the safety values fails to meet the at least one safety threshold or the time of travel threshold, generating at least one of a new route or a new time of departure that would cause the generated safety values to meet the safety threshold or the time of travel threshold; and presenting the generated new route or new time of departure to a user or interested party associated with the route request. In one embodiment, the database data includes COF/slip information collected from a plurality of sensors located on a plurality of ground vehicles.
[0099] As noted, vehicle sensor and/or profile information may be usefully combined into a vehicle library or database in the cloud. This library or database will allow estimation of COF/slip performance in weather and/or road conditions for a specified vehicle, even if that vehicle does not have a profile that extends to the current environmental and/or conditions, by comparing this specified vehicle with other vehicles with similar properties and/or using sensor outputs from other vehicles. Similar properties may include, but are not limited to, similar model/make, similar tires, similar number of miles on the tires, similar profiles in measured weather conditions, COF measurements of vehicles traveling over current trip path of a vehicle, etc.
[0100] Such a process is shown in FIG. 12 , where sensor measurements and/or profiles from multiple vehicles 1201 , 1202 , 1203 , etc. are combined into a library 1204 . In such an arrangement, a vehicle with an incomplete profile 1205 does not necessarily have measured data that correlates to the specific weather conditions. As a result, its performance can be estimated by the vehicle prediction module 1206 by extrapolating from data for similar vehicles profiles in the library.
[0101] In one embodiment, a vehicle may receive information from the cloud based database (or other wirelessly accessible database) for use with vehicle profile information. For instance, FIG. 14 illustrates an expected travel path of a vehicle traveling between first and second locations (e.g., Idaho Springs, Colo. and Silverthorne, Colo.). Such an expected travel path may be inferred based on a current travel direction of a vehicle, previous user information, or entered by a user. The database may provide information for the expected travel path to the vehicle. In this regard, the database may include measurements and/or profiles of vehicles having previously traveled over the expected travel path. Such information may be for vehicles that have traveled over the expected travel path within a predetermined time period (e.g., previous fifteen minutes, hour, six hours, day etc.) In the present embodiment, the database may provide prior COF information/measurements of vehicles passing over the travel path. In this regard, prior COF information 1402 may be provided for predetermined road segments (e.g., every quarter mile) and/or for changes in road geography, surface and/or road structure (e.g., changes in road grade, changes from asphalt to concrete, changes from new asphalt to worn asphalt, bridge susceptible to icing, etc.). This is illustrated on the map shown in FIG. 14 which shows prior COF information 1402 that is provided for different segments of the travel path.
[0102] The prior COF information for the travel path may be determined in any manner from previously reported COF information. For instance, the prior COF information may be an average of all COFs reported by vehicles having previously passed over all or portions of the travel path. Any other mathematical representation (e.g., mode, mean etc.) of the prior COFs may be provided. The prior COF information may be further analyzed based on, for example vehicle type. In this regard, the type of vehicle on the travel path may be known and the vehicle may request or otherwise receive COF information for like vehicles: rear wheel drive vehicles, small all wheel drive, large all wheel drive, trucks, etc. That is, prior COF information for like vehicles may be provided along the travel path.
[0103] Upon receiving prior COF information, the vehicle may correlate the prior COF information for upcoming segments with the profiles 1302 a - n stored in the on-board vehicle profile database 907 . Alternatively, the vehicle may access stored profiles from the cloud based database 908 . See FIG. 9 . The cloud based profiles may be generated by the subject vehicle or may be profiles of other like vehicles. In any arrangement, the vehicle profile computation module 906 may utilize the prior COF information with the profiles 1302 a - n to determine the expected performance of the vehicle on the upcoming road segment. For instance, an expected wheel slip percentage may be calculated.
[0104] As shown in FIG. 13 , using the prior COF information as an input with the profiles 1302 allows for determining an expected slip percentage if the environmental conditions of the road segment is known or determinable. Such environmental conditions may be determined using sensors of the vehicle. Alternatively, prior environmental conditions 1404 may be provided to the vehicle with the prior COF information. See FIG. 14 . Stated otherwise, the library may, in addition to providing prior COF information, provide prior environmental information 1404 as reported by previous vehicles passing over the expected travel path. More generally, the library may provide road surface information (e.g., COF information and environmental information) to the vehicle. In either case, the vehicle traveling on the travel path may utilize the COF information and/or environmental information with stored profiles (See FIG. 13 ) to determine performance/safety information for the vehicle prior to the vehicle passing over upcoming segments of the travel path.
[0105] Based on the estimated wheel slip of the vehicle, various outputs (e.g., predictions) may be provided to the driver of the vehicle and/or to the control systems of the vehicle. For instance, if a slip percentage for an upcoming road segment exceeds a predetermined threshold, a warning output may be generated. In a further arrangement, an alternate route 1502 may be suggested if a slip percentage for an upcoming road segment exceeds a predetermined threshold. See FIG. 15 .
[0106] FIG. 16 illustrates a process 1600 for utilizing prior road surface information at a vehicle. The process begins with the establishing 1602 of a wireless connection between a vehicle and a road surface database. Once communications exist between the vehicle and the database, the vehicle may request and/or receive 1604 road surface information from the database for a travel path of the vehicle. In some instances, the database may be operative to push data to the vehicle without a request originating from the vehicle. That is, if conditions warrant providing data, the database may initiate contact and/or automatically provide data to a vehicle. The road surface information typically includes COF information for one or more segments of the travel path. The road surface information may further include environmental information for the one or more segments of the travel path. An on-board processor of the vehicle then accesses 1606 one or more profiles of the vehicle. Such access may be from local storage or via the wireless connection. Using the road surface information and the profile(s), the processor is operative to calculate 1608 estimated wheel slip for one or more upcoming segments of the travel path. If one or more of the wheel slip estimates exceed a predetermined threshold(s), an output may be generated 1610 for receipt by the driver of the vehicle and/or vehicle control systems. Such driver outputs may be related to speed reduction recommendations and alternate route suggestions among others.
[0107] FIG. 17 illustrates a process 1700 for gathering and distributing road surface information. Initially, a processing platform/database receives 1702 road surface reports from a plurality of vehicles traveling over roads. These road surface reports typically include COF information determined by the vehicles along with location information identifying where the COF information was determined. The road surface reports may also include environmental information measured directly or from which environmental information for the location may be determined (e.g., in conjunction with a weather model). The processing platform processes and stores 1704 information from or derived from the road surface reports. At a subsequent time, a request for road surface information for a travel path is received 1706 from a vehicle or the processing platform determines a vehicle is traveling a travel path for which pertinent road surface information is available. In the latter regard, the processing platform may be receiving road surface reports from a vehicle and if no adverse road conditions are known, not information may be provided. Conversely, if upcoming road conditions are determined adverse (e.g., COF for a road segment drops below a predetermined threshold) information may be pushed to the vehicle absent a request from the vehicle. In any case, stored road surface information is then processed to identify 1708 prior road surface information for the travel path. The identified road surface information is then sent 1710 to the requesting vehicle.
[0108] The modules 904 , 906 , 1004 , 1005 , 1101 , 1103 , 1105 , 1107 , and 1206 and/or processes described in relation to FIGS. 9-12 and 16 - 17 are processing functions that may be performed by processors located at one or more of the locations such as the lug nut, bumper or windshield systems, or at a processor located on-board or off-board the vehicle.
[0109] The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the relevant art can be made within the scope of the present invention. The embodiments described hereinabove are further intended to explain best modes known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
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Systems and methods for obtaining data about road conditions as they pertain to an individual vehicle, using this information to build a model of vehicle behavior as a function of its environment, and aggregating information concerning multiple vehicles along with data from other sources in order to predict vehicle behavior in future environments.
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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 generally to breakaway devices for rigid poles and posts implanted along roadways. The purpose of a breakaway device is to limit the amount of force and energy imparted to an impacting vehicle and its occupants by incorporating some form of failure mechanism into the pole base or into the pole itself.
With the ever increasing presence of the automobile on roadways and the corresponding increase in the number of utility poles, luminaires and road signs ground-mounted at the side of roadways, it became evident years ago that the risk of vehicles crashing into these ground-mounted structures would also become increasingly greater.
In a report entitled "Accident Analysis-Breakaway and Non-Breakaway Poles Including Sign and Light Standards Along Highways" Chapter 2, by King K. Mac and Robert L. Mason, DOT-HS-805-605, August, 1980, the authors reported that single-vehicle fixed object accidents account for only a small portion of all reported accidents. However, there is a disproportionate number of fatal accidents resulting from these relatively few accidents. Poles, such as utility poles, luminaires, sign or traffic signal supports are the most frequently struck objects in urban areas and among the more frequently struck objects in rural areas. The resultant injury severity of pole collisions, particularly those involving utility poles, is very high. Over half of these pole impacts are injury producing, and the injury frequency ranks right behind that corresponding to rollovers and impacts with bridge embankments.
In an effort to lessen the effects of these vehicular/pole collisions, D. L. Hawkins of the Texas Highway Department conceptualized the idea for slip base mounts for ground-mounted signs in the mid-1960's. The basic idea behind the slip base is to prevent a ground-mounted structure from rigidly resisting the impact momentum of an impacting vehicle by slipping off of its base in response to the force of the impact.
Breakaway designs for these ground-mounted structures were first applied for luminaires. Basic designs were classified in four categories namely (1) frangible base, (2) progressive shear, (3) slip base, (4) other types of breakaway designs.
With any type of breakaway system, the design criteria were to decrease as much as possible the momentum change to the vehicle from the time the vehicle impacts the ground-mounted structure until it passes through the structure after breakaway. According to present safety standards, an impacting vehicle should experience no more than a 1,000 lb.-sec. momentum change and preferably less than 750 lb.-sec. If the momentum change is kept below the maximum values, the likelihood of occupants surviving a pole impact is much greater.
The frangible and progressive shear bases used in connection with luminaires are designed to either fracture or shear metal in the base at a specified base fracture energy. These designs, however, are only good for aluminum or other metal type mounts where the frangible characteristics can be built into the pole and mount.
The slip base design utilized in connection with luminaries uses a totally different concept. It consists generally of two plates with cut slots. One plate is welded to the base of the luminaire pole and the other plate is welded to a luminaire mount which is embedded into the ground. Bolts are inserted into the slots to keep the two plates together. The bolts are tightened to a predetermined torque. Upon impact, the top plate, with the luminaire support attached, tends to slide in the direction of vehicle travel. Thus, the bolts are forced to slide out of the slots, freeing the luminaire support to move with the vehicle.
Similar slip base designs have been utilized in connection with sign supports. Often the slip base will be inclined at an angle such that an impacting vehicle will give an upward acceleration to the support and sign so that the sign will pass over the top of the vehicle.
The Texas Transportation Institute has developed a notable slip base design utilizing a triangular shape with slots situated at the corners of the triangle. It is designed such that it is capable of breaking away or slipping off the base when a vehicle impacts at sufficient speed from any direction.
Although these types of slip designs have been used in connection with luminaires and sign or signal supports, there has been no indication that the same types of slip designs could be utilized in connection with timber utility poles. It has been previously thought that such timber poles were too heavy for treatment using conventional slip base technology.
In fact, up until approximately 1982, most of the work to apply breakaway technology to timber utility poles involved various arrangements of holes, grooves and saw cuts placed at strategic locations in the pole base used to weaken the pole so that it would fall or fail more easily during a vehicle impact. However, this produced problems relating to the downing of the conducting wires and transformers which created significant safety hazards, significant power outages and significant repair costs. Thereafter, another weakened zone was introduced near the top of the pole underneath the conducting wires so that the entire middle section of the pole would breakaway leaving the top portion still connected to the conductors. These designs proved to be undesirable due to the total unpredictability of the time and mode of failure. Specifically, the bored holes, saw cuts or grooves severely reduced the pole's resistance to environmental loads creating a risk that the pole would break under severe ice and/or winter storm conditions which could then create a disastrous chain reaction of downed poles. The boring of holes in the pole would also greatly decrease its service life, rendering it more susceptible to rotting. See Mac and Mason supra.
Various slip base designs were studied and tested for use in connection with utility poles. A design which has met with some approval is an adaptation of the triangular, three bolt multi-directional slip base referred to above and used in connection with luminaire and sign breakaway supports. Another design is the Hawkins Breakaway System (HBS), designed by the inventor of the subject invention and reported in a government report entitled "Safer Timber Utility Poles" by Don L. Ivey and James R. Morgan, DTFH-61-83-0-00009, September 1985. The HBS is used with timber poles which are divided lengthwise into several segments. The HBS includes a circular lower connection or slip base, an upper connection or hinge mechanism, and structural support cables. The slip base and hinge mechanism are designed to activate upon impact and are intended to reduce the inertial effects of the pole on the errant vehicle while minimizing the adverse effects on utility service. The circular slip base is also designed to withstand the overturning moments imposed by in-service wind loads and at the same time slip when subjected to the forces of a collision.
The upper hinge mechanism of the HBS is sized so as to adequately support in-service loads while providing for hinging during a collision to allow the bottom segment of the pole to rotate up and out of a vehicle's path. The upper connection reduces the effective inertia of the pole and minimizes the effect of any variation in hardware attached to the upper portion of the pole during a collision. Overhead guys serve to stabilize the upper portion of the pole during a collision and to help insure proper behavior of the upper connection. The HBS is adapted for use specifically in connection with timber utility poles and is designed to provide minimum momentum change for an impacting vehicle and to allow activation by a broad range of vehicle sizes and impact speeds while avoiding the danger of the pole falling on top of the vehicle.
The lower connection of the HBS slip base includes the installation of a circular slip base at an elevation of three inches above grade. This low elevation is intended to avoid snagging the underside of an errant vehicle. The shear plane consists of two 5/8 inch thick plates separated by a 26 gauge keeper plate (intended to maintain a 151/2 inch diameter bolt circle) and by 21/2 inch diameter by 1/8 inch washers. The circular base plates are connected to each other by six 1 inch diameter high strength bolts arranged in circular fashion in slots provided in the circular base plates. The bolts are torqued to 200 ft.-lbs. Connection of the wooden utility pole to the slip base is through a steel pipe or mechanical tubing which is nominally 12 inches in diameter and 30 inches long and is welded to the base plates. In addition, the base plates are braced by 5/8 inch thick stiffeners which are welded to both the base plate and the steel tube.
In the HBS, it is contemplated that the timber pole will fit entirely within the steel pipe or mechanical tube which is welded on the base plate. Moderate trimming of the timber pole can be accomplished without seriously affecting the bending strength of the pole. It is recommended that slip base tube sizes be chosen that will minimize the need for trimming. Any gaps between the tube and the timber pole can be filled with materials such as POLESET which is a 1200 psi, high-density, non-shrinking polyurethane foam available from Utility Structural Systems of Houston, Tex. for use in back filling and protecting poles in the ground.
The upper hinge connection of the HBS system consists of two four-part pole bands installed above and below a saw cut through the pole. The pole bands are secured to the pole by means of bolts. Steel straps are provided to connect the four-part pole bands above and below the saw cut through the pole. One inch diameter bolts pass entirely through the timber pole, both above and below the saw cut, in such a manner as to pass through the pole bands and the steel straps. A vertical slot located below the bolt hole in the bottom of the steel strap is separated from the bolt hole by a small margin of steel. This provides initial bending resistance. However, once the margin is punched out, as by an impacting vehicle, the resistance is greatly lessened and resistance is thereafter offered by friction between the straps and bolts, and by bending of the straps. In addition, the force required to punch out the margin can vary greatly with only small deviations in machining accuracy. Once significant rotation has occurred, the bolts bear on the end of the slot, thereby providing the required ultimate bending strength.
Steel support cables are placed immediately above the upper connection and also near the cross-arm of the utility pole. The lower structural cable serves as a pivot point for the lower pole segment when the pole is struck by an errant vehicle. This cable could be eliminated on poles where a telephone cable is present. The upper steel cable serves to stabilize the upper pole segment and minimize damage to the electrical conductors.
The Hawkins Breakaway System offers many advantages to both utility companies and occupants of impacting vehicles. In almost all cases of vehicle impact, the HBS will prevent conductor damage. In addition, extreme wind gusts, which often cause non-breakaway poles to fail close to grade bringing down and damaging conductors, will not have the same effect on poles modified by the HBS. Such poles will simply bend at the upper connection, absorbing the energy transmitted by the short duration, intense wind gusts, thus preserving the integrity of the transmission facility.
In addition, pole rot is greatly reduced by the installation of the protective sleeve and grouting material around the timber pole in the area most susceptible to pole rot.
Finally, and most importantly, the HBS saves lives by allowing an impacting vehicle to break through a slip base of a timber utility pole rather than be stopped suddenly by the rigid non-modified pole.
SUMMARY OF THE INVENTION
The present invention, which is sometimes referred to as the AD-IV system, also makes use of a shear plane concept in providing a failure mode at ground level in response to a vehicle impact The AD-IV system presents significant advantages over the HBS and other prior art. These advantages include a shear plane base which comprises a unique geometrically arranged four bolt design, having a square shape with bolts in the corners. The angle of the corner planes adjacent to the bolts minimizes the amount of steel required in manufacture while making the activation mechanism operate for any direction of collision loading. The unique geometry of the shear plane base reduces the weight of the base and thereby reduces the forces on an impacting vehicle by reducing the mass that must be accelerated to vehicle speed.
In addition, the upper connection, titled the Del-Hinge, represents significant design, performance, and economic improvements over earlier, less practical designs in the prior art. The Del-Hinge is typically used with wind straps. The simplicity of the strap design, the highly predictable load at which the strap will fail, without small tolerance machining accuracy as exists in the "small margin" of the HBS, and lower maintenance costs make this design more advantageous.
In addition, a "wind bolt" option may be used in place of the "wind strap", having all the advantages of the wind strap plus an additional very important feature. It allows the connection to be retightened subsequent to installation and during the life of the AD-IV pole after high wind, snow or other environmental loads have caused minor tilting to occur in the upper pole segment. Both the wind strap and wind bolts are used in combination with rotation straps and allow the designer to select the appropriate level of resistance to wind and ice loads while producing a mechanism which will allow rotation of the lower portion of the pole when a vehicle impact occurs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 (a)-(d) depicts a sequence beginning with a vehicle collision with a pole modified by the present invention and shows in schematic form how the pole breaks away and allows the impacting vehicle to safely proceed through the impact zone while the pole maintains the structural stability of the conductors.
FIG. 2(a) depicts the lower portion of a utility pole modified according to the present invention.
FIG. 2(b) depicts the lower portion of a utility pole inserted into a protective sleeve wherein gaps between the pole and sleeve are filled with grout.
FIG. 3 shows a side view of the lower tube and shear base in a concrete footing showing the steel bars and cage.
FIG. 4 shows a plan view of the tube and shear base with welded stiffeners into which a timber utility pole is put.
FIG. 5 shows an acceptable bolt connection detail wherein the upper base plate is connected to a lower base plate and also shows the appropriate washers and keeper plates interposed between the base plates.
FIG. 6(a) depicts the upper Del-Hinge connection with pole bands, rotation straps and wind straps.
FIG. 6(b) depicts a plan view of the pole bands and through bolts taken along line 6b shown in FIG. 6(a).
FIG. 7(a) depicts the upper connection or Del Hinge according to the present invention showing rotation straps and wind bolts attached to wind bolt brackets.
FIG. 7(b) shows a plan view of the attachment orientation of the pole bands and through bolts taken along line 7b of FIG. 7(a).
FIG. 8 depicts a wind bolt and bracket assembly showing the brackets attached to the pole bands and interconnected by the wind bolt.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1(a)-(d), the present invention relates to a system of modifying timber utility poles to provide a slip base at a lower connection and a hinge at an upper connection such that when a vehicle impacts the lower portion of the utility pole, the pole slips off the slip base and rotates upward around the upper hinge allowing the vehicle to proceed completely under the pole as the pole is suspended, and finally allowing for continuation of conductor integrity. A method is provided to make these modifications on poles already in service and on new installations of utility poles.
Referring to FIG. 2(a), there is shown a first embodiment of the present invention. A utility pole 10 which is already in service is cut in two at or near ground level. The portion 12 of the utility pole which is below ground remains in its below ground state. A protective sleeve or tube 14 which is connected to the bottom face of a lower shear base plate 16 is placed over the lower pole portion 12 and is itself pounded or otherwise inserted into the ground until the top of the lower pole portion which is at or near ground level comes into contact with the lower surface of the lower shear base plate 16. The length of the protective sleeve or tube 14 is variable depending on the desired bending resistance and on the depth of the pole subject to pole rot. Grouting material 18 may be placed in the protective sleeve or tube to tighten the fit between the pole 12 and the protective sleeve or tube 14.
Referring still to FIG. 2(a) and also to FIG. 4, an upper tube 20 is attached to an upper shear base plate 22 and is adapted to fit on top of the lower shear base plate 16. The base plates 16 and 22 are of generally square shape and have a notch 24 cut out of the corners of each plate to receive bolts 26 for connecting the upper and lower base plates together A keeper plate 17 is inserted between upper shear base plate 22 and lower shear base plate 16 to maintain the square bolt orientation and to prevent the bolts 26 from vibrating out of the notches 24 under environmental loads The keeper plate is light weight and is easily sheared upon vehicle impact. The bolts 26 are tightened a predetermined amount depending on the desired resistance to vehicle impact Once tightened, the upper base plate 22 and attached protective sleeve or tube 20 are ready to receive the upper portion 28 of the utility pole 10. FIG. 5 depicts a cut away section showing the bolt 26 holding together the upper and lower base plates.
It is anticipated that the size of the sleeve 20 is determined based on the size of the utility pole 10. However, in the event the utility pole 10 is larger in diameter than the protective sleeve 20, moderate trimming of the timber pole can be done to accommodate the protective sleeve. Care must be taken, however, to avoid significant reductions in the moment of inertia of the pole which would render the pole incapable of withstanding environmental loads. As shown in FIG. 2(b), in the event the pole fits easily within the protective tube, grouting material 18 may be inserted between the pole 10 and inner walls of the protective tube 20 to tighten the fit of the pole. A specially formulated asphaltic extended polyurethane foam available from Utility Structural Systems is a suitable grout for this application.
Referring still to FIGS. 2 and 4, both the upper and lower shear base plates are provided with a plurality of stiffeners 30 situated on either side of each of the four bolts. Stiffeners 30 on the upper shear base plate begin from the top surface of the plate 22 and extend upwardly on the protective tube 20. Conversely, stiffeners 30 on the lower base plate 16 protrude from the bottom face thereof and extend downward along the protective tube 14. The stiffeners are welded or otherwise joined to the base plates and the protective tubes.
The distance above ground level which the lower base plate 16 and protective tube 14 extends is small so as to avoid snagging the underside of an errant vehicle. Based on the weight of the upper base plate 22 and protective tube 20 with inserted pole 28 and pole load, an activation boundary, which is the lowest momentum which will activate the system, can be predetermined. The desired activation boundary for the AD-IV system of the present invention is contemplated to be relatively low or at about ten miles per hour. Obviously, the size of the impacting vehicle has substantial effect on the activation boundary. Vehicles weighing more are capable of activating the slip base at a slower speed than vehicles of a lighter weight.
The square shape of the base plates 16 and 22 renders the base section lighter than the circumferential design of the prior art because less steel is required to form the square plates. The reduction in weight reduces the momentum change occurring in an impacting vehicle. In addition, manufacturing the square plate generates substantially less waste in steel than the manufacture of the circular plate. In addition, the four corner bolt geometry allows for biaxial symmetry of the slip base. In other words, the square base plate of the present invention has the same resistance to sliding whether impacted at zero degrees or impacted at 90 degrees. In the circumferential design of the prior art, there is no biaxial symmetry. In the prior art HBS system, the circumferential design is more difficult to activate when impacted at 90 degrees than when impacted at zero degrees.
FIG. 3 depicts a second embodiment of the lower connection of the invention which is especially suitable for new installations. In this embodiment, the step of first implanting the utility pole in the ground can be avoided. Rather a concrete footing 32 is placed in the ground. The concrete footing has steel reinforcement 34 running the entire length of the footing, and is adapted to receive a lower tube portion 14 which is connected to the bottom face of a lower shear base plate 16. The footing may also be prefabricated with the lower tube portion cast in place Steel reinforcement 34 is shown in FIG. 3 as being a steel coil.
Steel bars 36 are designed to fit within the lower tube 14 and concrete footing 32 to maintain the relative orientation of the lower tube and shear base plate with the footing 32.
An upper tube 20 is attached to the upper face of an upper shear base plate 22 and is placed upon the lower shear base plate 16 and bolted together at the four corners of the base plates in much the same manner as the previous embodiment. FIGS. 4 and 5 may be considered to apply to the embodiment of FIG. 3 as well as the embodiment of FIG. 2. When the bolts 26 are tightened to a desired torque, the utility pole 28 is inserted into the upper protective tube 20 and either trimmed or grouted to form a tight desirable fit. As in the previous embodiment, the lower connection is designed to be activated at the predetermined activation boundary.
Referring now to FIG. 6(a), there is depicted a first embodiment of the upper connection 60 of a utility pole according to the present invention. In this first embodiment, the pole 10 is cut in two pieces at a desired location above ground level, generally between ten and fourteen feet, or higher as needed. For a utility pole already in service, it is necessary to maintain the vertical position of the upper segment 38 of the pole as there will be nothing else holding the pole in place during modification. Two four-part pole bands 40 are installed above and below the saw cut 42 through the pole. The pole bands 40 are secured to the pole by tightening the bolt connections 44 which interconnect the four parts. In addition, the pole bands 40 are further secured to the pole by means of through bolts 46 which are drilled entirely through the timber pole 10, passing through the pole bands 40. There are two such through bolts 46 in each of the upper and lower four-part pole bands 40. Further, the through bolts 46 preferably pass through the utility pole 10 in perpendicular relation to one another. Thus, in the upper four-part pole band, two through bolts are installed in perpendicular relation to one another and preferably in parallel orientation with respect to the corresponding through bolts in the lower four-part pole band. The upper through bolts are in a plane parallel to, but in vertical separation from, the lower through bolts, being on the opposite side of the saw cut 42 FIG. 6(b) depicts a plan view showing the orientation of pole bands and through bolts in accordance with the present invention.
Before nuts are attached to the through bolts 46 to tighten the pole bands 40 to the pole in this first embodiment, a combination of rotation straps 48 and wind straps 50 is placed on the through bolts 40 such that the upper portions of both a rotation strap 48 and a wind strap 50 are attached to an upper through bolt 46. The straps run vertically downward parallel to the longitudinal axis of the utility pole and are attached at their lower portions to the lower through bolt 46. Each rotation strap 48 has a vertical slot 52 in the lower portion thereof which provides the lower attachment with the lower through bolt 46. The wind straps 50 provide initial resistance to bending. But, when a sufficient force is applied to the lower connection of the utility pole causing the lower connection to slip, the wind strap 50 fails. The bolt 46 is then free to slide along the slot 52, and the straps 48 are free to bend. Once significant rotation has occurred, the bolts 46 bear on the end of the slot 52, thereby limiting the angular extension of the straps 48 and providing the required ultimate bending strength.
Referring still to FIG. 6(a), the winds straps 50, which are attached in similar fashion between the upper and lower through bolts 40 on four sides of the pole spaced about ninety degrees from each other, provide a significant advantage not present in the prior art. Specifically, the wind straps 50 allow a designer to select the appropriate level of resistance to wind and ice loads while producing a mechanism which will allow rotation of the lower portion 28 of the pole when a vehicle impact occurs. This is accomplished by adjusting the cross-section of the wind straps 50 at the middle portion thereof and by varying the steel strength of the wind straps. Based on the wind straps' cross-sectional area and steel strength, it is possible to determine very accurately the load under which strap failure will occur.
During normal operation, when the utility pole is in its full upright position, the wind straps are capable of resisting environmental loads which would tend to bend the upper pole portion 38 relative to the lower pole portion 28. If the environmental load exceeds the straps' strength as determined by cross-sectional area and steel strength, then the wind straps will fail leaving the rotation straps as the only remaining resistance to rotation. However, the rotation straps 48 would most likely give way or bend given that there would no longer be any initial resistance to rotation and the upper portion 38 of the utility pole would be free to rotate around the upper hinge 60. This is obviously an undesirable effect.
Therefore, it is desired to select a cross-sectional area and steel strength for the straps capable of resisting most of the anticipated environmental loads. However, it is also important to avoid making the wind strap 50 of such strength such that it would resist rotation resulting from an impacting vehicle at the lower connection of the utility pole. If the wind strap provided this type of resistance, then disastrous effects could occur--e.g., a domino effect downing a series of utility poles or at least downing the utility pole in question and damaging the conductors and transformers attached to the utility pole. However, the presence of the wind straps allows the designer this type of flexibility. Without the wind straps, the rotation straps may not be capable of withstanding commonly occurring environmental loads.
Referring now to FIGS. 7 and 8, therein is depicted a second embodiment for the upper hinge 60, wherein wind bolts 56 are provided in place of the wind straps. As shown in FIG. 7(a), the wind bolts are placed in parallel alignment with the longitudinal axis of the utility pole and are also parallel to the rotation straps 48. They are held in place by and run between wind bolt brackets 58. The wind bolt brackets are attached to the upper and lower pole bands 40 at the location of the through bolt 46. Each wind bolt bracket 58 is designed in an L shape with the short leg 62 of the L-bracket being perpendicular to the length of the utility pole and the long leg 64 of the L-bracket being flush with the rotation strap 48. A hole is placed in the outermost portion of leg 64 for receiving the through bolt 46. The short leg 62 of the L-bracket has a bolt hole 66 adapted to receive the wind bolts 56. One bolt bracket 58 is attached at the upper pole band such that the short leg 62 of the L-bracket is at the lower end of the longer leg 64. A second bolt bracket 58 is attached to the lower pole band such that the short leg 62 of the L-bracket is at the upper end of the long leg 64. The wind bolt 56 extends through the short legs 62 of each L-bracket and a nut 68 is attached to the lower portion thereof at the lower bracket and is tightened as needed.
The wind bolt 56 serves essentially the same function as the wind strap 50. It is intended to provide resistance to environmental loads. As with the wind strap, the failure strength of the wind bolt is determined based on the steel strength and cross-sectional area of the bolts. This failure strength can be very accurately determined. An advantage of this alternative is that the connection between the upper pole segment 38 and lower pole segment 28 can be tightened subsequent to installation and during the life of the AD-IV pole after high wind or snow or other environmental loads have caused minor tilting to occur in the upper pole segment. Tightening is done to the wind bolt sufficient to bring the upper pole segment into axial alignment with the lower pole segment.
Both the wind bolt and the wind strap serve to maintain the axial alignment of the upper and lower AD-IV pole sections.
Various modifications and improvements may be made to the disclosed embodiments of the present invention without departing from the overall scope and spirit of the invention.
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A breakaway system is disclosed for timber utility poles. The breakaway system limits the amount of force and energy imparted to an impacting vehicle and its occupants by incorporating an arrangement of slip plates and bolts to form a shear plane on the utility pole at or near ground level, and by providing a hinge mechanism on an upper section of the utility pole below conducting lines and the like. The material and configuration of the lower shear plates are selected to permit activation for any direction of collision loading. The material and configuration of the upper connection or hinge are selected to allow for adequate resistance to environmental loads while at the same time allowing for precise determination of the magnitude of failure load. In addition, the combination of upper connectors prevents the lower portion of the utility pole from rotating upward into the conducting wires after a vehicle impact. In this manner, impact by a moving vehicle with a timber utility pole equipped with the breakaway device shears the lower connection causing a middle portion of the timber utility pole to rotate upward. The upper connection allows limited rotation sufficient to permit the impacting vehicle safely to travel completely beneath the middle section of the utility pole while at the same time preventing the middle section from impacting the conducting wires carried by the utility pole.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is being filed simultaneously with the U.S. patent application Ser. No. 773,397 disclosing common subject matter entitled "CASING HANGER LOCKING DEVICE", inventor William David Wightman.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to subsea wellhead equipment, and in particular to a casing or tubing hanger having a metal-to-metal seal.
2. Description of the Prior Art
A typical subsea wellhead assembly includes a wellhead housing mounted within a permanent guide base that is supported on the ocean floor by a temporary guide base. Large diameter conductor pipe is secured to the wellhead housing and extends downward into the earth a short distance. A wellhead is mounted inside the wellhead housing and to a permanent guide base which mounts on the top of the temporary guide base. Surface casing secured to the wellhead extends a few hundred feet down into the well. The top of the wellhead is connected to pressure equipment and risers that extend to a drilling vessel at the surface. As the well is drilled deeper, a first string of casing may be set to a certain depth. Subsequently, a second string of casing may be set.
In a typical installation, the casing hanger includes a casing hanger body which is secured to the upper end of the casing string. The body is supported on an annular shoulder in the wellhead. A seal and a locking means are located in annular clearances between the casing hanger body and wellhead bore. The seal normally includes an elastomeric ring which is compressed by compression rings between the casing hanger body and the wellhead bore. The locking means includes a split ring and/or various wedges, which are normally actuated by rotation of a running tool to lock the elastomeric seal in compression and to lock the casing hanger in the wellhead. Wickers, which are small parallel grooves, may be located in the wellhead bore for engagement by the split ring or wedges. The locking means provides support for the casing hanger.
While successful, elastomeric seals may not have as long of a life as a metal-to-metal seal, particularly if subjected to heat. Metal seals, and combinations of metal and rubber seals, are commercially available for casing hangers. Improvements, however, are desirable.
SUMMARY OF THE INVENTION
The metal seal ring of this invention has inner and outer walls radially separated by annular cavity. An energizing ring is movable into a lower engaged position in the cavity. In this lower position, the energizing ring pushes the walls outward, causing them to seal tightly against the casing hanger body and the wellhead to form a seal. The inner and outer walls each have a seal section which contacts either the hanger or the wellhead to form the seal. A gripping section is located on each wall above the seal section. The gripping section contains a plurality of vertical slots to facilitate expansion of the walls outward. The seal section contains circumferential grooves to concentrate the sealing forces.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial vertical sectional view of a wellhead having a seal constructed in accordance with this invention, and also is showing a locking means for locking the casing hanger in place.
FIG. 2 is an enlarged sectional view of the seal of FIG. 1, shown in the disengaged position.
FIG. 3 is a top partial view of the seal ring for the seal of FIG. 1.
FIG. 4 is a side view of a seal ring shown in FIG. 3.
FIG. 5 is an enlarged vertical sectional view of the locking and supporting means for the casing hanger of FIG. 1, shown in a storage position prior to locking engagement.
FIG. 6 is a further enlarged vertical sectional view of one of the washers of the locking and supporting means, shown in a set position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The subsea well assembly shown in Fig. 1 includes a wellhead 11. Wellhead 11 is a tubular member located at the sea floor at the top of the well. Wellhead 11 has a bore 13 that contains an upwardly facing landing shoulder 15. Landing shoulder 15 is inclined downwardly. A plurality of locking grooves 17 are located a short distance above the landing shoulder 15 in the bore 13. The locking grooves 17 are approximately 1/4 inch deep in the preferred embodiment, and the centers of each groove are about one inch apart. Locking grooves 17 are circumferential, parallel to each other and have rounded edges.
A plurality of wickers 19 are located in a set spaced above the locking grooves 17. The wickers 19 are much smaller grooves. They are parallel, circular, and formed perpendicular to the axis of bore 13. Preferably there are about eight grooves of wickers 19 per inch. Wickers 19 are generally triangular in cross-section.
A casing hanger 21 is secured to a string of casing (not shown) and lowered into a landing position in the wellhead 11. Often there will be more than one casing hanger 21, each secured to a string of casing of smaller diameter than the casing supported by the casing hanger immediately below. Casing hanger 21 has a body 23 that has an axial bore or passage 25. Body 23 is a tubular member with an outer diameter smaller in diameter than the wellhead bore 13, except for an annular band 27 located intermediate the ends of casing hanger 21. Band 27 closely fits within the bore 13. This results in an upper annular clearance 29 above band 27 and between the casing hanger body 23 and wellhead 11, and a lower annular clearance 31 located below annular band 27. A lock assembly 33 is located in the lower clearance 31 for locking the casing hanger 21 to the wellhead 11. A seal assembly 35 is located in the upper clearance 29 for sealing the casing hanger 21 to the wellhead 11.
Referring to FIG. 5, the lock assembly 33 includes a collar 37 on the lower end. Collar 37 has an upper flange 39 with a downwardly facing surface that is adapted to mate with and engage the landing shoulder 15 in the wellhead bore 13. A shear pin 41 releasably secures the collar 37 to the casing hanger body 23. When flange 39 contacts the landing shoulder 15, the weight is applied, the shear pin 41 will shear, allowing the hanger body 23 to move downwardly a short distance. A plurality of vertical flutes 43 extend up the hanger body for allowing return flow during cementing of the casing string.
Collar 37 has an interior annular recess 45. Recess 45 is adapted to receive a plurality of washers. Washers 47 are flat steel members, having a hardness of about 60 Rockwell B, which is not as hard as collar 37 or hanger body 23. Each washer 47 is split. The outer diameters of the washers 47 engage the inner wall of recess 45 in a snug fit. The inner diameter of each washer 47 will be located adjacent to a reduced diameter portion 49 formed on the hanger body 23, and will not contact the portion 49. When collar 37 lands on shoulder 15, and hanger body 23 moves downwardly relative to collar 37, the washers 47 will contact an enlarged diameter portion 50 of hanger body 23, which is located above the reduced diameter portion 49 and slightly greater in diameter. The enlarged diameter portion 50 has a diameter that is about 0.016 inch greater than the inner diameter of each washer 47. This causes the washers 47 to deflect downward into a locking position as shown in FIG. 6. The washers 47 undergo permanent deformation beyond their yield strengths when deflected. In the locking position, the hanger body 23 cannot be readily pulled upward relative to the collar 37.
In the locking position, the flat surfaces of the washers 47 incline at an angle a from 5° to 15°, preferably about 10°, with respect to a line perpendicular to the axis of hanger body 23. A 45° bevelled surface 47a is located on the outer lower edge of each washer 47. A 45° bevelled surface 47b is located on the inner upper edge of each washer 47. This results in better surface contact between the washers 47 and the collar 37 and hanger body 23 when in the set position.
A split ring 51 has its lower end in contact with the collar 37. Split ring 51 comprises an expansible annular ring spaced around the hanger body 23. The split ring 51 has a plurality of grooves 53 located on the exterior. Grooves 53 have the same dimension as the locking grooves 17 in the wellhead bore 13. Split ring 51 has three inclined reacting surfaces 55, 57, and 59 located on the interior.
An upper load ring 61 is secured by threads on its interior to the hanger body 23. Upper ring 61 has an outwardly extending flange 62 with an inclined lower surface. Upper ring 61 also has two cam surfaces 63 and 65 which are inclined at the same angle to mate with the reacting surfaces 57 and 59 of the split ring 51. The hanger body 23 also has a cam surface 67 which is inclined at the same angle as reacting surface 55. When collar 37 lands on the landing shoulder 15 and the hanger body 23 continues downward movement, the split ring 51 will not be able to move downward along with body 23 due to its contact with the collar 37. The reacting surfaces 55, 57, and 59 act against the cam surfaces 63, 65, and 67 to result in a radial outward movement. Grooves 53 will engage the locking grooves 17 to lock the casing hanger 21 in place and provide support. Downward force on casing hanger 23 is transmitted through split ring 51 to the grooves 17 and wellhead 11. The locked position is shown is FIG. 1.
A retaining ring 69 is located below the collar 37 for retaining the collar 37 and split ring 51 should the casing hanger 21 later be withdrawn to the surface. To withdraw the casing hanger 21, a force sufficient to overcome the resistance of the washers 47 must be exerted. Preferably this force is around 200,000 pounds.
Referring to FIG. 2, the seal assembly 35 has a metal seal ring 71. Seal ring 71 has an outer annular wall 73 that is spaced radially outward from an inner annular wall 75. This results in an annular cavity 77 located between the walls 73 and 75. A plurality of grooves 79 are located in a seal section 78 of the walls 73 and 75. The grooves 79 on inner wall 75 face inwardly for engaging hanger body 23. The grooves 79 on the outer wall 73 face outwardly for engaging the bore 13 of wellhead 11. Grooves 79 are circumferential grooves parallel to each other. They are larger than the wickers 19 in the wellhead bore 13 and smaller than the locking grooves 17 in the wellhead bore 13. Preferably each groove 79 has a depth of about 1/8 inch, and its centerline is spaced from the centerlines of adjacent grooves by about 1/4 inch. The grooves 79 are rounded, and cylindrical sealing surfaces 80 are located between each groove 79 for sealing contact with the wellhead bore 13 or the hanger body 23. Each sealing surface 80 has a longitudinal height or dimension that is from 1/16 to 3/32 inch. There is a lower groove 81 on each wall 73 and 75 which has a greater depth than the grooves 79. The lower groove 81 is located adjacent to the bottom of the cavity 77 between the walls 73 and 75. Prior to energizing, the radial dimension from the sealing surfaces 80 of grooves 79 on inner wall 75 to the sealing surfaces on outer wall 73 is preferably about 0.030 inch less than the width of upper clearance 29.
A gripping section 83 is located above the seal section on outer wall 73. The gripping section 83 does not contain any grooves 79, and it terminates in a rim 85 on outer wall 73. A plurality of vertical slots 87 extend through the outer wall 73 in the gripping section 83, as shown more clearly in FIGS. 3 and 4. Gripping section 83 aligns with wickers 19 in wellhead 111.
There is a gripping section 89 also on the inner wall 75 located radially inward from the gripping section 83. Gripping section 89 is located above the grooves 79 and adapted to align with a set of wickers 91 formed on the exterior of the hanger body 23. Wickers 91 are located adjacent to the wickers 19 in the wellhead bore 13 when the casing hanger 21 is landed in the wellhead 11. The gripping section 89 is located below the rim 93 of the inner wall 75, which is threaded. A plurality of vertical slots 95 extend through the gripping section in radial alignment with the slots 87. Slots 95, however, do not extend to the top of the rim 93, rather terminate a selected distance below as shown in FIG. 4. A retaining ring 97 is secured to the threads of the rim 93 and located on the exterior of the inner wall 75. The inner wall 75 extends above the outer wall 73 a considerable distance.
An energizing ring 99 is carried with the seal ring 71. Energizing ring 99 has a lower section 101 that is adapted to be forced into the cavity 77. Prior to actuating the seal ring 71, as shown in FIG. 2, the energizing ring 99 is located with its lower section 101 at the entrance of the cavity 77. The lower section 101 is greater in radial thickness than the cavity 77 by at least 0.030 inch, so as to wedge tightly therein and force the inner and outer walls 73 and 75 outward into sealing engagement with the hanger body 23 and the wellhead bore 13. The energizing ring 99 also has a middle section 103 which is of greater radial thickness than the lower section 101 and the cavity 77 between gripping sections 83 and 89. The middle section 103 when in the engaged position as shown in FIG. 1, locates in the upper portion of cavity 77 between the slotted or gripping sections 83 and 89. A tapered area exists between the lower section 101 and middle section 103. Energizing ring 99 also has an upper section 105 that extends above the retaining ring 97 while in the disengaged position. A shoulder 107 is located generally at the junction of the middle section 103 and the upper section 105. Shoulder 107 is located on the interior to contact the lower side of the retaining ring 97 if the seal assembly is being withdrawn.
Energizing ring 99 has a circumferential recess 109 formed in the interior of the upper section 105. Vertical channels 111 extend downwardly in the interior of ring 99 from the upper edge of ring 99 to recess 109. Recess 105 is adapted to be engaged by handling tools with members that enter through slots 111. Rotating the handling tool after the members reach recess 105 will secure the energizing ring 99 to the handling tool. A handling or setting tool shown schematically with dotted lines 112 will extend through channels 111 and contact the upper edge of recess 109 to move downwardly. A different handling tool (not shown) will be used to release energizing ring 99 by moving it upwardly. It will contact a dowardly facing shoulder 115 in recess 109 to move energizing ring 99 upwardly. A passage 113 extends through the lower section 101 to allow liquids contained in the cavity 77 to be purged as the energizing ring 99 enters the cavity 77.
The seal ring 71 is constructed of a mild steel which has a hardness less than about 150 BHN. The material should preferably have a hardness 40-50 BHN less than the hardness of wellhead 11 and hanger body 23. This material is sufficiently soft to permanently deform and seal against the hanger body 23 and the wellhead bore 13.
In operation, the lock assembly 33 will be secured to the hanger body 23 by the shear pin 41. The hanger body 23 will be secured to the upper end of the string of casing (not shown) as it is being lowered into the well. When the flange 39 contacts the landing shoulder 15 (FIG. 5), pin 41 will shear, and hanger body 23 will move downwardly relative to the collar 37 and the split ring 51. The washers 47 deflect downwardly because of the interference fit of the washers 47 between the hanger body 23 and the recess 45 that occurs when the hanger body 23 moves downwardly. The washers 47 serve as wedge means to allow downward movement of the hanger body 23 relative to the collar 37, but to resist any upward movement.
As the hanger body 23 moves downwardly, the cam surfaces 63, 65, and 67, serve as cam means to act against the reacting surfaces 55, 57, and 59 to urge the split ring 51 out into engagement with the grooves 17. The upper end of the split ring 61 will contact flange 62 of the upper ring 61. This will stop downward movement of the hanger body 23. The landing of the casing hanger 21 can be checked by pulling upwardly on the hanger body 23. If the washers 47 resist the upward movement, this indicates that the pin 41 has sheared properly and that the casing hanger 21 is properly locked in place. The split ring 51 will transmit forces on the hanger body 23 to the wellhead 11. Cement can then be pumped down through the casing hanger 21 and string to cement the string in place, with returns flowing through the flutes 43 to the surface.
After the cement has set, the seal assembly 35 can be lowered in place with the setting tool 112. The energizing ring 99 will be secured to the setting tool 112 by shear pins (not shown). The energizing ring 99 will be in the position shown in Fig. 2 while the setting tool 112 lowers the seal assembly 35 into the annular clearance 29. When in place, further downward movement of the setting tool 112 causes the energizing ring 99 to move downwardly. The lower and middle sections 101 and 103 spread the walls 73 and 75 apart. The seal sections 78 seal tightly against the hanger body 23 and the wellhead bore 13. The slotted or gripping sections 83 and 89 are pressed tightly against the wickers 19 and 91 to retain the seal ring 71 in place. The setting tool 112 can then be removed and withdrawn to the surface. The gripping sections 83 and 89 resist upward force tending to push the seal assembly 35 upwardly due to pressure.
To release the seal assembly 35, a handling tool (not shown) is lowered into engagement with the recess 109 and rotated to the right 45° to engage the upper shoulder 114 for release. The handling tool is picked up, causing the shoulder 107 of energizing ring 99 to move up into contact with the retaining ring 97. The entire seal assembly 35 may be withdrawn.
To remove the casing hanger 21, a handling tool must grip the casing hanger 21 and pull it upwardly sufficiently to deform the washers 47. The upward movement allows the split ring 51 to disengage from the grooves 17, allowing the casing hanger 21 to be pulled upwardly.
The invention has significant advantages. The seal is of metal, thus not subject to deterioriation that occurs with some elastomeric seals. The seal can be released. The small cylindrical lands between the sealing grooves provide good sealing surfaces and conform to irregularities. The vertically slotted gripping sections reduce the force required to energize the seal.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention.
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A casing hanger seal for a subsea well uses a seal ring having inner and outer walls spaced radially apart from each other. An energizing ring is moved from disengaged position to an engaged position between the walls, wedging them apart to form the metal seal. Vertical slots are formed in the walls to facilitate expansion. The slots ae located in a gripping section that engages wickers formed on the inner and outer tubular members of the well. Circumferential grooves are located in the sealing areas.
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FIELD OF THE INVENTION
[0001] The present invention relates to water management during drilling, especially as relates to overhead drilling operations such as is typical in underground mines and tunnel construction. In particular, the present invention is concerned with apparatus for recovery and/or catchment of liquids used for cooling rock cutting tools such as rotary drill steels or bits and/or flushing drill cuttings from a bore hole.
BACKGROUND TO THE INVENTION
[0002] Overhead and rock face drilling is frequently performed in mining, in particular underground mining such as coal mining, and in the course of excavation, tunnelling and so forth.
[0003] Short and long bore drilling into a rock face or other material produces drill cuttings and other debris that require removal from the bore during drilling. Fines and dust particles are also created in the process, which need to be entrapped and prevented from freely escaping the bore and thus creating potentially hazardous dust clouds in a mine shaft or tunnel, in particular when coal seam mining.
[0004] Early attempts to address dust cloud creation in coal mining using purely air-cooled drilling steels and bits include the use of dedicated dust collector devices, generally comprising some form of dust confinement hoods or similar structures which are positionable at the rock face about the location of the bore to be drilled. An opening in the hood which allows passage of the drill string towards the capped-off bore location at the cutting face may or may not comprise some type of curtain or sluice structure to minimise egress of dust past the drill string from within the hood. A duct leading from within the hood provides a discharge to remove dust and cuttings created during drilling. These are extracted using forced air flow or suction devices, into a suitable receptacle/collection container. U.S. Pat. No. 2,634,952 (Brinkley) describes one such apparatus.
[0005] Equally applicable/transferable to mining/tunnelling operations involving drilling, U.S. Pat. No. 4,921,375 (Femulari) describes an anti-scattering device for the collection of waste material produced in the course of drilling, milling, grinding and similar machining operations, comprising a cylindrical or frusto conical bellows screen whose one open end can be secured to the front of the housing of the tool about the location where the chuck and drilling/milling/grinding bit protrude from the housing, and whose opposite open end (carrying an annular sealing ring), can be pressed against the surface to be machined, to seal off the space surrounding the cutting tool. A fan or vacuum device is in communication with the inside of the bellows structure to remove cuttings into a container that is coupled via a discharge tube to the inside of the bellows structure.
[0006] More commonly used nowadays are rock (and other strata) drilling apparatus and rigs which utilise liquids to (a) cool the drilling bit or cutting elements of the tool, (b) supress dust generation and (c) flush away the drill cuttings from short and long bore drilling holes. Many drill masts and rigs often employ hollow drill strings, which attach to a drill bit, or other rock/strata cutting tool, through which cooling/flushing/lubricating liquid is delivered to the cutting face. In some devices, the pressurised liquid passes through the drill motor, but in any event the flushing/cooling liquid is injected into and pumped through the hollow drill string, through the drill chuck and into or past the cutting device proper (steel of bit) to cool and/or lubricate the cutting elements at the drill face location.
[0007] The cooling/lubricating liquid, which may be simply water with or without additives, or a type of drilling mud, washes away the drill cuttings and fines out of the drill hole. Air-borne dust is thus avoided, though there is considerable ‘spent’ cooling/flushing liquid generated as a result, which represents a significant logistical compromise and environmental load, if disposed without treatment or otherwise re-cycled.
[0008] As an example, in some instances, it is not uncommon to use 1500 L/hour in drilling processes, which if not methodically collected and evacuated can quickly cause the surrounding ground to become unstable and hazardous. Such hazards are compounded by the difficulty of underground conditions.
[0009] Different cooling/flushing liquid management solutions have been suggested and/or used in the prior art.
[0010] One ad hoc solution, which is still widely used today, is to place a pan or basin of some sort directly below the drilling site, and use special pumps that are resistant to abrasion by the cuttings/fines entrapped in the flushing liquid, to convey the ‘spent’ liquid and the cuttings (also referred to as “drilling slurry”) into a separate facility for separating the liquid from the solids to a required degree of filtration.
[0011] As the drilling slurry contains drill cuttings of various sizes, it can be particularly difficult to pump this material, even using special slurry pumps. Conventional, general purpose water pumps can not be used, as these would malfunction under such operating conditions.
[0012] Another solution is to use dedicated drill liquid/drilling slurry collection structures in close proximity to the drilling hole location or otherwise carried at the drill rig, such as to receive most of the discharged drilling slurry. Some of these devices have an operating principle very similar to that of the Brinkley patent device.
[0013] For example, U.S. Pat. No. 7,726,417 (Larsson), assigned to Husqvarna A B of Sweden, describes a drill cooling water collecting device (collector) arranged above a drilling machine so as to capture drilling slurry and thus prevent it from running down and into the drill rig's motor, thus preventing damage being caused to the machine. The water collector comprises a squat, open-top cylindrical vessel having a flat bottom and a relatively short cylindrical side wall. The flat bottom has a draining hole connecting to an associated draining duct through which drilling slurry collected in the collector can be pumped for subsequent treatment/reclamation.
[0014] The water collector pan is used in conjunction with an anti-scatter screen, in form of a cylindrical bellows of smaller diameter than the collector pan, which surrounds the drill string that passes through a hole in the flat bottom in which a bearing and sealing structure for the drill string is received, and which extends all the way from the drill hole location (and thus drill bit/steel tip) to the water collector pan. The anti-scatter screen thus confines drilling slurry to drop towards the collector pan, catching most if not all the water for subsequent recycling. Other features are mentioned, but the water collecting arrangement described and depicted by Larsson suffers some limitations which compromise its practicality.
[0015] As is the case with the ad-hoc solution described above, special (and costly) suction pumps which are abrasion-resistant to drilling slurry, are required for draining away the liquid and drill cuttings that are gathered in the collector pan, towards a non-illustrated, separate liquid-cuttings separator tank or device.
[0016] U.S. Pat. No. 6,712,162 (Britz) describes a collector structure that is very much similar to that of Larsson (but for use in horizontal drilling applications) wherein, a squat cylindrical slurry collection pan is provided, which has a through hole in its flat base to allow passage, in sealing but movement-permitting manner, of a hollow-core, cylindrical drill bit. The rim of the cylindrical wall of the pan, which carries an annular sealing lip, can be pressed onto the cutting face and thus enclose the area surrounding the location where the drill bit is to cut a bore. The slurry draining port is located in the cylindrical wall and connects to a slurry discharge line.
[0017] The device of Britz thus obviates the need for a bellows screen to prevent scattering, as per Larsson. More relevantly, Britz illustrates a cooling/flushing liquid re-cycling circuit and system by way of which cooling/flushing liquid is recovered from the slurry. Two closed liquid holding tanks, a first on of which receives the slurry (and thus is a holding tank) and the second one of which houses a filtration device (and thus is a filtration unit) form part of the recycling circuit. A pressure pump is used to convey slurry from the first into the second tank. It will be noted that such arrangement, with its separate components still requires a special pump capable of pumping slurries with a potentially high drill cuttings and fines load. Given that the second filtration tank is a closed one, removal of the residual particulate material (ie the fines and cuttings) requires intermittent operation to effect cleaning and prevent clogging of the recirculation circuit.
[0018] An object of the present invention is to provide an apparatus for recovery of cutting tool cooling liquid/drill cuttings flushing liquid that at least ameliorates one or more limitations of existing approaches to managing spent rinse water arising from drilling operations.
[0019] Another object is to provide an apparatus that simplifies separation of drilling slurry into fractions comprising a liquid fraction that can be re-cycled substantially for re-use without filtration at a separate unit, and a slurry fraction comprising the bulk of solid particulates from the bore hole drilling operation.
[0020] Another object is to provide an apparatus of aforementioned type that can be easily retrofitted onto existing overhead rock drilling rigs and apparatus.
SUMMARY OF THE INVENTION
[0021] The present invention arises from the insight that drilling slurry from drilling operations can not only be advantageously collected close to the drill hole location, but can be effectively filtered in a purpose-designed collection device to a desired degree to obtain an effluent liquid stream that can be recycled into the cooling/flushing liquid supply for the drilling machine/rig. The drill cuttings and fines separated at the device, which represent a substantially ‘de-watered’, primarily particulate refuse stream, can be discharged to the ground surrounding the drilling rig, or into a separate container that can then be easily transported away from the drilling site to land fill or further processing.
[0022] The present invention in one aspect advantageously provides a drilling fluid recovery apparatus, comprising: a mounting structure shaped to allow removable mounting of the apparatus to a housing part of an overhead drilling apparatus; a funnel structure having a base with an aperture for passage of a drill steel or drill chuck of the drilling apparatus and having a slurry discharge port proximate the base, the funnel structure adapted for receiving a slurry mixture of drill cuttings and spent drill liquid produced during a drilling operation; and a spillway structure having at a lower end thereof a liquid catchment zone with a liquid discharge port and at an upper end thereof a liquid draining zone with a filtering grate operatively fitted thereto at an inclined angle vs the vertical, the spillway structure arranged such that slurry mixture exiting the slurry discharge port from the funnel structure gravity feeds onto an upper end and upper side of the filtering grate to move along the filtering grate towards a lower end for discharging from the spillway structure while liquid is drained from the slurry mixture towards the liquid catchment zone located underneath the filtering grate.
[0023] One advantage which the presently devised drilling fluid recovery apparatus provides is that there is no need for a bellows-like skirt to surround the drilling zone between the drill liquid catchment pan and rock face, as per the Larsson patent document. The drill chuck remains open to visual inspection to operators, and can be readily changed as required. Furthermore, adding, swapping or removing drill steels is relatively straightforward, as the apparatus does not prevent access to the drill chuck.
[0024] The filtering grate of the spillway structure will advantageously comprise a plurality of rods arranged in a grid, preferably an orthogonal grid of square or rectangular cross-section steel rods, wherein the spacing between lengthwise and width-wise running rods can be chosen to be the same or different. The spacing between the width-wise extending rods may also be varied along the extension of the grate from its upper, slurry receiving zone towards the lower, slurry discharging zone, to cater for hydraulic changes in the slurry as liquid is drained away as the ‘dewatering’ slurry spills/moves under gravity influence along the grate.
[0025] Advantageously, the funnel structure will be dimensioned to have an internal volume that is sufficient to temporarily receive and store drill cuttings and spent drilling liquid expected during a drilling operation, without overspilling, while simultaneously discharging the slurry towards the spillway for liquid removal.
[0026] To this end, the funnel structure may advantageously comprise a removable collar extension with a vertical peripheral wall, mountable to the open top end of a lower funnel section having at least in part inclined inner faces terminating at the base of the funnel structure. The collar can advantageously be formed of a resilient material which is transparent or at least translucent to permit ready visual inspection. Further, the slurry discharge port of the funnel structure will preferably communicates with a conduit pipe for draining the funnel structure into the spillway in controlled manner, the pipe's dimensions being chosen such that an expected, predetermined amount of drill cuttings and spent drilling liquid can be discharged at a defined flow rate without blockage.
[0027] A wide mesh or grate guard of suitable size can advantageously be fitted inside or above the open top end of the funnel structure, to avoid ingress of rocks above a certain size amongst the drill cuttings, which might otherwise block the funnel.
[0028] In a particularly preferred form, the spillway can have, at least in part, a duct-like channel configuration, with opposite vertical side walls and a rear wall spanning the side walls forming a vertical, u-shaped, front-side open channel. The filtering grate having a flat, planar configuration is then located to extend between the side walls in inclined fashion from near an upper end close to the rear wall towards a lower end distant from the rear wall and flush with a vertical front wall spanning the side walls and which closes the u-channel to define an enclosed zone below the liquid catchment zone located underneath the filtering grate; in other words, the filtering grate provides a front side closing the u-channel, but in inclined manner, separating the front where the slurry cascades downwards as consequence of the incline of the grate, and the liquid catchment part at the rear of the duct.
[0029] Advantageously, an upper end of the spillway structure may comprise a removable access door, fitted opposite the location where the slurry discharge port/conduit pipe drains into the spillway/is located. This allows an operator to have access to unblock the pipe/port if required. The inside of the door acts as a ‘splatter’ element to diffuse and distribute the incoming slurry prior to it being deposited onto the filter grate.
[0030] A baffle is advantageously positioned in an upper end of the spillway, opposite the outlet of the slurry discharge conduit pipe to moderate flow of the slurry mixture onto the filtering grate in the spillway. The baffle is preferably formed of a resilient material, and advantageously provided in the form of a concave strip running over the entire width of the spillway. Advantageously, the baffle can then be mounted in removable manner at the access door. The baffle in this form assists in spreading the slurry being discharged from the pipe and scattered against the removable door (access plate) into a more uniform band of slurry from where it cascades onto the filtering grate (which may also be called a screen) fitted to the spillway. This also allows one to use filtering grates of smaller dimensions in the cascading direction (flow or length direction) as a more spread-out flow is achieved over the width of the grate right at the top of it.
[0031] The liquid catchment zone of the spillway is advantageously provided with or connected to a rain water head structure, with or without an additional filtering mesh, which in turn drains to a downpipe for directing the liquid removed from the slurry to further use or discharge.
[0032] The filtering screen (grate), which is preferably a planar grate structure comprising of traversing and intersecting square cross-section rods, is advantageously angled in the spillway at between 45° and 65° to a horizontal plane, and more preferably at approximately 55° to a horizontal plane, so that the slurry mixture cascades down the filtering grate in a controlled manner as it is ‘dewatered’ prior to discharge of the ‘dewatered’ drill cuttings.
[0033] It will be understood that the grate is designed to remove a substantial part of the liquid, without fully filtering the reclaimed liquid of drilling fines. The reclaimed liquid may carry fines in suspension of an average particle size which does not substantially impede pumping of the liquid using conventional eg ring pumps as used in overhead drill rigs to supply flushing water ((liquid) via the drill bit into the bore for flushing the cuttings out of the bore.
[0034] The present invention thus in another but related aspect provides a system for recovering bore hole flushing or rinse fluid from drilling slurry comprised of drill cuttings and liquid obtained in a strata drilling operation, comprising an apparatus as described above, mounted atop an overhead drilling rig, a drainage pipe connected to the apparatus for receiving fluid drained by the apparatus from the slurry mixture, a holding tank connected to the drainage pipe for temporary storage of drained liquid, plumbing connecting the storage tank to the drill rig flushing liquid supply line(s), and a pump for pumping drained liquid from the holding tank via the plumbing to the drill rig for re-use in bore hole drilling.
[0035] In yet a further aspect, the invention also provides an overhead drill rig with recycled borehole flushing water delivery arrangement, comprising an overhead drilling rig with a drill motor and drilling tools, an apparatus as above described, a drainage pipe connected to the apparatus for receiving liquid drained from the slurry mixture via the liquid catchment zone located underneath the filtering grate of the apparatus, a holding tank connected to the drainage pipe, and a water pump for delivering reclaimed liquid stored in the holding tank to the drill motor for re-use during a drilling operation.
[0036] Further aspects of the present invention, and preferred and/or optional features thereof will become apparent also to the skilled reader from the following description of a preferred embodiment which is provided with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIGS. 1 and 2 are perspective views of an apparatus according to an embodiment of the invention, as seen from offset angles from the front and rear of the apparatus.
[0038] FIG. 3 is an exploded view depicting components of the apparatus of FIGS. 1 and 2 , as viewed from the front perspective view of FIG. 1 .
[0039] FIG. 4 is a front elevation of the apparatus of FIGS. 1 and 2 , with an access door and filtering screen of the apparatus removed.
[0040] FIG. 5 is a top plan of the apparatus of FIGS. 1 and 2 .
[0041] FIGS. 6A and 6B are cross-sectional views of the apparatus of FIGS. 1 and 2 , from respective sides of the apparatus. FIG. 6A depicts a cross-sectional view through a centre line of the apparatus, while FIG. 6A depicts a cross-sectional view at a minimal offset from a near side of the apparatus.
[0042] FIGS. 7A and 7B are a front elevation and associated cross-sectional view through a centre line of the apparatus installed in situ atop a housing for a drill motor, around a drill chuck extending from the drill motor housing, and with a drainage hose leading away from the apparatus.
[0043] FIGS. 8A and 8B are associated perspective and front elevation views of a chamfered drill chuck for use with the apparatus of FIGS. 1 and 2 , as depicted in FIGS. 7A and 7B , with hidden lines depicted in dash in the front elevation of FIG. 8B .
[0044] FIG. 9 depicts a system for reticulating drill water embodying the apparatus of FIGS. 1 and 2 , shown in a cross-sectional view corresponding to that of FIG. 7B , which depicts a detail of FIG. 9 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0045] Referring first to FIGS. 1, 2 and 3 , reference number 10 identifies an apparatus for recovery of liquid (hereinafter simply referred to as water) employed during an overhead drilling operation into strata (eg a rock face) for flushing out drill cuttings (fines, rock pieces, dust etc) as drilling is performed with a rock drilling rig, and cooling the drill tool head (drill bit or steel) according to one particular preferred embodiment of the present invention.
[0046] The apparatus 10 comprises principally a funnel structure 12 , a mounting structure 14 and a spillway structure 16 , integral with one another. For ease of reference, relative terms such as front, rear, side, upper, lower, etc, will be used also to facilitate understanding. It will thus be noted that funnel structure 12 is located at the top above the mounting structure 14 and the spillway structure 16 is located directly adjacent on the front but offset and below the funnel structure 12 .
[0047] Before describing the apparatus 10 in further detail, it is instructive to briefly review its application in context, as depicted in FIGS. 7A and 7B, and 9 . The apparatus 10 is, as depicted, mounted at the housing 22 on top of a drill motor 18 , which has a drill chuck 20 projecting upwardly, of an overhead drilling rig (not shown). The apparatus 10 is devised to capture the slurry mixture of drill cuttings and spent bore hole flushing (or rinse) water that falls during an overhead drilling operation and which otherwise would impact on and run down the side of the drill rig 22 . A drainage hose 24 connected to apparatus 10 removes spent rinse water drained from the slurry mixture collected by apparatus 10 .
[0048] Overhead drilling rigs will not be described herein any further, and reference should be made to appropriate literature. The broad principle of operation of apparatus 10 is to collect the slurry mixture of spent rinse water and drill cuttings as this heterogeneous mass falls—and remove a substantial part of the spent rinse water from the drill cuttings, which are discarded, while the recovered spent rinse water is drained away for collection in a sedimentation or storage tank 26 from where it can be extracted through pipe 28 by a normal water suction pump 30 (as compared to specialist slurry pumps used in mining) for recirculation via suitable pipe work (plumbing) 32 for re-use as flushing water for a drill string and bit. The collected spent rinse water can be stored and continuously reticulated, as depicted, or drained—or pumped away as waste as requirements dictate. Apparatus 10 is devised to drain water with some fines in it, ie not to entirely filter the spent rinse water at the apparatus of all particulate matter above a certain particle size. Discarding the drill cuttings from the slurry to a relatively fine level at the apparatus is sufficient to allow reliable pumping using general-purpose pumping equipment, avoiding pump failure which can otherwise occur if particulate matter such as drill cuttings is attempted to be pumped using conventional water pumps.
[0049] Returning to FIGS. 1 to 3 , funnel structure 12 comprises a lower funnel pan 34 having an upright back wall 36 , an inclined, partially frustoconical wall 38 and an annular base part 40 with a circular central aperture 42 for accommodating and allowing passage from below the base of drill chuck 20 (as depicted in FIGS. 7A and 7B ). It will be noted that the funnel structure 12 overall is not strictly speaking frustoconical in mathematical or geometrical sense, and does not imply that the funnel is exactly or even approximately circular in shape, but only that it defines an receptacle zone with a substantial part of the inward facing surface inclined to direct material towards the base part 40 . The top edge of lower funnel pan 34 is in fact not circular but is clipped at its rear. This is not of any especial significance, beyond the fact that this particular configuration is adopted so that the funnel section 12 , in plan view, not exceed the footprint of the drill motor housing 22 to which the apparatus 10 is fitted (as best seen in FIG. 7B ).
[0050] The funnel pan 34 provides a lowest drainage point for slurry mixture falling into and collected by the funnel structure 12 , as is noted below.
[0051] Within the aperture 42 of annular base part 40 there is located and seated a circular gasket 44 , which serves to seal the funnel pan's bottom against the head part of the drill housing 22 from leaking slurry mixture onto the drill motor 18 located beneath the apparatus 10 .
[0052] As noted, whilst the mayor part 38 of the side wall of funnel pan 34 is generally angled upwardly and outwardly from the flat annular base part 40 , a minor portion of the funnel sidewall 36 is angled vertically at the rear. It will be furthermore noted that the uppermost terminal rim portion 46 of the inclined wall 38 also extends vertically. This portion 46 serves to help collect slurry mixture, and permits convenient and secure fitting of an optional, removable collar 48 , which has a footprint of similar contour as the open top of funnel pan 34 and by way of which the volume of funnel section 12 can be increased by vertically extending the peripheral walls 36 , 38 upwards.
[0053] The collar 48 is secured by a suitable clamp or tie, and is preferably made of a hard-wearing, transparent (or translucent) and resilient rubber-like material, such as a silicone or urethane based material. This permits ready visual inspection into the funnel 12 , and can be replaced as required if damaged or worn. In contrast, the remainder of funnel section 12 is made from suitably gauged steel sheet material.
[0054] The open mouth (top) 50 of lower funnel pan 34 is preferably covered by a wide gauge grate 52 that is supported at discrete horizontally extending lugs 54 welded onto inclined and upright side walls 38 , 36 of pan 34 . The gauge of grate 52 is selected to catch rocks that may be fall with drill cuttings into the funnel section 12 . The contour of grate 52 is best seen in FIG. 3 , and is shaped to fit inside the funnel section 12 , and match the central aperture 42 in the annular base part 40 of funnel pan 34 and the profile of the funnel sidewalls. The gauge of the grate 52 is selected to pass all but the largest drill cuttings—and in the preferred embodiment is formed as grid spaced at approximately 25 mm by 25 mm. Such larger pieces of material may cause blockages during operation, and accordingly are best caught before attempting to pass through the funnel section 12 . Periodically clearing the grate 52 by hand removes further impediment from outsized pieces trapped by the mesh 210 .
[0055] Slurry mixture falling to and captured by funnel section 12 is passed to the adjacent spillway section 16 via cylindrical pipe stump 56 , which is welded to the outside of inclined wall 38 about or within a corresponding circular port (or through hole) provided in the inclined funnel sidewall 38 at the front and centre of the apparatus. The lowest extent of cylindrical pipe stump 56 is flush with the funnel pan 34 , ie the annular base wall 34 , to avoid collecting excess slurry mixture within the funnel pan 34 . The diameter of the conduit (pipe stump) 56 is approximately 40 mm, though a variety of other configurations and dimensions may be used. The conduit 56 terminates within the spillway section 16 , where slurry mixture from the funnel section 12 is discharged.
[0056] The spillway section 16 comprises a duct-like vertical structure 58 with three closed wall components, a rear wall 60 and two side walls 62 , 64 which define an essentially bracket or angular u-shaped vertical channel or through 66 open to the front side of apparatus 10 . Duct-like vertical structure 58 in the preferred embodiment extends vertically, and in use is positioned against a vertical side of the housing 22 of the drill motor 18 . This ensures that the apparatus 10 has a compact footprint.
[0057] The spillway sidewalls 62 , 64 are flush with and formed integrally with side skirts 67 , 68 that extend downwardly from and at the sides of the funnel section 12 . The skirts 66 , 68 form part of the mounting structure 14 of apparatus 10 in that they serve to locate the apparatus 10 relative to the drill motor housing 22 .
[0058] At an upper end of spillway section 16 , where the spillway sidewalls 62 , 64 meet the funnel section 12 , there is mounted a 90 degree curved access door 70 positioned to span between the sidewalls 62 , 64 . The access door 70 has a handle 72 , and is conveniently retained in place to close the upper end of spillway channel or through 66 by an interference fit, and also with assistance from retaining clips 74 or similar fixtures that are fitted in association with co-operating lugs 76 extending from the sidewalls 62 , 64 .
[0059] The access door 70 (as best seen in FIG. 3 ) is shaped to fit flush with the edges of the side walls 62 , 64 of spillway section 16 and has a rearwards located arcuate edge so that it can fit flush against an outer surface of the partially frustoconical inclined sidewall 38 of lower funnel pan 34 . The access door 70 curves down from its horizontal rear portion to its vertical front portion such as to be located horizontally displaced from the terminal end of slurry discharge pipe stump 56 . Thus, access door 70 serves the double purpose of providing a splatter surface for slurry discharged from pipe stump 56 and allow access to it in case of blockage.
[0060] The access door 70 has attached to its lower terminal front edge via mounting angle 77 , a resilient but otherwise form-stable baffle 78 . As best seen in FIG. 6A , the baffle 78 is provided as a concave strip of material, (or lip) curved slightly upwardly and extending in rearward direction towards the rear wall of spillway section 16 to end about level with the discharge location of pipe stump 56 . Baffle 78 thus provides a channel extending width wise between the spillway side walls 62 , 64 by way of which the slurry discharged from pipe stump 56 and splattered by the inner, curved face of door 70 is caught and spread along the width of the spillway, and subsequently discharged curtain-like into the vertical channel/through 66 of the duct-like structure 58 . The baffle 78 moderates and to a practical extent controls flow of incoming slurry mixture, so that the incoming slurry mixture is collected by the baffle 78 , and then with the continual arrival of slurry mixture spills over the free rim of baffle 78 into spillway duct 66 .
[0061] It will be noted from FIGS. 3 and 6 a - 6 b in particular, that an inclined filtering (in the sense of de-watering) grate (or screen) 80 is mounted within through 66 between the side walls 62 , 64 such as to subdivide the channel 66 into a portion 66 a that is open towards the front of apparatus 10 and a rear portion 66 b, serving as a liquid catchment zone for water separated at the grate 80 from the mixed slurry that is discharged onto it by baffle 78 . The upper edge of grate 80 is supported at suitably shaped locating bars, schematically illustrated at 82 , 83 , positioned horizontally spanning the spillway sidewalls 62 , 64 , whereas the lower end is equally supported at locating bar 84 such that grate 80 can be inserted and removed from channel 66 as and when required. The planar dimensions of grate 80 are chosen such that it can fit snuggly between the spillway side walls 62 , 64 and extend from near spillway rear wall 60 just below the terminal edge of baffle 80 at an angle towards a vertically extending front wall 86 at the lower end of the duct-like vertical structure 58 . Thus, slurry mixture discharged onto the de-watering grate is cascaded along the grate 80 for discharge at its lower end and along vertical front wall 86 .
[0062] The filtering screen (dewatering grate) 80 is preferably simple and robust in construction, and in the preferred embodiment consists of a series of spaced apart rails connected by a series of underlying spaced apart studs. The pitch of the rails is relatively tight, and each rail is approximately 1.5 mm in width, with adjacent edges spaced apart by a comparable amount. The rails have a depth of approximately 2 mm, and with sufficiently heavy studs the screen 80 is suitably robust. The grate 80 in basic configuration is evocative of window louvres, or a cattle grid in miniature. A variety of different configurations may be used to achieve a desired rate and amount of dewatering of the mixed slurry, as a matter of trial and experimentation.
[0063] As noted, in operation of apparatus 10 , the slurry mixture spills from the baffle 78 onto an upper region of the dewatering grate 80 , into zone 66 a of the trough, and progressively runs down the screen towards its lower region. As it progresses, spent rinse water in the slurry mixture drains away through the rails of the grate 80 , and into the rearward liquid catchment zone 66 b of channel/through 66 of spillway 16 . Fine particles in the slurry mixture will also pass through the screen 80 , though larger particles will run down the screen 80 , and be discharged at the bottom of the screen 80 , at which point the slurry mixture is largely drained of spent rinse water.
[0064] With extended use of the apparatus 10 , the dewatering grate (screen) 80 wears as a consequence of the abrasive effect of slurry mixture and specifically the suspended drill cuttings rubbing against the screen. The leading edges of the rails become rounded slightly with use, which marginally reduces the efficiency of the grate 80 . The grate 80 is less able to effectively ‘cut’ into the slurry mixture as a consequence. A perceptible slowing of the drainage rate drainage can be noticed with careful observation. The grate 80 can be removed and replaced ‘upside down’ to expose the opposite (unworn) corners of the rails of the screen 80 . Should the screen 80 become worn in both orientations, the screen 80 can be substituted with a replacement if necessary. Specially engineered screens having greater complexity may be contemplated, but are not necessary for effective operation of the apparatus 10 .
[0065] The ‘water screening’ grate 80 is angled relatively steeply, and in the preferred embodiment approximately 55° from a horizontal plane. This angle permits a relatively compact footprint for the apparatus 10 whilst also effectively draining the slurry mixture. A broader range of angles is of course possible, with angles between 30° and 80° to a horizontal plane being feasible, and angles between 45° and 65° being favoured for reasons already mentioned. Should the angle be too steep there will be insufficient drainage, and too shallow an angle will tend to clog the screen 80 , and also extend the footprint of the apparatus 10 .
[0066] The grate 80 may appear to be particularly steep, but is found to be remarkably effective in efficiently draining slurry mixture in operation, with a high recovery rate of spent rinse water.
[0067] The apparatus 10 as a whole is advantageously fabricated from laser cut stainless steel, welded together. Use of a suitable gauge stainless steel plate results in a robust unit which is well able to resist corrosion and is unlikely to require in field repair, and which weighs of the order of 10 kg. Certain components as mentioned are desirably provided in a suitable rubber-like material, such as collar 48 , gasket 44 , and baffle 70 . Certain parts may require periodic replacement, such as the flexible components noted, as well as screen 80 , mesh 52 , and retaining clips 74 .
[0068] The spillway section 16 incorporates at its lower end a rain water head structure 88 similar to those found in many downpipes of roof gutter structures of houses. The discharge duct 90 from rain water head structure 88 extends outwardly and downwardly to connect to drainage hose 22 as shown in FIG. 9 . The rain head 88 is angled inwardly to collect the spent rinse water delivered from the spillway 16 , which is then delivered out the hose 22 .
[0069] FIGS. 7A and 7B depict use of the apparatus 10 in conjunction with a drill motor 18 . The tip of the drill steel typically terminates in a drill bit or other rock-working tool adapted for working the drilling surface.
[0070] The apparatus 10 in use is centred around the drill chuck 20 and resting atop the drill motor 18 . The drill motor 18 as depicted has a generally rectangular housing, with a flat top surface, and vertical sides.
[0071] The apparatus 10 is generally shaped to fit around the top surface of the housing of the drill motor 22 , and against a vertical side of the housing. The drill chuck 20 fits into the drill motor 18 for receiving torque from the motor and transferring to the drill steel. The drill chuck 20 can freely rotate within the apparatus 10 owing to the central aperture 42 of the lower funnel base 34 .
[0072] During operation, pressurised rinse water is fed through the housing of the drill motor 18 , through the drill chuck 22 , and into the hollow interior of the drill steel. When working a rock face of the like, the rinse water is forced through the end of a dill bit attached to the drill steel, and rinses away drill cuttings and fines, and any other dirt, debris or vegetative material that is scored by drilling. The spend rinse water, mixed with the drill cuttings and the like, forming a slurry mixture as described, falls from the working surface downwards adjacent the drill steel.
[0073] A typical site uses a hydraulically-driven mast which tracks adjacent the drill steel. At the drilling site working surface, a timber jack and attached plate is pressed and holds firm up against the surface surrounding the drilling site to be drilled by the drill bit. A jawed clamp attached to the mast is used to hold the drill steel when required—such as when a further drill steel is to be added or swapped or removed. The drill steel is driven by the chuck 20 by means of a square brace arrangement which allow for torque transfer from the motor via the chuck 20 .
[0074] A rubber shroud (not shown) may optionally be provided and attached to the accompanying mast, and disposed around the drill bit or drill steel at or near the working surface as drilling takes place. This can assist in collimating the mixture as it falls. Moreover, one can minimise the spent rinse water and drill cuttings from flying too far afield, and containing most of the mixture to a relatively confined perimeter within a contained radius from the drill steel.
[0075] While the drill steel is implied as operating in a dead vertical orientation, it can in fact operate at an angle. The apparatus 10 can accommodate such angles, though the use of the collar 48 as described may need to modified or removed to assist in collecting as much spent rinse water as practicable.
[0076] FIGS. 8A and 8B are provided for completeness, and provide views of an exemplary drill chuck 800 used in proximity to the apparatus 10 . The drill chuck 800 comprises a chuck head 810 , and extending along a longitudinal axis of the chuck head 810 a shank 820 which is circular in cross-sectional profile. Disposed along the shank 820 is a brace 830 , which as depicted is of square-profile, and is adapted to fit in a matching recess in a drive piece of the drill motor. The shank 820 and brace 830 are conventional in construction, and used to transfer torque from the drill motor to the chuck 800 and thence to a drill steel, associated rock working tool, and ultimately the working face of the rock.
[0077] FIG. 9 depicts an integrated system 100 which relies upon the apparatus 10 to collect spent rinse water. The drainage hose 24 is connected at one end to the downpipe attached to the rainhead 88 of the apparatus 10 . At its other end the drainage hose 24 discharges spent rinse water to a (schematically depicted) holding tank 26 . A pump 30 (also schematically depicted) and associated feed hose 28 removes spent rinse water from the holding tank, and pumps to back via return line 32 to the drill motor 18 to reuse. Any suitable general-purpose pump may be used, whilst the spent rinse water circling through the system 100 will not be clear, filtering by the apparatus 10 ensures that drill cuttings of sufficient size to inhibit reliable operation is largely removed. The pump 30 should be suitably rated, and adequate to sustain the desired flow rate—an indicative exemplary flow rate 1500 L/hour is mentioned above.
[0078] As a proportion of the rinse water is inevitably lost during operation, provision for injecting supplementary water (for example, into the holding tank 26 ) is advantageously provided—such as via a pressurised inlet and control float, for example, or any other suitable means.
[0079] A reticulation circuit is thus formed and requires the circulation of far less water than if spent rinse water is simply left to soak into or collect around adjacent ground.
[0080] While the apparatus 10 and system 100 described and depicted herein is presented according to one particular preferred embodiment, there are in fact many varied alternative forms the present invention can be embodied. Various additions, modifications and substitutions regarding design and construction can be made without departing from the spirit and scope of the invention.
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An apparatus ( 10 ) for handling drill water comprises a funnel ( 12 ) and a spillway ( 16 ) which act in concert to receive and then separate a slurry mixture into constituent drill cuttings and spent rinse water. The funnel ( 12 ) collects the falling slurry mixture, which is channelled via conduit ( 56 ) into a spillway ( 16 ). The spillway ( 16 ) is fitted with a dewatering grate ( 80 ) onto which the slurry mixture from the funnel ( 12 ) is channelled. The flow of slurry mixture is moderated by a baffle ( 78 ) which both catches and discharges slurry mixture delivered by the conduit ( 56 ). The slurry mixture is discharged over the dewatering grate ( 80 ), which drains the spend rinse water into a section of the spillway ( 16 ), and discharges the drill cuttings away from the grate ( 80 ).
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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 restraints and, more particularly, to a restraint employed to restrict the movement of infants and small children.
Child restraints long have been in use to confine infants and small children to a desired area, or to prevent them from wandering into areas in which they are not permitted. Commonly, the gates are mounted within accessways, that is doorways or passageways, or at the top or bottom of stairs.
A child or infant restraint should satisfy at least two requirements. First, by blocking or impeding the passage of an infant or child through the accessway, the restraint also significantly impedes passage of an adult. If the restraint can be relatively easily removed from the accessway, the restraint can be removed to allow the adult to pass, and then remounted. However, a better solution is provided if the restraint includes a barrier or gate that can be opened to permit passage without removing the restraint entirely from the accessway. Second, if the gate can be disengaged and opened to permit passage through the accessway without removing the restraint entirely, it is important to be able to secure the gate in the closed position with a fastener or locking mechanism that is difficult for infants and children to open. However, an adult must be able to open the barrier quickly and easily and, therefore, the fastener should be easily and quickly operable by an adult.
It is also helpful if the gate satisfies two additional requirements. During a typical day in the home, the parent attending a child commonly needs to confine the child to the area occupied by the parent. Since that area changes throughout the home during a typical day, the area in which the child is confined changes. Since the child restraint is an integral component of the means used to confine the area of movement of the child, the parent should be able to move the restraint from accessway to accessway as the day progresses. Therefore, it should be easy to mount the restraint within and remove the restraint from an accessway. Also, accessways within a typical home can be of different widths. Therefore, it should be easy to adjust the width of the restraint.
None of the known restraints includes a gate that can be quickly and easily opened and closed by an adult, but which is difficult for a child to open. Further, none of the known restraints can meet those requirements while providing a restraint whose width is easily adjustable and that can be easily and quickly mounted within and removed from an accessway. Known restraints commonly include a barrier or gate that can be positioned in the accessway to block it, a mounting by which the restraint can be secured within the accessway and a fastener or locking mechanism that is provided to prevent children and infants from retracting the gate. The gate can be extended and retracted in a number of ways. Commonly, the gate can be folded or collapsed against one side of the accessway to permit passage, and extended to a locking mechanism mounted to the remaining side of the accessway. Another type of restraint forms a gate consisting of a pair of partitions that can be slid along each other to increase or reduce the width spanned by the gate. Still other gates are mounted on spring biased telescoping rods which can be compressed or allowed to expand to adapt the gate to different sized accessways. Other restraints include gates that are hinge mounted to one side of the accessway to allow the gate to swing between opened and closed positions.
SUMMARY OF THE INVENTION
The present invention provides a restraint for impeding passage through an accessway that includes a barrier sized to impede passage through the accessway when the barrier is secured in a closed position. A mounting secures the barrier at a first mounting location, the mounting permitting the barrier to be moved to and from the closed position. A closing fastener releasably secures the barrier in the closed position at a second mounting location. At least two sequential manipulations of the closing fastener are required to release the barrier from the closed position. Preferably, the door remains releasably secured in the closed position after conducting the first manipulation and prior to conducting the second manipulation.
Preferably, the width of the restraint can be adjusted to accommodate accessways of different widths. Also preferably, the device includes apparatus for quickly and easily mounting the device within an accessway and removing the device from an accessway.
The present invention also provides a fastener for releasably securing an article in a desired position, comprising three fastening members. An intermediate fastening member is adapted to be releasably secured to each of the remaining two fastening members. At least two sequential manipulations of the fastening members are required to move the article from the desired position. The article remains releasably secured in the desired position after conducting the first manipulation and prior to conducting the second manipulation.
BRIEF DESCRIPTIONS OF THE DRAWINGS
The following detail description of the preferred embodiments can be understood better if reference is made to the accompanying drawing, in which:
FIG. 1 is a perspective view of a child restraint provided by the present invention;
FIG. 2 is a cutaway view of a portion of the gate or barrier of the restraint shown in FIG. 1;
FIG. 3 is a perspective view of a portion of the restraint shown in FIG. 1, showing a fastener;
FIG. 4 is a top plan view of an alternate embodiment of the present invention;
FIG. 5 is a perspective view showing an alternate embodiment of the present invention mounted at the top of a set of stairs;
FIG. 6 is a top sectional view showing the fastener of the restraint shown in FIG. 5; and
FIG. 7 is a perspective view of a portion of the restraint shown in FIG. 5, showing in particular the gate fastener.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 through 3 show the details of a child restraint that can be adjusted to accommodate accessways of different widths. The restraint can be constructed of any suitable wood, metal, plastic and fiberboard. The restraint provided by the present invention can include a number of types of gates or barriers that are mounted in a variety of ways to permit the gate to be moved between an opened and closed position. However, for purposes of illustration only, restraint 10 includes a gate that is mounted to swing on a bar between an opened and closed position. Restraint 10 also includes a frame that is mounted directly to the accessway and to which the gate is mounted. The frame includes a pair of telescoping members that can be slid with respect to each other to adjust the width of the frame to permit it to be mounted in accessways of different widths. The gate itself defines a frame having telescoping members that also are slidable relative to each other to permit the width of the gate to be adjusted to match the width of the restraint frame. The gate also includes panels that are located within the gate frame and block passage through the opening defined by the frame. Some of the panels also are slidable with respect to each other to permit adjustment to the width of the area spanned by the panel assembly to ensure that no openings are provided through the frame when it is extended. The restraint frame includes a suitable fastener or locking mechanism, for example a hook and loop type fastener, which permits mounting of the restraint frame quickly and easily to the accessway. Restraint 10 includes a pair of hook and loop fastener assemblies which are used to secure the gate to the restraint frame in the closed position. The gate hook and loop fastener assemblies are easily unfastened by adults but cannot be unfastened easily by small children or infants. Also, the sound made by a hook and loop fastener when it is released provides an audible indication that the infant or child is attempting to release the fastener to open the gate.
FIGS. 5 through 7 show an alternate restraint provided by the present invention. Restraint 200 is designed to be installed substantially permanently in an accessway. Accordingly, the gate of restraint 200 is hinged to one side of the accessway, for example a wall, to permit it to swing between its opened and closed positions. Because the width of restraint 200 need not be adjustable, the gate can be a rigid planar member. Gate fasteners of the type employed with restraint 10 are employed with restraint 200.
Restraint 10 includes, generally, a frame 12, which is mounted to the accessway, and a barrier or gate 14. The exact configuration of frame 12 will depend on the nature of the accessway. Frame 12 defines a pair of planar mounting surfaces 16 and 18, which are adapted to engage the walls forming the boundaries of the accessway. A pair of loop fasteners 20 is secured to each surface 16 and 18. A pair of hook fasteners (not shown) is secured to each wall defining the accessway. The hook fasteners are so spaced that they are aligned with loop fasteners 20 when frame 12 is positioned as desired in the accessway.
Frame 12 is formed from a pair of frame members 22 and 24. Frame member 22 defines upper member 26, lower member 28, and side member 30, which defines mounting surface 16. Upper member 26 and lower member 28 extend from side member 30 in the same direction at generally right angles to side member 30. A fastening bar 32 is mounted at one end to lower member 28 and at the remaining end to upper member 26. Fastener bar 32 can be mounted in any suitable fashion, for example by gluing the ends of bar 32 into offsets formed in members 26 and 28.
Similarly, frame member 24 defines an upper member 34, a lower member 36 and a side member 38, which defines mounting surface 18. A mounting bar 40 is mounted to frame member 24. One end of bar 40 is secured to the underside of upper member 34 and the remaining end of bar 40 is secured to the upper surface of member 36. Bar 40 can be secured to members 34 and 36 in the same fashion as bar 32 is secured to members 26 and 28
Member 28 is adapted to slide within member 36 of frame member 24. Accordingly, member 36 defines a U-shaped track 42 that is sized to receive end 45 of lower member 28. Frame members 22 and 24 can be slid toward each other to retract or collapse frame 12, to reduce the width of frame 12, or slid apart to extend frame 12 and widen it.
Gate 14 is mounted on mounting post 40. Gate 14 is adapted to pivot around post 40 to permit gate 14 to be swung between its opened and closed positions. Gate 14 includes a frame 44 and four panels, a pair of distal panels 74 and 76, and a pair of proximal panels 78 and a panel not shown. Gate frame 44 is formed from central frame member 81 and side frame members 52 and 54. Panels 74 and 76 are mounted to frame member 52; and panel 78 and the proximal panel not shown are mounted to frame member 54. Central frame member 81 defines upper member 48, lower member 50 and central panels 82 and 83.
Side member 52 defines upper member 62 and lower member 64, which extend generally in the same direction from a side member 66 at right angles to member 66. Similarly, side member 54 defines upper member 68 and lower member 70, which extend from a side member 72 generally in the same direction at right angles to member 72. Central members 48 and 50 form shoulder 49, 51, 53 and a shoulder not shown at which panels 82 and 83, respectively, are joined, and which define square-shaped channels 85 and 87 which receive members 62 and 64, as can be seen more clearly in FIG. 2 with respect to upper member 62 and central member 48 of gate frame 44. The arrangement for supporting members 64, 68 and 70 is the same as that shown in FIG. 2.
Gate frame 44 receives panels 74, 76, 78 and the proximal panel not shown and restricts their lateral movement. In particular, gate 14 includes a pair of distal panels 74 and 76, a pair of proximal panels, proximal panel member 78 and a second panel member not shown, and central panel members 82 and 83, which are part of central frame member 81. Panel members 74, 76, 78, 82, 83 and the proximal panel member not shown cooperate to permit the extension and collapse of gate 14 while preventing the development of an opening in gate 14 through which an infant or child can pass.
Panels 74 and 76 are secured within gate frame side member 52 in any suitable fashion. FIG. 2 shows the manner of securing panel members 74 and 76 within gate frame members 62 and 66. In particular, the edges of panel members 74 and 76 are secured to the inner surfaces of members 62 and 66. Also, the sides of panels 74 and 76 can be secured to the flanges 84, 86, 88 and 90 of members 62 and 66. The proximal side panels are mounted to frame member 54 in similar fashion.
Post 40 passes through an opening 41 defined at the top of member 72 and another opening (not shown) defined at the bottom of member 72. Then, member 72 is secured to post 40 in any suitable fashion that permits gate 14 to swing on post 40.
The proximal and distal panel members are free to slide toward each other when gate frame 44 is collapsed and away from each other when gate frame 44 is extended without creating an opening in gate 14 through which a child or infant could pass.
A pair of hook and loop locking mechanisms or fasteners 92 and 94 is secured to gate frame members 62 and 64, respectively. Fasteners 92 and 94 are used to releasably secure gate 14 in its closed position. Each fastener includes three fastener strips 96, 98 and 100. Each of intermediate strip 98 and outer strip 100 are secured at one end to a gate frame member using three rivets 102. In particular, one end of outer strip 100 is positioned directly on the gate frame member and one end of intermediate member 98 is positioned on top of it. Rivets 102 then are inserted through both strips. The length of strip 96 is substantially identical to the circumference of mounting bar 32 so that it completely encircles it. Strip 96 can be secured to bar 32 in any suitable fashion, for example, by gluing.
To close fastener 92 or 94, strip 98 is first wrapped around strip 96 and then strip 100 is wrapped around strips 96 and 98. The side of strip 100 facing the gate frame member is smooth, while the remaining side constitutes the loop material of a hook and loop fastener along its entire length. Strip 98 includes a segment constituting the hook material of a hook and loop fastener and a second segment constituting loop material. In particular, surface 104 of strip 98 defines a smooth segment 108 and a hook segment 110. Similarly, surface 106 of strip 98 defines a smooth segment 116 and a loop segment 114. Loop segment 114 extends to the end of strip 98.
Gate 10 is secured within an accessway by collapsing frame 12 and gate 14 sufficiently to permit gate 10 to be placed in the accessway. Fasteners 92 and 94 are secured to bar 32 and loop fasteners 20 are aligned with the corresponding hook fasteners on the sides of the accessway. Frame 12 is extended until loop fasteners 2 mate with the corresponding hook fasteners. As frame 12 is expanded gate 14 also expands as required. Removal of restraint 10 from the accessway is accomplished simply by collapsing frame 12 until loop fasteners 20 become disengaged from the corresponding hook fasteners.
Fasteners 92 and 94 are fastened to bar 32 by moving gate 14 to its closed position. Strip 98 is wrapped around strip 96 so that loop segment 114 of strip surface 104 is engaged with strip 96. Then, strip 100 is wrapped in the opposite direction around strip 96 and strip 98 until its loop fasteners are engaged with both the hook fasteners of strip 96 and hook segment 110 of surface 104 of strip 98. The relative lengths of strips 98 and 100 and of segments 110 and 114 should be chosen to permit proper engagement of hook segments 114 with strip 96 and loop member 100 with both strip 96 and hook segment 110 of strip 98. Fasteners 92 and 94 are unfastened by reversing the fastening procedure.
As an alternative member 81, member 54 and the proximals panels can form a single unit.
FIGS. 5 through 7 show child restraint 200. Child restraint 200 is designed for substantially permanent mounting in an accessway. Accordingly, its width is not adjustable and it is not readily removable for remounting in another accessway.
Restraint 200 includes gate 210, fasteners 212 and 214 and hinges 216 and 218. One side of each of hinges 216 and 218 is suitably fastened, for example with screws, to wall 220 while the remaining side is suitably secured to gate 210. Gate 210 can be constructed from a suitable fiberboard. Accordingly, gate 210 can swing between an opened and closed position on hinges 216 and 218.
Gate 210 is secured in the closed position to post 222 with fasteners 212 and 214. Each fastener 212 and 214 includes strips 224, 226 and 228. Each of intermediate strip 226 and outer strip 228 is secured to gate 210 at one edge with a rivet 230. Inner strip 224 is wrapped around and secured to post 222. With the exception of their lengths and the lengths of the hook and loop segments of intermediate strip 226, the construction and use of fasteners 212 and 214 are identical to those of fasteners 92 and 94 of restraint 10, with the exception of their dimensions and the fact that the hook member and loop members are reversed. Strips 224, 226, 228 and the hook and loop segments of strip 226 should be dimensioned to permit proper fastening as described with respect to fasteners 92 and 94.
FIG. 4 shows a restraint 250 that is identical to gate 200 except that it has been adapted for use in an accessway defined by two walls rather than by a wall and a railing post. In particular, FIG. 4 shows a fastener 252 that has been adapted from fasteners 212 and 214 to accommodate the securing of the open end of gate 254 to wall 256 rather than to a post. Fastener 252 includes strips 258, 260 and 262. Each of inner strip 258 and outer strip 262 is secured at one end to wall 256 with a screw 264. Strip 258 is secured at its remaining end to wall 256 with another screw 266. The exposed surface of strip 258 constitutes the loop material of a hook and loop fastener. One end of intermediate strip 260 is secured to gate 254 with a screw 268. Segments 270 and 272 of strip 260 constitute hook material. Surface 274 of strip 262 is smooth, while side 276 constitutes loop material.
Gate 254 is fastened in the closed position by moving gate 254 to the closed position shown in FIG. 4 and securing hook material 270 to strip 258. The loop material 276 of strip 262 is overlaid onto segment 272 to secure those two surfaces together. Unfastening fastener 252 is accomplished by reversing the fastening procedure.
With respect to each of fasteners 92, 94, 212, 214 and 252, the gate remains fastened in place when the outer strip is disengaged from the intermediate strip. Accordingly, an adult supervising a child can facilitate opening and closing the gate by leaving the outer strip disengaged. If more secure closure is desired, for example if the adult must leave the area occupied by the child or infant, the outer strip should remain engaged with the intermediate strip to increase the difficulty with which the child or infant can unfasten the fastener.
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A child restraint includes a gate that can be closed to impede passage by a child or infant through an accessway. The restraint includes a fastener for releasably securing the gate in its closed position. Two separate sequential manipulations are required to unfasten the fastener, which renders it difficult for an infant or child to unfasten the fastener, yet permits quick and easy unfastening by an adult. The restraint can include a gate that is collapsible to permit the restraint to be quickly and easily removed from one accessway and remounted in another accessway.
A fastener for releasably securing an article in a desired position includes three strips of hook and loop type fastening material. An intermediate strip can be positioned between the two remaining strips. The hook and loop material releasably secures the three members together as a unit. Two sequential operations are required to release the members from each other, thereby requiring two sequential manipulations to release the article from its position.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
In connection with the completion of oil and gas wells, it is frequently necessary to utilize packers in both open and cased bore holes. The walls of the well or casing are plugged or packed from time to time for a number of reasons. For example, a section of the well may be packed off to permit applying pressure to a particular section of the well, such as when fracturing a hydrocarbon bearing formation, while protecting the remainder of the well from the applied pressure.
In a staged frac operation, for example, multiple zones of a formation need to be isolated sequentially for treatment. To achieve this, operators install a fracture assembly 10 as shown in FIG. 1 in a wellbore 12 . Typically, the assembly 10 has a top liner packer (not shown) supporting a tubing string 14 in the wellbore 12 . Open hole packers 50 on the tubing string 14 isolate the wellbore 12 into zones 16 A-C, and various sliding sleeves 20 on the tubing string 14 can selectively communicate the tubing string 14 with the various zones 16 A-C. When the zones 16 A-C do not need to be closed after opening, operators may use single shot sliding sleeves 20 for the frac treatment. These types of sleeves 20 are usually ball-actuated and lock open once actuated. Another type of sleeve 20 is also ball-actuated, but can be shifted closed after opening.
Initially, all of the sliding sleeves 20 are closed. Operators then deploy a setting ball to close a wellbore isolation valve (not shown), which seals off the downhole end of the tubing string 14 . At this point, the packers 50 are hydraulically set by pumping fluid with a pump system 35 connected to the wellbore's rig 30 . The build-up of tubing pressure in the tubing string 14 actuates the packers 50 to isolate the annulus 18 into the multiple zones 16 A-C. With the packers 50 set, operators rig up fracturing surface equipment and pump fluid down the tubing string 14 to open a pressure actuated sleeve (not shown) so a first downhole zone (not shown) can be treated.
As the operation continues, operators drop successively larger balls down the tubing string 14 to open successive sleeves 20 and pump fluid to treat the separate zones 16 A-C in stages. When a dropped ball meets its matching seat in a sliding sleeve 20 , fluid is pumped by the pump system 35 down the tubing string 14 and forced against the seated ball. The pumped fluid forced against the seated ball shifts the sleeve 20 open. In turn, the seated ball diverts the pumped fluid out ports in the sleeve 20 to the surrounding annulus 18 between packers 50 and into the adjacent zone 16 A-C and prevents the fluid from passing to lower zones 16 A-C. By dropping successively increasing sized balls to actuate corresponding sleeves 20 , operators can accurately treat each zone 16 A-C up the wellbore 12 .
The packers 50 typically have a first diameter to allow the packer 50 to be run into the wellbore 12 and have a second radially larger size to seal in the wellbore 12 . The packer 50 typically consists of a mandrel about which the other portions of the packer 50 are assembled. A setting apparatus includes a port from the inner throughbore of the packer 50 to an interior cavity. The interior cavity may have a piston that is arranged to apply force either directly to a sealing element or to a rod or other force transmitter that will apply the force to the sealing element.
Typically, when the packer 50 is set, fluid pressure is applied from the surface via the tubular string 14 and typically through the bore of the tubular string 14 . The fluid pressure is in turn applied through a port on the packer 50 to the packer's piston. The fluid pressure applied over the surface of the piston is then transmitted to the packer's sealing element to compress the sealing element longitudinally.
Most sealing elements are an elastomeric material, such as rubber. When the sealing element is compressed in one direction it expands in another. Therefore, as the sealing element is compressed longitudinally, it expands radially to form a seal with the well or casing wall.
In some situations, operators may want to utilize comparatively long sealing elements in their packers 50 . In these instances, however, as the packer's piston pushes the sealing element to compress the sealing element longitudinally, friction and other forces combine to cause the sealing element to bunch up or otherwise bind near the packer's piston, preventing the sealing element from uniformly compressing longitudinally and thereby preventing the uniform radial expansion of the sealing element. The lack of uniform expansion tends to prevent the packer 50 from forming a seal that meets the operator's expectations, thereby defeating the purpose of utilizing a longer sealing element. For this reason, operators may not use an unset sealing element on a packer 50 that is more than about 24-inches long. Instead, a typical length of an unset seal element is only about 10-inches.
Therefore, a need exists for a packer that is able to utilize an extended length sealing element. The present invention fulfills these needs and provides further related advantages.
SUMMARY
A dual-set hydraulic packer disclosed herein allows a sealing element to be set from both ends so that more setting force and more uniform or balance setting can be applied to the sealing element. The sealing element can be relatively longer than conventionally used. Firstly, the packer is set by applying fluid pressure through the interior throughbore of the packer's mandrel to a first piston on an end of the sealing element. Then secondly, the packer is set by using pressure in the annulus to set a second piston on the other end of the sealing element. The setting order depends upon the desire of the operator because the packer can be installed either with the annular set piston on top and the tubular set piston on the bottom or vice versa.
Accordingly, the disclosed packer has an upper hydraulic setting mechanism, a lower hydraulic setting mechanism, and a sealing element disposed therebetween. The sealing element is sequentially longitudinally compressed separately by the upper hydraulic setting mechanism and the lower hydraulic setting mechanism so that the sealing element experiences compression from both ends during a fracture treatment, acid stimulation, or other operation or treatment where the pressure in a zone is increased.
The packer may have a mandrel with an interior and an exterior. The upper hydraulic setting mechanism, the lower hydraulic setting mechanism, and the sealing element are attached to the exterior of the mandrel. Fluid pressure in the mandrel interior typically actuates one or the other of the upper hydraulic setting mechanism or the lower hydraulic setting mechanism, but not both. Also, fluid pressure on the mandrel exterior typically actuates one or the other of the upper hydraulic setting mechanism or the lower hydraulic setting mechanism but not both.
The packer may have one or more sealing elements. In one embodiment, the packer may have at least two sealing elements separated by a barrier. The upper hydraulic setting mechanism may have a first piston adjacent to a first of the sealing elements, and the lower hydraulic setting mechanism may have a second piston adjacent to a second of the sealing elements. During operation, internal fluid pressure in the packer may act upon the first piston to radially expand a portion of (or the entire extent of) the sealing element(s). Additionally, external fluid pressure in the surrounding annulus may act upon the second piston to radially expand a portion of (or the entire extent of) the sealing element(s).
The packer may have a mandrel with an interior throughbore and an exterior. A first housing may be attached to a first end of the mandrel exterior and a second housing may be attached to a second end of the mandrel exterior. A first cylinder may be located within the first housing and a second cylinder may be located within the second housing. A first piston may be located within the first cylinder and the first piston is in fluid communication with the mandrel interior. A second piston may be located within the second cylinder and the second piston is in fluid communication with the mandrel exterior.
The first piston is disposed adjacent to the sealing element and the second piston is also disposed adjacent to the sealing element. Fluid pressure acts upon the first piston or the second piston to radially expand a portion of the sealing element. The first cylinder may be located between the first housing and the mandrel. The second cylinder may be located between the second housing and the mandrel.
In use, a packer having an interior, an exterior, a first hydraulic actuating mechanism, and a second hydraulic actuating mechanism may be run into a well. The interior of the packer is pressurized to actuate the first hydraulic actuating mechanism causing the sealing element to radially expand. The exterior of the packer is then pressurized to actuate the second hydraulic actuating mechanism causing the sealing element to radially expand.
As used herein, the terms such as lower, downward, downhole, and the like refer to a direction towards the bottom of the well, while the terms such as upper, upwards, uphole, and the like refer to a direction towards the surface. The uphole end is referred to and is depicted in the figures at the top of each page, while the downhole end is referred to and is depicted in the figures at the bottom of each page. This is done for illustrative purposes in the following figures. The tool may be run in a reverse orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagrammatically illustrates a tubing string having multiple sleeves and openhole packers of a fracture system.
FIG. 2 depicts a double-set hydraulic packer according to the present disclosure in a run-in condition.
FIG. 3 depicts the double-set hydraulic packer with a first (downhole) hydraulic setting mechanism in an actuated condition.
FIG. 4 depicts the double-set hydraulic packer with the downhole hydraulic setting mechanism and a second (uphole) hydraulic setting mechanism in actuated conditions.
FIG. 5 depicts a double-set hydraulic packer having first and second hydraulic setting mechanisms in actuated conditions and having a barrier disposed between first and second members of a sealing element.
DETAILED DESCRIPTION
The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
FIG. 2 depicts a double-set hydraulic packer 100 according to the present disclosure in an unset or run-in condition in a wellbore 12 , which may be a cased or open hole. The packer 100 includes a mandrel 110 with an internal bore 112 passing therethrough that connects on a tubing string ( 14 : FIG. 1 ) using known techniques. The packer 100 has first and second hydraulic setting mechanisms 150 and 160 disposed adjacent to ends of a sealing element 140 . As will be appreciated, the sealing element 140 may be longer or shorter than depicted and may comprise several pieces. In fact, the sealing element 140 for the disclosed packer 100 may be considerably longer than conventional elements used on packers and can be greater than 10-in. in length depending on the implementation.
In general and as shown in FIG. 2 , the first hydraulic setting mechanism 150 can be disposed on a downhole end of the packer 100 , while the second hydraulic setting mechanism 160 can be disposed on an uphole end. As will be appreciated with the benefit of the present disclosure, however, a reverse arrangement can be used, depending on the implementation, orientation, and access to tubing and annulus pressures in the wellbore 12 .
A first (downhole) end of the packer 100 has a first end ring 120 fixed to the mandrel 110 by lock wire 118 , pins, or the like. Part of this first end ring 120 forms a first housing 124 having an inner surface, which forms a first internal cylinder chamber 122 in conjunction with the external surface of the mandrel 110 . A first push rod or piston 152 resides in the first cylinder chamber 122 and has its end surface exposed to the chamber 122 . Accordingly, the first push rod 152 acts as a first piston in the presence of pressurized fluid F ( FIG. 3 ) communicated from the internal bore 112 of the mandrel 110 into the chamber 122 through one or more ports 115 .
During a setting operation, for example, fluid pressure is communicated downhole through the tubing string ( 14 : FIG. 1 ) and eventually enters the internal bore 112 of the packer's mandrel 110 . This setting operation can be performed after run-in of the packer 100 in the wellbore 12 so that the packer 100 can be set and zones of the wellbore's annulus 18 can be isolated from one another. While the tubing pressure inside the packer 100 is increased, external fluid pressure in the annulus 18 surrounding the packer 100 remains below the tubing pressure. During this setting operation, the packer 100 begins a first setting procedure in which the first setting mechanism 150 is activated to compress the sealing element 140 .
FIG. 3 depicts the packer 100 during this first setting procedure where only the first hydraulic setting mechanism 150 is being utilized. Pressurized fluid F in the mandrel's bore 112 accesses the first piston 152 in the first cylinder chamber 122 through the one or more first ports 115 in the mandrel 110 . Building in the chamber 122 , the pressurized fluid F acts on the first piston 152 and forces the piston's end 154 against one end 144 of the sealing element 140 disposed on the mandrel 110 . As the piston 152 moves along the mandrel 110 , it longitudinally compresses the sealing element 140 . In turn, as the sealing element 140 is longitudinally compressed, the element 140 radially expands from a first diameter D 1 to a second diameter D 2 toward the surrounding borehole 12 .
As depicted in FIG. 3 , the radial expansion is shown as occurring partially along the length of the sealing element 140 . This may or may not be the case depending on the length of the sealing element 140 and the friction and other forces encountered. In any event, the radial expansion of the sealing element 140 against the wellbore 12 separates the annulus 18 into an uphole annular region 18 U and a downhole annular region 18 D.
As will be appreciated, fluid pressure in the mandrel 110 entering second ports 116 for the second mechanism 160 does not activate this mechanism 160 , for reasons that will be apparent below. Instead, fluid pressure entering a chamber 170 of the second mechanism 160 during the first setting procedure actually tends to keep the second mechanism 160 in its original position so that the mechanism 160 acts as a fixed stop for the compression of the sealing element 140 .
During setting, the increased second diameter D 2 tends to cause the sealing element 140 to experience an increase in friction that can eventually limit the radial expansion of the sealing element 140 . In general, all or only a portion of the sealing element 140 may longitudinally compress and radially expand to a full or nearly full extent against the surrounding wellbore 12 . FIG. 3 only shows partial activation for the purposes of illustration. The compression and expansion can proceed at least until the friction and any other external forces equal the force used to compress the element 140 .
FIG. 3 also depicts further details of the second hydraulic setting mechanism 160 at the second end of the packer 100 . A second end ring 130 is fixed to the mandrel 110 by lock wires 118 or the like is disposed adjacent to a second piston 162 of the mechanism 160 . As shown, the piston 162 can be composed of several components, including a push rod end 164 connected by an intermediate sleeve 165 to a piston end 166 . Use of these multiple components 164 , 165 , and 166 can facilitate assembly of the mechanism 160 , but other configurations can be used.
The push rod end 164 of the second piston 162 is disposed against a second end 146 of the sealing element 140 . On the other end, the piston end 166 is disposed adjacent to the second end ring 130 , but the piston end 166 is subject to effects of fluid pressure in the uphole annular region 18 U, as will be discussed further below. A fixed piston 168 is attached to the mandrel 110 by lock wire 118 to enclose the second piston chamber 170 of the second piston 162 . The chamber 170 is isolated by various seals (not shown) from fluid pressure in the uphole annular region 18 U formed by the packer 100 and the wellbore 12 . As long as the second hydraulic setting mechanism 160 remains in an unactuated state as in FIG. 3 , the chamber 170 does not decrease or increase in volume.
During operations after the first mechanism 150 is actuated and the sealing element 140 set, fluid pressure in the uphole annular region 18 U may be increased, which will then actuate the second mechanism 160 . For example, during a fracture treatment, operators fracture zones downhole from the disclosed packer 100 by pumping fluid pressure downhole, which merely communicates through the mandrel's bore 112 to further downhole components. The buildup of tubing pressure may tend to further set the first hydraulic setting mechanism 150 , but may tend to keep the second hydraulic setting mechanism 160 unactuated, as noted above.
Then, operators isolate the packer's internal bore 112 uphole of the packer 100 . For example, operators may drop a ball down the tubing string ( 14 : FIG. 1 ) to land in a seat of a sliding sleeve ( 20 : FIG. 1 ) uphole of this packer 100 . When the sliding sleeve ( 20 ) is opened and fracture pressure is applied to the formation through the open sleeve ( 20 ), the borehole pressure in the uphole annular region 18 U increases above the isolated tubing pressure in the mandrel's bore 112 . However, the internal pressure in the mandrel's bore 112 does not increase due to the plugging by the set ball on the seat in the uphole sliding sleeve ( 20 ). It is this buildup of borehole pressure in the uphole annular region 18 U outside the packer 100 compared to the tubing pressure inside the packer 100 that activates the second mechanism 160 .
In particular, FIG. 4 depicts the packer 100 with both the first and second hydraulic setting mechanisms 150 and 160 having been actuated. For the second hydraulic setting mechanism 160 to actuate, the tubing pressure in the inner bore 112 of the mandrel 110 is relieved, reduced, or isolated as noted above, while the borehole pressure in the uphole annular region 18 U around the packer 100 is increased. In certain instances, it may not be necessary to relieve the fluid pressure in the inner bore 112 as long as the pressure in the uphole annular region 18 U may be increased to overcome any pressure in the inner bore 112 to a sufficient level to actuate the second hydraulic setting mechanism 160 .
With a sufficient buildup of pressure in the uphole annular region 18 U, the external pressurized fluid in the region 18 U acts upon the external face of the piston end 166 . Chamber 170 , which is at the lower tubing pressure, is sealed from the external pressure from the annular region 18 U. Thus, an internal face of the piston end 166 is exposed to the lower tubing pressure in the chamber 170 . Consequently, the pressure differential causes the second piston 162 to move along the mandrel 110 and exert a force against the sealing element 140 .
As the second piston 162 moves, it further compresses the sealing element 140 . The lower tubing pressure in the chamber 170 can escape into the mandrel's bore 112 through ports 116 while the chamber 170 decreases in volume with any movement of the second piston 162 . As the piston 162 moves, it longitudinally compresses against the sealing element 140 , which can radially expand further or more fully against the wellbore 12 , thereby completing the radial expansion of the sealing element 140 against the surrounding wellbore 12 . As noted above, the first mechanism 150 may compress the sealing element 140 practically to its full extent at least until a level of friction and other force is met. The second mechanism 160 can overcome the built-up friction to even further compress the sealing element 140 , which can further radially expand the element 140 .
As can be seen in the above embodiment, the packer 100 has a first hydraulic setting mechanism 150 for the sealing element 140 that uses an internal piston and cylinder arrangement moved with fluid pressure F from the interior bore 112 of the packer's mandrel 110 to at least partially set the sealing element 140 . In this first setting procedure, the interior bore 112 has a high pressure, while the annulus 18 has a lower pressure. The second setting mechanism 160 remains unactivated and acts as a stop against the other end of the sealing element 140 . This can be useful when fracturing a formation downhole of the packer 100 , for example.
As also seen above, the packer 100 has the second hydraulic setting mechanism 160 for the sealing element 140 . This second mechanism 160 has an annulus piston and cylinder arrangement moved by fluid pressure in the uphole annular region 18 U surrounding the packer 100 . In the second setting procedure, the second mechanism 160 is actuated when there is a higher pressure in the annular region 18 U and a lower pressure in the mandrel's interior bore 112 . This procedure can be useful when fracturing the formation uphole of the packer 100 , for example. The two setting mechanisms 150 and 160 may have the same or different setting pressures depending on the implementation.
Having the second setting mechanism 160 allows the sealing element 140 to be set additionally, and more uniformly with more force from the opposite side, after the packer 100 has already completed a first setting procedure and engagement with the wellbore 12 . Accordingly, the length of the sealing element 140 can be longer than conventionally used to seal over longer cracks in a formation. In other words, the sealing element 140 can be greater than the conventional 10-in. length usually used, and the mechanisms 150 and 160 may overcome the issues typically experienced with longer sealing elements.
The second setting procedure of the sealing element 140 can be performed when the element 140 has been allowed to cool and contract due to cold fluid flowing through the packer's mandrel 110 . The second setting procedure also overcomes the friction issue encountered with longer sealing elements used on the packer 100 . The second setting procedure of the sealing element 140 after it has contracted can also give the packer 100 a much better long term sealing capability. Finally, the annular pressure applied in the second setting procedure can act against a larger annular area to set the packer 100 and can provide a much higher total setting force.
In certain instances, it may be desirable to isolate one end of the sealing element 140 from the other end, thereby allowing separate sealing actions to work together while each end is actuated independently. FIG. 5 depicts an embodiment of a packer 100 having a central sealing element 140 with at least two members 142 a - b between the mechanisms 150 and 160 . The first hydraulic setting mechanism 150 sets a first sealing member 142 a of the packer's central sealing element 140 , and the second hydraulic setting mechanism 160 sets a second sealing member 142 b of the packer's element 140 .
A barrier 148 isolates the first sealing member 142 a from the second sealing member 142 b . The barrier 148 may or may not be anchored to the mandrel 110 and can be composed of any suitable material (e.g., metal, plastic, elastomer, etc.). If the barrier 148 is anchored to the mandrel 110 , the barrier 148 allows either sealing member 142 a - b to be set without regard to the other sealing element. If the barrier 148 is not anchored to the mandrel 110 , it will move with the elastomer if either mechanism 150 or 160 sets. In other words, the sealing members 142 a - b will behave like a single element 140 .
While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.
For example, although not shown in the figures, the packer 100 may use any of the conventional mechanisms for locking the push rods or pistons 152 and 162 in place on the mandrel 110 once set against the sealing element 140 . Accordingly, ratchet mechanisms, lock rings, or the like (not shown) can be used to prevent the rods or pistons 152 and 162 from moving back away from the sealing element 140 once set. Additionally, various internal seals, threads, and other conventional features for components of the packer 110 are not shown in the figures for simplicity, but would be evident to one skilled in the art.
The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. It will be appreciated with the benefit of the present disclosure that features described above in accordance with any embodiment or aspect of the disclosed subject matter can be utilized, either alone or in combination, with any other described feature, in any other embodiment or aspect of the disclosed subject matter.
In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.
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A device and method allow a longer sealing element to be used on a packer or other downhole tool while providing an increase in the total amount of setting force that can be used and providing for more uniform or balanced setting of the sealing element. The packer may be first set using internal bore pressure to radially expand one end of the sealing element with a first hydraulic setting mechanism. The packer may then be set a second time using annulus pressure to continue the radial expansion of the sealing element with a second hydraulic setting mechanism.
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FIELD OF THE INVENTION
The invention relates to a false floor as well as to a method and a device for the installation of this false floor.
BACKGROUND OF THE INVENTION
False floors are often installed in large modern buildings. As described in EP0309399A1, a false floor consists of floor panels, which are mounted on false-floor supports, that are adjustable in height and that are placed on the building floor, i.e. on the bare floor of the building. Hence, a small space results between the bare floor and the false floor, in which media lines of all kinds, such as water lines, gas lines and electrical cable, can be installed in the shortest distances, wherefore a detailed planning of the installation is not required.
EP0309399A1 further discloses a false-floor support with a foot member and a base plate, on which a support tube stands vertically, and with a head member with a holding cone, on which corners of a false floor panel are placed. The foot member and the head member are connected in such a way by screw elements, that a desired height of the false-floor support can be adjusted.
These false-floor supports exhibit disadvantages in the event that the bare floor is uneven. Then undesirable inclinations of the false-floor supports result. Due to the inclination of the holding cone the supported corners of the floor panels exhibit different heights a, wherefore irregular changes in height occur at the surface of the false floor.
A bothersome unevenness of the bare floor was initially corrected by outpouring the area of support of the foot member or by applying wedges below the foot member. However with this measure, a sufficiently precise alignment of the false-floor supports could be reached only with considerable efforts.
For solving this problem, EP0309399A1 proposes a false-floor support that comprises a support dish with adjustable inclination that is provided with an enclosed spherically domed inner member, which can be clamped between a spherically-domed ring-dish and a spherically-domed pressure plate after the inclination has been adjusted.
EP0479720A1 discloses the false-floor support shown below in FIG. 1 . This false-floor support comprises a foot member 220 with a base plate 221 , which via a connection device 223 is elastically connected to a foot tube 222 , which can vertically be aligned to the base plate 221 . The foot tube 222 can therefore be inclined by a specific angle relative to the base plate 221 , in order to compensate the unevenness of the floor. In the event that a larger unevenness cannot be compensated by means of the connection device 223 , a pedestal 310 is provided below the base plate 221 . A head tube 212 , which comprises a head member 210 with a head plate 211 , is telescopically entered into the foot tube 222 . The head member 210 , which is supported by a spring 230 , is movable towards the foot member 220 until a screw stop 240 , which is connected to the head tube 212 contacts the foot tube 222 . The screw stop 240 is held by a thread and can be set to a desired height.
Known installations of a false floor are done step-by-step, floor panel by floor panel. I.e., when installing the false floor, false-floor supports are sequentially mounted and adjusted. Afterwards floor panels are mounted. After mounting each floor panel the alignment is measured with a water-level and the false-floor support is adjusted. In this way, the false floor is extended step-by-step, whereby the individual steps of mounting a floor panel and adjusting a false-floor support are repeated alternatingly. In total a considerable installation effort results. It must further be noted that the floor panels are typically removed again after the false floor has been installed, so that the concerned personnel can install media lines, e.g. electrical cables, on the bare floor. After installing the media lines the floor panels are mounted on the false-floor supports again, whereafter additional adjustments are often required.
EP0479720A1 further discloses a method for installing false floors with floor panels that are arranged alongside one another in rows and that are supported by adjustable false-floor supports, which are placed in a regular grid pattern on the bare floor. With this method an auxiliary plane is levelled in a desired distance or in a predefined height above a section of the bare floor which comprises several grid intersections. Afterwards the false-floor supports are placed onto the grid intersections between the auxiliary plane and the bare floor and set onto the predefined height and fixed. Then the floor panels are mounted on the fixed false-floor supports.
In contrast thereto, in JP2002089022 it is proposed to mount a beam consisting of two rail elements by means of false-floor supports. The false-floor supports comprise each a massive head member, which by means of a screw nut is vertically movable along a threaded shaft of a foot member and is connectable by means of screws with rail elements fitted on both sides.
From said documents it can be derived, that the known false-floor supports have a complex design required for compensating an unevenness of the bare floor in view of height and inclination. However, not only the construction of the false-floor supports requires efforts, but also the adjustment, in order to compensate unevenness, bothersome differences in elevation and inclinations of the bare floor at the installation sites. In the event that false-floor supports get shifted laterally, then readjustments are required. In the event that an earthquake should occur it is likely, that the false-floor supports shift under the load of the room installations due to vibrations and oscillations. Afterwards differences in elevation of the floor panels need to be corrected with significant effort.
SUMMARY OF THE INVENTION
The present invention is therefore based on the object of providing an improved false floor as well as a method and a device for the installation of the false floor, with which the above described deficiencies are avoided.
Particularly a method shall be provided that allows to install a false floor quickly and precisely with minimal effort and independently of the unevenness of the bare floor.
For the inventive false floor false-floor supports with a simple design shall be usable. Adjustments of the false-floor supports shall not be necessary.
It shall be possible, to create the false floor with high precision and low-cost. Further the false floor shall be immune against mechanical impacts and vibrations so that adjustments after the installation shall also not be required.
It shall be possible to rapidly install and uninstall the false floor. In particular, the exchange of the false floor, e.g. if required with a change in elevation, shall be possible with minimal time and effort.
The method and the device serve for the installation of a false floor above a bare floor. The false floor comprises false-floor supports, which are placed preferably in a regular grid pattern on the bare floor and on which floor panels are arranged alongside one another in rows.
According to the invention, mounting positions are determined for the false-floor supports and the false-floor supports to be installed are correspondingly positioned. Furthermore, a mounting plane lying at a mounting height is at least partially determined preferably by using laser devices. The false-floor supports to be installed are then positioned relative to the mounting plane. Pedestals, which are composed of solidifying pedestal material that is binding to the bare floor and which project beyond the mounting plane, are provided at the mounting positions before, during or after the positioning of the false-floor supports. The false-floor supports are then held each in the respective pedestal until the latter has solidified.
In the event that the floor panels were not already connected to the false-floor supports, then the floor panels are mounted on the false-floor supports after the solidification of the pedestals.
Since the false-floor supports are all on the same height in a horizontal mounting plane, adjustment is not required. Consequently, simply designed false-floor supports can be used, which in the simplest embodiment consist of a hollow cylindrical or rectangular tube. One end of the tube forms the foot member and the other end forms the head member of the false-floor support. If the diameter of the tube is sufficiently large and the false-floor supports are precisely positioned, then the corners of four floor panels can be seated on the tube. The false-floor support can also comprise a foot member with such a tube and a head member, e.g. a round or quadratic plate. Preferably, identical false-floor supports are used that are made from metal or plastic.
The false-floor support can consist of one part or a plurality of parts. It is of particular advantage to use a false-floor support with a foot member that is inserted into a pedestal, whereafter a suitable head member is mounted, e.g. in order to adjust the height of the false floor. Furthermore, the false floor can completely be uninstalled in a very short time and reinstalled again. For a renovation of a room the false floor can be removed with the exception of the remaining foot members. Afterwards the equipment required for the renovation can be moved into the room.
E.g., the false-floor supports are made from iron sheet with round or polygonal cross-sections. E.g., a part of an iron sheet is cut out and partitioned in four sections, which are then bent step-by-step by 90° against one another. In order to firmly anchor the false-floor supports in the pedestals, the foot member is preferably provided with anchor elements that are cut out of the iron sheet and are bent to the outside.
The inventive method can be executed in several variations, as individually desired by the user, wherein specific method steps may be interchanged.
The mounting positions for the false-floor supports can be determined sequentially or in groups. The pedestals can also be created sequentially or in groups. The false-floor supports, which consist of one or more parts, can also be inserted into the pedestals sequentially or in groups. A plurality of false-floor supports, preferably four, can already be connected to a floor panel, so that the false-floor supports can be positioned together with the floor panels. The mounting plane can also be selected in such a way, that the mounting plane lies on the height of the plane, in which the installed floor panels will be arranged. In this way the floor panels can be aligned with their upper edge with the mounting plane.
The pedestal material used for creating the pedestals is preferably filled into a structural member, which determines the final form of the pedestal and which prevents the pedestal material from being displaced when the false-floor supports are inserted. The structural member, e.g. a conically shaped, thin-walled tubular member, is preferably made from plastic or iron sheet. The conical shape allows stapling of the structural members and removal after solidification of the pedestals so that they can further be used. Furthermore, reinforcement elements made from metal or plastic can be provided.
Alternatively, the pedestal material used for creating the pedestals can be filled into containers, such as bags or bellows that are individually attached to the foot members of each false-floor support and that are preferably flexible. E.g., the container adjoins the foot member in such a way that the pedestal material can be filled through the false-floor support into the container. Infilling of the pedestal material can be done immediately before mounting the false-floor supports or the floor panels, so that the pedestal material can harden within a few minutes, without adding an activator. Alternatively, an activator can be added, e.g. if the pedestal material had been filled earlier into the container. Alternatively, it is also possible that the hardening of the pedestal material is done after the removal of the container, e.g. by exposing the pedestal to air or heat.
The pedestal material used for creating the pedestals is for example a concrete mix, a concrete for floors, a cement mix or a plaster, which is composed and applied in such a way that it solidifies only after a timespan, in which the false-floor supports have been inserted. It is further possible to apply means or energy, e.g. heating the pedestals, in order to accelerate solidification. Said materials exhibit the advantage, that they quickly get bound to the bare floor. However, the inventive method also allows placing false-floor supports in groups and holding the false-floor supports until the pedestals are solidified.
According to the invention the dimensions of the pedestals are created preferably uniformly in such a way that even the false-floor support at the lowest mounting position can be inserted with the required penetration depth into the pedestals. If the bare floor is substantially even, then smaller pedestals can be provided, which allow secure holding of the false-floor supports at even height. By examining or measuring the bare floor the use of the material can be optimized.
For the installation of the false-floor supports an inventive installation device can advantageously be used. The installation device comprises a holding device with a device grid arranged in a device plane that corresponds to the mounting grid and that exhibits two or more device positions where coupling devices are mounted, which serve for holding false-floor supports.
After fixing the false-floor supports on the holding device, the holding device is aligned with its device plane in parallel or congruent to the reference plane and lowered towards the mounting plane until the lower ends of the false-floor supports reach the mounting plane.
Thereby pedestals are prepared with pedestal material that is not solidified before positioning the false-floor supports or after positioning the false-floor support. It is particularly advantageous to prepare the pedestals after the positioning the false-floor supports. Thereby the requirement of determining mounting positions on the bare floor, where pedestals would be prepared before, is avoided. The mounting positions are determined by alignment of the false-floor supports e.g. in a grid pattern with a grid distance of 60 cm. After lowering the false-floor supports preferably vertically the positions of the pedestals are determined. Now, the pedestals can be built in a simple manner by providing a structural member each at the positions of the false-floor supports. This task can be executed particularly simple by coupling the structural members to the false-floor supports so that the false-floor supports and the structural members can be lowered together towards the bare floor after positioning of the false-floor supports. In this way, the structural members and hence the pedestals are always at the correct position without additional effort. The releasable connection or coupling of the structural member to the false-floor support is executed preferably by means of at least one clamp element, which is inserted in addition or is formed on the false-floor support or the structural member. Preferably, the structural member and the at least one clamp element, as well as the false-floor support, are preferably formed from an iron-sheet.
Shifting the false-floor supports into the mounting positions can be done in two different alternatives. In the first alternative the holding device is shifted along a calculated distance. If the holding device is held by a plurality of supports that comprise each an identical drive device, e.g. a spindle drive, then it is sufficient to actuate each drive device in the same manner, so that the holding device is shifted always in alignment in parallel to the reference plane along the desired distance.
Alternatively, the holding device is shifted preferably in parallel to the reference plane until a mounting or reference plane is reached at a lower level. E.g., the holding device is provided with optical sensors, which capture the light of a laser system present in the reference plane and/or the mounting plane. Signals of these sensors allow a control system to adjust the holding device in the reference plane and/or the mounting plane or in a specific distance in parallel thereto.
The holding device is supported with at least three, preferably four lifting devices and is vertically movable with these lifting devices. E.g., the holding device is held by supports that are provided with drive devices, e.g. electric motors, which drive a spindle. The spindle is engaged in a bearing block that is connected to the holding device and that is vertically shifted upwards or downwards together with the holding device when the spindle is turned. Such spindle drives are available for example by maxon company (see maxonmotor.com). Any other preferably controllable lifting device, hydraulic and pneumatic lifting devices, can be used, which allow vertical shifting of the holding device.
After the installation, the lifting devices and/or the drive devices are preferably released from the holding device and used for another holding device, so that these devices need not be present in multiples.
DESCRIPTION OF THE DRAWINGS
Below, the invention is described with reference to the drawings.
FIG. 1 shows the prior art false floor described above, which comprises adjustable false-floor supports that support the floor panels;
FIG. 1 a shows a false-floor support of FIG. 1 , which supports the corners of four floor panels;
FIG. 2 shows a part of an inventive false floor with an inventive false-floor support installed in a pedestal as well as a simple inventive installation device in schematic illustration;
FIG. 3 shows the creation of a pedestal, as well as the operation of the installation device of FIG. 2 ;
FIG. 4 shows an inventive installation device with which false-floor supports can be inserted in groups by means of lifting devices precisely into prefabricated pedestals;
FIG. 5 shows the false-floor supports of FIG. 4 after insertion into the pedestals and the exchange of the lifting devices by auxiliary supports;
FIG. 6 shows the false-floor supports of FIG. 5 firmly installed in the solidified pedestals, on which false-floor supports floor panels have been mounted for creating the false floor;
FIG. 7 shows a false floor with false-floor supports that consist of two parts and that are inserted in a common pedestal;
FIG. 7 a shows a two-part false-floor support with two tubes that are movable into one another;
FIG. 7 b shows a single-part false-floor support that comprises a head member and a foot member that has been prefabricated from rectangular pipes;
FIG. 7 c shows false-floor supports in form of simple tubes that have been inserted into pedestals;
FIG. 8 a shows a part of a holding device made of rectangular pipes with coupling devices, with which false-floor supports can be fixed with a movement by hand;
FIG. 8 b shows the part of the holding device of FIG. 8 a after fixing a false-floor support, with a lifting device that can be operated manually or with a drive device;
FIG. 9 a shows the holding device of FIG. 8 a after attaching 16 false-floor supports;
FIG. 9 b shows the holding device of FIG. 9 a with false-floor supports directed downwards towards the bare floor and four symbolically shown drive devices;
FIG. 10 shows the attachment of false-floor supports together with a structural member on a beam-shaped element of a holding device;
FIG. 11 a shows infilling of pedestal material into the structural member, while the false-floor support is held by the beam-shaped element of the holding device;
FIG. 11 b shows a false-floor support with anchor elements;
FIG. 11 c shows the false-floor support held in the solidified pedestal, after removal of the beam-shaped element; and
FIG. 12 shows four false-floor supports, which are preferably firmly connected to a floor panel and which comprise foot members that are connected to containers that are filled with pedestal material.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the prior art false floor 100 , which has been described above and which comprises adjustable false-floor supports 200 which support the floor panels 1 . FIG. 1 a shows the false-floor support 200 of FIG. 1 , which supports the corners of four floor panels 1 of the false floor 100 .
FIG. 2 shows a part of an inventive false floor 10 with a false-floor support 2 A installed according to the invention, which supports four floor panels 1 in the manner shown in FIG. 1 a.
Use of the inventive method, which is described below, allows mounting of all false-floor supports 2 A, 2 B with little effort at the same height h M in a mounting plane E M above the bare floor 3 .
For this purpose, mounting positions 30 A; 30 B; . . . for the false-floor supports 2 are determined on the bare floor 3 . This can be done precisely with a laser system, which forms a grid pattern, whose intersection points P R indicate the mounting positions 30 A; 30 B; . . . .
At the mounting position 30 A; 30 B; . . . pedestals 23 are provided that consist of pedestal material that is solidifying and bonding onto the bare floor 3 .
Subsequently, preferably by means of laser devices 91 , at least a part of a reference grid R R is created that lies in a horizontal reference plane E R , whereby at least one mounting plane E M is partly defined, which lies in a selected distance d in parallel thereto on a mounting height h M . The mounting plane E M intersects the pedestals 23 at the mounting height h M , which is selected in such a way that the false-floor supports 2 , which are inserted down to the mounting plane E M , are securely held in each pedestal 23 .
In a further installation step the false-floor supports are inserted from above at least approximately vertical into the pedestals 23 that are not yet solidified, until the lower end of the false-floor support 2 lies at least approximately at the level of the mounting height h M .
The false-floor supports 2 are then held each in a related pedestal 23 , until this pedestal 23 has hardened, whereafter the holding device 99 is removed. Subsequently the floor panels 1 mounted.
The false-floor supports 2 , which are made preferably from metal or plastic, can have a simple design and comprise in the shown embodiment a tubular foot member 22 and a head member 21 in the a form of a head plate. The false-floor support 2 does not require an adjustment device. Only in preferred embodiments two-part false-floor supports 2 are provided that are adjustable.
The length or height the false-floor supports 2 corresponds to the difference of the height h M of the at least one mounting plane E M to the height h DB of the false floor 10 (the height h DB is measured at the lower side of the floor panels 1 ). By selecting false-floor supports 2 with a specific height or by stepwise adjustment of the false-floor supports 2 the height the false floor 10 can be selected. This is of particular advantage in the event that a new false floor 10 shall be installed at a different height h DB , when a renovation or restoration is performed.
FIG. 2 shows that the false-floor supports 2 are positioned with the precision of the laser-device 91 and are firmly held in the pedestal 23 . Hence, in principle, a head plate 21 is not required. The corners of the floor panels 1 can securely be mounted on a tube that exhibits a corresponding diameter. Even under massive mechanical impacts, shifting of the false-floor supports 2 is practically excluded, wherefore the inventive false floor 10 can advantageously be installed in areas, where earthquakes may occur.
FIG. 2 shows a simply designed installation device 9 , which comprises, besides a preferably used laser device 91 , also sensors 92 that provide a sensor signal, as soon as a laser beam is captured. The installation device 9 comprises a holding device 99 with which a false-floor support 2 or a group of false-floor supports 2 A, 2 B, . . . can be held and aligned in a reference plane E R or a reference grid R R and can be driven towards the mounting plane E M .
With the laser device 91 a reference grid R R with intersection points P R is created at a height h R , vertically below which intersection points P R mounting positions 30 are marked on the bare floor 3 . The reference grid R R serves further for the alignment of the holding device 99 , on which at least one optical sensor 92 is provided, which indicates reaching the reference plane E R and correct alignment within the reference plane E R .
The holding device 99 comprises coupling devices 98 at the lower side, with which false-floor supports 2 can be attached vertically aligned to the holding device 99 . In the embodiment shown, the coupling devices 98 comprise individual grafters or a common grafter that can be shifted over the head members of the false-floor supports 2 , in order to fix the false-floor supports 2 . The false-floor supports 2 are held for example by flange elements 981 that are mounted on the holding device 99 . Hence, the false-floor supports 2 can be inserted and fixed in the flange elements 981 in a simple manner. FIG. 8 and FIG. 9 show instead of a grafter a clamp device, with which each false-floor support 2 can be fixed by manually operating a lever.
FIG. 2 shows further that the holding device 99 can be adjusted in height and can be aligned horizontally in the reference plane E R by means of laser devices 91 , 92 or by means of a water-level and further measurement instruments, particularly optical measurement instruments.
The holding device 99 forms a frame with longitudinal bars and transversal bars, preferably rectangular pipes, which are aligned in a plane, namely the device plane E V , corresponding to the reference grid R R . The mutual distance of the crossing points of the longitudinal bars and transversal bars corresponds thereby to the mutual distance of the mounting positions 30 A, 30 B of the false-floor supports on the bare floor 3 . In the event that an installation company installs floor panels with different dimensions, then the distance between the crossing points of the longitudinal bars and transversal bars is preferably adjustable. For this purpose preferably longitudinal bars and transversal bars are used, which can be shifted telescopically into one another or can be connected with one another in different grid distances.
FIG. 3 illustrates two different options of operating the installation device 9 of FIG. 2 .
With the first option the holding device 99 with the device plane E V is aligned in parallel or congruent to the reference plane E R . After alignment of the holding device 99 in the reference plane E R or parallel to the reference plane E R a vertical movement is performed over a predetermined distance d M in parallel towards the mounting plane E M . The distance d M is selected in such a way, that after traversing the distance d M the lower ends of the false-floor supports 2 reach the mounting plane E M and lie at the mounting height h M . Precise traversal of the distance d M can be performed in several ways. Movements of the holding device 99 can be measured and controlled. Sensors and end stops can be provided, which indicate the traversal of the distance d M , in order to stop the drive devices 95 , or to block a further movement. Further, it can be arranged that the manually or electrically operated drive devices 95 can perform only a predetermined number of steps or turns, which correspond to the distance d M . If the drive devices 95 each comprise a stepper motor, then this stepper motor is controlled accordingly.
Alternatively, the holding device 99 with the device plane E V is aligned preferably horizontally, if appropriate in parallel or congruent to the reference plane E R and then moved towards the mounting plane E M , until one or a plurality of sensors 92 ; 92 A, . . . indicate reaching of a mounting or reference plane E MR , which is selected in such a way that the lower ends of the false-floor supports 2 are at the height h M of the mounting plane E M , when the sensors 92 ; 92 A, . . . are activated. In principle it is sufficient, when a laser device or, more general, a line generator is provided as a reference for reaching the mounting or reference plane E MR . Since the pedestals 23 are not solidified when the false-floor supports 2 are entered, only one reference line R L can be provided and the horizontal alignment of the holding device 99 can be examined and corrected again when the reference line R L is reached.
FIG. 3 shows a further preferred option for creating the pedestals 23 . In this option a structural member 300 is provided at each mounting position 30 A, 30 B, . . . , and is filled with pedestal material 2300 that is used for creating the pedestals 23 , such as a concrete mix, concrete for floors, a cement mix or a plaster. The structural member 300 shown comprises the form of a conically shaped tube, through which the pedestal material 2300 is transferred to the bare floor 3 so that it is laterally held and pedestals 23 in the form of a cake are obtained. After hardening of the pedestal 23 the structural members 300 are preferably removed and reused.
FIG. 4 shows an inventive installation device 9 , with which the false-floor supports 2 can be entered in groups by means of lifting devices 95 , 96 and a holding device 99 at the exact positions into prefabricated pedestals 23 .
The lifting devices 95 , 96 comprise each a support 96 , with which a spindle drive 95 is held at constant height. For each lifting device 95 , 96 the holding device 99 , which comprises a frame structure with longitudinal bars 991 and transversal bars 992 , comprises a bearing block 952 , in which the spindle 951 of the drive device 95 is entered. With each turn of the spindle 951 , the related bearing block 952 and therefore the holding device 99 is shifted upwards or downwards, depending on the turning direction. Hence, each lifting device 95 , 96 is connected via a spindle 951 and a bearing block 952 with the holding device 99 and can be released therefrom in a simple manner. For this purpose the spindle 951 is turned, until the bearing block 952 is released. Hence, the lifting devices 95 , 96 can be used for adjusting and moving the holding device 99 and can then be released and used with a further holding device 99 .
FIG. 4 shows that the installation device 9 can be controlled and completely automated with a control unit 90 . Processing of the signals of the sensors 92 and the measuring device 97 as well as controlling the drive units 95 can be done e.g. with a notebook computer 90 . Communication is performed preferably via a wireless network.
FIG. 5 shows the holding device 99 after the removal of the lifting devices 95 , 96 , which are used for the installation of a further holding device 99 . In order to hold the holding device 99 in position until the pedestals 23 are solidified, it has been fixed by means of auxiliary supports 960 , which are removed as soon as the pedestals 23 are solidified.
FIG. 6 shows the false-floor supports 2 of FIG. 5 firmly installed in the solidified pedestals 23 . On the false-floor supports 2 the floor panels 1 were amounted for creating the false floor 10 . It is shown that the false-floor supports 2 can advantageously be round or polygonal pipes, which do not comprise a head plate. Due to precise mounting and precise alignment of the false-floor supports 2 pipes with small cross sections can be used. E.g., round pipes with a diameter in the range of 8 cm-16 cm or polygonal pipes with a side length in the range of 8 cm-16 cm and a material thickness in the range of 1.5-3 mm are used. Depending on the load and the length of the false-floor supports 2 deviating dimensions can be selected. Further, enforcing elements such as reinforcing seams can be integrated into the pipes, which enhance solidity. Further, preferably anchoring elements are provided in the foot region of the tubes, i.e. the false-floor supports 2 , which hold the false-floor supports 2 firmly within the pedestals 23 . For this purpose, grooves that are arranged like a thread can be provided in the foot member. The length of the false-floor supports 2 can be selected by the user in a wide range. E.g., a unitary length in the range of 8 cm-16 cm is selected.
It is also possible to adapt the method to a bare floor 3 , which exhibits a gradient, e.g. steps. With adaptations of the installation device 9 a plurality of mounting planes E M can be provided and false-floor supports 2 with different lengths can be installed. E.g., the distance d M that needs to be traversed can be adapted to the selected mounting plane E M and to the selected length of the false-floor supports 2 .
FIG. 7 shows an inventive false floor 10 with a plurality of two-part false-floor supports 2 , which comprise each a foot member 22 held in a common pedestal 230 and a head member 21 serving for holding floor panels 1 .
The height h M of the mounting plane E M within the common pedestal 230 lies above the height h P of the highest point of the bare floor 3 . Hence, when lowering the false-floor supports 2 the bare floor 3 is not reached by them. This application is preferably then used, when the bare floor 3 needs to be covered anyway with an additional layer that can advantageously be used as a common pedestal 230 . The false-floor supports 2 are inserted in the same way into the common pedestal 230 , as this has been described for individual pedestals 23 .
FIG. 7 a shows a two-part false-floor support 2 with two tubes with a head member 21 and of a foot member 22 that can be inserted into one another.
FIG. 7 b shows a one-part false-floor support 2 that comprises a foot member 22 in form of a rectangular pipe and a head member 21 in form of a plate. The rectangular pipe allows safe mounting of floor panels 1 even with a small cross section.
FIG. 7 c shows in a three-dimensional view false-floor supports 2 which are simple round pipes.
FIG. 8 a shows from below a part of a holding device 99 , consisting of rectangular pipes with a coupling device 98 , with which a false-floor support 2 can be fixed by executing a single manual operation of a lever. The coupling device 98 comprises a U-profiled flange element 981 , which is connected to the holding device 99 and into which a false-floor support 2 can be inserted in a form locking manner and can be fixed by means of the clamp 982 .
FIG. 8 b shows from above a part of the holding device 99 of FIG. 8 a after fixing the false-floor supports 2 , with a lifting device 96 that is operated manually or by means of a drive device 95 . It is shown that a drive motor 95 is set up on a spindle 961 , which is turned in order to vertically move the holding device 99 .
FIG. 9 a shows the holding device 99 of FIG. 8 a after fixing sixteen false-floor supports 2 . For mounting the false-floor supports 2 , the holding device 99 has been laid with the upper side onto the bare floor 3 .
FIG. 9 b shows the holding device 99 of FIG. 9 a with the false-floor supports 2 directed towards the bare floor 3 . Subsequently, the false-floor supports 2 are transferred into the pedestals 23 according to the inventive method.
FIGS. 10 , 11 a and 11 b relate to a preferred option of the inventive installation method, which has also the object of anchoring all false-floor supports 2 at the same height within pedestals 23 . With this option, the installation is performed with minimal effort.
FIG. 10 shows that the false-floor supports 2 A, 2 B, 2 C are mounted by means of coupling devices 98 on a beam-shaped element 991 of a holding device 99 . The coupling devices 98 comprise an elastic element, which can be connected to the beam-shaped element 991 and to the false-floor supports 2 . E.g., a hook is cut out of the false-floor supports 2 , in which the elastic element, e.g. a simple rubber ring, can be engaged. Further, the structural members 300 are guided over each false-floor support 2 A, 2 B, 2 C and are fixed by means of clamp elements 7 . The clamp elements 7 comprises tongues 72 which are adjoining the false-floor support 2 and which are mounted on a ring 71 , which adjoins the structural member 300 and presses the structural member 300 against the beam 991 . Hence, the beam 991 can be turned, without getting the mounted false-floor support 2 and the structural member 300 released. For the attachment of the structural members 300 , the structural members 300 and the false-floor supports 2 A, 2 B, 2 C can also be provided with openings facing one another, through which a bar-shaped locking element can be guided. After positioning the false-floor supports 2 A, 2 B, 2 C the bar-shaped locking elements are removed so that the structural members 300 can be shifted against the bare floor. In preferred embodiments, centering elements can be provided, which can be part of the structural members 300 or the false-floor supports 2 A, 2 B, 2 C, which hold the movable structural members 300 and the false-floor supports 2 A, 2 B, 2 C in coaxial alignment.
Subsequently, the beam 991 is lowered as described above until the lower side of the false-floor supports 2 A, 2 B, 2 C reach the mounting positions on the height of the mounting plane E M . Then the structural members 300 are moved downwards until they reach the bare floor 3 , as shown in FIG. 11 a and FIG. 11 b . It is shown that the cross-section of the false-floor supports 2 A, 2 B, 2 C is smaller than the cross-section of the smaller one of the openings of the conically-shaped structural member 300 , wherefore between the outer side of the false-floor supports 2 A, 2 B, 2 C and the inner side of the structural member 300 space remains for infilling pedestal material 2300 , e.g. a concrete mix. The false-floor supports 2 A, 2 B, 2 C preferably comprise openings, which allow the liquid pedestal material to enter the false-floor supports 2 A, 2 B, 2 C.
FIG. 11 a shows infilling of pedestal material 2300 into the structural member 300 A while the false-floor support 2 A is still held by the beam-shaped element 991 of the holding device 99 .
FIG. 11 b shows a false-floor support 2 with anchor elements 29 , which are designed to firmly hold the false-floor support 2 in the pedestal 23 . Further, the false-floor support 2 comprises reinforcing seams that run in parallel close to the edges. With the reinforcing seams the stability of the false-floor support 2 is increased.
FIG. 11 c shows the false-floor support 2 B, which is held in the solidified pedestal 23 B after the beam-shaped element 991 has been removed.
In a preferred embodiment the holding device 99 is installed stepwise in the reference plane E R after the positioning of the first beam 991 and then uninstalled again.
FIG. 12 shows four false-floor supports 2 A, 2 B, 2 C and 2 D that are preferably firmly connected with a floor panel 1 and that comprise containers 3000 A, . . . 3000 D at the foot members that are filled with pedestal material 2300 . If the false-floor supports 2 A, 2 B, 2 C and 2 D have a tubular design then the pedestal material 2300 can be introduced through the false-floor supports 2 A, 2 B, 2 C and 2 D transferred into the containers 3000 .
In this preferred embodiment of the invention, floor panels 1 are connected with false-floor supports 2 A, 2 B, 2 C and 2 D and can be positioned at a desired height, whereafter the pedestal material 2300 adapts to the bare floor 3 and is hardened. By positioning and aligning the floor panels 1 the pedestal material is pressed against the bare floor 3 and is laterally displaced as far as required. Thereby, the container 3000 can be removed or can remain. E.g., a container is provided, which consists of at least partially perforated material, e.g. a plastic foil, which allows air and/or water to pass. Symbolically it is shown that a material 2301 can be applied which allows acceleration of the curing process.
With this embodiment of the invention, floor panels 1 that are equipped with corresponding false-floor supports 2 A, 2 B, 2 C and 2 D and containers can quickly be positioned, aligned and therefore mounted in a short period of time. By the process of positioning the floor panels 1 , the floor panels 1 can sequentially be coupled with one another, so that they lie precisely in a plane.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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A method and a device serve for the installation of a false floor above a bare floor include false-floor supports that are placed in a regular grid pattern on the bare floor, on which floor panels are arranged alongside one another in rows. Mounting positions are determined for the false-floor supports and the false-floor supports to be installed are correspondingly positioned. Furthermore, a mounting plane lying at a mounting height is at least partially determined preferably by using laser devices. The false-floor supports to be installed are then positioned relative to the mounting plane. Pedestals, which are composed of solidifying pedestal material that is binding to the bare floor and which project beyond the mounting plane, are provided at the mounting positions before, during or after the positioning of the false-floor supports. The false-floor supports are then held each in the respective pedestal until the latter has solidified.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
HISTORY OF THE INVENTION
This Application is a continuation application of our parent application titled VALVED VOLUME DIVIDING MEANS having Ser. No. 816,900, filed July 18, 1977, now U.S. Pat. No. 4,143,430.
The concept of selecting the amount of water to flush a toilet according to the nature and the quantity of the materials to be flushed is not new. For instance, C. W. Brown in U.S. Pat. No. 1,805,204 issued to him in 1931 proposes a "Closet Flushing Device" wherein the tank is divided into two unequal compartments. The user, as a result, is provided with the option of three flushing volumes; namely the volume of the small compartment or of the larger compartment, or of both compartments together.
The Brown Patent is interesting, further, in the sense that the in-tank mechanisms illustrated by him and of course used eariler are functionally identical to, and physically nearly identical to, the in-tank mechanisms employed today in the overwhelming majority of toilet tanks.
Considerable amount of effort has been invested by different people, as the large number of patents issued over the years indicates, to bring the concepts exemplified by Brown into the general usage. However, their efforts have met with limited success at best. For the most part, the devices and means proposed in the prior art appear to be able to perform their intended functions satisfactorily. Yet, none of these patented inventions has made any significant impact on the industry. Toilets, water closets, toilet in-take mechanisms and flush actuators are essentially the same today as they were several decades ago. The following sets forth some of the inadequacies of the prior art devices and explains why they have not made any commercial impact.
First, the prior art devices generally do not employ the existing in-tank mechanisms, as such. To employ these devices the in-tank mechanisms, or the flush actuating means have to be replaced or modified significantly. Secondly, a large proportion of the prior art devices are cumbersome and therefore, they either have to be incorporated in the original equipment at the factory, or require the services of a skilled craftsman, if installed in the existing toilets of a home. Thirdly, the prior art devices frequently require a change of user habits in manipulating the flushing mechanism. Fourth, a number of devices in the prior art utilize an additional discharge valve connected to the main discharge column of a toilet. But in doing so they introduce an extra risk of water leakage by way of the second discharge valve. The loss of water due to valve leakage is considered a major problem of the toilet tanks. The following examples will serve to illustrate the above points.
U.S. Pat. No. 3,344,439 to Davies, involves the insertion of a box-like compartment in the water closet and utilizes a counter balanced flapper valve, both of which require modification or replacement of the flush actuating means. The so called "double-flush" proposals such as U.S. Pat. No. 3,795,016 to Eastman and U.S. Pat. No. 3,380,077 to Armstrong, also suffer from one or more of the shortcomings listed above.
Therefore, it is the objects of this invention to provide a multiple flush volume means which,
1. requires no modifications or replacements of the tank or its inside mechanisms.
2. does not introduce any additional risk of water loss due to a valve leakage.
3. requires no specialized skills or tools for its installation.
4. is simple and economical in structure.
5. resists corrosion and functions reliably in the presence of in-tank incrustations common in many parts of the country.
6. requires a minimum change of habit or adaption for the user.
7. may be installed and removed from existing toilet tanks without disturbing the in-tank mechanisms significantly.
BRIEF DESCRIPTION OF THE INVENTION
The invention is a device which when installed in a tank permits an operator to selectively discharge various volumes of liquid from the tank. Specifically, it is a valved tank dividing means which is operably connected to the trip lever of a water closet so as to permit the user to discharge a part or the full tank volume of water to the toilet bowl. This is done by rotating the flush handle in the usual manner either partially or fully.
The invention is comprised of four principle units;
1. the `compartmentalizing unit` by means of which the toilet tank is divided into two or more separate volumes.
2. a `valve unit` to permit the liquid to flow from one compartment to the other.
3. an `adjustment means` whereby the angle of rotation of the trip lever between the first and the second valve actuation is adjusted.
4. an `actuator linking unit` by means of which an `adjustment lever` is operably connected to the existing trip lever of the tank.
The `compartmentalizing unit` may be a bulkhead or divider wall which is expanded against the sides of the water closet and sealed therewith by soft gasketing material. Alternatively, the compartmentalizing unit may be a tank or a container which is placed within the water closet. In either instance, the compartmentalizing unit is designed to permit water to enter the second compartment, once the water in the first compartment reaches a predetermined level.
The `valve unit` is preferably a flapper type valve. It is located in the wall of the vertical compartmentalizing unit or may be at the bottom of the tank unit. In the preferred embodiment, a flapper valve is employed having a magnetic closure and a floatation means.
The `adjustment means` which is located above the flapper valve is connected with the valve with a flexible linkage. The adjustment means provides a means of adjusting the angle of rotation of the trip lever within the available free space in the tank. It may also provide an adjustment for the `feel` of the opening of the flapper valve. In the preferred embodiment the adjustment means comprises a small strip of an appropriate length with a series of holes along its length. It is hinged to the divider wall or to one of the vertical walls of the tank unit. Alternatively the adjustment means may be a series of split tubes of various lengths which snap over the stem of the flush valve so as to reduce the degree of flush handle rotation required to open the toilet flush valve. It should be understood that both adjustment means may be employed advantageously in the same installation.
The `actuator linkage` unit provides a connection between the existing trip lever of the water closet and the valve. In the preferred embodiment, an extension arm is secured to the end of the existing trip lever. This is further connected to the adjustment lever with an adjustable linkage. The adjustment lever is also connected to the valve means by way of a flexible linkage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view of the in-tank flush mechanisms of a conventional toilet tank.
FIG. 2 is a schematic elevational view similar to that of FIG. 1 showing the units of a preferred embodiment of the invention in place.
FIG. 3 is a schematic elevational view similar to that of FIG. 1 showing the elements of another preferred embodiment of the invention in place.
FIG. 4 is a pictorial view of valve actuator adaptor of this invention.
FIG. 5 is a pictorial view of another valve actuator adaptor of this invention.
FIG. 6 is a pictorial view of an actuator linkage unit of this invention which is secured to the flush arm by threaded means.
FIG. 7 is a pictorial view of an actuator linkage unit whereby the connecting cord is coupled directly to the flush arm.
FIG. 8 is a pictorial view of an alternative means of linking the valve unit of this invention to the existing flush arm.
FIG. 9 is a pictorial view of a compartmentalizing unit of this invention.
FIG. 10 is a sectioned elevational view of the compartmentalizing unit installed in a toilet tank and having the valve closed.
FIG. 11 is a sectioned view similar to that of FIG. 10 with the valve open.
FIG. 12 is a fragmentic pictorial view of the valve unit.
FIG. 13 is a pictorial view of another compartmentalizing unit of this invention.
FIG. 14 is a sectioned elevational view of a device similar to that of FIG. 13 with alternative tank securing means.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, like terms and like numbers will refer to like objects.
Referring now to FIGS. 1 through 3. The in-tank elements are shown here in schematic representation for the sake of clarity. The general components of tank 1 are flush valve 2, flush valve actuating mechanism 3 and float valve 4.
Referring now to FIG. 1. The sequence of events which occur when the toilet is flushed are as follows: Trip lever 10 is rotated downward causing flush arm 11 to rotate upward. Flush arm 11 carries with it valve linkage 12 which rises until it engages valve stem 13. Flush arm 11 is now in the position 14 which is outlined in dashed lines. Continued rotation of flush arm 11 causes stopper 15 to raise and permit the water in tank 1 to exit through valve 2 and flush the toilet. Flush arm 11 generally continues to rotate to the upper limit of its travel which is shown as upper position 16 in dashed lines. Trip lever 10 is then released to permit flush arm 11 and valve linkage 12 to return to their original position. As water flows out of tank 1, float 18 of float valve 4 descends with the level of the water in tank 1 until it opens water intake valve 20 which admits water into tank 1 at a rate slower than water flowing out of tank 1 through flush valve 2. When the water in tank 1 drops to a low enough level, stopper 15 which was buoyed up by the water, seats to close flush valve 2 and tank 1 begins to refill with water. As the water level in tank 1 approaches the full level float 18 rises and thereby closes intake valve 20 which terminates the influx of water into tank 1 and the flush cycle is completed.
Referring now to FIGS. 2 and 3. Two embodiments of the device of this invention are shown in schematic representation. In FIG. 2 a bulkhead or divider wall type of compartmentalizing unit 50 is illustrated while in FIG. 3 an insert tank type of compartmentalizing unit 50' is illustrated. Valve actuator adapter unit 52 is shown in place surrounding valve stem 13. Actuator linkage unit 51 is shown attached to flush arm 11 and joined to valve unit 53 as shown. Units 50, 51', 51, 52, 53 will be discussed in detail hereinafter.
Referring now specifically to FIG. 2. Trip lever 10 is rotated downward rotating flush arm 11 upward until flush valve linkage 12 brings adapter unit 52 into contact with valve stem 13 at a point where flush arm 11 has rotated a very short distance. Continued rotation of trip lever 10 will cause valve 2 to open as described above. If the flush handle 10 is released after opening valve 2 the water in tank 1 minus the water retained by compartmentalizing unit 50 will be free to exit tank 1 as described above permitting a partial discharge of tank 1.
However, if rotation of flush handle 10 is continued to a location 60 shown dashed, linkage unit 51 draws cord 65 taut. Continued rotation of trip lever 10 will cause flush arm 11 to be rotated to position 61 shown dashed and thereby, cause linkage unit 51 acting through connector 55 to raise adapter arm 56 which creates a tension in cord 65, to open valve unit 53. Floatation means 67 serves to maintain valve unit 53 in the open position until water has drained out of the volume contained by compartmentalizing units 50 thereby permitting a full discharge of tank 1.
It should be noted that an operator without knowledge that the device of this invention was located in the toilet tank would rotate trip lever 10 fully and affect a full discharge of tank 1 as would be normal. A knowledgable operator could at his option use a partial discharge to flush liquids or to do light disposal work when flushing away a facial tissue or the like.
Referring now to FIG. 3. Tank type compartmentalizing unit 50' is here shown to have valve unit 53 positioned at the bottom of the tank. Cord 65 joins valve unit 53 to flush arm 11 by way of linkage unit 51'. Tank type compartmentalizing unit 50' is shown to be secured to the top of toilet tank 1 by a conventional clamping arrangement 30. Clamping arrangement 30 is provided for the purpose of securing tank type compartmentalizing unit 50' against the buoyant forces exerted upon it during the period that compartmentalizing unit 50' is empty and tank 1 is filling with water. As tank 1 becomes completely filled water will flow over the top of compartmentalizing unit 50' and thereby bring the pressures inside and outside compartmentalizing unit 50' to equilibrium.
Referring now to FIGS. 4 and 5. Valve actuator adapter 52 and 52' are shown to encompass valve stem 13 below stem ring 75 and above linkage ring 76 of valve linkage 12. Adapter 52 and 52' are substantially cylinders through which stem 13 may freely slide. The raising of linkage 12 causes ring 76 to raise towards ring 75. The engaging of ring 76 with ring 75 ordinarily precedes the raising of stem 13 which opens the toilet valve 2. The interposing of adapter 52 or 52' between rings 75 and 76 causes the raising of valve stem 13 when ring 76 is lower than ring 75 by a distance equal to the height of adapter 52 or 52'. The employment of adapter 52 or 52' enables the user to adjust the amount of vertical travel required before linkage 12 causes stem 13 to be raised.
Adapter 52 of FIG. 4 is shown as a split tube type of adapter which may be snapped onto stem 13 as shown without the need for any tools and without the need for disturbing the existing mechanisms. If it is desired to change the length of adapter 52 it may be removed from stem 13 and a suitable length of adapter cut off.
Adapter 52' is shown as a cylinder having scored segments 77 and a longitudinal slot 78. The length of adapter 52' may be reduced by removing one or more scored segments 77 from adapter 52'.
Referring now to FIGS. 6, 7, and 8 which show actuator linkages of this invention which may be secured to flush arm 11 without disturbing any of the in-tank mechanisms.
Referring now to FIG. 6. Actuator linkage 80 is secured to flush arm 11 by means of screws 82 or similar means passing through holes in flush arm 11. The holes in flush arm 11 are provided as alternate locations for the positioning of valve linkage 12. Cord 65 may be secured to actuator linkage 80 by means of knot 64 as shown so as to engage actuator linkage 80 when flush arm 11 is rotated upward.
Referring now to FIG. 7. The valve unit of this invention may be operably linked to flush arm 11 by means of cord 65 being secured directly to flush arm 11 substantially as shown. Although the linkage shown in FIG. 7 is operable, it is not preferred in that the direct connection of cord 65 to flush arm 11 does not ordinarily provide the best mechanical arrangement for actuating the valve unit.
Referring now to FIG. 8. Actuator linkage 80' may be frictionally engaged with flush arm 11 by means of sleeve 83 which may be of rubber or plastic or other such resilient material which will provide a secure frictional engagement of actuator linkage 80' with flush arm 11. Cord 65 may be snapped into clevis 84 as shown.
Referring now to FIGS. 9, 10, 11, and 12. Compartmentalizing unit 50 serves to divide the tank into two separate liquid holding compartments, reserve compartment 91 and main compartment 92. Port 93 provides a passage through which liquid may pass from reserve compartment 91 into main compartment 92. Port 93 is opened and closed by means of valve unit 53 which will be discussed in detail hereinafter.
Referring now to FIG. 9. Compartmentalizing unit 50 comprises an adjustable bulkhead 100 formed of two movable segments, first segment 94 and second segment 95, a flexible gasket 96 and fastening means 97. Bulkhead 100 is installed by placing bulkhead 100 in toilet tank 1 (not shown) in the desired position and adjusting bulkhead 100 so that it presses gasket 96 against the sides and bottom of tank 1. Fastening means 97 are then secured to hold bulkhead 100 in position.
Two points should be noted. The first being that the seal afforded by gasket 96 between bulkhead 100 and tank 1 need not be 100% effective in order that the device of this invention perform its intended function satisfactorily. A small amount of leakage between reserve compartment 91 and main compartment 92 can be tolerated without any adverse affect on the performance of the unit. The second point being that leakage around bulkhead 100 or through valve unit 53 will not result in water loss from tank 1 which is in counter distinction to what is the case with many prior art devices.
Referring now to FIGS. 10, 11, and 12. Valve unit 53 serves to open and close port 93. Valve unit 53 comprises a flapper 110, a float means 111 which may be any buoyant means and is here shown as a styrofoam block attached to flapper 110 a first magnetic member 112 and a second magnetic member 113 with first magnetic member 112 being a part of flapper and second magnetic member 113 being a part of the compartmentalizing unit, a flapper guide means here shown as being 114 and a cord attachment means here shown as eye 115.
Referring now to FIGS. 10 and 11. Valve means 53 is maintained in a closed position primarily by the magnetic attraction between first magnetic member 112 and second magnetic member 113. When flush arm 11 acting through linkage unit 51 by way of adapter arm 56 and connector 55 causes tension in cord 65, flapper 110 is caused to rotate on hinge 114 and open port 93 to permit water to exit reserve compartment 91. The buoyancy of float 111 exceeds the magnetic attraction between first magnetic member 112 and second magnetic member 113 once the two members are drawn apart from each other a short distance. As the water level in reserve compartment 91 drops, float 111 permits flapper 110 to drop until the magnetic attraction between first magnetic member 112 and second magnetic member 113 draws flapper 110 against bulkhead 100 thereby closing port 93 and to complete the cycle.
Referring now to FIG. 13. Compartmentalizing unit 50' comprises a minitank 130 which is secured to tank 1 by means of screw clamps 120 and supported above the bottom of tank 1 by feet 133. Screw clamps 120 serve to frictionally engage compartmentalizing unit 50' with toilet tank. Minitank 130 may thereby be quickly and conveniently installed and secured in tank 1. The operation of compartmentalizing unit 50' is substantially as described in conjunction with FIGS. 9 through 12.
Referring now to FIG. 14. Compartmentalizing unit 50' comprises a minitank 130 which may be secured to tank 1 by means of adjustable clamps 131 which are secured by fastening means 132 and supported above the bottom of tank 1 by feet 133. Valve unit 53 and port 93 are located at the bottom surface of minitank 130. Minitank 130 is provided with adjustable clamps 131 so as to enable minitank 130 to resist the buoyant forces which will be exerted upon it when main compartment 92 of tank 1 is filling with water after both tanks have been emptied and valve unit 53 has sealed. Feet 133 are provided to permit leveling of minitank 130 and to provide a space under minitank 130 through which water may flow out of minitank 130. The operation of valve unit 53 is similar to that discussed in conjunction with FIGS. 9 through 12.
It will become apparent to one skilled in the art that equivalent means may be provided to perform the functions of the units discussed herein. For example a conventional bulb type flush valve may replace the valve unit in compartment 50' or a spring or toggle means may replace the magnetic closure securing means of valve unit 53, or that a chain or linkage may replace cord 65 and so on.
However, the recitation of such equivalent means would cause the specifications to become prolix and to unduly multiply the drawings and claims. For that reason the preferred embodiments of the invention have been set forth in the specifications but the invention should be understood to be limited only by the appended claims and to all equivalents thereto which would become apparent to one skilled in the art.
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This invention relates to water conserving devices to be used in the water closets of bathroom toilets. The devices may also find applications in other liquid containing and discharging vessels. The invention consists of a partition wall or alternatively a minitank installable in the water closet of a toilet so as to divide the water closet into two separate liquid holding compartments. A flapper valve with a magnetic closure, fitted into the partition wall or into the minitank, opens and closes a port which communicates between the compartments. The actuating means of the flapper valve is operably connected to the existing trip lever of the water closet in such a way that the valve will be actuated only after the existing discharge valve has been actuated first. This arrangement permits the user to discharge water from one or both compartments of the water closet according to his needs. In the preferred embodiments, the devices are installable by anyone possessing only the skills and tools commonly found in an ordinary household.
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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 multipurpose panels, particularly for use in soundproof and fireproof partition walls.
In modern construction art, soundproof partition walls are a common requirement. However, fire-resisting properties are less sought for in the instance of such walls. This because the traditional building materials are inherently fire-resistant, thereby the serious hazard represented by a wall which is not fireproof is not always perceived.
Quite often it is considered enough that the material employed be non-conductive of heat, which is generally a common property of soundproofing materials, and incombustible. Such requisites fail, however, to provide adequate safety in the event of a conflagration because the organic materials, as currently employed in today's constructional projects, while affording good thermal and acoustical insulation and being incombustible, do decompose with heat absorption at high temperatures, thus losing their mechanical as well as insulating properties; in general, they carbonize and/or evolve into gases, depending on whether oxygen is present or not. And yet, the function of a fire-resisting wall is not restricted to being fireproof but rather extended to include the formation of a barrier against flame propagation. To this end, it is not enough that the wall be just capable of withstanding high temperatures, but it also must not transmit heat, not even at open flame temperatures. Thus, and contrary to a widespread notion, shared even by some experts, a steel wall or door has very poor fire arresting capabilities, far less than a wooden one. The old wall of bricks or concrete were excellent from the viewpoint of their ability to withstand fire, but they are not sound absorbent and do not lend themselves very well to the modern techniques of prefabrication and erection of walls and panels. Heretofore, it may be said that there has been made available no panel designed in accordance with modern building wall prefabrication practice, in particular for use in partition or inner walls, that fulfils all of the requisites set forth above at one time.
SUMMARY OF THE INVENTION
Accordingly, this invention is mainly directed to filling the above mentioned gap in the prior art building prefabrication art.
More specifically, it is a primary object of this invention to provide a panel, specially for inner or partition walls, which is at one time soundproof and fireproof.
It is another object of the invention to provide such a panel which is reinforced with steel plates that enclose it and form an integral unit therewith, the two plates being thermally insulated from each other.
It is a further object of the invention to provide a panel structure as above, which is easily adaptable for predetermined ratings of resistance to fire.
Still another object is to provide a soundproof and fireproof wall made up with such panels.
These and other objects, such as will be apparent hereinafter, are achieved by a panel for soundproof and fireproof inner walls, of a type comprising two parallel reinforcing metal plates mechanically interconnected to form an interspace therebetween and a filler of insulating material, constituted essentially of rock-wool like material in said interspace characterized in that it comprises at least one continuous diaphragm extending parallel to said reinforcing metal plates and deviding said filler into parallel layers, said diaphragm comprising a plate of solid refractory material and having projecting edges projecting from said filler, said reinforcing metal plates having folded edges constituting section member like portions thereof, said projecting edges being in engagement with said folded edges of said metal plates, said folded edges being seam folded to hold said metal plates together.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention features and advantages will be more clearly understood from the following detailed description of practical embodiments thereof, being preferred but not restrictive ones, which will be described hereinbelow by way of example only, with reference to the accompanying drawing, where:
FIG. 1 is a vertical cross-sectional view of a panel according to this invention, shown as installed;
FIG. 2 is a section taken through the line II--II of
FIG. 1;
FIG. 3 is an enlarged detail view of FIG. 3;
FIG. 4 shows a variation of a FIG. 1 detail; and
FIG. 5 is a detail view of FIG. 2, in accordance with another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Making reference first to FIGS. 1 and 2, the numeral 1 denotes generally a wall formed with panels 2. As is common practice in the installation of panels to form a wall, a single panel is mounted in the height direction of the wall, and plural panels are laid side by side in the length direction of the wall, with gaps or interruptions known per se, for doorposts or other inserts. The panels are held aligned and close together at the ceiling and floor by upper stringers 3 and lower stringers 4, between two abreast panels there intervening a vertical joint 5. In addition to the panel 2, this invention also provides for the stringers 3, 4 and joint 5, as accessory items which are integral parts of the instant panel; these will be explained in that order, as will be explained their arrangements and their mode of cooperation.
A panel 2 comprises two metal plates or sheets 6 and 7 forming the outer faces thereof and thus the panel enclosing walls, such plates being preferably zinc galvanized. The plates 6 and 7 are flat along their entire surfaces, being only folded or bent at the edges, as will be explained hereinafter. In the interspace left between the two plates, and adherent to the plates, there are located horizontal ribs or stiffening crossmembers 8, also of zinc galvanized metal plate or sheet, only thinner, at arbitrary distances and positions, and either on one face or both, either facing one another or intermingled, at the designer's discretion; these may also be left out entirely, their function being merely a mechanical one, thus foreign to this invention. At the centerplane of the panel, a refractoy plate 9 is positioned, preferably of the asbesto-cement known in the trade as "Eternit", said plate being 6 mm thick and dividing the interspace into two equal parts which are filled with two layers of rock wool 10 and 11, thermally insulated from each other. The edges 6a and 7a of the plates 6 and 7, both at the upper and lower ends, are folded onto the ends 8' of the plate forming the nearest rib 8 or an equivalent crossmember to retain the rock wool contained therein. The edge fold seam of the plates 6 and 7 at the panel edges is effective to anchor the plates to each other without establishing, however, a thermal contact therebetween.
As may be seen best in FIG. 3, each plate 6, 7 is folded over itself to form a side edge 6a, 7a, respectively, then the plate is folded to form a transverse portion or cross barrier 6b, 7b and a second portion which bears or abuts as a resilient bracket for a length 6c, 7c against the edge of the plate 9, to terminate in a wing or flange 6d, 7d transverse thereto, i.e. which is brought back externally, level with the edge or rim 10 of the plate 9. In order to unite the two ends 6d and 7d of the plates without involving any thermal contact at the wings or flanges 6d and 7d, small ceramic insulators 111, for high temperatures and having a U-like shape , e.g. of calcium oxide or aluminium oxide, are set astride, a C-like clamp 12 of thermal steel being inserted on the wings with in the insulators to anchor them tensively. Preferably, rather than a continuous clamping strip, several clamps are provided spaced apart in order to reduce heat transmission between the plates. As may be observed, that same fastening of the plates 6 and 7 is effected along the horizontal and vertical edges.
The upper stringer 3 is also formed from two metal plates or sheets, 13 and 14, which create together a U-like section, being united along the bridging portion of the "U" by screws 15 with the interposition of an asbesto-cement strip 16. The bridge of the "U" of the stringer 3 is arranged to face the ceiling, whereon it bears with the interposition of a refractory seal or gasket 17, e.g. made of Dutral. The section side wings or expansions, i.e. of the plates 13, 14, are inserted to act as guides between the upper horizontal edges of the panel, being spaced apart and centered with respect to said edges by refractory insulating strips 18, made of a material similar to that of the gasket 17 and having the purpose the preventing the heat from one panel wall from being transmitted to to the ceiling and vice versa. The upper stringer 3 is filled with a pad of soft asbesto 19, or of an equivalent material. The lower stringer 4 is also formed, as a bearing structure, by a "U" section 20, but is of one piece construction and entirely wrapped externally in a refractory gasket 21, similar to the gaskets 17 and 18, and performing itself both functions thereof, i.e. that of insulating the stringer from the floor and edges 6a, 7a of the panel, and of centering the same with respect thereto. The section 20 is filled with either rock wool, or soft asbesto, or the like.
Two abreast panels are held aligned and in place by the opposite stringers 3 and 4, wherein they are inserted guide or runway fashion. However, in order to prevent a flame from leaking through the junction line of the two panels, or high temperature heat from propagating to expand fire, a vertical joint or coupling member 5 is interposed between two contiguous panels, said joint being a force fit, or slight pressure fit, between the edge pairs 6a and 7a of the two panels. The joint 5 (FIG. 2) includes as its web or core two paired strips 22, of asbesto-cement, which are cut from a plate similar to the plate 9 and united together by two brackets 23 or by π -like sections which are inserted on their edges, the strips being positioned with the plane containing them perpendicular to the panel plane. Onto the edges and roof of the π -like sections, there are inserted, one on each side, two gaskets 24 of a refractory material, which define with their projections a jointing section which serves to retain in a symmetrical position with respect to the strips 22 two projecting sections 25 of soft asbesto, which occupy most of the space between the two contiguous panels by engaging their projections or extensions with cross barriers 6b, 7b retaining the insulating material respectively, of each panel, thus intercepting any flame leakage path. In discussing the structure of a panel wall, it has been mentioned how the latter is installed, while pointing out elements of likeness and difference from similar prior art walls.
For an explanation of how the added fireproof function is performed, the meaning assigned herein to the term "fireproof function" must be given first. The specifications and tests of a fireproof wall or door, require that these, when exposed with one face to a flame at the typical temperature of a fire, can withstand it, before the opposite face reaches virtually the same temperature level, for a specified time which is of 30-60 minutes for Class F30, and longer than 60 minutes for Class F60. The instant structure conforms to this practice. The rock wool mass has a very high insulating power, not only because it is a refractory material, but also, and better, on account of air trapped in the bundles. If temperature rises to the point of melting rock wool, or softening or sintering it, then the insulating power decreases considerably, both where air pockets are formed which transmit heat by convection, and where clots of molten or softened insulating material are formed, which transmit by conduction; thus, upon rock wool softening or melting, hot wall spots also occur on the other panel face, which may trigger flames in the adjacent room.
The presence, at the middle portion of the panel, of an asbesto-concrete plate or board has the function of preventing the insurgence of such transmission areas through deterioration of the insulating material. The plate or board has a thermal conductivity which is higher than rock wool, but also a higher melting point, thereby even if the first layer of wool, i.e. the one toward the flame, melts or loses insulating power, the plate will protect the second layer for a sufficiently long time, even with strong flames. The advantage of placing the central plate or board rather than, for example, against the walls resides in that the intervening layer, albeit deteriorated, does protect the plate enough to preserve its properties, for at least a long time interval, whereas if in contact with the wall which is directly exposed to flame it could also deteriorate rapidly.
A similar behavior in fire has been achieved for the stringers and joints. FIG. 4 illustrates a variation, indicated at 3', of the upper stringer 3, which variation similarly applies to the lower stringer 4. This consists of the application at the cited stringer 3, which remains the same per se, of an asbesto-cement strip 30, on each face, having a slightly greater height than the stringer. The strip 30 is covered externally by a zinc galvanized metal plate or sheet 31, and is fastened with screws 32 to the metal plates 13, or respectively 14, of the stringer. Its function is that of increasing the thermal insulation and resistance to fire of the stringer 3, by avoiding a direct exposure thereof to flame. The edges 6'a and 7'a are also modified.
FIG. 5 shows another embodiment of the invention intended to provide a wall with higher class fire resisting properties. To obtain a higher resistance to fire, the panels 2' of FIG. 5 have greater thickness, there intervening between such panels two plates or boards 9, parallel to each other and spaced apart from each other, which are identical to the single one shown in FIGS. 1 and 2. Thus three layers 40, 41, and 42, of rock wool or equivalent insulating material, become defined. Between the edges of the two plates 9 intervenes a metal sheet bracket 43 effective to keep them apart and join together, through the clamps 12 and bracket 43, the two wall plates 6 and 7. For their remaining portion, the panels 2' are constructed like the panel 2 and provided for installation with similar stringers, not shown. FIG. 5 also shows a variation of the preferred joint 45 for such panels, which may also be adapted in smaller sizes to the panels 2. The joint 45 comprises a strip 44 of asbesto-cement, located at the centerline and parallel to the planes containing the panels 2'. Two W-like opposite sections 48 rest with their bases thereon, two outwardly extending gaskets 46 being adapted to said sections. For the engagement between the joint and panels there are provided W-like sections of soft asbesto 47 which are part of the joint and ensure a tight seal. This joint utilizes for insulation the effect of small air chambers interposed between the insulating materials, which are effective on account of their small size.
It should be noted that, by way of example, a panel 2 with the proposed materials and a thickness of 60 mm falls within the fireproof class F30, while a panel 2' having a thickness of 100 mm is in class F60.
Without departing from the instant inventive concept, which is that of a sandwich panel including outer plates, layers of rock wool or equivalent thereof, and a middle plate or board of asbesto-cement or equivalent thereof, the embodiment described hereinabove may be varied or modified. Thus for example, instead of a zinc galvanized metal plate a calorized (aluminized) plate may be used at the expense of a slightly higher cost, but with the advantage of an increased resistance to oxidation of the plate at high temperature. As mentioned already, the panels, stringers, and joints may be differently combined together in the various embodiments proposed. The panels also lend themselves to use for partly glazed walls, movable partitions, and other applications.
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Panel for soundproof and fireproof inner walls, of a type comprising two parallel reinforcing metal plates mechanically interconnected to form an interspace therebetween and a filler of insulating material, constituted essentially of rock-wool like material arranged in the interspace. At least one continuous diaphragm extends parallel to the reinforcing metal plates and divides the filler into parallel layers. The diaphragm comprises a plate of solid refractory material having projecting edges projecting beyond the filler. The reinforcing metal plates have folded edges constituting section member like portions thereof. The projecting edges are in engagement with the folded edges of the metal plates. The folded edges are seam folded to hold the metal plates together.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] The present invention relates to latching mechanisms for preventing relative movement of components in a plurality of mutually perpendicular dimensional axes. More particularly, the present invention relates to a load latch mechanism featuring a lock ball connected to one component which is receivable into a socket formed by rotation of rotatable rollers connected to another component.
BACKGROUND OF THE INVENTION
[0002] There is a ubiquitous need for location control mechanisms which reliably locate one component relative to another. For example, in automotive applications a door latch is used to hold a door closed relative to the frame, and a wedge block and wedge combination may be additionally used to prevent the door from twisting out of alignment with the frame during driving of the automobile.
[0003] A drawback of conventional wedge block and wedge combinations is that position control depends upon the depth of the wedge into its complementarily shaped wedge seat of the wedge block, and the component location control operates in only two mutually perpendicular dimensional axes.
[0004] What remains needed in the art is a location control mechanism having a simple and robust structure, featuring latch capability, and featuring an ability to control location of components along all three mutually perpendicular dimensional axes.
SUMMARY OF THE INVENTION
[0005] The present invention is a location control mechanism having a simple and robust structure, featuring latch capability, and featuring an ability to control location of components along all three mutually perpendicular dimensional axes, wherein the location control mechanism is in the form of a load latch mechanism featuring a lock ball connected to one component which is receivable into a lock socket formed by rotation of rotatable rollers connected to another component.
[0006] The load latch mechanism according to the present invention includes a striker having a preferably spherically shaped lock ball and a pair of mutually adjacent socket rollers, each socket roller having a complementing preferably hemispherically shaped semi-socket which collectively provide a single preferably spherically shaped lock socket when the rollers are appropriately rotated relative to each other. The striker is connected to a first component and the socket rollers are rotatably mounted to a second component, wherein the first and second components are positionally located in relation to each other by action of the lock ball being trapped in the lock socket.
[0007] Operatively, the socket rollers rotate about mutually parallel rotation axes between a socket open position and a socket closed position, and the striker approaches and recedes from the socket rollers along a striking axis which is perpendicular to the rotation axes. Initially, the lock ball of the striker is separated from the socket rollers, and the socket rollers are in a socket open position, whereat each semi-socket is freely open in the direction of the striking axis. As the striker moves toward the socket rollers, the lock ball contactingly interacts with the semi-sockets. This interaction causes the socket rollers to rotate such that the semi-sockets move into mutual complement, whereupon the socket rollers are at a socket closed position, whereat the lock socket is formed. Now, the lock ball is trapped in the lock socket, and the first and second components are located relative to each other and prevented from movement in at least two mutually perpendicular dimensional axes. Thereafter, the lock ball can recede from the socket rollers only if the socket rollers reverse rotate to so as to release the lock ball, whereupon the semi-sockets are again at the socket open position.
[0008] A number of features may be included. For example, the socket rollers can be asymmetrically shaped to interferingly abut each other and thereby automatically “self-bottom” so as to prevent over rotation when the semi-sockets mutually complement at the socket closed position. For another example, the socket rollers may each have an off-set rotation axis, so that as the socket rollers rotate they cam toward each other as the semi-sockets move into the socket closed position. For yet another example, the socket rollers may be selectively prevented from rotating when the semi-sockets have moved into the socket closed position, thereby providing three mutually perpendicular dimensional axes of relative movement prevention between the components, yet the lock ball may have joystick pivotability relative to the lock socket. Still further for example, the socket rollers may be splined so as to be gearingly engaged with each other, whereupon the socket rollers must rotate in unison. Finally for example, the striker may be configured in the form of a series of mutually spaced lock balls, wherein the lock balls serially engage periodically forming lock sockets as the socket rollers continually rotate over 360 degrees.
[0009] Accordingly, it is an object of the present invention to provide a load latch in the form of a lock ball and socket rollers combination, featuring latch capability, and featuring an ability to control location of components along all three mutually perpendicular dimensional axes.
[0010] This and additional objects, features and advantages of the present invention will become clearer from the following specification of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a perspective view of a striker and asymmetrical socket rollers load latch according to the present invention, wherein the lock ball of the striker is separated from the socket rollers.
[0012] [0012]FIG. 2 is a partly sectional view of the striker and socket rollers, as seen at FIG. 1.
[0013] [0013]FIG. 3 is a perspective view of a striker and asymmetrical socket rollers load latch as in FIGS. 1 and 2, wherein now the lock ball of the striker is engaged with a lock socket formed by rotation of the socket rollers.
[0014] [0014]FIG. 4 is a partly sectional view of the striker and socket rollers, as seen at FIG. 3.
[0015] [0015]FIGS. 5A through 5C are a series of partly sectional side views of lock ball engagement with asymmetrical socket rollers according to an aspect of the present invention, wherein a detent mechanism selectively controls entrapment of the lock ball in the lock socket.
[0016] [0016]FIGS. 6A and 6B are a series of partly sectional side views similar to FIGS. 5A and 5B, wherein now the asymmetrical socket rollers are splined.
[0017] [0017]FIGS. 7A and 7B are a series of partly sectional side views similar to FIGS. 5A and 5B, wherein now the socket rollers are symmetrical.
[0018] [0018]FIG. 8 is a partly sectional side view similar to FIG. 6A, wherein now the splined socket rollers are symmetrical.
[0019] [0019]FIGS. 9A and 9B are a series of partly sectional side views of symmetrical socket rollers similar to FIGS. 7A and 7B, wherein now the socket rollers have off-set rotation axes and cam toward each other as they approach the closed socket position.
[0020] [0020]FIG. 10 is a front elevational view of splined symmetrical socket rollers which are spring loaded and motor driven.
[0021] [0021]FIG. 11 is partly section side view of splined symmetrical socket rollers having a ratchet regulator.
[0022] [0022]FIG. 12A is a perspective view of a motor driven set of splined symmetrical socket rollers adapted for receiving a serially balled striker.
[0023] [0023]FIG. 12B is a partly sectional side view of the socket rollers of FIG. 12A now engaged with a serially balled striker according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring now to the Drawing, FIGS. 1 through 4 depict an operational overview of the ball and socket rollers load latch mechanism 100 according to the present invention.
[0025] A pair of mutually adjacent socket rollers 102 , 104 is provided, wherein each socket roller rotates on a respective roller axle 106 a , 106 b , and wherein each end of each roller axle is connected to a rollers retainer 108 . The rollers retainer 108 is, in turn, connected to a first component, as for example a frame of a motor vehicle. The rotation of each socket roller 102 , 104 is about a respective rotation axis A Y , A Y ′ that is parallel to a first axis Y (see FIG. 1).
[0026] Each socket roller 102 , 104 has a hemispherically shaped semi-socket 110 , 112 , wherein rotation of the socket rollers provides a complementing conjoinder of the semi-sockets, whereupon the two semi-sockets collectively provide a spherically shaped lock socket 114 . In this regard, the socket rollers 102 , 104 rotate from an open socket position, as shown at FIGS. 1 and 2, to a closed socket position as shown at FIGS. 3 and 4, whereat the aforementioned lock socket 114 is formed collectively of the semi-sockets 110 , 112 .
[0027] A striker 116 has a spherically shaped lock ball 118 formed at a distal end thereof. Opposite the distal end, the striker is connected to a second component, for example an automotive door. The semi-sockets 110 , 112 are sized to match the lock ball 118 , in that the spherical surface 114 s of the lock socket 114 is closely matched in a snug, complementary manner to the spherical surface 118 s of the lock ball. A groove 125 , 125 ′ is formed on the distal side of each of the semi-sockets 110 , 112 , so that at the closed socket position, as shown at FIGS. 3 and 4, there is spatial accommodation of the striker 116 .
[0028] Operatively, the lock ball 118 of the striker 116 is, as shown at FIGS. 1 and 2, initially separated from the socket rollers 102 , 104 , and the socket rollers 102 , 104 are in the socket open position, whereat each semi-socket is freely open in the direction of a striking axis Ax which is parallel to a second axis X, wherein the striking axis is the direction of movement of the striker perpendicular to the rotation axes. As the striker moves along the striker axis toward the socket rollers, the lock ball contactingly interacts with the semi-sockets. This interaction causes the socket rollers to rotate such that the semi-sockets move into mutual complement, whereupon the socket rollers are at the socket closed position and the lock socket 114 is formed. As shown at FIGS. 3 and 4, the lock ball 118 is now trapped in the lock socket 114 . As a consequence, a first component (not shown) connected to the rollers retainer 108 is located relative to a second component (not shown) connected to the striker 116 and prevented from movement relative to the first component in at least two mutually perpendicular dimensional axes Y, Z.
[0029] Since the socket rollers 102 , 104 are asymmetric, the flats 120 , 122 are placed so that they mutually abut when at the socket closed position of FIG. 4. The abutment of the flats 120 , 122 prevents further rotation of the socket rollers 102 , 104 (in other words, the flats “bottom-out” and stop “over rotation”) such that the striker 116 can advance no further toward the rollers retainer and socket rollers.
[0030] Thereafter, the lock ball can recede from the rollers retainer and socket rollers only if the socket rollers reverse rotate so as to release the lock ball, whereupon the semi-sockets are again at the socket open position of FIGS. 1 and 2. In order that the first and second components be located in all three dimensions X, Y, Z, the socket rollers 102 , 104 need to be prevented from reverse rotating.
[0031] Referring now to FIGS. 5A through 5C, an example of a detent mechanism 124 will be described which selectively prevents the socket rollers from rotating. In this regard, a socket roller 104 ′ is provided with an external indentation 126 . The detent mechanism 124 is connected to the rollers retainer 108 ′ and has a pin 128 which passes through the rollers retainer and interferingly engages the indentation 126 (see FIG. 5B) at the closed socket position. The pin 126 may be biased toward the indentation by a spring 130 , and an external actuator 132 may be used to lift the pin from the indentation when it is desired to release the lock ball 118 from the lock socket 114 .
[0032] [0032]FIGS. 6A and 6B depict a variation of the foregoing, wherein the socket rollers 102 ′, 104 ″ are now provided with splines 134 , 136 which gearingly interface with each other. Accordingly, in the operational scenario detailed with respect to FIGS. 5A through 5C, when the pin 128 of the detent mechanism 124 engages the indentation 126 , even though one socket roller 104 ″ is so engaged, both socket rollers 102 ′, 104 ″ are frozen from rotation by the gearing engagement of the splines 134 , 136 .
[0033] Turning attention now to FIGS. 7A and 7B, which depict views similar to FIGS. 2 and 4 with like numbers identifying like parts, it will be noted that the socket rollers 102 a , 104 a are now symmetrical, that is, circularly cylindrical, as opposed to the asymmetrical shape previously shown and described. Because the socket rollers 102 a , 104 a are symmetrical, they are capable of 360 degree rotation without bottoming out, the rotation of the socket rollers being responsive simply to the movements of the lock ball of the striker.
[0034] [0034]FIG. 8 depicts a view similar to FIG. 6A with like numbers identifying like parts, except now a socket roller 104 a ′ is provided with the aforedescribed detent mechanism 124 so as to prevent rotation when the pin 128 is engaged in the indentation 126 . As an additional aspect, the symmetrical socket rollers 102 a ′, 104 a ′ are provided with gearlingly engaged splines 134 ′, 136 ′ operating on the principles described with respect to FIGS. 6A and 6B.
[0035] [0035]FIGS. 9A and 9B depict socket rollers 102 b , 104 b which have the roller axles 106 a ′, 106 b ′ mounted to the rollers retainer 108 ″ off-set in relation to the circular cylindrical axes A C , A C ′ of the socket rollers, respectively. As a consequence, as the socket rollers 102 b , 104 b rotate due to movement of the striker 116 , the socket rollers cam toward each other as they reach the closed socket position of FIG. 9B. When cammed together, the semi-sockets 110 , 112 press upon the lock ball 118 .
[0036] Moving on now to FIG. 10, a pair of socket rollers 102 c , 104 c are rotatably connected to a rollers retainer 108 a , wherein the socket rollers are gearingly joined by splines 134 ″, 136 ″ and one of the socket rollers 104 c is rotatably driven by an electric motor 140 . Because of the splines 134 ′, 136 ′, the motor 140 drives both socket rollers 102 c , 104 c . The motor can have its own gearing and controls so as to provide a rotation lock for the socket rollers in the sense of the aforedescribed detent mechanism. Additional to, or independent of, the motor 140 is a drive spring 142 which is connected between the rollers retainer 108 a and a socket roller 104 c so as to bias the socket rollers to a predetermined position, as for example the open socket position or the closed socket position.
[0037] Turning attention to FIG. 11, a pair of splined symmetrical socket rollers 102 d , 104 d , are now rotatably regulated by a spring biased ratchet mechanism 146 ratchetably engaging a spline 134 ′″. The ratchet mechanism 146 keeps the rotative position of the socket rollers from reverse rotating at any movement of the striker. A release actuator (for example, not unlike that described above with respect to the detent mechanism) can serve to release the ratchet mechanism 146 should it be desired to release the lock ball from the lock socket.
[0038] Finally, FIGS. 12A and 12 b depict a variation on the above discussion. Now, splined symmetrical socket rollers 102 e , 104 e are rotatably mounted on a rollers retainer 108 b . The socket rollers 102 e , 104 e respectively have a plurality of semi-sockets 110 a , 112 a formed therein serially thereabout, each semi-socket being interconnected by a groove 125 a , 125 a ′. The socket rollers 102 e , 104 e are gearingly joined by splines 134 a , 136 a and driven by a motor 140 a . The striker 116 a is now in the form of a series of lock balls 118 a connected by links 152 which may be flexible or inflexible.
[0039] In operation, as the socket rollers 102 e , 104 e rotate, a lock ball 118 a is received into each forming lock socket 114 a and the links 152 are respectively received by the grooves 150 . Accordingly, the striker is movably driven forward or backward as the socket rollers rotate in the analogous sense of a chain and sprocket drive.
[0040] Additional variations on the ball and socket rollers principles outlined above may occur to those having ordinary skills in the related art. For example, an ordinary artisan could envision a conveyance device which operates in the manner of FIGS. 1 through 4, wherein the rollers retainer grips the striker, moves from one location to another, and then deposits the striker thereat.
[0041] To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims.
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A location control mechanism includes a striker having a preferably spherically shaped lock ball and a pair of mutually adjacent socket rollers, each socket roller having a complementing preferably hemispherically shaped semi-socket which collectively provide a single preferably spherically shaped lock socket when the rollers are appropriately rotated relative to each other. The striker is connected to a first component and the socket rollers are rotatably mounted to a second component, wherein the first and second components are positionally located relative to each other by action of the lock ball being trapped in the lock socket formed when the socket rollers have been appropriately rotated.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to double-acting forging hammers and, more particularly, to forging hammers actuated by pressurized gas and/or hydraulic fluid.
In its most basic form, a forging hammer consists of a frame which supports a lower die and a cylinder oriented vertically above the lower die, a piston slidably mounted within the cylinder and having a piston rod extending downwardly therefrom, a relatively large and massive hammer connected to the piston rod and mounting an upper die in registry with the lower die, and means for introducing a pressurized gas or fluid into the cylinder below the piston to raise the piston and hammer. Early forms of such forging hammers utilized steam as the pressurized gas which was introduced into the cylinder to raise the hammer. The downward force which lowered the hammer in the forging stroke consisted solely of the force resulting from the pull of gravity on the mass of the hammer, piston and piston rod.
Later embodiments of forging hammers included means for introducing steam into the cylinder above the piston to urge the piston downwardly during the forging stroke thereby accelerating the rate at which the hammer fell during the forging stroke. The force generated could exceed the force generated by a similarly sized hammer which was urged downwardly merely by the force of gravity.
However, steam-operated forging hammers possessed many disadvantages. Generating steam required the use of boilers which had to be tended by firemen and had relatively high maintenance and safety-related costs, all adding to the expense of operation. Furthermore, the steam powered hammers were relatively inefficient in that the steam evacuated from the cylinder during a forging or return stroke was typically vented to the atmosphere, resulting in a loss of energy in the form of heat from the overall system. Proper operation of such hammers required highly skilled and trained operators who had learned how to control the steam or air valves to achieve just the right impact force.
Subsequent forging hammers utilized pneumatic or hydraulic systems in which a compressible gas or a hydraulic fluid was forced into the cylinder by pumps in place of steam. A disadvantage of pneumatic systems, such as that disclosed in Weyer U.S. Pat. No. 3,464,315, is that at least a portion of the air is exhausted to the atmosphere at the end of the forging and/or return strokes, requiring the pumps to generate additional compressed air and decreasing the overall operating efficiency of the system. Another disadvantage of such systems is that relatively high pressure air must be generated, requiring heavy duty compressors which add to the cost of the system.
Hydraulic systems, such as that disclosed in the Hassel U.S. Pat. No. 3,727,519, were typically closed systems in which hydraulic fluid would be stored in a reservoir and supplied to the cylinder by pumps to move the piston. At the same time, the hydraulic fluid within cylinder which was not acting on the piston therein would be evacuated from the cylinder and would flow back to the reservoir. A disadvantage of such systems is that they required complex components and extensive piping, which add to the overall cost of the system.
Accordingly, there is a need for a double-acting forging hammer which utilizes pneumatic and/or hydraulic hammer driving systems, yet does not have the energy losses associated with pneumatic systems or the complex and sophisticated components of hydraulic systems. Furthermore, there is a need for a pneumatic and/or hydraulic hammer driving system which can be retrofitted easily to existing forging hammers.
SUMMARY OF THE INVENTION
The present invention provides a double-acting forging hammer and method in which the hammer is urged downwardly and is accelerated in the forging stroke by compressed gas delivered to the cylinder above the piston from a gas accumulator, and the piston is urged upwardly in a return stroke by hydraulic fluid supplied by a fluid accumulator such that the gas is evacuated from the cylinder to the gas accumulator where it is stored for reuse during the next forging stroke of the hammer. Thus, the compressed gas supplied to the cylinder is reused and not vented to the atmosphere, thereby increasing the overall efficiency of the system. Another advantage of the present invention is that a hydraulic system is utilized only to displace the piston upwardly during the return stroke and is not used to urge the piston downwardly during the forging stroke. Therefore, the hydraulic system requires fewer components and is less expensive to fabricate and maintain than prior hydraulic systems which urge both the piston and the hammer upwardly and downwardly.
The present invention is used with a double-acting forging hammer of the type having a vertically oriented cylinder, a piston slidably mounted within the cylinder having a downwardly depending piston rod extending along the cylinder and attached to a hammer, and a housing or frame for supporting the cylinder and including a die or dies associated with the hammer. The invention includes a gas accumulator which is connected to introduce a gas under pressure into the cylinder above the piston to urge the piston, rod and hammer downwardly in a forging stroke, and a fluid accumulator connected to introduce hydraulic fluid at a relatively higher pressure into the cylinder below the piston to urge the piston, rod and hammer upwardly in a return stroke, simultaneously causing gas within the cylinder to be evacuated therefrom and forced back to the gas accumulator. The invention includes a hydraulic fluid holding tank and a pump for pumping fluid from the tank to charge and maintain the fluid accumulator at the proper pressure.
During the forging stroke, compressed gas, for example nitrogen, within the gas accumulator flows into the cylinder above the piston and urges the piston and hammer downwardly with a substantially constant force. At the same time, an adjustable and controllable valve is opened to permit the hydraulic fluid below the piston to flow from the cylinder to the holding tank. By controlling the opening and the closing of the valve and the rate of flow of hydraulic fluid through the valve, the rate at which the hammer falls during the forming stroke, and therefore the impact energy, may be precisely controlled.
In another preferred embodiment, the gas accumulator and cylinder communicate with a source of shop air at a relatively lower pressure which is used to charge the gas accumulator. Air from the source of shop air is drawn into the cylinder during a downward movement of the piston, then forced from the cylinder to the accumulator by a subsequent upward movement of the piston; the supply line from the source of shop air includes a check valve to prevent the compressed gas from flowing back to the source. By repeated cycling of the hammer, the gas accumulator is "pumped up" by the piston with air from the source of shop air to a suitable operating pressure.
Also in the preferred embodiments, the fluid supply tank is mounted on top of the forging hammer housing and surrounds the cylinder and gas accumulator. The hydraulic system, consisting of the pump and attendant motor, fluid accumulator, and requisite valves, can be mounted alongside the fluid supply tank. Thus, the present invention is ideally suited for retrofitting existing forging hammers. In addition, by mounting the gas accumulator within the fluid supply tank, the fluid receives heat from the gas accumulator such that a cooling system for cooling fluid also cools the gas accumulator, and the gas therein is maintained at a substantially constant temperature.
The present invention is also well-suited for fully automatic operation. In such an application, the invention includes a transducer associated with the piston and cylinder which senses the position of the piston within the cylinder and generates a responsive signal to a microprocessor. The microprocessor can be programmed to actuate the hydraulic valves such that a series of hammer blows can be effected, each with an individually predetermined stroke height, velocity and blow energy. With such an automated system, an operator need not possess mechanical skill in order to control the stroke and force of repeated hammer blows.
Accordingly, it is an object of the present invention to provide a forging hammer and method of operating the same which utilize an efficient, completely closed pneumatic system to accelerate the hammer during the forging stroke; which utilize an efficient hydraulic system both to displace the piston and hammer upwardly for the return stroke and control the rate at which the hammer falls during the forging stroke; which can be retrofitted easily to existing forging hammers; and which can be adapted to utilize microprocessors for fully automated operation.
Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the double-acting forging hammer of the preferred embodiment;
FIG. 2 is a somewhat schematic detail of the upper portion of the hammer of FIG. 1 in which the cylinder, piston, and a portion of the hammer housing are in section;
FIG. 3 is a somewhat schematic detail of an alternate embodiment of the pneumatic system of the invention in which the cylinder is in section; and
FIG. 4 is a schematic of the circuit diagram of an alternate embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the double-acting forging hammer of the present invention, generally designated 10, includes a frame 12 having a base 14 with a ram support structure 16. The base 14 also includes a lower die 18 slidably mounted or keyed to a die shoe 20. The ram support structure 16 includes a guide 22 which slidably receives an upper die 24. The upper die 24 is attached to a hammer 26 which is supported on a piston rod 28.
The hammer 26 and upper die 24 are actuated by a pneumatic-over-hydraulic system, generally designated 30, which is mounted to a top plate 31 of the ram support structure 16. As shown in FIGS. 1 and 2, the pneumatic-over-hydraulic system 30 includes a cylinder 32, having a piston 34 which is integrally joined to the piston rod 28. The piston rod 28 is preferably integral with the piston 34 and extends through the cylinder 32 at fluid packing 35. The piston 34 is slidably mounted within the cylinder 32 and includes seals 36 to prevent the leakage of compressed gas or fluid across the surface of the piston. The piston 34 thus divides the cylinder into an upper chamber 38 and a lower annular chamber 40. The upper annular chamber communicates with a gas accumulator A2 by a gas supply line 42. Accumulator A2 preferably is charged with an inert gas such as nitrogen to a pressure of about 350 psi.
The lower annular chamber or annulus space 40 communicates with a hydraulic fluid accumulator A1 through fluid supply line 44. The fluid line 44 includes a solenoid actuated valve V2 which starts and stops fluid flow through the supply line. The fluid accumulator A1 preferably is charged with hydraulic fluid to a pressure of approximately 5,000 psi.
A fluid supply tank 46 is mounted to the top plate 31 of the ram supply structure and encloses the cylinder 32 and accumulator A2. A motor E1 drives a hydraulic pump P1 mounted on line 48 to pump hydraulic fluid from the tank 46 to supply line 44 where it flows into the accumulator A1 to charge it. A check valve 50 is located on line 48 to prevent backflow of hydraulic fluid from the accumulator A1 to the tank 46. A pressure switch PS1 is located on line 44 to prevent the accumulator A1 from becoming overcharged by the pump P1. Should the pressure in the accumulator A1 exceed a predetermined level, pressure switch PS1 actuates overflow valve V1 on overflow line 52 so that the fluid in line 48 is dumped back to the tank 46.
Hydraulic fluid is evacuated from the lower annular chamber 40 through exhaust line 54 which extends from line 44, downstream of valve V2, to the fluid supply tank 46. An adjustable, infinitely positionable valve V4 is located on exhaust line 54 and can be adjusted to vary the flow of fluid through the exhaust line. Adjustable valve V4 may be any one of a number of proportionally adjustable valves, such as the solenoid valve disclosed in Cowan U.S. Pat. No. 3,725,747, or the flow control valve of Scheffel U.S. Pat. No. 4,311,296, the disclosures of which are incorporated herein by reference. While a proportionally operable valve V4 is shown, it is within the scope of this invention to use any suitable form of a controllable valve, such as a stepping motor-controlled valve, for adjusting the rate of flow of hydraulic fluid from the annulus space, to control the rate of fall of the hammer 26.
A bypass line 56 extends in parallel with valve V2 on line 44 and includes a three-way solenoid actuated valve V3. In series with valve V3 is a combination fixed fluid restrictor 58 and check valve 60. Valve V3 is shown in a closed position in FIG. 2, thereby preventing fluid through line 56. In a first position, in which the spool of valve V3 shown in FIG. 2 is displaced to the right, the valve opens to allow fluid flow from the accumulator A1 through lines 44 and 56 to the lower annular chamber 40 of the cylinder 32. When the spool is displaced to the left, fluid flow is directed from the annular chamber 40, through line 44, and back to the fluid supply tank 46 through auxiliary exhaust line 62 and exhaust line 54. Fluid flow in this reverse direction must pass through the fluid restrictor 58. Preferably valve V3 is undersized relative to valve V2 such that use of valve V3 enables the operator to displace the piston 34 more slowly than with valves V2 and V4.
The fluid within the tank 46 is drawn through a recirculating line 64 by a pump P2 driven by an electric motor E2. Recirculating line 64 includes a filter F1 and heat exchanger C1. Thus, operation of the pump P2 draws fluid from the tank 46 through line 64 where it is filtered and cooled, then is returned back to the tank.
The annular working area 65 of the underside of piston 34 is relatively small as compared to the area of the top 66 of the piston exposed to the upper space 38, preferably at a ratio of at least 1:6. Thus, there is a minimum of hydraulic fluid to be displaced to and from the space 40 during the cycle of operation. Since there is only a small amount of liquid or hydraulic fluid to be displaced, valves V2 and V4 provide only a minimum of back pressure and a minimum of effective area over which the back pressure would be effective.
For example, for the aforementioned minimum ratio of 1:6, 1 psi of back pressure during discharge of the hydraulic fluid would have 1/6 the effective force of 1 psi of gas pressure on the top of the piston 34. Since the amount of fluid which must be displaced is thus held to a minimum, the losses in energy are similarly held to a minimum. Valving of moderate size may be used without creating undue back pressure or restrictions. Accordingly, terminal velocities of 300" per second or more in the rate of fall of the hammer can be readily achieved, thus permitting a maximum amount of force to be directed to the work piece between the dies, where such is required.
To operate the forging hammer 10, the fluid and gas accumulators A1,A2, respectively, are first charged with hydraulic fluid and nitrogen gas. Because the gas accumulator A2 and upper chamber 38 are essentially a closed system, there is no need to recharge the accumulator before each period of use. The fluid accumulator A1 is charged by the pump P1 which is powered by electric motor E1 to pump hydraulic fluid through lines 48 and 44 to the accumulator. Once the fluid pressure within the accumulator A1 has reached the desired level, typically up to 5,000 psi, the pressure switch PS1 opens valve V1 to dump the fluid back to the tank 46 through overflow line 52.
Typically, the hammer 26 is in a lowered position prior to system operation. To raise the hammer, valve V2 is opened, allowing fluid to flow from accumulator A1 through line 44 to the lower annular chamber 40. The fluid expands against the underside of piston 34 and urges the piston upwardly, thereby drawing the hammer 26 upwardly with it. At the same time, the volume of the upper chamber 38 is decreased, forcing gas back into accumulator A2. Valve V2 is closed and the system is ready for the forging operation.
To initiate the downward movement of the hammer 26 in a forging stroke, valve V4 is opened a predetermined amount, allowing fluid within the annular chamber 40 to flow through line 44 and exhaust line 54 back to the tank 46. Since the valve V4 is adjustable, the flow rate of fluid through these lines can be maintained at a predetermined rate, thereby controlling the rate at which the piston 34 descends wihtin the cylinder 32. Fluid flow back to the accumulator is prevented by valves V2 and V3 which are closed during this portion of the hammer operation. The downward movement of the piston 34 and hammer 26 is accelerated by the force exerted on the upper surface of the piston by the gas entering the upper chamber 38 from the gas accumulator A2. The volume of the accumulator A2 preferably is relatively great as compared to the total displacement of the piston 34 in the cylinder so that gas pressure on the piston decreases very little during downward movement, and in fact may be considered as being relatively constant during operation.
Near or at the bottom of the forging stroke, valve V4 is closed and valve V2 is opened, allowing fluid once again to enter the lower annular chamber 40. For example, valve V4 may be signalled to close just prior to die impact, to control rebound. Although the surface area of the piston 34 against which the fluid acts in annular chamber 40 is substantially less than the surface area of the piston against which the gas acts in upper chamber 38, the fluid easily displaces the piston 34 upwardly and forces the gas back into the accumulator A2 because the fluid is at a much higher pressure than the gas. In contrast, the fluid pressure within the supply tank 46 is at a much lower pressure than the gas within the accumulator A2, enabling the fluid to be evacuated from the annular chamber 40 by the force of the expanding gas within the upper chamber 38 and the weight force of the hammer 26. Since fluid evacuated from the lower chamber 40 is returned to the tank 46 during the forging stroke, the pump P1 is operated continuously to maintain the accumulator A1 at the proper pressure and volume.
For setting the forging hammer 10 for operation in the aforementioned manner and for loading in the die sets, it is often necessary to produce very slow upward and downward movements of the hammer 26. For example, the top and bottom of the hammer stroke must be determined with accuracy. To accomplish such a slow movement easily, the valve V3 on bypass line 56 is utilized to permit fluid flow to and from the lower chamber 40 at a much slower rate. Fluid flow from the accumulator A1 to the lower chamber 40 through valve V3 and check valve 60 is reduced because of the relatively smaller size of valve V3 in comparison to valve V2. Fluid flow from the chamber 40 back to the supply tank 46 is reduced even further because the fluid flows through fixed restriction 58 as well as valve V3.
In both aforementioned modes of operation, the pneumatic portion of the system acts as a spring. As the piston 34 travels upwardly, the gas is compressed in the upper chamber 38 and forced back to the accumulator A2. The dumping of fluid from lower chamber 40 through valve V4 and back to supply tank 46 enables the gas to reenter the upper chamber 38 and expand against the piston 34 and accelerate the downward movement of the hammer 26. Thus, the pneumatic system does not require pumps or valves, and greatly reduces the overall cost of fabrication and maintenance of the forging hammer 10. Another advantage of this pneumatic system is that the gas accumulator A2 is located within the fluid supply tank so that heat generated by the compression of the gas or friction of gas flow may pass through the walls of the accumulator A2 to be absorbed by the fluid within the tank 46 where it can be cooled by passage through the heat exchanger C1 on line 64. Of equal importance is the fact that the hydraulic fluid in the tank 46 will be maintained, in use, at a relatively constant temperature and will thus provide a correspondingly constant temperature bath for the accumulator A2, thereby transferring or receiving heat from the accumulator to reduce variations in gas pressure due to variations in temperature within the accumulator.
An alternate embodiment of the pneumatic system is shown schematically in FIG. 3. The upper chamber 38 of the cylinder 32 is joined to a source 67 of relatively low pressure shop air by supply line 68. A branch 70 of supply line 68 extends to accumulator A2' and includes valve V7. A bypass line 72 extends from line 68 to line 70 and is oriented in parallel with valve V7. Bypass line 72 includes a check valve V8 and a pressure relief valve V10 which is signalled by pressure switch PS2. The pneumatic system is further modified in that the gas accumulator A2' includes a fluid drain line 74 which extends from the bottom of the accumulator to the fluid supply tank 46'. A float switch FS1 is mounted within the accumulator A2' and actuates a valve V9 on line 74.
To operate the modified system shown in FIG. 3, the spool of valve V7 is moved to the right blocking flow from line 68 to line 70 and the piston 34 is lowered within the cylinder 32 in a manner previously described, thereby expanding the volume of the upper chamber 38. This expanding volume is filled with shop air from the source 67 along line 68 through air dryer 77 and check valve 78. A return stroke of the hammer 26 in the manner previously described causes the piston 34 to move upwardly, thereby forcing the air within the upper chamber 38 back through line 68 and through the bypass line 72 and check valve V8 where it enters the accumulator A2'. Air is prevented from traveling back through supply line 68 by check valve 78. This cycle of operation is repeated, and each time the air within the upper chamber 38 is forced through lines 68 and 72 to the accumulator A2'. The pressure of the air within accumulator A2' is thus gradually increased or "pumped up" until it reaches a predetermined operating pressure, typically not more than 350 psi. The accumulator A2' is prevented from being overcharged by the relief valve V10 which vents the shop air to the atmosphere in response to a signal from pressure switch PS2.
After this charging sequence has been completed, the forging hammer 10 is ready for operation in the manner described in relation to FIGS. 1 and 2. Valve V7, which was closed during the charging sequence, is now opened to allow compressed air to flow through lines 70 and 68 to the upper chamber 38. The gas is prevented from flowing through lines 72 and 68 by check valves V8 and 78, respectively.
For fully automatic use, a system such as that shown schematically in FIG. 4 is incorporated into the invention. The cylinder 32 (also shown in FIGS. 2 and 3) mounts a linear displacement transducer 79 or similar electrical devices which includes a shaft 80 extending downwardly through the cylinder, piston 34, and piston rod 36. The transducer 79 includes a magnetic ring 81 which is mounted to the piston 34 such that the ring moves with the piston. Transducers of this type are well-known, an example of which is the linear displacement transducer, series DCTM, manufactured by Temposonics, Inc., Plainview, N.Y.
The transducer 79 generates a signal which varies in response to the position of the piston 34 within the cylinder 32, and hence the position of the hammer 26 relative to the lower die 18 (FIG. 1), to a microprocessor 82. The microprocessor 82 is driven by a power supply 83 which also powers the electric motors E1 and E2 which drive the fluid pumps P1 and P2 (FIG. 2), and supplies power to the electric solenoids of valves V1, V2, V3, V4, V7, and V9. The microprocessor 82 preferably is of modular design and is progammable by means such as a keyboard 84. In addition, the microprocessor can be programmed to respond to manual inputs such as a joystick 86 or a foot pedal 88. A mode selection switch 90 is used to switch on the system, switch the system from fully automatic to fully manual, or to switch the system to "inch" the hammer 26 upwardly or downwardly during a setting up period (thereby actuating valve V3).
During operation, the central processing unit of the microprocessor unit interrogates the input from the transducer 79 and determines when the hammer slows down or stops and at that time effects a return stroke. The microprocessor also interrogates the input signals generated from a predetermined program and actuates the solenoids of the valves in the proper sequence. The microprocessor 82 can be programmed to display pertinent information on a cathode ray tube 92 or other display means. By utilizing the programming keyboard 84, an operator can preset the topmost and lowermost positions of the hammer during a forging stroke. By controlling the length of the stroke, the ultimate force delivered to the workpiece is controlled. In addition, the valve V4 (FIG. 2) which is adjustable, can be actuated by the microprocessor 82 to open gradually and close gradually, thereby enabling the hammer 26 to be brought against the workpiece at a first velocity, then slowed as the hammer makes contact with the workpiece as the valve is gradually closed. Furthermore, the microprocessor 82 may be programmed by the keyboard 84 to deliver a sequence or series of hammer blows in which each blow is different in stroke and force from the blow preceding or succeeding it.
The invention further includes means for detecting the rate of change of velocity of the hammer 26 as it falls. The rate of change may be detected by differentiating a signal from the transducer 79, or by differentiating any other signal which may readily be derived relating to the rate of movement of the hammer, and utilizing this signal within the control system for providing an indication of the time when the hammer is slowing down or when the hammer stops. Thus, an operator may, for example, work with a long stroke and not enter return signal data, and the stopping of the hammer may be detected and used to operate the return valve V2.
While the forms of apparatus and method herein described constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to these precise forms of apparatus and method, and that changes may be made therein without departing from the scope of the invention.
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A double-acting accelerated forging hammer and method of operation are disclosed. The hammer is of the type having a vertically oriented cylinder, a piston slidably mounted within the cylinder having a downwardly depending piston rod extending along the cylinder and attached to a hammer. A gas accumulator communicates with the cylinder above the piston for supplying gas under pressure thereto during a forging stroke, and a fluid accumulator communicating with the cylinder below the piston for supplying fluid thereto at a higher pressure than the gas to dirve the piston upwardly during a return stroke. A fluid tank supplies fluid to recharge the accumulator and receives fluid from the cylinder during the forging stroke. Variable valves control the rate of fluid flow from the cylinder and thereby control the rate at which the piston descends within the cylinder. In a preferred emboldiment, the gas accumulator is supplied with relatively low pressure shop air which is forced into the accumulator by repeated cycling of the piston to raise the pressure within the accumulator above that of the source of shop air.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
Cabinets with currently available single-lock drawer locking systems are such that, when locked, all of the drawers in the cabinet are locked and cannot be opened. When the lock is unlocked, all of the drawers can be opened or closed as desired. There are situations in which it is desirable that one or more of the drawers in the cabinet be opened while the rest of the drawers remain locked. Presently available locking systems do not accommodate such an operation. Furthermore, present systems do not enable the open drawers later to be closed and automatically locked without requiring a key. Another shortcoming of present systems is they must be tailored to the drawer configuration. If drawers of different heights are to be used in the same cabinet enclosure, the locking system must be suitably modified. Drawers are also used in shelving systems. Presently available locking systems have not been altogether satisfactory in being useable in that kind of installation in addition to being useable in a cabinet.
SUMMARY OF THE INVENTION
It is therefore an important object of the present invention to provide a drawer locking system in which some of the drawers may be closed and locked while others of the drawers are open.
In connection with the foregoing object, it is another object to provide a drawer locking system in which the open drawers can thereafter be closed and automatically locked without the use of a key. Another object is to provide a drawer locking system which can accommodate drawers of various heights without modification.
Another object is to provide an improved drawer locking system which is capable of use not only in cabinets but also in shelving systems.
In summary, there is provided a drawer locking system for use with a frame having a front, a rear, a pair of sides and upper and lower ends, and at least two drawers carried by the frame and movable between a forwardly open position and a rearwardly closed position, the drawer locking system comprising an elongated latching bar having a longitudinal axis substantially perpendicular to the ends of the frame and extending adjacent to the drawers, the latching bar being rotatable about the longitudinal axis between latching and unlatching positions, means for biasing the latching bar to the latching position thereof, and a latching clip on each of the drawers and having camming means for engaging the latching bar and causing rotation thereof to the unlatching position thereof as the associated drawer is moved toward the closed position thereof, whereupon the associated drawer can be moved further toward the closed position until the camming means passes the latching bar, whereupon the latching bar tends toward the latching position thereof, the latching clip further having keeper means for receiving the latching bar as it rotates toward the latching position thereof.
Further features of the invention pertain to the particular arrangement of the parts of the drawer locking system, whereby the above-outlined and additional operating features thereof are attained.
The invention, both as to its organization and method of operation, together with further objects and advantages thereof will best be understood by reference to the following specification taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a cabinet incorporating the drawer locking system of the present invention;
FIG. 2 is a fragmentary view in vertical cross section taken along the line 2--2 of FIG. 1, on a greatly enlarged scale;
FIG. 3 is a fragmentary view in horizontal cross section taken along the line 3--3 of FIG. 2;
FIG. 4 is a fragmentary view in horizontal section taken along the line 4--4 of FIG. 2;
FIG. 5 is a fragmentary view on an enlarged scale taken along the line 5--5 of FIG. 4;
FIG. 6 is a perspective view of the drawer locking system and its relationship to some of the parts of the cabinet;
FIG. 7 is a view of the latching clip and latching bar with the corresponding drawer open;
FIG. 8 is a view like FIG. 7 but with the locking bar being rotated preparatory to the drawer being moved to its closed position; and
FIG. 9 is a fragmentary, perspective view of the top end of the latching bar.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and particularly to FIG. 1 thereof, there is illustrated a cabinet 20 made in accordance with and embodying the principles of the present invention. The cabinet 20 includes a case 21 having a substantially rectangular rear wall 22 and a pair of substantially rectangular side walls 23 extending forwardly therefrom and disposed substantially perpendicular thereto and parallel to each other. The case 21 further includes a top 25 and a base 27. Eleven drawers 30 are disposed in the case 21, each being provided with a pull 31.
Referring now to FIGS. 2 and 3, further details of the cabinet 20 and the drawers 30 will be described. Attached to the inside surface of each of the side walls 23 is a set of longitudinally extending, vertically spaced apart channel members 24. Attached to the inside surface of the top 25 are longitudinally extending, horizontally spaced apart channel members 26. Attached to the inside surface of the base 27 are longitudinally extending, horizontally spaced apart channel members 28. For each drawer 30, there is provided a pair of longitudinally extending, parallel cabinet rails 29 respectively fixedly attached to the channel members 24. As will be described, the cabinet rails 29 provide the means by which each drawer 30 is suspended.
Each drawer 30 has a bottom wall 32 that is generally rectangular in shape and has a width slightly less than the inner width of the cabinet case 21 and a length slightly less than that of the cabinet case 21, the longitudinally extending inner edges of the bottom wall 32 carrying side walls 33. The rear end of the drawer 30 is closed by a rear wall 34. Each drawer 30 rests upon a carrier assembly 36, the details of which are not particularly important to the present invention. Suffice it to say, that the carrier assembly 36 carries rollers (not shown) which are located within the cabinet rails 29. The drawer 30 in turn carries rollers (not shown) which rest on the carrier assembly 36. Thus, a three-element suspension assembly is provided: the cabinet rails 29, the carrier assembly 36, and the drawers 30.
The drawer locking system according to the present invention includes several elements the first of which is a latching bar 40. Reference will be made particularly to FIGS. 2, 6 and 9 to describe the same. The latching bar 40 includes a vertically extending main wall 41. At the front of such main wall 41 is a flange 42 which is folded over upon itself and forms an acute angle with the main wall 41. In an operative embodiment, the acute angle between the main wall 41 and folded over portion 42 was 50°. The latching bar 40 further includes a pair of coaxial pins 43 located adjacent to the rear of the main wall 41 respectively at the upper and lower ends thereof. The pins 43 are welded to the main wall 41. Between the pins 43 there is provided a reinforcing flange 45, being a continuation of the main wall 41. As is best seen in FIG. 9 the metal forming the latching bar 40 is only partially folded at the upper end thereof, thereby forming an attachment flange 46 having holes 47 and 48 therein.
The drawer locking system includes attachment members 50 and 60 for mounting the latching bar 40. Referring to FIGS. 2, 4 and 6, the attachment member 50 includes a main wall 51, a pair of depending side walls 52 along the sides thereof and a rear depending flange 53 at the rear thereof. A U-shaped slit is formed in the main wall 51 and the tab remaining is bent to form an upstanding flange 54. The attachment member 50 is attached to the channel members 26 by means of fasteners 55 and is attached to the rear wall 22 by means of fasteners 56 passing therethrough and through the rear flange 53.
The attachment member 60 has basically the same construction, including a main wall 61, a pair of depending side walls 62 along the sides thereof and a rear depending flange 63 at the rear thereof. A U-shaped slit is formed in the main wall 61 and the tab remaining is bent to form an upstanding flange 64. The attachment member 60 is attached to the channel members 28 by means of fasteners 65 and is attached to the rear wall 22 by means of fasteners 66 passing therethrough and through the rear flange 63.
The upper pin 43 on the latching bar 40 extends through a complementary hole (not shown) in the main wall 51 of the attachment member 50. Similarly, the lower pin 43 extends through a complementary hole in the main wall 51 of the attachment member 60. A nylon spacer member 67 surrounds the lower pin 43 and is located between the lower end of the main wall 41 and the main wall 61. The elongated latching bar 40 may be said to have a longitudinal axis defined by the pins 43, which axis is substantially perpendicular to both the top 25 and the base 27 of the cabinet 20. The latching bar 40 is rotatable about such longitudinal axis.
The drawer locking system further includes a tension spring 70 having one end in the hole 57 of the attachment member 50 and the other end in the hole 47 of the attachment flange 46 of the latching bar 40. The spring 70 biases the latching bar in a clockwise direction, as viewed in FIG. 4. The surface of the upstanding flange 54 to the right, as viewed in FIG. 4, constitutes a stop engaged by the surface of the main wall 41, thereby to limit the extent of clockwise rotation of the latching bar 40. The right-hand (as viewed in FIG. 6) surface (not shown) of the upstanding flange 64 on the lower attachment member 60 also defines a stop which is engaged by the main wall 41.
The drawer locking system further comprises a latching clip 80, the details of which are best seen in FIGS. 3 and 6. The latching clip 80 is platelike and has a generally rectangular shape. Its front half defines an attachment portion 81 secured to the underside of the associated drawer 30 by means of fasteners 83. The clip 80 has a pair of laterally spaced apart bosses 82 which are simply sheared from the metal body of the clip 80. These bosses 82 butt up against the rear end of the rear wall 34 of the drawer 30 as is best seen in FIG. 2. The bosses 82 in combination with the fasteners 83 fixedly attach the latching clip 80 to the drawer 30 and prevent rotation thereof. The latching clip 80 is preferably mounted at a point centered with respect to the side walls 33 of the drawer 30. Formed on the rear of the clip 80 on one side thereof is a camming surface 84 which is inclined rearwardly and toward one of the side walls. In an operative embodiment, the acute angle between the longitudinal axis front to back of the cabinet, and the camming surface 84 was 30°. When the latching clip 80 is mounted approximately in the center of the drawer 30, its camming surface 84 will be aligned with the folded-over flange 42 of the latching bar 40 as will be described. The latching clip 80 further has a keeper slot 85 opening toward one side thereof and extending rearwardly and towards the other side thereof.
The manner in which the latching bar 40 and the latching clip 80 co-act is best seen in FIGS. 7 and 8. As shown in FIG. 7, the latching bar 40 is in its latching position, that is, it is rotated as far as possible in a clockwise direction and is limited by the stop surfaces on the upstanding flanges 54 and 64. The camming surface 84 of the latching clip 80 is aligned with the folded-over flange 42 of the latching bar 40. As the drawer 30 is pushed toward the closed position thereof, the camming surface 84 engages the folded-over flange 42. Continued rearward pushing of the drawer 30 causes the latching bar 40 to rotate counterclockwise as shown in FIG. 8. When the camming surface 84 is moved it causes rotation of the latching bar 40 to a point where the tip of the folded-over flange 42 clears the latching clip 80, whereupon the latching bar 40 will be in its unlatching position. Continued pushing of the drawer 30 to its closed position causes the folded-over flange 42 to become aligned with the keeper slot 85. The spring 70 snaps the folded-over flange 42 into the keeper slot 85, whereupon the latching bar 40 has reverted to its latching position. The drawer 30 cannot be withdrawn unless and until the latching bar 40 is placed in its unlatching position. The device for performing this function is the release mechanism 90 which is best shown in FIGS. 4, 5 and 6.
The release mechanism 90 includes the usual tumbler lock 91 in which the tumbler is rotatable only when a key of the correct configuration is inserted into the slot. The tumbler is attached to a finger 92 which carries a lug 93. A cable 94 has one end attached to the lug 93 by means of a connector 95 and the other end connected to the latching bar 40 by means of a connector 97, and specifically into the hole 48 (FIG. 9) of the attachment flange 46. Each of the connectors 95 is simply a wire bent as shown with its ends spaced apart, and a sleeve to hold the cable in place. A cable cover 100 includes a longitudinally extending channel 101 and a pair of attachment flanges 102. As is best seen in FIG. 2, the attachment flanges 102 are secured to the channel members 26 by means of fasteners 103. At each end of the channel 101 is a nylon cable guide 104 which is semicircular in outline. As is best seen in FIG. 5, each cable guide 104 has a semicircular track 106 and a pair of confining lips 107. The cable 94 extends along about 90° of the track 96 in the cable guide 104 at the rear and also 90° of the track 106 in the cable guide 104 at the front. The cable guides are mounted to the channel 101 by means of fasteners 105. The lips 107 insure that the cable 94 remains on the associated track. The two cable guides 104 divide the cable into three flights 94a, 94b and 94c. The flight 94a is generally coaxial with the biasing direction of the spring 70, as best seen in FIG. 4, so that outward pulling on the flight 94a causes counterclockwise rotation of the latching bar 40 against the action of the spring 70. The second flight 94b extends generally parallel to the side walls 23 of the cabinet 20. The third flight 94c is generally perpendicular to the flight 94b.
In FIGS. 4, 5 and 6, the lock 91 is shown in its locking position; in other words the finger 92, shown in solid line, is directed to the right. In that condition, tension on the cable 94 is at a minimum, the spring 70 is holding the latching bar 40 in its latching position and all of the drawers 30 theretofore closed cannot be opened. Insertion of a key into the lock 91 and rotating the tumbler therein will cause the finger 92 to move to the phantom-line position, whereupon the cable 94 is tensed and the latching bar 40 is rotated to its unlatching position; i.e. the folded-over flange 42 is withdrawn from the keeper slots 85 of the latching clip 80 on each of the eleven drawers 30. Now, any such drawers can be opened.
If it is desired to maintain access to a selected drawer, that drawer can remain open. The lock 91 can be moved to its locking position, as shown in solid line in FIGS. 4-6. The folded-over flange 42 of the latching bar 40 is caused to enter the keeper slot 85 of each of the remaining ten drawers 30. After one has completed his use of the one drawer, he can close the same and automatically cause it to become locked and closed. While open, the latching clip 80 relative to the latching bar 40 will be as shown in FIG. 7. When he closes it, as previously described, the latching bar 40 will be rotated counterclockwise by the camming surface 84 until the drawer becomes locked once again. While this example was described with respect to ten closed drawers and one open drawer, it may be appreciated that any number of the drawers can be left open and the rest locked. Those open drawers can be examined as desired and then closed one at a time and automatically locked.
The drawer locking system of the present invention has been described in the context of a cabinet. However, it is to be understood that the system can be employed in other environments such as a shelving system. There are instances where drawers on shelves need to be locked and unlocked in the manner achieved by the present invention.
What has been described is a drawer locking system which can be locked while one or more of drawers 30 is still open. As each drawer 30 is closed, it becomes automatically locked and closed. Such prelocking eliminates possible damage to the entire drawer locking system caused when the cabinet is unintentionally locked with one or more of the drawers open. Without the present invention, trying to close those drawers could damage the locking system.
A very important feature of the invention is its ability to accommodate drawers of a variety of heights. In the embodiment described above, there are eleven drawers in the cabinet of a few different heights. The same cabinet could accommodate a lesser number of drawers where all or some are of greater height than the drawers shown. With the present invention, no modification of the locking system is necessary. A latching clip 80 applied to the rear of each drawer 30 is all that is necessary since the latching bar 40 is continuous. Of course, the locations of the cabinet rail 29 would have to be modified.
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The system includes an elongated latching bar located behind the drawers and rotatable between latching and unlatching positions. A spring biases the latching bar to its latching position. A latching clip is mounted on each drawer and has a cam for engaging the latching bar and causing rotation thereof to its unlatching position as the drawer is closed. The latching clip has a keeper for receiving the latching bar as it rotates back to its latching position.
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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 field of lifting devices for lifting and removing covers for spas and hot tubs.
BACKGROUND OF THE INVENTION
Spas and hot tubs have long been utilized by people for relaxation and physical therapy. To allow for optimal enjoyment and utilization of a spa or hot tub it is desirable that dirt, leaves and other types of debris be prevented from falling into the water to the greatest extent possible. Additionally, since spas and hot tubs are heated in normal use, it is desirable to reduce as much as possible the heat loss from the heated water to the surrounding atmosphere. A reduction of heat loss results in a reduction of the spa owner's energy bill to heat the spa.
To address the problems of debris in the water and heat loss, spa owners have long utilized covers for their spas. The spa covers are generally sized and configured to completely cover the spa. To prevent or reduce heat loss, they are typically formed of an insulating material, such as foam, encased within a waterproof cover. Commonly, the covers are formed of two half sections connected by a folding seam or joint formed in the waterproof cover. This construction allows one half of the cover to be folded back on the other half when removing the cover from the spa. Although, satisfactorily dealing with the problems of debris and heat loss, the spa covers created a new problem due to their size and bulkiness. Spas and hot tubs commonly have diameters of up to eight (8) feet or more. Covers large enough to cover spas of this size create problems in terms of removal of the cover to allow access to the spa and storage or placement of the cover once it is removed. Due to their size and weight, it frequently requires two individuals to remove the spa cover without it dragging on the ground. When the spa covers come into contact with the ground they potentially can pick up debris and their useful life span can be severely shortened due to undesired wear and tear on the cover.
Prior attempts to deal with the problem of handling of the spa covers have been directed towards devices which still require excessive effort on the part of the individual user or designs limited in application to a specific spa cover. Prior devices are illustrated in U.S. Pat. No. 4,991,238 to Forrest and U.S. Pat. No. 4,857,374 to Perry.
The Forrest patent, U.S. Pat. No. 4,991,238 is directed to a device which is mounted on the side of the spa enclosure. This device requires that an open space equal to at least one half the diameter of the spa cover be provided on the side of the spa upon which the device is mounted. It also requires that the spa user push or pull the spa cover off of the spa and onto the device. In addition to problems of space constraint, the Forrest device also presents problems to the elderly or to small individuals who are unable to handle the spa cover without the assistance of another individual.
The Perry patent, U.S. Pat. No. 4,857,374 is directed to a spa/hot tub cover which is utilized in connection with a gas spring apparatus to assist in the lifting of the spa cover. The device of the Perry patent is not adjustable and can only be used in connection with a particular spa cover. As illustrated in Perry, the spa cover is hinged to the spa frame and the gas spring assembly is rigidly fastened to the side of the spa cover. This type of construction requires a special plastic cover or layer on the waterproof cover to provide the rigidity necessary for a durable connection.
Given the shortcomings of these prior devices, a need exists for a spa cover lifting apparatus which can be mounted on the spa or spa frame without regard to external space available about the spa. A need also exists for a spa cover lifting apparatus which can be utilized with a variety of spa covers and does not require any external connections between the spa cover and the spa frame or rigid connections between the apparatus and the cover.
SUMMARY OF THE INVENTION
The subject invention provides a spa cover lifting device which can be utilized with a variety of spa and/or hot tub covers. In the context of the subject invention the term spa is interchangeable with the term hot tub and references to a "spa" are equally applicable to "hot tub."
The subject invention comprises a mounting bracket which is fastened to the spa housing or frame. An adjustable or telescoping lifting arm is pivotally connected at its fixed or non-adjustable end to the mounting bracket. A pair of engagement arms are positioned at the opposite end of the lifting arm. The engagement arms extend perpendicularly from the lifting arm and are spaced apart both latitudinally and longitudinally.
The standard or common spa cover, regardless of the size and/or configuration of the specific spa is typically comprised of two half-sections joined together by a hinged joint which allows one half of the cover to be folded back upon the other half. Typically, each half section, which is constructed from an insulating foam, is encased within a durable, waterproof material such as vinyl. The hinged joint is normally formed by means of a reinforced seam in the vinyl covering connecting the two sections.
The engagement arms of the subject invention are inserted along the hinged joint in the spa cover such that, when viewed from the side with the cover lying in a horizontal plane atop the spa, one of said engagement arms is positioned above or on top of the hinged portion of the spa cover and the second engagement arm is positioned underneath the hinged joint between the two half sections. This construction allows for a non-invasive or non-rigid connection between the lifting device and the spa cover.
A support cylinder is provided between the mounting bracket and an intermediate point on the lifting arm. The support cylinder is preferably a gas strut which assists in lifting the cover, holding it in place when raised and cushioning its downward release.
In operation, two of the lifting devices are commonly utilized, one being mounted on each side of the spa. When it is desired to raise the cover, the front section of the spa is folded back on top of the rear section. The user then raises up on the lift assembly and the lifting arm, assisted by the gas shock, raises to a vertical position. The extended gas shock then serves to maintain the device in the raised position. In this position the spa cover is suspended vertically from the engagement arms leaving the spa completely free and unobstructed for use by the owner.
To lower the cover, the user simply pulls down on the lifting arm and returns the arm to a horizontal position. During this lowering process the gas shock serves to provide a cushioning or braking force to allow the controlled lowering of the cover. Once the cover is lowered, the rear section of the spa cover is in place over the spa. The user then unfolds the front section of the cover onto the remaining portion of the spa.
BRIEF DESCRIPTION OF THE DRAWINGS
The various aspects, advantages, and novel features of the subject invention will be more clearly understood from the following detailed description when read in conjunction with the appended drawings, in which:
FIG. 1 is a perspective view of the spa lifting apparatus of the subject invention deployed in a closed position.
FIG. 2 is a perspective view of the spa lifting apparatus of the subject invention deployed in the raised position.
FIG. 3 is a partial top view of the spa lifting apparatus of the subject invention in a closed position, taken along line 3--3 of FIG. 1.
FIG. 4 is a partial side view of the spa lifting apparatus of the subject invention in a closed position.
FIG. 5 is a side view of the spa lifting apparatus of the subject invention in an open or upright raised position.
FIG. 6 is a cross-sectional side view of the subject invention, taken along line 6--6 of FIG. 3.
FIG. 7 is a partial top section view of the lower support member connector of the subject invention.
FIG. 8 is a partial front view of the upper support member of the subject invention, taken along line 8--8 of FIG. 6.
FIG. 9 is a partial cross-section side view of the lift assembly engagement member taken along line 9--9 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The spa cover lifting device of the subject invention is illustrated in accompanying FIGS. 1-9. The various elements of the device are designated by reference numerals which are commonly utilized throughout the various views of the invention illustrated in the drawings.
Turning initially to FIG. 1 and FIG. 2, the subject spa cover lifting device is shown mounted on a spa and spa cover combination in a closed position, FIG. 1, and a raised position, FIG. 2.
Typically, a spa 1 is formed from fiberglass or a high strength molded plastic. When actually installed it is placed or enclosed within a spa frame 2. The frame provides an enclosure around the spa body and a rim 3 around the edge of the spa 1. Typically, the spa frames are constructed out of wood. However, it is to be understood that the subject invention may be utilized in connection with spas and spa frames constructed from any variety of materials known to those skilled in the art.
As shown in FIG. 1, the spa cover 10 typically consists of two sections or halves 12 and 14 joined together by a seam 16 formed in the covering material or fabric of the cover 10. To insulate against heat loss the spa cover 10 is normally several inches thick and is formed from any of the many known insulating foams commercially available. The cover 10 is thicker at the center point along the seam 16 and tapers slightly towards the outer edges 18a and 18b. A typical spa cover may have a thickness of 4 inches at the center adjacent seam 16 and a thickness of 2.25 inches of the outer edges 18a and 18b. This taper allows for runoff of rainwater and prevents standing pools of water from forming on the cover.
As shown in FIG. 2 when in use, the subject spa cover lifting device serves to first raise the spa cover 10 off of the spa and secondly retain the spa cover 10 in an upright position providing complete, unrestricted access to the spa.
The construction and operation of the subject invention will now be described in detail in connection with FIGS. 3-9.
With specific reference to FIG. 6, the components of the invention are described herein. A mounting bracket 20 is provided for mounting the spa cover lifting device to the spa frame 2. As shown in FIG. 6, the bracket 20 is mounted to the frame 2 by means of a plurality of wood screws 22 inserted through mounting apertures 24 in the base 26 of bracket 20. As illustrated in the drawings, in a first embodiment bracket 20 is mounted on the rim 3 of the frame 2. In those instances in which the rim 3 is not of a width sufficient to accommodate the mounting of bracket 20, a side mount bracket (not shown) may be utilized. In this embodiment, the side mount bracket is mounted to the side wall of spa frame 2. Bracket 20 is then mounted on the side mount bracket. In a preferred embodiment bracket 20 is a channel bracket having opposing lateral walls 28 and 30 and rear wall 32.
Bracket 20 also includes vertical arm or extension 34. In the preferred embodiment, arm 34 is a height slightly less than the combined thickness of the spa lip and spa cover 10. As discussed, a typical spa cover is approximately 2.25 inches thick at its outer edge and a typical spa extends 3 inches above the frame.
Adjustable lifting arm 40 is pivotally connected to the end of vertical arm 34 at pivot point 42. Lifting arm 40 is comprised of a pivot arm 44 and a telescoping arm 46. As shown in FIG. 6, pivot arm 44 is a rectangular cross-sectioned tube and telescoping arm 46 is slidably positioned with pivot arm 44. Locking screw 45 is provided for locking telescoping arm 46 in the desired position. In a preferred embodiment locking screw 45 is threaded through locking nut 47 which is welded to the lower outer wall 41 of lifting arm 40. The aperture 48 in nut 47 is aligned with aperture 49 in outer wall 41. Other adjustable or telescoping configurations obvious to those in the an may be used without departing from the scope of the subject invention.
Engagement arms 50 and 52 are provided at the distal end of telescoping arm 46. Engagement arm 50 is corrected to the upper surface 43 of telescoping arm 46 while engagement arm 52 is connected to the front end 51 of arm 46. As illustrated in FIG. 3, engagement arms 50 and 52 extend perpendicularly in an inward direction, with respect to the spa cover, from arm 46.
A telescoping support member 60 is provided between mounting bracket 20 and pivot arm 44. One end of support member 60 is pivotally connected to pivot arm 44. In a preferred embodiment both pivot connections are made by standard ball stud connectors as shown in more detail in FIGS. 7 and 8. A ball stud 62 is mounted on wall 28 of bracket 20. A female receptacle 61 is mounted on the end of support member 60 which receives ball stud 62. As shown in FIG. 7, in a preferred embodiment, ball stud 62 is connected to wall 28 by means of its threaded end 63 being inserted through aperture 65 and retained in place by nut 64.
The opposite end of support member 60 is pivotally connected to pivot arm 44 in a similar manner. Ball stud 66 is connected to a bracket 67 extending downward from arm 44. A female receptacle 68 is provided of the end of arm 44 for receiving ball stud 66. The threaded end 69 of ball stud 66 extends through an aperture 70 in bracket 67 and is retained in place by nut 72.
It is to be understood that other types of pivoting or rotating connections may be utilized for connecting support member 60 to bracket 20 and pivot arm 44.
In a preferred embodiment, support member 60 is a gas strut. The strength of the strut can be varied depending upon the size of the spa. For example, a 250 newton gas shock or strut is suitable for a seven foot diameter spa, while a 400 newton strut will be used for an eight foot diameter spa. Similarly, for spa covers incorporating a denser material, a 500 newton gas strut would be utilized in connection with an eight foot diameter spa.
The connection of the subject invention to a spa cover is illustrated in FIGS. 3, 4, and 9. As shown in FIG. 3, the engagement arms 50 and 52 are inserted along seam 16 with arm 50 being positioned above the cover and arm 52 below the cover. The positioning of arms 50 and 52 is shown in greater detail in FIG. 9, which is not drawn to scale. Arms 50 and 52 engage seam 16 and provide a non-invasive and non-rigid connection.
To allow for its utilization in connection with spa covers of differing sizes, the subject spa cover lifting device is adjustable by means of telescoping arm 46 previously described. Arm 46 is drawn outward from within pivot arm 44 to a position where engagement arms 50 and 52 are aligned with seam 16. Arm 46 is then locked in this position by means of locking screw 45.
As shown in FIGS. 1 and 2, in normal operation a pair of the lifting devices are utilized with one of the devices being positioned on each side of the spa.
To remove the spa cover 10, one simply folds the front section 12 backwards over engagement arm 44 so that it lays on top of rear section 14. Then the user raises up on lifting arm 40 until the spa cover is raised to a vertical position as shown in FIG. 5. To prevent the two spa cover sections 12 and 14 from swinging about arm 44, stabilizer arm 74 is provided on pivot arm 44. Stabilizer arm 74 is positioned between sections 12 and 14 when the spa cover is folded over upon itself.
Having described the preferred embodiments of the subject invention, it is to be understood that the scope of the said invention is not to be limited to the specific embodiment described and illustrated herein but is to be accorded the full breadth and scope of the appended claims.
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A spa cover lifting apparatus which can be adjusted to accommodate spa covers of different sizes and which can be attached to the spa cover without damaging said spa cover or requiring special fastening means. The spa cover lifting apparatus mounts on the spa frame and raises the spa cover from its horizontal engagement position to a vertical position freeing the spa for use. The lifting action of the apparatus being assisted by a telescoping gas strut.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND TO THE INVENTION
a) Field of the Invention
This invention relates to containing apparatus for the storage of one or more products. In particular, this invention concerns such apparatus which is inflatable to define a storage chamber within which the products may be stored. Though such products may take a variety of different forms, the invention is particularly--but not exclusively--concerned with the storage of motor vehicles such as vintage cars, classic motor cycles and so on.
b) Description of the Prior Art
In my prior U.S. Pat. No. 5,566,512 I have described and claimed an inflatable storage chamber also intended for use with motor vehicles but which can be used for the storage of other products as well. That storage chamber comprises a base sheet, a cover sheet releasably connected to the base sheet, and a fan arrangement which blows air into the chamber in order to inflate that chamber, once a vehicle has been positioned on the base sheet and the cover sheet connected therearound. By controlling the flow of air through the chamber, it is found that the vehicle is stored in an excellent environment, protected against the harmful effects of moisture, dust, dirt and so on.
The storage chamber of my prior U.S. Pat. No. 5,566,512 is really only suitable for use within some other building, such as a garage. If the chamber is used out-of-doors, there are likely to be significant problems resulting from condensation within the chamber. Drops are likely to form on the inner surface of the cover sheet which then fall on the stored vehicle and this can give rise to damaged paint-work. Also, the plastics materials such as polyethylene from which the storage chamber of my prior patent are made are degraded by the UV rays in sunlight and the cover sheet thus has a relatively short life.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to reduce the problems associated with the use out-of-doors of the storage chamber of my prior U.S. Pat. No. 5,566,512.
According to the present invention, there is provided containing apparatus for the storage of one or more products comprising:
a base sheet;
an inner cover sheet defining in combination with the base sheet a storage chamber;
an outer cover sheet substantially wholly overlying the inner cover sheet;
releasable fastener means permitting the inner and outer cover sheets to be at least partially disconnected from and re-attached to the base sheet so as to give access to the interior of the storage chamber;
fan means arranged to drive air from the external ambient into the storage chamber so as thereby to inflate the storage chamber;
means to control leakage of air from the storage chamber directly or indirectly to the external ambient; and
means to supply air to the space between the inner and outer cover sheets so as thereby to inflate said space.
The storage chamber is defined by a base sheet together with a cover sheet itself comprising inner and outer cover sheets which substantially wholly overlie each other, but with a space therebetween so as to permit air under pressure to be supplied thereto and thus to inflate that space and separate the sheets. By providing a storage chamber with a double skinned cover sheet, and arranging for there to be air flow through at least the chamber but possibly also through the space between the inner and outer cover sheets, problems associated with condensation can be essentially wholly eliminated. This allows the storage chamber to be used out-of-doors, without any significant probability of condensation droplets forming on the cover sheet, falling on a stored motor vehicle and damaging the paint-work.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may better be understood, it will now be described in greater detail, with reference to preferred arrangements thereof. Moreover two specific embodiments of storage apparatus of this invention will also be described by way of example, reference being made to the accompanying drawings:
FIG. 1 is a general perspective view of the apparatus, with parts partially cut away for clarity;
FIG. 2 is a vertical section transversely through the apparatus of FIG. 1 but with the fan units shown in end elevation;
FIG. 3 is a detailed view on the join between the cover sheet and the base sheet;
FIG. 4 is a vertical section through one embodiment of fan unit;
FIG. 5 is a vertical section through an alternative embodiment of fan unit;
FIG. 6 is a view similar to that of FIG. 4 but of a modified form of fan unit; and
FIG. 7 is a view similar to that of FIG. 1, but of a further embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred form of the apparatus of this invention, the air supply means to said space between the inner and outer cover sheets comprises means allowing air to bleed from within the storage chamber into the space between the inner and outer cover sheets, so as to inflate that space and separate the cover sheets. In this case, the air leakage control means may be arranged to control the leakage of air from the space between the inner and outer cover sheets. Separate air leakage control means may also be provided, to control the leakage of air directly from the storage chamber itself.
In an alternative arrangement, the fan means may be arranged to drive air from the external ambient into the space between the inner and outer cover sheets so as thereby to separate the cover sheets and inflate the space therebetween. In this case, air bleeds means may be provided to permit air in the space between the inner and outer cover sheets to bleed into and thus inflate the storage chamber defined by the base sheet and the inner cover sheet, the air leakage control means then controlling the leakage of air directly from the storage chamber to the external ambient.
In any embodiment of the invention, the air leakage control means may comprise one or more special vents provided for the purpose of allowing air flow. In such a case, the vents may be made adjustable in order that the air flow rate may be controlled to some suitable value to minimise power consumption by the fan means and yet to be high enough to prevent the formation of condensation. Alternatively, or possibly in addition, the inner cover sheet may be air-permeable, at least over a part of its area, whereby the air flow between the storage chamber and the space between the inner and outer cover sheets may take place by permeation of the air through the inner cover sheet.
As with the cover sheet of the storage chamber described in my U.S. Pat. No. 5,566,512, the inner and outer cover sheets may be releasably attached to the base sheet around the whole of the periphery of the base sheet. Alternatively, the inner and outer cover sheets could be permanently attached to the base sheet around one, two or even three sides of the base sheet, so long as when the releasable edges are freed from the base sheet, there is still adequate access to the interior of the chamber for the article to be stored within the chamber. In the case of apparatus intended for the storage of a motor vehicle, it is convenient for both the inner and outer cover sheets to be together wholly removable from the base sheet to permit the vehicle to be driven on to the base sheet, whereafter the cover sheet may be thrown over the vehicle and the peripheral edges of the rover sheet then secured to the edges of the base sheet, all the way around the base sheet.
Various forms of releasable fasteners means may be employed for securing the cover sheet to the base sheet. Conveniently, a clasp fastener (such as that conventionally sold under the name Zip fastener) may be used. Other forms of similar fastener, but not using interengageable clasps, may be employed. One such fastener has a continuous pair of ribs running in a parallel manner along the edge of one component and on the other component there is a similar corresponding pair of ribs, a fastener element being slidably engaged with the ribs to urge one pair into engagement with the other pair or to release one pair from the other, dependent upon the direction of movement of the fastener element. Other possibilities would include hook-and-loop type two-part fasteners (such as those sold under the Trade Mark Velcro), lacing systems and so on. Adjustment of the fasteners will allow a degree of control of the air leakage from the storage chamber and so in turn the air flow through that chamber.
In order better to isolate the interior of the chamber from the external ground, it is preferred for the base sheet to have two layers with thermal insulation between the layers.
At least the outer cover sheet is preferably made from a plastics material which has been UV stabilised. For example, the outer sheet may be made from a polyamide sheet, suitably treated for UV stabilisation. Such a sheet may be aluminium coated and impregnated with a silicone, so as to give the material advantageous properties, including protection from up to 99% of solar UV radiation and protection against the build-up of heat due to infra-red light, as well as air, water and moisture impermeability.
Though it would be possible to operate the fan means continuously and to control the air flow solely by means of adjustable vents and controlled leakage, for certain conditions it may be advantageous for the fans means to be operated with a duty cycle of less than 100% the operation of the fan could be controlled simply on a time basis, though the fan means may be operated under the control of a sensor so as to perform a cyclic action, thus inflating the chamber to a maximum value and then allowing partial collapsing of the chamber before re-inflating the chamber back to the maximum value. The sensor may be arranged to monitor the pressure within the chamber, or perhaps in the space between the inner and outer cover sheets, and to control the operation to the fan means dependent upon the sensed pressure. Other possibilities include having a humidity sensor or a temperature sensor and to control the fan means dependent upon the sensed humidity or temperature, respectively.
In a preferred form of the invention the fan means comprises a pair of electric motor driven fans, mounted spaced apart at one end of the storage chamber, on the cover sheet, so as to draw air from the external ambient and drive that air directly into the storage chamber. Preferably, each fan is a relatively small unit driven by a low-powered 12 v dc electric motor. Each fan may be mounted in a carrier which is secured to the cover sheet, the carrier including a filter panel and also a one-way valve to prevent air leaking out of the storage chamber when the fan is not operating. Such a valve conveniently comprises a flap valve located over the exit duct of the fan and which may move under gravity or under a spring to a closed position when the fan is not operating. The carrier may also include a drain hole to allow any moisture collecting within the carrier to drain externally of the storage chamber.
In a modified form of fan unit, there is provided a secondary electric motor driven fan mounted on the carrier of the main motor-driven fan. A control arrangement may be provided for the secondary fan selectively to cause operation of that fan dependent upon the conditions prevailing within the chamber and possibly also externally of the apparatus. For example, to increase the air flow through the chamber, the secondary fan may be operated so as also to drive air into the chamber, in parallel with the main fan. Should the external humidity be higher than the humidity within the chamber, then the secondary fan may be turned off so that air flows out of the chamber through the secondary fan, for recirculation into the chamber by the main fan. To assist this, the main and secondary fans may draw air from a common plenum chamber. A filter may be provided over the external inlet to that plenum chamber.
The power supply for the or each electric motor driven fan may comprise the battery of a vehicle stored within the chamber and in this case a suitable control unit should be provided to prevent the battery voltage falling below some minimum value. The battery may be recharged for example by one or more solar panels, a wind generator or a mains operated charger. Another possibility includes operating the fan motors from the mains supply via a suitable transformer.
The first embodiment of storage chamber will now be described with reference to FIGS. 1 to 6. Referring to those drawings, there is shown an inflatable storage chamber comprising a generally rectangular base sheet 10, an inner cover sheet 11 and an outer cover sheet 12, the inner and outer cover sheets being of substantially the same shape and size with the outer cover sheet overlying the inner cover sheet. The inner cover sheet is releasably secured to the base sheet around its four edges, by means of a two part clasp fastener 13 (such as that kind of fastener sold under the name Zip fastener) extending wholly around the base sheet. Rather than having one long continuous fastener, it may be more convenient for some applications to have four or even more separate fasteners extending along the sides of the base sheet. The outer cover sheet 12 is secured at 14 to the inner cover sheet around the entire periphery of the inner cover sheet, just above the fastener 13. That securing should be effected in a substantially air tight manner though drainage tubes 15 may be provided at intervals along the length of the join, which tubes also allow air to leak out of the space between the two cover sheets.
The base sheet 10 may be relatively stiff or even semi-rigid and though not shown in the drawings, may be made from upper and lower impermeable sheets together with a layer of thermal insulating material between those sheets. The inner cover sheet 11 may be of an air-permeable material such as a microporous plastic sheet. The outer cover sheet should be air and water impermeable and typically is a polyamide sheet carrying on its inner surface a coating of aluminium and on its outer surface a silicon coating. The silicone coating renders the sheet wholly waterproof and allows easy cleaning, whereas the aluminium coating makes the sheet substantially opaque and shields any object located within the inner cover sheet from harmful solar UV radiation. In addition, the coating will reflect infra-red light and so assist in preventing a build-up in temperature within the chamber, during hours of daylight.
Though not shown in FIGS. 1 to 3, an additional fastener may be provided between the free edge 17 of the outer sheet 12 and the base sheet 10, so as to permit joining of the outer sheet to the base sheet.
Mounted in end wall 18 of the inner and outer cover sheets 11 and 12 is a pair of electric motor driven fan units 19, each of the same construction. One such fan unit is shown in FIG. 4. This has an electric motor 20 mounted on a carrier 21 attached around an opening through the inner and outer cover sheets 11 and 12. The carrier has a louvered cap 22, a foam air filter 23 being mounted between the motor 20 and the cap 22. The motor 20 drives a fan impeller (not shown) to draw-air through the unit in the direction of the arrows, a flap valve 24 being mounted on the exit duct which flap valve opens during operation of the motor but which closes when the motor is not operated, to prevent back-leakage of air. A finger guard 25 may be mounted over the inlet side of the duct within which the fan impeller rotates.
FIG. 5 shows a similar fan unit, but having a significantly larger air filter, as well as better shielding from atmospheric precipitation. In this arrangement, like parts are given like numbers and will not be described again here. Water drain holes 26 are provided in the bottom of the cover sheet 12. Similar holes may of course be provided in the arrangement of FIG. 4, if required.
The motors of the two fan units are connected in parallel to a power supply unit, for the delivery of a 12 v dc supply to the fan motors when the fans are to inflate the chamber. The power supply unit may comprise a transformer for the 240 v domestic mains supply or may be arranged to supply power from the battery of a vehicle stored within the apparatus. The power supply unit may include a sensor for monitoring one or more of the air pressure, humidity and temperature within the chamber and to control the operation of the fans dependent thereon.
In use, the two cover sheets are removed from the base sheet and a motor vehicle is driven on to the base sheet. The cover sheets are thrown over the vehicle and then the inner cover sheet 11 is secured to the base sheet, using the fastener 13. If a further fastener is provided around the outer cover sheet 12, then that fastener is also secured to the base sheet 10. The fan units are then operated to draw air from the external ambient so as to inflate the volume between the base sheet and the inner cover sheet 11, so that the inner cover sheet is wholly free of the vehicle stored within the chamber defined by the base sheet and inner cover sheet. The air blown into the chamber permeates through the inner cover sheet into the space 27 between the inner and outer cover sheets so as also to inflate that space as shown in FIG. 2. From there, the air leaks out of the drain tubes 15, back to the external ambient. The double-sealed construction, if used around the free edge of the outer cover sheet 12, serves to restrict leakage of air out of the chamber and also to give better control of the air flow.
Air holes 28 may be provided in the inner cover sheet, so as to increase the air flow from the chamber to the space 27, to ensure complete inflation of that space and also increase air flow through the chamber. The air holes may be made adjustable (for example for providing flaps secured by hook and loop fasteners) or an adjustable vent may be mounted over each air hole. If a greater air flow is required through the chamber, for example to dry a vehicle put into the chamber when wet, the Zip fastener 13 may be released for a short distance, so allowing increased leakage directly from the chamber. Alternatively, adjustable vents (not shown) may be provided from the chamber direct to the external ambient and in this case such vents should be provided in the wall of the cover sheet opposed to the wall carrying the fan units.
FIG. 6 shows a modified form of the fan unit shown in FIG. 4. Here, a secondary electric motor-driven fan 30 is mounted on the carrier 21, to draw air (when operated) from the space between the carrier 21 and filter 23. The operation of the secondary fan may be under the control of internal and external humidity sensors. In the event that the humidity within the chamber is greater than the external humidity (for example if a wet vehicle has been placed within the chamber) then both main and secondary fans may be operated together, to increase the air flow through the chamber and so to assist drying of the air in the chamber. On the other hand, if the humidity externally is greater than that within the chamber, the secondary fan 30 may be turned off so that air will flow in the reverse direction through the secondary fan, back into the space between carrier 21 and filter 23. From there, the air will be recirculated into the chamber, so minimising the amount of relatively wet air drawn from the exterior, into the chamber.
FIG. 7 shows a second embodiment of storage chamber generally similar to that of FIG. 1 and like parts are given like reference characters; these parts will not be described in detail again here. The storage chamber of FIG. 7 differs from that of FIG. 1 in that there is a plurality of spaced, substantially parallel seams 32 joining together the inner cover sheet 11 and the outer cover sheet 12, so forming a multiplicity of elongate tubular pockets 33 extending up one side of the cover sheet, over the top and down the other side. Further more, similar seams are provided on the end panels of the inner and outer cover sheets, so forming further elongate tubular pockets 34 on those end panels. In the illustrated embodiment, a passageway 35 extends around the cover sheets adjacent there lower edges, interconnecting all of the tubular pockets 33 and 34, which passageway is provided with an inlet valve to permit the inflation of all of the pockets, simultaneously. In this embodiment, no communication is provided between the space between the inner and outer cover sheets and the principal volume of the storage chamber, between the inner cover sheet and the base sheet. Thus, the pockets may be inflated separately from the inflation of the main chamber and, when the pockets are inflated, the structure will be self-supporting even without the inflation of the main chamber.
In the embodiment of FIG. 7, means are provided to allow the leakage of air from the main chamber, such as one or more adjustable vents (not shown) provided at the opposite end of the chamber from the fan units 19, to permit a through-flow of air through that main chamber, during operation of those fan units. In other respects, the embodiment of FIG. 7 is similar to that of FIG. 1.
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Apparatus primarily for the storage of a motor vehicle comprises a base sheet (10), an inner cover sheet (11) defining in combination with the base sheet (10) a storage chamber and an outer cover sheet (12) substantially wholly overlying the inner cover sheet. The inner and outer cover sheets are joined together around their peripheral edges and are at least partially releasable from the base sheet, so as to give access to the interior of the storage chamber. At least one fan assembly (19) is provided to drive air from the external ambient into the storage chamber so as to inflate it and air is allowed slowly to leak out of that chamber, either directly or indirectly through the space between the inner and outer cover sheets (11) and (12), to the external ambient. The space between the inner and outer cover sheets may be inflated by air bleeding from the storage chamber into that space, or that space may separately be inflated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to wellbore construction and more particularly to the construction of multiple wellbores which are interconnected downhole to form a manifold of pipelines in the reservoirs of interest. Provision is made for flow controls, sensors, data transmission, power generation, and other operations positioned in the lateral wellbores during the drilling, completion and production phases of such wellbores.
2. Background of the Related Art
To obtain hydrocarbons such as oil and gas, wellbores or boreholes are drilled from one or more surface locations into hydrocarbon-bearing subterranean geological strata or formations (also referred to herein as reservoirs). A large proportion of the current drilling activity involves drilling deviated and/or substantially horizontal wellbores extending through such reservoirs. To develop an oil and gas field, especially offshore, multiple wellbores are drilled from an offshore rig or platform stationed at a fixed location. A template is placed on the sea bed, defining the location and size of each of the multiple wellbores to be drilled. The various wellbores are then drilled from the template along their respective pre-determined wellpaths (or drilling course) to their respective reservoir targets. Frequently, ten to thirty offshore wells are drilled from an offshore rig stationed at a single location. In some regions such as the North Sea, as many as sixty separate wellbores have been drilled from an offshore platform stationed at a single location. The initial drilling direction of several thousand feet of each such wellbore is generally vertical and typically lies in a non-producing (non-hydrocarbon bearing) formation.
Each wellbore is then completed to produce hydrocarbons from its associated subsurface formations. Completion of a wellbore typically includes placing casings through the entire length of the wellbore, perforating production zones, and installing safety devices, flow control devices, zone isolation devices, and other devices within the wellbore. Additionally each wellbore has associated wellhead equipment, generally referred to as a “tree” and includes closure valves, connections to flowlines, connections for risers and blowout preventors, and other devices.
As an example, ten wellbores may be drilled from a single offshore platform, each wellbore having a nine-inch internal diameter. Assuming that there is no production zone for the initial five thousand feet for any of the wellbores, there would be a total of fifty thousand feet (five thousand for each of ten wellbores) of non-producing wellbore that must be drilled and completed, serving little useful purpose. It may, therefore, be desirable to drill as few upper portions as necessary from a single location or site, especially as the cost of the drilling and completing offshore wellbores can range from $100 to $300 per foot of wellbore drilled and completed.
Multilateral well schemes have been proposed since the 1920's. Various methods of constructing these well geometry's have been disclosed showing methods of creating the wellbores, methods of mechanically connecting casings in the various wellbores drilled, methods of sealing the casing junctions, and various methods of providing re-entry access to the lateral wellbores for remedial treatments.
Multilateral wellbore junction construction is currently thought of as fitting into one of six levels of complexity. Level 1 is generally thought of as open hole sidetracks where lateral wellbores are drilled from an open hole (uncased) section of the main well. No casing is present in the main well or lateral well at the junction of the two wellbores. This method is generally the least expensive but does not ensure wellbore stability, does not provide a method of easy lateral re-entry, and it does not seal the junction in a manner to allow future flow control of the lateral versus the main wellbore.
Level 2 multilateral junctions are those where the lateral exits from a cased main well using section miling or whipstock methods to create the exit. The lateral wellbore may be left as open hole or a liner may be run and “dropped off” outside the main well casing exit such that the lateral liner and main casing are not connected and an openhole junction results. This method is currently a little more costly than Level 1; it provides some more assurance of re-entry access to laterals, and it can provide some flow control of the various wellbores. It does not however protect or reinforce the junction area against potential collapse of the open hole wellbore wall.
Level 3 junctions provide laterals exiting from a cased main well and a lateral liner is run in the lateral wellbore and mechanically connected to the main casing but no seal of the junction is achieved. This method supports the borehole created and provides access to laterals but the lack of a seal at the junction can lead to sand production or fluid inflow or outflow into the junction rock strata. In many applications this inflow or outflow of fluids at junction depth is not desirable as the laterals may penetrate strata of different pressures and the unsealed junction could result in an underground blow out.
Level 4 junctions also provide a lateral wellbore exiting from a cased main well and a lateral liner is run into the lateral wellbore with the top end of the lateral casing extending back to the main casing with the junction of the lateral liner and main casing sealed with cement or some other hardening liquid material that can be pumped in place around the junction. This method achieves isolation of the junction from adjoining strata providing a sufficient length annular seal can be placed around the lateral liner and provided the main casing has an annular seal between the casing and the main wellbore wall. Various methods of reentry access to the laterals is provided using deflectors or other devices. The pressure seal integrity achieved in this type of wellbore junction is generally dependent on rock properties of the junction strata and cannot exceed the junction strata fracture pressure by more than a few hundred pounds per square inch. In addition the guaranteed placement and strength of liquid cementatious hardening materials in a downhole environment is extremely difficult with washouts causing slow fluid velocities, debris causing contamination of sealing materials, fluid mixing causing dilution, gelled drilling muds resisting displacement, etc. The junction may be isolated from adjoining zones but seal reliability specifically at the junction is difficult.
Level 5 systems generally provide lateral wellbores exiting from a cased main well. Liners are run in the lateral wellbore and may be “dropped off” outside the window in the main casing or a Level 4 type cemented intersection may be created. The Level 5 systems however use production tubulars and mechanical packer devices to mechanically connect and seal the main casing and lateral liners to each other. Level 5 systems can achieve a junction seal exceeding the junction strata capability by five to ten thousand psi. These systems do however restrict the diameter of access to the lateral and main casings below the junctions due to the relatively small tubular diameters compared to casing sizes. Well designs must also generally consider the possibility of a leak in the junction tubulars. This limits the application of Level 5 systems to generally those applications where the junction pressures are abnormal for the junction rock only due to surface applied pressures such as may be encountered in injection wells or during well stimulations. Flow rates achievable through such junctions are also restricted to the rates possible through the smaller diameter tubulars.
Level 6 junctions create a mechanically sealed junction between the main casing and lateral liner without using the restricting bores of production tubulars to achieve the seal. The methods devised to date generally are of two categories. One category uses prefabricated junctions in which one or both bores are deformed. This prefabricated piece is lowered into the well bore on a casing string and located in an enlarged or underreamed section of hole such that it can be expanded or unfolded into its original shape/size. The casing string with the prefabricated junction is then cemented in the wellbore. The lateral borehole is then drilled from the lateral stub outlet and a lateral liner is hung/sealed in the lateral stub outlet. A second category of Level 6 junction currently used creates an oversized main well borehole and full size underformed junctions are run into the main wellbore on the main casing. Laterals can then be drilled from a lateral stub outlet as described from the previous category.
FIGS. 1 a to 1 f illustrate several conventional methods 200 a to 200 f for forming multiple lateral wellbores into reservoirs 202 a and 202 b . Multiple lateral wellbores or drainholes 204 are conventionally drilled from the cased main wellbore 208 or from the openhole section 206 of the main wellbore. When constructing the laterals 204 a from a cased hole 208 , a whipstock 214 is usually anchored in main well casing 208 by means of a packer or anchoring mechanism 216 . A milling tool (not shown) is deflected by the whipstock face 218 to cut a window 210 in the casing 208 . The lateral wellbore 204 a is then directionally drilled to intersect its targeted reservoir 202 a . The whipstock face 218 is typically 1 to 6 degrees out of alignment with the longitudinal axis of the whipstock 214 and the lateral wellbore 204 a is directed away from the main wellbore casing 208 at a substantially equal angle. The intersection or junction between the lateral liner 220 and the main well casing 208 thus created is elliptical in its side view, curved in its cross section, and lengthy due to the shallow angle of departure from the main well casing 208 . This conventional prior art method 200 a-d creates a geometry that is difficult to seal with appreciable mechanical strength or differential pressure resistance. Method 200 e of FIG. 1 e uses tubulars and packers to mechanically seal the junction but restricts the final production flow area and access diameters to the two production bores. Method 200 f of FIG. 1 f uses a prefabricated junction which is deployed in place in an underreamed or enlarged section of the wellbore. This method requires an enlarged wellbore to the surface or an underreamed portion. If the underreamed wellbore approach is used then current technology deforms the junction piece in the underrearned section and by nature of design uses a low yield strength material which causes low pressure ratings. Alternatively this method may use an oversized diameter main wellbore to allow a prefabricated junction to be placed at the desired depth.
In the conventional multilateral wellbore construction methods described above, the lateral borehole is typically drilled from the main casing and departs the main casing at a shallow angle of 1 to 6 degrees relative to the longitudinal axis of the main casing. Recently, however, multilateral wellbores have been constructed by drilling separate lateral wellbores towards the main well casing, from the outside of the main casing so that the downhole end of the lateral wellbore is located proximate perforations in the main wellbore or even intersecting with the main wellbore if possible. Production fluids such as hydrocarbons can, therefore, be flowed between the main wellbore and the lateral wellbores.
However, such prior methods of constructing multilateral wellbores do not provide a mechanical connection or other suitable seal against downhole pressures between the main wellbore and the lateral wellbores. Accordingly, in a particular application such conventional techniques may only be desirable in situations in which the lateral wellbore intersects a production zone co-extensive with a production zone of the main wellbore. The present invention provides a method of mechanically connecting the lateral liner to the main casing and sealing the junction, which may be beneficial for multilateral wellbore construction where it is desirable to intersect a main wellbore with lateral wellbores drilled from outside the main wellbore in a direction generally towards the main wellbore.
In operations in which high pressure connections are desired, the less desirable conventional drilling techniques described above may heretofore have been employed which require deviating the lateral wellbores from within the main, or parent, wellbore. However, these conventional multilateral wellbore construction techniques may also cause undue casing wear in the parent wellbore when many lateral wellbores are drilled from a common parent well. In such a case, the parent well casing may be exposed to thousands of drillpipe rotations and reciprocations executed in the drilling. This drilling process wears away the metal walls of the casing internal diameter. Drill pipe is also used over and over and is therefore commonly treated with a hard coating on the tool joints to minimize the wear on the drill pipe itself. This wear resistant coating on the drill pipe can increase the wear on the casing. Since the production of the wellbore typically flows through the parent wellbore to the surface, the parent casing typically must have sufficient strength after drilling wear to contain wellbore pressures while also accounting for corrosion and erosion expected during the production phase of the well. Accordingly, a need has arisen to provide mechanical connection methods and apparatus between lateral wellbores and parent wellbores for operations in which it may be beneficial to drill the lateral wellbores from outside the parent wellbore in a direction towards the parent wellbore.
Further, during the completion of a wellbore, a number of devices are utilized in the wellbore to perform specific functions or operations. Such devices may include packers, sliding sleeves, perforating guns, fluid flow control devices, and a number of sensors. To efficiently produce hydrocarbons from wellbores drilled from a single location or from multilateral wellbores, various remotely actuated devices can be installed to control fluid flow from various subterranean zones. Some operators are now permanently installing a variety of devices and sensors in the wellbores. Some of these devices, such as sleeves, can be remotely controlled to control the fluid flow from the producing zones into the wellbore. The sensors are used to periodically provide information about formation parameters, condition of the wellbore, fluid properties, etc. Until now the flow control devices and sensors have been installed in the main well production tubing necessitating a reduction in the production flow area for a given main casing size. For example devices are now available matching 5½ inch nominal tubing to fit in 9⅝ inch nominal casing. 7 inch nominal tubing could be used in 9⅝ inch casing but the remotely operated production control devices are restricted to 5½. The present invention provides a method of placing the production control devices out of the main casing and into the lateral wellbore so they do not restrict the main casing tubular design or size and yet production of each lateral wellbore is controlled independently.
In deepwater fields (generally oil and gas fields lying below ocean water depths greater than 1000 ft), the costs of field development are even more extreme than the costs previously mentioned. In these environments satellite wells might be used with seafloor flowlines connected back to a central seafloor manifold for processing and a flowline extends from the central manifold to the sea surface where it is connected to a floating vessel or from the central manifold along the seafloor to a nearby existing platform or pipeline infrastructure. In these deepwater applications the reservoir fluids are subjected to cold ocean floor temperatures (which are generally 40 degrees Fahrenheit or less). These cold temperatures can cause problems in flow assurance since many hydrocarbons contain waxes which will crystallize when the fluid is cooled and can plug pipelines or flowlines especially if flow is stopped for any reason. The typical solution is to insulate individual wellbore risers from the seafloor to the sea surface and/or to insulate flowlines on the seafloor or even make provisions for flowline heating. These solutions have an associated high cost. The present invention provides for connecting wellbores at reservoir depth such that the wellbore fluids remain at substantially reservoir temperatures and pressures until they reach a common outflow wellbore to the surface thus addressing a portion of the well flow assurance concerns.
Accordingly, there is a need for a method and apparatus for providing mechanical connections between a main wellbore and a lateral wellbore, in which the lateral wellbore has been drilled from outside the main wellbore in a direction generally towards the main wellbore. The present invention provides a method and apparatus for providing mechanical connections between a main wellbore and a lateral wellbore, in which the lateral wellbore has been drilled from outside the main wellbore in a direction generally towards the main wellbore
In addition, there is a need for measurement and control apparatus in the lateral wellbores so that production through the lateral wellbores can be controlled independent of the production through the main wellbore. The present invention provides measurement and control apparatus in the lateral wellbores so that production through the lateral wellbores can be controlled independent of the production through the main wellbore.
SUMMARY OF THE INVENTION
In a particular aspect, the present invention is directed to downhole well system including a main wellbore and a lateral wellbore, wherein the lateral wellbore is drilled from outside the main wellbore in a direction generally towards the main wellbore, a wellbore junction, comprising: a mechanical seal between the lateral wellbore and the main wellbore.
A feature of this aspect of the invention is that the main wellbore may include a lateral receiver coupling, and wherein a fluid sealant such as cement has been pumped through the lateral wellbore and hardened to mechanically seal the lateral wellbore within the lateral receiver coupling.
Another feature of this aspect of the invention is that the fluid sealant may be pumped through a cementing port collar disposed within the lateral wellbore. The main wellbore may include a lateral receiver coupling, wherein the lateral wellbore includes a mechanical latching mechanism adapted to engage with the lateral receiver coupling of the main wellbore. The mechanical latching mechanism may be spring-actuated; and the spring-actuated latching mechanism may include at least one locking dog adapted to mate with a latch profile within the lateral receiver coupling.
Yet another feature of this aspect of the invention is that the mechanical latching mechanism may comprises: a plurality of tapered keys spaced apart and disposed about an outer surface of the lateral liner; and a plurality of tapered keys spaced apart and disposed about an inside surface of the lateral receiver coupling, whereby a keyway is provided between each of the plurality of tapered keys, and whereby rotation of the lateral liner causes the keys of the lateral liner to engage with the keys of the lateral receiver coupling to urge the lateral liner against a sealing surface associated with the lateral receiver coupling.
In another aspect, the present invention is directed to a latching system for mechanically interconnecting a lateral wellbore with a main wellbore, comprising: a lateral receiver coupling associated with the main wellbore; and a mechanical latching mechanism associated with the lateral wellbore. A feature of this aspect of the present invention is that the lateral receiver coupling may be adapted to receive a portion of the lateral wellbore therein. The lateral wellbore liner may also include the mechanical latching mechanism on its distal end proximate the main wellbore; and the lateral receiver coupling may also be an axial receiver coupling for joining two axially oriented wellbores.
Another feature of this aspect of the invention is that the lateral receiver coupling may include a receiving bore for receiving a lateral liner of the lateral wellbore. The receiving bore may extend from the main wellbore at an angle substantially 90 degrees from the long axis of the main wellbore, the receiving bore may extend from the main wellbore at an angle generally towards the wellhead, or the receiving bore may extend from the main wellbore at an angle generally away from the wellhead.
In yet another aspect, the present invention is directed to a method of forming a plurality of interconnected wellbores for producing hydrocarbons from or injecting fluids into earth formations comprising the steps of: forming a parent wellbore with a parent wellbore casing with one or more lateral wellbore receiver couplings placed in its casing; forming a lateral wellbore with a lateral wellbore liner to intersect the parent wellbore casing proximate the lateral wellbore receiver coupling; and mechanically connecting the lateral wellbore liner to the parent wellbore casing.
A feature of this aspect of the invention is that the step of forming the lateral wellbore to intersect the parent wellbore casing proximate the lateral wellbore receiver coupling may further compirse the steps of: providing a beacon within proximate the receiver coupling to emit signals adapted to be received by a sensor in a lateral wellbore drilling assembly; and steering the drilling assembly towards the lateral wellbore receiver coupling in response to the signals emitted by the beacon and received by the sensor in the drilling assembly.
Another feature of this aspect of the invention is that the signal emitted by the beacon may be of a type selected from the group consisting of acoustic, electromagnetic, or thermographic signals. The main wellbore may be formed in an oilfield having at least one existing wellbore and the method may further comprise the steps of establishing fluid communication between one or more of the existing wellbores and the main wellbore.
Yet another feature of this aspect of the invention is that the method may further comprise a step of underreaming the end of the lateral wellbore adjacent the receiver coupling to allow lateral movement and flexibility of the lateral liner for minor alignment adjustments in the mating of the lateral liner to the receiver coupling.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIGS. 1 a - 1 f illustrate conventional methods of constructing multilateral wellbore junctions.
FIG. 2 is a perspective view of a main wellbore according to a first embodiment of the present invention wherein the intersection to be formed is perpendiculars
FIG. 3 a is a cross-sectional view of the main wellbore of FIG. 2 showing a drilling assembly being guided by guidance beacons to intersect with a lateral receiver coupling according to an embodiment of the present invention.
FIG. 3 b is a cross-sectional view of the main wellbore of FIG. 2 showing the lateral wellbore drilled according to the embodiment of FIG. 3 a , and also showing an under-reamed portion of the wellbore proximate the lateral receiver coupling according to an embodiment of the present invention.
FIG. 3 c is a cross-sectional view of the main wellbore of FIG. 2 showing a lateral liner run into the lateral borehole of FIG. 3 b and coupled to the lateral receiver coupling of the main wellbore of FIG. 2 .
FIG. 4 is a cross-sectional view of an embodiment of a wellbore intersection according to the present invention wherein the intersection of the two wellbores is axial.
FIG. 5 is a cross-sectional view of the intersected and connected liners of the main wellbore and lateral wellbore according to the embodiment shown in FIG. 2 .
FIG. 6 is a cross-sectional view of a portion of the lateral liner of FIG. 5, taken along section 6 — 6 .
FIG. 7 is a cross-sectional view of a portion of the lateral liner of FIG. 5, taken along section 7 — 7 .
FIG. 8 is a cross-sectional view of the intersected and connected liners of a main wellbore and a lateral wellbore according to the embodiment of FIG. 2 with flow controls and other equipment installed.
FIG. 9 a is a cross-sectional view of a latching mechanism according to a first embodiment of the present invention.
FIG. 9 b is a perspective view of a locking dog of the latching mechanism of FIG. 9 a according to an embodiment of the present invention.
FIG. 9 c is a side view of the locking dog within the sleeve of the latching mechanism of FIG. 9 a and also showing the spring and push ring thereof.
FIG. 10 is a cross-sectional view of a latching mechanism according to a second embodiment of the present invention.
FIG. 11 is a projected plan view of the keys and keyways of the latching mechanism of FIG. 10 .
FIG. 12 is a cross-sectional view of the intersected and connected liners of a main wellbore and a lateral wellbore according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention generally provides a method and apparatus for interconnecting multilateral wellbores with a main, or parent, wellbore whereby the lateral wellbores are drilled from outside the main wellbore in a direction generally towards the main wellbore. A wellbore junction according to the present invention is generally provided by a lateral receiver coupling 22 engaged by mechanical connection with a lateral liner 50 , as described further hereinbelow.
Referring to FIG. 2, a perspective view of a main wellbore casing 32 is shown having lateral receiver coupling 22 connected to or otherwise disposed in connection with the outer surface thereof. The main wellbore casing 32 is adapted to be lowered or otherwise provided in a main, or parent wellbore using conventional casing methods known in the art. A plurality of guidance beacons 34 are placed at multiple positions along the lateral receiver coupling 22 or on the adjoining main well casing 32 and are known distances from the centerline 37 of the connecting lateral bore opening 36 formed by the walls of lateral receiver coupling 22 .
Referring now to FIG. 3 a , main wellbore casing 32 is shown in partial cross-section lowered in place within a main, or parent, wellbore 18 . It should be noted that the main wellbore may be vertical, horizontal, or have any other orientation in a particular application. In addition, the main wellbore may have separate sections which may be independently vertical, horizontal, or some other orientation relative to the surface. The main, or parent, wellbore may typically be a primary production wellbore; however, to the extent consistent herewith, the terms “main wellbore” or “parent wellbore” herein refer to any wellbore to which it may be desired to remotely couple a separate wellbore drilled from a location outside the main wellbore towards the main wellbore after the main wellbore is already in place. To the extent the context herein does not indicate anything to the contrary, the term “wellbore” herein refers to a conduit drilled through a particular geological formation and may also refer to the drilled conduit including well casing, tubing, or other members therein. The term “lateral wellbore” refers generally to the separate wellbore being drilled towards and intended to connect with the main wellbore.
Still with reference to FIG. 3 a , wellbore casing 32 includes lateral receiver coupling 22 disposed in connection therewith. A conventional guidance system known in the art such as guidance beacons 34 are shown in connection with the casing 32 and preferably send signals into the surrounding strata. Preferably, a plurality of guidance beacons 34 are provided on the well casing 32 and are spaced-apart from centerline 37 , which passes through the center of receiving bore 36 . A separate guidance beacon 34 may also be preferably provided on a receiving bore cap 35 initially connected to the lateral receiving coupling 22 . It should be noted that the guidance system described herein is illustrative only and that other guidance systems as may be known in the art may also be employed.
Still with reference to FIG. 3 a , lateral borehole 44 is shown being drilled by bit 38 provided at the end of a drilling string. Bit 38 is steered by conventional directional steering tools known in the art such as directional steering tool 41 . In the directional steering tool 41 shown, the path of the drilling bit 38 is adjusted as conventional guidance sensors 40 detect and interpret the current borehole location relative to the centerline 37 of receiving bore 36 . Receiving bore 36 is in a known spatial relationship relative to the guidance beacons 34 . Preferably, a rotary steerable drilling assembly such as the “Autotrak” drilling assembly available from Baker Oil Tools or other suitable steering drill assembly may be modified to have an added guidance sensor 40 to detect the source location of guidance beacons 34 .
Referring now to FIG. 3 b , the lateral borehole 44 has preferably been drilled so that the centerline of the lateral receiver coupling 22 and the centerline of the lateral borehole 44 are generally co-extensive. An under-reamed section 46 of borehole 44 is created as shown proximate lateral receiver coupling 22 using conventional drilling techniques. Although not shown, a conventional running tool may be run through the lateral borehole 44 and used to remove the cover 35 from the lateral receiver coupling 22 so that a lateral liner may be inserted within the receiving bore 36 of the lateral receiver coupling 22 as described further below.
Hardenable Fluid Sealant Embodiment
Referring now to FIG. 3 c , lateral liner 50 , which may be wellbore casing or some other suitable tubular assembly, has been run into the lateral borehole 44 using conventional techniques and is inserted into the receiving bore 36 of lateral receiver coupling 22 . A stage tool or cementing port collar 52 may be provided within lateral liner 50 proximate the end of the lateral liner 50 inserted into the receiving bore 36 of lateral receiver coupling 22 . A hardenable liquid sealant or cement 48 may then be pumped through the lateral liner 50 , through cementing port collar or stage tool 52 , and into annulus 49 formed defined by the under-reamed section 46 . The stage tool or port collar 52 may then be closed, thus creating in one embodiment a mechanical seal between the lateral liner 50 and the lateral receiver coupling 22 and, accordingly, the main wellbore casing 32 to which the lateral receiver coupling 22 is connected. It should be noted that, in this embodiment, essentially no sealing mechanism or sealing substance is provided within the production bore of either the lateral liner 50 or the main wellbore casing 32 so that flow therethrough is not significantly impeded. It should further be noted that this embodiment may be used as a primary mechanical seal or it may be used in connection with the latching mechanism embodiments described below.
Referring to FIGS. 2-3, 5 , and 12 , the lateral receiver coupling 22 is shown having a receiving bore 36 extending generally 90 degrees to direction of the main wellbore casing 32 to form a “T” intersection. However, the receiving bore 36 of lateral receiver coupling 22 may also extend at any desired angle relative to the main wellbore casing 32 . Referring to FIG. 4, it will be readily apparent that receiver coupling 24 may also be an axial receiver coupling 24 provided axially at a distal end of the main wellbore casing 32 to form an “end-to-end” intersection. In this embodiment, guidance beacons 34 may preferably be spaced apart and on opposing sidewalls of axial lateral receiver coupling 24 .
Lateral Connector
Referring now to FIG. 5, lateral liner 50 is shown intersecting with and connected to lateral receiving coupling 22 . Lateral liner 50 may include lateral connector 62 , which may be attached to the distal end 66 of the lateral liner 50 to be connected to the lateral receiver coupling 22 of the main wellbore casing 32 . The lateral connector 62 generally comprises: seal bore receptacle 76 , equipment receptacle 74 , and latch mechanism 56 . Seal bore receptacle 76 is preferably threadedly attached to the distal end 66 of the lateral liner 50 and receptacle 76 preferably has a polished seal bore surface 80 suitable for mating with a sealing member (not shown). Equipment receptacle 74 is preferably threadedly attached to the opposite end of the seal bore receptacle 76 .
A cylindrical wall of equipment receptacle 74 preferably defines bore 78 therewithin. Referring now to FIG. 6, equipment receptacle 74 is shown in a cross-section taken along section 6 — 6 of FIG. 5 . As shown in FIG. 6, the cross-section of bore 78 of equipment receptacle 74 may preferably be square (shown in FIG. 6 ). It should be noted, however, that the cross-section of bore 78 of equipment receptacle 74 may also be cylindrical (not shown) or have some other suitable cross-section. In the preferred embodiment, the cross-section of bore 78 is rectangular.
In the event that the cross-section of bore 78 is rectangular, transitional cross-sectional areas may be required to suitably mate with the preferably cylindrical cross-sectional area of seal bore 80 of seal bore receptacle 76 . Accordingly, surface 82 may preferably be spherical or conical to provide the transition from the preferably square equipment receptacle bore 78 to the preferably cylindrical seal bore 80 .
Referring now to FIG. 7, seal bore receptacle 76 is shown in a cross-sectional view taken along section 7 — 7 of FIG. 5 . The preferred diameter of seal bore receptacle 76 defining seal bore surface 80 is shown relative to the internal diameter of the bore 88 of the lateral liner 50 and also relative to the outer diameter of the outside surface 86 of lateral liner 50 . Referring again to FIG. 5, latch mechanism 56 is shown threadedly attached to the end of the equipment receptacle 74 .
Latch mechanism 56 will be described in more detail below with reference to FIGS. 9, 10 and 11 .
Equipment Assembly
Referring now to FIG. 8, lateral connector 62 is shown having equipment assembly 89 disposed within equipment receptacle 74 . Equipment assembly 89 comprises seal assembly 92 , which has a proximal end adapted to sealingly engage seal bore surface 80 to create a hydraulic pressure retaining seal between the outside diameter of the seal assembly 92 and the inside diameter of the seal bore receptacle 76 . A portion of seal assembly 92 preferably has an enlarged outside diameter 93 defining shoulder 95 . Shoulder 95 is adapted to bear on landing 97 associated with equipment receptacle 74 to limit the movement of the seal assembly 92 beyond a given point in the seal bore 76 .
A face seal 94 is preferably located on the distal end of the seal assembly 92 . A sealing force may be applied to an adjoining equipment module 90 against seal assembly 92 , whereby the face seal 94 will create a pressure seal between the equipment module 90 and the seal assembly 92 . A plurality of equipment modules 90 may be similarly joined with face seals 94 provided between each set of adjoining module 90 . Each of the equipment modules 90 , the seal assembly 92 , and the latch module 99 include a flow through bore 100 . Equipment modules 90 may preferably include conventional monitoring or control modules, providing, for example: a) well flow control devices (having choked positions or full open or full closed positions); b) monitoring devices for sensing wellbore parameters such as water cut, gas/oil ratios, fluid composition, temperature, pressure, solids content, clay content, or tracer/marker identification; c) a fuel cell, battery, or power generation device; or d) a pumping device.
The last module 90 to be inserted into the equipment receptacle 74 proximate the distal end of the lateral liner 50 is preferably latch module 99 . Latch module 99 preferably includes a face seal 94 to seal it to the adjoining equipment module 90 , and also preferably includes a conventional latch mechanism 98 adapted to retain the latch module 99 within the equipment receptacle 74 by engaging a recessed profile 101 within the lateral liner 50 .
First Latching Mechanism Embodiment
Referring now to FIG. 9 a , a first embodiment of latching mechanism 56 is shown in detail. Main mandrel 241 of latch mechanism 56 is preferably threadedly attached to the equipment receptacle 76 (shown in FIG. 5) as previously described. A plurality of seals 244 may be mounted on an outer seal surface 247 of main mandrel 241 . A snap ring 249 is preferably installed in groove 251 to hold the seals in place about the main mandrel 241 . Stop nut 242 preferably has a threaded inner surface and is preferably screwed onto a threaded portion of mandrel 241 until it reaches stop shoulder 237 . Sleeve 252 is preferably provided about the main mandrel 241 proximate the distal end of main mandrel 241 . End cap 240 , is threadedly attached to the main mandrel to provide a tapered, conical, surface 255 between the main mandrel 241 and the sleeve 252 .
A plurality of locking dogs 248 , preferably having wings 235 extending therefrom (as shown in FIG. 9 b ), are provided within sleeve 252 and have a portion thereof which are adapted to selectively extend through slots 253 provided in sleeve 252 (as shown in FIG. 9 c ). Locking dogs 248 are adapted and positioned to partially extend through slots 253 as they slide along tapered surface 255 of end cap 240 . Locking dogs 248 are further adapted to include a latching portion adapted to protrude past the outside diameter of a sleeve 252 . Locking dogs 248 are retained within sleeve 252 by wings 235 (shown in FIG. 9 b and 9 c ) which engage the inner surface of sleeve 252 .
Push ring 254 is provided between the end cap 240 and sleeve 252 to press uniformly on the ends of the locking dogs 248 as spring 246 inserted behind the push ring 254 biases push ring 254 away from stop nut 242 . The slots 253 allow the locking dogs 248 to slide axially along the tapered surface 255 of end cap 240 . As the latching mechanism 56 is inserted into the lateral receiver coupling 22 , the latching dogs slide backward against spring 246 or other biasing member and inward toward the smaller diameter of conical surface 255 . When the latching mechanism 56 reaches the full insertion depth into the lateral receiver coupling 22 , the latch dogs 248 mate with a latch profile within the lateral receiver coupling 22 and are pushed up the conical surface 255 by spring 246 such that they protrude into the latch profile and engage bearing shoulder 257 .
Accordingly, a spring-actuated latching mechanism 56 is provided to automatically engage the lateral liner 50 within the lateral receiver coupling as the lateral liner 50 is inserted into the lateral receiver coupling 22 .
To ensure alignment of the locking dogs 248 and the mating latch profile as the latching mechanism 56 is inserted into the lateral receiver coupling 22 , key 245 may be machined into the outer surface of the main mandrel 241 and adapted to engage a matching keyway 250 provided in the lateral receiver coupling 22 to index the rotational position of the lateral connector 62 relative to the receiver coupling 22 . Seals 244 may be elastomeric interference fit, or chevron shaped non-elastomeric interference fit, or non-elastomeric spring metal energized or expandable metal or shape memory alloy or lens ring crush seals or other suitable seal design and material.
Second Latching Mechanism Embodiment
With reference now to FIGS. 10 and 11, a second embodiment of latching mechanism 56 is shown intersecting lateral receiver coupling 22 . In this embodiment, at least one seal 244 is mounted onto the main mandrel 24 Ion a surface 263 . A plurality of seals 244 may be separated and held in position by a snap ring 249 positioned in a groove 267 . A stop shoulder 268 retains seals 244 on main mandrel 241 . In this embodiment, a plurality of keys 260 are preferably machined onto the outer surface of main mandrel 241 . Keys 260 preferably have a flat lower face 261 facing the distal end of the main mandrel 241 and also facing lateral receiver coupling 22 . Keys 260 preferably further include an angled upper face 259 facing the running length of the lateral liner 50 . A plurality of opposing keys 273 are preferably machined onto the inner surface of lateral receiver coupling 22 .
Referring now to FIG. 11, a set of keys 273 of lateral receiver coupling 22 and the keys 260 of main mandrel 241 are shown in a flat projection to illustrates the relationship of the various keys and keyways. The keys 273 are machined into the lateral receiver coupling 22 to create a set of keyways 269 therebetween. The keys 260 of main mandrel 241 are adapted to fit through the keyways 269 of the lateral receiver coupling 22 as main mandrel 241 is inserted within the lateral receiver coupling 22 . In particular, a set of latch keys 271 includes a plurality of narrow keys 260 a and a wide key 260 b . The narrow keys 260 a fit through a mating plurality of narrow keyways 269 a and the wide key 260 b must pass through a wide keyway 269 b . When the latch mandrel 241 is inserted into the coupling 22 , the set of latch keys 271 follows the path of arrow y and pass beyond the plurality of latch keys 273 . Thereafter, main mandrel 241 is rotated clockwise in the direction of arrow x so that angled faces 259 engage angled faces 275 interlocking the lateral connector 62 with the lateral receiver coupling 22 . Due to the singular wide key 260 b there is only one orientation in which the two parts will engage. As the lateral connector is rotated clockwise the angled faces 259 and 275 bear against one another creating an axial movement of the connector 62 into the coupling 22 . Referring again to FIG. 10, a nose seal 258 is preferably machined into the end of the mandrel 266 with a gap 256 ensuring that the nose seal 258 has suitable flexibility to sealingly engage a seal face 270 as the angled faces 259 and 275 move the seal mandrel 266 into the coupling 22 . Stop shoulder 272 prevents the rotational over travel of the keys to rotationally index the connector 62 and coupling 22 and to prevent improper deformation of the nose seal 258 .
FIG. 12 shows a cross section of an alternative embodiment of the receiver coupling 22 and a lateral connector 362 . In this embodiment the lateral connector 362 need not be rotationally indexed with the coupling 22 since the connector 362 in this case only consists of a latch mechanism 56 connected directly to the lateral liner 277 . A seal bore 276 and an equipment receptacle 278 are in this case suspended below a packer 274 which is set in lateral liner 277 to anchor these devices in the lateral liner. An indexing member 280 engages a mating profile in the coupling 22 before the packer 274 is set. The indexing member may be a clutch mechanism as described relative to FIG. 9 or it may be a spring loaded key which finds a mating recess in coupling 22 or other such devices known to those skilled in the art. The full bore of liner 277 is available for operations in the lateral liner in this embodiment until the assembly comprising items 278 , 280 , 274 , and 276 is inserted. This inserted assembly may also be retrievable through lateral liner 277 or permanently installed.
In operation, a main vertical wellbore 18 may be drilled through which production fluids are desired to be pumped or otherwise recovered to the surface. Thereafter, a production string of main wellbore casing, including lateral receiver coupling is inserted within the main vertical wellbore. A lateral wellbore, which may be horizontal or have some other orientation, is drilled from a location outside of the main wellbore casing in a direction generally towards the lateral receiver coupling until the lateral wellbore interconnects with the main wellbore. Thereafter, lateral liner having a latching mechanism according to the present invention connected to the distal end thereof is inserted within the lateral wellbore until it reaches the lateral receiver coupling. The lateral liner is then inserted further within the lateral receiver coupling until the latching mechanism engages within the lateral receiver coupling. In a first embodiment, the latching mechanism is automatically engaged with the lateral receiver coupling as the locking dogs reach the matching profile within the lateral receiver coupling. In the second embodiment, the latching mechanism is engaged with the lateral receiver coupling by rotating the lateral liner and thereby rotating the locking mechanism until the tapered keys associated with the lateral liner engage with the matched tapered keys associated with the lateral receiver coupling.
After the lateral wellbore has been connected to the main, substantially vertical wellbore, the lateral wellbore may be referred to as the main wellbore. Consequently, this new main wellbore may include axial receiver couplings to interconnect successive lengths of lateral liners 50 and/or include lateral receiver couplings to receive locking mechanisms of other lateral wellbores. Accordingly, a wide variety of downbole manifold systems may be contemplated using the method and apparatus of the present invention. By incorporating measurement and flow control devices within the lateral wellbores, each of the lateral wellbores can be independently monitored and/or controlled to have complete control of the downhole manifold system. Accordingly, since there may be redundant pathways to the surface through multiple lateral wellbores, the production of all feeder laterals need not be halted to service the main wellbore. Only the wellbores between the bore to be used for servicing and the target wellbore to be serviced need be remotely closed. Flow of other wellbores may be diverted to the alternate main wellbore until servicing operations are complete. Servicing robots may contain “equipment cars” alternated with “push/pull cars”. The equipment cars carry items such as the seal assembly 92 , the modules 90 , or the latch modules 98 and the pushlpull devices may move the equipment between the cars and the lateral connector equipment receptacles 74 . The robot “train” may also include “cars” containing repair modules, inspection modules, testing modules, data downloading modules, or device activation modules.
Service work on the feeder wellbores can also be performed through the wellbore from which the feeder wellbores were drilled to allow more extended access or more complete workover/treatment capability without risking operations in the main wellbore.
While the foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basis scope thereof. For example, the mechanical connection between the lateral receiver coupling and the lateral connector may be achieved by threading the two mating parts and screwing them together downhole, or they may be joined by expanding or swaging the end of the lateral connector inside the receiver coupling, or by a collet on the connector snapped into a groove in the coupling with a sleeve shifted behind the collet to lock it in place, or other such connection methods as are known in the art. Further, the guidance beacons 34 on the lateral receiver coupling 22 may also be sensors receiving signals generated by a drilling tool. The location data collected by these sensors may then be used to guide the corresponding drilling assembly to the desired intersection point. The beacons or sensors may be permanently mounted on the main casing or they may be retrievably located in the main casing in known spatial relationship to the receiver coupling. Accordingly, the scope of the present invention is determined only by the claims that follow.
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The present invention provides a method and apparatus for mechanically interconnecting a lateral wellbore liner to a main, or parent, wellbore casing. The present invention further provides a method of wellbore construction for the construction of multiple wellbores which are interconnected downhole to form a manifold of pipelines in a reservoirs of interest. Provision is made for flow controls, sensors, data transmission, power generation, and other operations positioned in the lateral wellbores during the drilling, completion and production phases of such wellbores.
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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 systems utilizing an air pump to evacuate odors from a toilet.
2. Description of the Related Art
Most contemporary toilets share common features. A commode is an integrated body (i.e., a cast single piece) with a bowl and a rim. Water, either from a reservoir or a pipe, is piped through the integrated body to outlets beneath the rim when the toilet is flushed. A drain pipe is formed in the integrated body and leads from the bowl to a sewer line. To prevent sewer gases from escaping the sewer line through the drain of the toilet, the drain includes a trap. The trap is formed by a U-shaped section of piping followed by an inverted-U-shaped section of piping. The U-shaped section of pipe remains filled with water, even between flushes. The water in the U-shaped section of pipe blocks the passage of sewer gas.
A problem with the common toilet is that odors accumulate before the toilet can be flushed. Many attempts have been made to provide means for removing these odors.
One set of proposed solutions involves using filter systems to remove odors from the bowl of the toilet and scrub them with a filter before releasing the air back into the room. Any use of filters involves the costs of buying and replacing or regenerating filters. Furthermore, if the filter is spent, the system will pump unfiltered odor-filled air into the room.
Another set of proposed solutions involve using a pump system for removing odors from a toilet bowl to outside of the lavatory. Typically, the odors are pumped to the exterior of the building. This solution requires architectural improvements to be made to the building to allow for passages through which to pump the odor-filled gas. Another shortcoming is that the odors are merely being displaced, not treated or completely removed.
Another set of proposed solutions teach customized toilets that have integrated odor removing systems. The cost of such systems is significantly higher than a system that can be retrofitted to an existing toilet. Furthermore, homeowners will be limited as to the selection of styles and brand of toilets if an integrated system is used.
SUMMARY OF INVENTION
It is accordingly an object of the invention to provide a device for removing odors from a toilet bowl by pumping them to the drain of the toilet downstream of the trap, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type
With the foregoing and other objects in view there is provided, in accordance with the invention, an odor elimination system for a toilet can be added to a toilet. The system includes an air pump or other similar device for moving air having a pump inlet and a pump outlet. The inlet hose connects to the pump inlet and has an opening. The opening of the inlet hose communicates with the bottom of the seat assembly. The outlet hose is air-tightedly connectable to a channel leading to the trap of an exit pipe formed in the commode.
To retrofit an existing toilet, a channel is drilled in the porcelain unified body of the toilet to a spot above the water level in the inverted-U-section of the trap. To prevent water that is flushed from the toilet from escaping through the channel, the channel should be sloped downward (preferably vertically) into the trap. For example, the channel can be formed by drilling a channel from the top of the toilet, near the seat into the trap. The outlet tube is then connected to the channel. To prevent the odors from escaping and to prevent sewer gases from escaping the trap, the outlet tube must fit in an airtight manner.
In accordance with another feature of the invention, a switch is included for actuating the pump. In the preferred embodiment, the switch is a pressure activated switch that turns on the pump motor when a person sits on the toilet. It is also possible for the switch to be manually actuated on and off by the user. The preferred embodiment, i.e., the pressure-activated switch requires no intervention by the user and it ensures and guarantees the removal of odors at a time when the generation of odors is typically at its peak.
In accordance with another feature of the invention, the inlet house may be connected to a plurality of openings that encircle the seat. That is, the seat has a plurality of holes that are strategically distributed about the opening of the bowl. By having a plurality of inlets holes, odors can be more efficiently and effectively removed from the toilet bowl.
In accordance with another feature of the invention, a simple type of air pump that might be used is a fan. The fan would blow air from the inlet or inlets to the outlet.
In accordance with another feature of the invention, the air pump can be connected to an exterior of the integrated body. In the case of a retrofitted system, the air pump can be bolted or cemented to the integrated body of the toilet.
In accordance with another feature of the invention, the odor removing system is completely integrated into a toilet seat/cover assembly to form a unit. In such a case, the air pump is concealed within the toilet seat cover, the switch is activated by pressure from a person sitting on the commode, the air inlet opening(s) is/are formed in the toilet seat, and the exhausted, odorous air is exhausted into the toilet trap through a hole leading from the seat and cover assembly downward into the trap.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an odor eliminating system for retrofitting a toilet and a toilet including the odor eliminating system, it is nevertheless not intended to be limited to the details shown, because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic front perspective view of a commode for a toilet prepared for assembly of a system for removing odors according to the invention;
FIG. 2 is a sectional view through a toilet commode;
FIG. 3 is a bottom perspective view of a toilet seat according to the invention;
FIG. 4 is a partial front perspective view of a toilet with a system for removing odors according to the invention;
FIG. 5 is a section taken through a toilet seat cover according to the invention; and
FIG. 6 front top perspective view of a toilet seat assembly according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIGS. 1 and 2 thereof, there is seen a commode 2 that has been readied for installing a system for removing odors from a toilet. The toilet 1 is a conventional toilet 1 with an integrated body having the bowl or commode 2 with a rim 3 . When the toilet 1 is flushed, water is released from a tank 7 and enters the bowl 2 from flush outlets, which are not shown, beneath the rim 3 . An exit pipe 4 is connected to the bottom of the bowl 2 and leads to a sewer pipe 20 . A trap 5 , which includes a U-shaped section 21 followed by an inverted U-shaped section 22 in the exit pipe 4 , prevents gases from escaping the sewer pipe 20 . As the bowl 2 fills, the water level will eventually fill to a level in the inverted U-shaped section 22 that causes the toilet to flush. Even when flushing, water remains in the U-shaped section 21 to prevent gases from escaping the trap 5 .
In the commode according to the invention, a bore has been drilled from a top surface between the bowl opening and the flush tank support and down into the trap. A pipe section 8 is then inserted into the bore, forming a channel to the trap. In order to avoid odors from entering through the trap and up through the pipe section 8 , the latter may be provided with a membrane. As will be seen in the following, the pipe section may also be dispensed with.
A seat/cover assembly for the commode includes a rim seat 24 , as illustrated in bottom perspective view in FIG. 3 . The seat 24 is formed with openings 15 that are distributed about the rim seat 24 . When the seat 24 is in its horizontal position, the openings circumscribe the bowl opening peripherally. As vacuum is applied to the openings 15 , the seat 24 becomes a vacuum device and, accordingly, the bowl is evacuated and the odorous air is drawn off. While the seat 24 in FIG. 3 is shown with a hose assembly, it will be understood that the openings may be completely integrated in the seat.
FIG. 4 illustrates the seat/cover assembly placed on the commode 3 . An air pump 10 is integrated in an opening in the seat cover 23 . The air pump 10 has an inlet communicating with the openings 15 along the seat 24 and an outlet communicating with the trap. The pump 10 moves air from the bowl of the toilet to the inverted U-section 22 of the trap 5 . The air taken by the pump 10 from the bowl 2 includes odors in the bowl 2 and prevents their escape.
An inlet hose 13 leads from the openings 15 in the rim seat 24 to a pump housing inlet and an exhaust pipe in the form of a hose 14 leads from the pump to the opening 8 and down into the trap.
The seat cover 23 in FIG. 6 has been pivoted upward about a hinge 25 interconnecting the cover 23 and the seat 24 .
An alternative embodiment of the seat cover 23 is illustrated in FIG. 5 . There the seat cover 23 has an opening housing the pump, i.e., it forms the pump housing with an intake 13 and an outlet 14 . A pump motor 11 drives a fan blade 12 to form the necessary vacuum on the intake 13 chamber side and the necessary overpressure at the outlet 14 chamber side.
The motor 11 of either embodiment may be driven with any type of source of electrical energy, such as battery power (with the necessary user-accessible battery compartment suitable placed), mains power (in light of the fact that the toilet bowl is a water appliance, the supply power is provided through an adapter at 6 or 12 V), or even photovoltaic cell-generated power.
The air pump 10 is preferably dimensioned in accordance with the air volume of the bowl 2 . For example, it is advisable to evacuate one third of the gas volume of the bowl 2 per second. Other pumping capacities may, of course, be adjusted as well.
The motor 11 may be activated by a switch 16 . In the preferred embodiment, the switch 16 is integrated in the bottom of the rim seat 24 and it closes (or opens, depending on the electrical diagram) when a person sits on the seat 24 . That is, when a certain amount of pressure (e.g., weight of approx. 25 kg) causes the seat to be downwardly biased onto the rim 3 , the switch 16 turns on the motor. Typically, the rim seat 24 is spaced from the rim 3 by resilient stubs. In this case, the switch 16 may be advantageously integrated in one of the stubs.
A standard toilet 1 can be retrofitted with the system for removing odors. In fact, the entire novel system may be distributed in kit form, including the seat 24 with the integrated intake openings 15 , the switch 16 , the pump inlet 13 , the seat cover 23 with the integrated pump 10 , and the pump outlet 14 . It is then only necessary to drill the hole down into the trap, to insert the downpipe 8 , and to connect the downpipe 8 to the pump outlet 14 in a fluid-tight manner.
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An odor eliminating system utilizes an air pump to remove odors from a bowl of a toilet to a trap of the toilet. By moving the odors to the trap, the odors cannot escape back to the bowl and can only proceed out of the toilet to the sewer. The system can be adapted to existing toilets by drilling a channel to the trap or the system can be incorporated into new toilets.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention relates to a portable, temporary guard rail support and, more particularly, to a novel guard rail support for use in the erection of a safety barrier or fence at sites under construction such as office buildings, high rise apartments or the like.
BACKGROUND TO THE INVENTION
[0002] Modern construction techniques, particularly those commonly employed in high rise apartment and office building construction, require that safety barriers or guard rails be erected around the perimeter of all uncompleted floors (i.e. along the drop-off edges of concrete floor slabs) for two reasons: Firstly, personal safety requires the erection of at least a single rail at about waist height around the exterior of such uncompleted floors. Secondly, it is also necessary that a retaining kick board be erected at floor level so as to prevent the accidental dislodgement of articles which would otherwise cause a substantial safety hazard to workmen on the floors below and around the construction site. In certain cases, the provision of a weather barrier, such as a plastic tarpaulin or the like, may be necessary so as to protect the site under construction as well as workmen from inclement weather conditions.
[0003] The general practice in the erection of such safety barriers involves the use of lengths of lumber stock such as long boards of the 2″×4″ variety (commonly referred to as “two-by-fours”). Such boards are cut to length and then nailed together in varying patterns in order to provide the desired guard railings. After such railings have served their purpose they are knocked down, the longer boards typically reserved for future use in the piecing together of future guard railings. The shorter boards are not always reusable. Furthermore, the longer lengths of lumber frequently become damaged by splitting or otherwise due to the application thereto of repeated impact blows and different nail placements. While such makeshift such guard railings meet safety requirements, they require more than one person and a fair amount of time to construct and often result in the destruction of the materials used when they are disassembled after completion of work at a construction site. Obviously, the additional labour and cost of materials used will add to the expense of the job. Many such railings also fail to pass the rigidity requirements of safety inspectors.
[0004] As a result, various structures have been proposed to aid in the construction of temporary safety barriers which prevent workmen from accidental falls and which meet strict safety guidelines. To a large extent, however, most of the proposed structures are impractical, expensive and too complicated to use. Furthermore, structures that are too complicated to use will not be used efficiently and/or properly by workmen at a construction site, thereby posing a safety risk.
[0005] Consequently, a need exists for a portable and simple guard rail system which is effective in preventing accidental falls, meets safety guidelines and which can be assembled and disassembled in an efficient manner.
SUMMARY OF THE INVENTION
[0006] A portable guard rail support and assembly for use in erecting a safety barrier to provide a safe work area for workmen working at dangerous heights, particularly in the construction industry, is provided.
[0007] In accordance with a first aspect of the present invention, a guard rail support for use in erecting a temporary safety barrier is provided wherein the guard rail support comprises a substantially flat bottomed base plate, an upright column affixed to the flat bottomed base plate, at least one guard rail support bracket affixed to the upright column, a kick board retaining flange affixed to the flat bottomed base plate in spaced proximal relationship to the upright column, an angular brace affixed to the upright column and the flat bottomed base plate and a safety tie-off ring affixed to the upright column and the flat bottomed base plate.
[0008] In accordance with a further aspect of the present invention, a concrete-filled steel base is also provided that is adapted to receive the portable guard rail support in circumstances where anchoring of the portable guard rail support to a floor or ground surface is not possible. The concrete-filled steel base has a retaining groove formed in a bottom surface thereof for slidably receiving the substantially flat bottomed base plate of the portable guard rail support. The steel base further comprises a channel integrally formed therein extending from a top surface of the steel base to the retaining groove and wherein the channel is in perpendicular relation to the retaining groove and dimensioned so as to be able to receive at least one kick-board.
[0009] In accordance with another aspect of the present invention, a portable safety barrier for use about a drop-off edge of a floor surface is provided comprising at least first and second portable guard rail supports located in spaced relation to one another along the drop-off edge and wherein each of the at least first and second portable guard rail supports comprises a substantially flat bottomed base plate, an upright column affixed to the substantially flat bottomed base plate, at least one guard rail support bracket affixed to the upright column, a kick board retaining flange affixed to the substantially flat base plate in spaced proximal relationship with the upright column, an angular brace affixed to the upright column and the substantially flat bottomed base plate, a safety tie-off ring affixed to the upright column and the substantially flat bottomed base plate, and wherein the at least one guard rail support bracket and the retaining flange of the at least first and second portable guard rail supports fixedly retain guard rails and kick boards.
[0010] 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 drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A better understanding of the invention will be obtained by considering the detailed description below, with reference to the following drawings in which:
[0012] FIG. 1 is a front perspective view of a portable guard rail support in accordance with the present invention.
[0013] FIG. 2 illustrates a rear perspective view of the portable guard rail support according to FIG. 1 .
[0014] FIG. 3 is a side view of the portable guard rail support according to FIG. 1 .
[0015] FIG. 4 depicts a portion of a safety barrier constructed with overlapping wooden guard rails in accordance with a preferred embodiment of the present invention.
[0016] FIG. 5 depicts a portion of a safety barrier constructed with wooden guard rails in accordance with another embodiment of the present invention.
[0017] FIG. 6 is a perspective view of a portable guard rail support having a concrete-filled steel base in accordance with an alternate embodiment of the present invention.
[0018] FIG. 7 depicts a portion of a safety barrier constructed with a safety mesh in accordance with a further aspect of the present invention.
DETAILED DESCRIPTION
[0019] Throughout the following detailed description, the same reference numerals are used to denote the same features in all of the drawings.
[0020] FIGS. 1 and 2 depict front and rear isometric views, respectively, of a guard rail support 10 according to a preferred aspect of the present invention. The guard rail support 10 consists of a rectangular upright column 12 , the lower end of which is affixed to a substantially flat rectangular metallic base plate 14 in a central symmetric axis thereof. The flat base plate 14 is provided with at least two bores or holes 24 a and 24 b for receiving suitable fastening means (not shown) in order to anchor or secure the guard rail support 10 to a floor or ground surface (not shown). In a preferred embodiment, the fastening means comprises expansion anchors well known to those skilled in the art. However, any suitable fastening means (e.g. screws) may be used. First and second L-shaped rail supporting brackets 16 are affixed one above the other to the upright column 12 as shown to provide supporting means for wooden guard rails (not shown). A retaining flange 17 , spaced apart from the upright column 12 , is affixed to the baseplate 14 of the guard rail support 10 in order to receive and secure a kick board (not shown) in position. The rail supporting brackets 16 and the retaining flange 17 have bores 19 formed therein for receiving fasteners to secure wooden guard rails within the rail supporting brackets 16 and the retaining flange 17 . An angle brace 20 is affixed between the upright column 12 and the base plate 14 in the manner shown to provide for structural stability of the guard rail support 10 . Finally, a fall protection (or safety) tie-off ring 22 is affixed to the lower end of the upright column 12 and to the base plate 14 .
[0021] Preferably, the L-shaped rail supporting brackets 16 and retaining flange member 17 are dimensioned to accommodate two adjacent, overlapping wooden rails which may be secured to each other and within the brackets 16 and retaining flange 17 by suitable fastening means such as nailing or the like. In a preferred embodiment, the wooden rails would be comprised of stock lumber such as lengths of two-by-four (2×4). In this case, the brackets would be dimensioned so as to accommodate two 2×4's i.e. a width, 2 w, of 4 inches and a height, h, of at least 4 inches. Thus, it may be seen that the rail supporting brackets 16 and retaining flange 17 may be dimensioned in any appropriate manner, 2 w×h, to accommodate any size, w×h, of stock lumber desired.
[0022] In order to implement a guard rail assembly (safety barrier) at a construction site according to a first aspect of the invention, a plurality of guard rail supports 10 are located at set distances apart (preferably slightly less than the length of stock lumber to be used for the guard rails) along the outer edge or perimeter of a floor undergoing construction. The guard rail supports 10 are secured to the floor via suitable fasteners driven through the bores 24 a , 24 b formed in the base plate 14 of each guard rail support 10 . Lengths of stock lumber (at least spanning the distance between the corresponding rail supporting brackets 16 and retaining flanges 17 of consecutively aligned guard rail supports 10 ) may then be positioned and secured within the corresponding rail supporting brackets 16 and retaining flanges 17 of adjacent guard rail supports 10 so as to form a guard rail assembly (safety barrier) consisting of upper and lower wooden guard rails and a kick board. The configuration of such a guard rail assembly is discussed further in relation to FIG. 4 .
[0023] As seen in FIGS. 1 and 2 , the fall protection tie-off (safety) ring 22 has the preferred shape of a sideways “U” with one end portion affixed to the lower end of the upright column 12 and the other end affixed to the base of the upright column 12 and the flat base plate 14 . The fall protection tie-off ring 22 provides for numerous advantages. Firstly, the fall protection tie-off ring 22 may serve as retaining and attachment means for a safety cable which is frequently used by workers at sites undergoing construction. In this respect, a continuous safety cable may be run through the fall protection tie-off rings 22 of consecutively aligned guard rails supports comprising a guard rail assembly (see FIG. 4 ) constructed in accordance with the present invention. A workman may then “tie off” to such a safety cable at any desired location thereby providing protection from accidental falls. Alternatively, a workman may tie off to the actual fall protection tie-off ring 22 of an individual guard rail support 10 , if desired. Secondly, the fall protection tie-off rings 22 of individual guard rail supports 10 comprising a guard rail assembly may be used to fasten weatherproof tarpaulins or the like (not shown) to protect workmen and the site under construction from inclement weather conditions.
[0024] FIG. 3 is a side view of the guard rail support 10 in FIGS. 1 and 2 wherein like features are denoted by like numerals.
[0025] FIG. 4 depicts a portion of a guard rail assembly or safety barrier 40 assembled along the perimeter of a floor 33 under construction in accordance with one aspect of the present invention. In FIG. 4 , first and second guard rail supports 10 a and 10 b are located at a set distance d apart and secured along an outer floor edge 34 via expansion anchors 31 driven through the corresponding bores 24 a , 24 b of each guard rail support 10 a , 10 b into the floor 33 . Upper and lower wooden rails 36 a and 37 a , (e.g. suitable lengths of 2×4) span at least the distance between corresponding rail supporting brackets 16 on the guard rail supports 10 a , 10 b . Similarly, kick board 39 a spans at least the distance between the retaining flanges 17 on the guard rail supports 10 a , 10 b . In a preferred embodiment, the distance d between guard rail supports 10 a and 10 b is slightly less than the lengths of 2×4 comprising the wooden rails such that the upper and lower wooden rails 36 a , 37 a and kick board 39 a will have some overshoot at each rail supporting bracket 16 or retaining flange 17 .
[0026] Considering guard rail support 10 a , upper and lower wooden rails 36 a , 37 a and kick board 39 a are secured with overlapping wooden rails 36 b , 37 b and 39 b within the corresponding rail supporting brackets 16 and retaining flange 17 via suitable fasteners 23 placed through bores 19 . Suitable fasteners 23 may include nails, screws, rivets or the like. Similarly, upper and lower wooden rails 36 a , 37 a and kick board 39 a are secured with overlapping wooden rails 36 c , 37 c and 39 c within the corresponding rail supporting brackets 16 and retaining flange 17 of guard rail support 10 b via suitable fasteners 23 placed through corresponding bores 19 . As shown, the left end of upper wooden rail 36 a overlaps with the right end of upper wooden rail 36 b at the uppermost rail supporting bracket 16 of the first guard rail support 10 a . Similarly, the right end of upper wooden rail 36 a overlaps with the left end of upper wooden rail 36 c at the uppermost rail supporting bracket 16 of the second guard rail support 10 b . It should be understood that the configuration described above for the upper wooden rails 36 holds for lower wooden rails 37 and kick boards 39 . It will further be appreciated that upper wooden rails 36 b and 36 c , lower wooden rails 37 b and 37 c and kick board 39 b and 39 c span the distance to other respective guard rail supports 10 (not shown) and may be secured within the corresponding rail supporting brackets and retaining flanges of the other guard rail supports 10 in the same manner as described above.
[0027] In cases where it is not desired or possible to use the overlapping wooden rail scheme depicted in FIG. 4 , for whatever reason, an alternative configuration may be used at each guard rail support 10 of the present invention to construct a safety barrier 50 as shown in FIG. 5 . In this case, a short stub 35 of the same stock lumber used for the wooden guard rails (e.g. 2×4) may be used at the rail supporting brackets 16 and retaining flange 17 of each guard rail support 10 in order to firmly secure the upper and lower wooden guard rails 36 , 37 and kickboard 39 in place. As before, at the rail supporting brackets 16 and retaining flange 17 of each guard rail support 10 , the upper and lower wooden rails 36 , 37 and kick board 39 may be secured to their corresponding short wooden stubs 35 and to the rail supporting brackets 16 and flanges 17 via suitable fasteners 23 such as nails or the like.
[0028] It will further be appreciated that the safety barrier configuration 50 depicted in FIG. 5 also represents the configuration present at the guard rail supports defining the ends of the safety barrier 40 constructed in accordance with the embodiment of FIG. 4 . As can be envisioned, at each guard rail support defining an end of the safety barrier 40 , there will be no overlapping wooden rail scheme at the rail supporting brackets 16 and retaining flange 17 . Thus, short stubs of stock lumber (preferably of the same type used for the wooden rails) will be needed to firmly secure the wooden rails within their respective brackets and retaining flanges.
[0029] FIG. 6 depicts a guard rail support 60 in accordance with a further aspect of the present invention. Again, like numerals are used to denote like features with the guard rail support 10 of FIGS. 1 and 2 . As can be seen, the guard rail support 60 comprises the guard rail support 10 of FIGS. 1 and 2 , slidably received within a concrete-filled steel base 68 . The steel base 68 provides for greater stability and adequate support in cases where it is not possible, for whatever reason, to secure the base plate 14 of the guard rail support 10 to a floor surface via fasteners (e.g. expansion anchors or screws) placed through holes 24 a , 24 b . As shown, the concrete-filled steel base 68 is constructed so as to have a groove formed on the bottom surface thereof for slidably receiving the base plate 14 of the guard rail support 10 . The groove extends to an open end 66 of the steel base 68 in order to provide means for allowing the guard rail support 10 to slide into the steel base 68 . It will be appreciated that the groove terminates before reaching an opposite end 69 of the steel base 68 such that the guard rail support 10 may only be slidably received within and removed from the steel base 68 at the open end 66 .
[0030] The concrete-filled steel base 68 has a first channel or cavity 67 formed along its central longitudinal axis and dimensioned accordingly to receive angular brace 20 , retaining flange 17 and tie-off ring 22 of the guard rail support 10 . Furthermore, the steel base 68 has a pass-through channel or cavity 64 formed therein proximal the flange 17 and dimensioned to correspond to the distance between the flange 17 and the upright column 12 . The pass-through cavity 64 advantageously provides for pass-through of kick board rails (not shown), as appropriate.
[0031] In the embodiment of FIG. 6 , the guard rail support 10 is securely maintained within the concrete-filled steel base 68 due to the precise tongue-groove type of fitting of the base plate 14 within the groove and the weight of the steel base 68 . Advantageously, the substantial weight afforded by the concrete-filled base 68 provides the necessary stability and support to maintain the guard rail support 10 in a fixed and upright position. It will be appreciated that a resilient, non-slip pad 63 may also be fastened by suitable adhesive means to the underside of the concrete-filled steel base 68 to provide a frictional wear resistant non-slip surface for contacting and engaging a floor surface. A plurality of such guard rail supports 60 may then be located along the outer edge of a floor under construction and a safety barrier constructed in the manner shown by either of FIG. 4 or 5 .
[0032] In accordance with a further aspect of the present invention, a mesh-like fence structure may be used in conjunction with any of the guard rail supports 10 or 60 described in relation to FIGS. 1 and 2 or 6 to form a mesh-like (or fence) safety barrier at any desired site under construction. For example, a portion of a fence-like safety barrier 79 constructed in accordance with the present invention is depicted in FIG. 7 . Again, like features are denoted by like numerals. As shown, a framed mesh 80 includes three projecting U-beams 78 affixed to opposite vertical sides thereof. The U-beams 78 are preferably made of metal and are supported and secured within the rail supporting brackets 16 and retaining flanges 17 of the guard rails supports 10 a , 10 b in the same overlapping manner as described in relation to FIG. 4 . In this case, however, holes corresponding to the holes 19 of the rail supporting brackets 16 and retaining flanges 17 are pre-drilled into each U-beam. In this manner, two overlapping U-beams may be placed within the rail supporting brackets 16 and retaining flanges 17 of each guard rail support 10 and secured with suitable fasteners. Thus, in this particular embodiment, the rail supporting brackets 16 and retaining flange 17 of each guard rail support 10 are dimensioned so as to accommodate two adjacent and overlapping U-beams. It will be appreciated that the mesh-like structure 80 of FIG. 7 need not include three U-beams projecting from each side, as shown. Two projecting U-beams may provide for sufficient stability and support. In this case, a single rail supporting bracket along with the retaining flange would be used, as required.
[0033] The guard rail supports 10 , 60 of the present invention each have two rail supporting brackets 16 affixed to their upright column 12 and a single retaining flange 17 affixed to their base plate 14 for supporting upper and lower wooden rails and kick boards, respectively. Although the retaining flange 17 on each guard rail support is a necessary requirement for supporting kick boards in accordance with safety standards and regulations, it will be appreciated that the precise number of rail supporting brackets 16 affixed to the upright column 12 of a given guard rail support is not material to the invention. Those skilled in the art will appreciate that construction safety regulations in most jurisdictions require guard rail systems of the type described to have a top rail, an intermediate rail and a toe or kick board as a minimum. Thus, at least two rail supporting brackets (for supporting upper and lower wooden guard rails) and a retaining flange (for supporting the kick board) are provided in the guard rail support of the present invention in order to adhere to safety regulations. However, more than two rail supporting brackets for supporting more than two rails in addition to the kick board may be employed in alternative embodiments without departing from the scope of the invention.
[0034] In addition, it will be appreciated that safety regulations in most jurisdictions require that the top rail of a guard rail barrier be located at least 3 feet but not more than 3.5 feet above the floor or ground surface to which the guard rail barrier is to be anchored while the intermediate rail be midway between the top rail and the floor surface. Thus, in a preferred embodiment of the present invention, the rail supporting brackets 16 are spaced along the upright column 12 of the guard rail support 10 , 60 in such a manner so as to adhere to the above-prescribed safety regulations when fitted with upper and lower rails. In addition, safety regulations generally dictate that the top and intermediate rails be at least 1.5 inches by 3.5 inches in dimension and that the kick board be at least 3.5 inches in height. Advantageously, the rail supporting brackets 16 and retaining flange 17 of the guard rail support 10 , 60 of the present invention are preferably dimensioned so as to accommodate 2″×4″ wooden rails, thereby conforming to safety regulations. It will be appreciated, however, that the rail supporting brackets and retaining flange may be dimensioned in any appropriate manner that meets the minimum safety guidelines in the jurisdiction of concern.
[0035] To further comply with safety regulations, it will be appreciated that the spacing between guard rail supports of the present invention when used in the construction of a safety barrier as described should not exceed approximately 8 feet. With regard to safety line anchorage points, most safety regulations specify that the anchorage must be capable of supporting a static load on the order of 17.8 kN (or 4000 lbs) in any direction, with proper provision to accept a safety line connection. Advantageously, the safety tie-off ring 22 of the guard rail support 10 , 60 of the present invention has been tested to support a static load of 5000 lbs.
[0036] A guard rail system constructed with the guard rail support of the present invention provides for easy installation at, and removal from, sites under construction. As will be appreciated, installation may be accomplished by a single worker, if necessary. A first step in the installation procedure is to locate a plurality of supports 10 at spaced intervals up to eight feet long about the perimeter of a ground surface under construction and to attach the baseplate of each support to the ground surface using suitable fasteners or anchors. Once a series of supports according to the present invention are located and secured to the floor of a building under construction, the upper and lower safety rails may be individually placed and secured within the brackets of adjacent supports in the manner shown in FIG. 4 , so that the rails extend completely about the perimeter of a floor under construction. Thus, the assembly of a safety guard rail fence or barrier, together with kick boards may be quickly mounted in place. An advantage of the preferred embodiment is that each support may be attached to the floor of an existing building structure prior to insertion of the wooden rails or safety fences, thereby minimizing weight and bulk so that a single worker may install a guard rail assembly without assistance from another worker. Additionally, once construction is completed, the disassembly of such a guard rail assembly as well as the removal of the guard rail supports, may also be carried our in an efficient manner.
[0037] Advantageously, the guard rail support and associated guard rail assembly of the present invention reduces or eliminates the liability which may result from inadequately re-installed guard rails. Specifically, at sites under construction, workmen sometimes need to temporarily remove portions of a guard rail in order to gain access to certain regions. With prior art conventional wooden rail assemblies, the workmen typically just hammer out the appropriate section when required. Inherently lazy, however, workmen do not usually return the guard rails back to their original state, thereby compromising the integrity of the guard rail assembly and causing safety concerns. The guard rail support 10 of the present invention provides for a fast and efficient disassembling and reassembling of a portion of a guard rail assembly if need be. Furthermore, by preventing the damage of lumber which would ordinarily result from such crude hammering out, the inventive guard rail support prevents the possible reassembly of a hammered out portion of a guard rail assembly with damaged lumber. The all-steel construction of the guard rail support of the present invention also ensures durability and repeated use for many years, thereby providing a high return on investment and cost savings.
[0038] The temporary guard rail support and associated assembly of the present invention have been described in connection with the provision of a safety guard rail along the outer drop-off edge or perimeter of a concrete floor slab which defines an upper story level of a building while it is under construction; the principle purpose being to protect workmen on the floor slab from falls. It will be appreciated, however, that the guard rail support and assembly may be useful in other embodiments and a guard rail support embodying the principles of the invention may, if desired and with or without modification as required, be employed for guard rail support purposes in a wide variety of other situations or environments as, for example, in the provision of a temporary guard railing around the perimeter of a roof structure, along the sides of a bridge construction until such time as the permanent guard railings are installed, or along any drop-off edge wherever it may occur.
[0039] While preferred embodiments have been described and illustrated, it will be apparent to one skilled in the art that numerous modifications, variations and adaptations may be made without departing from the scope of the invention as defined in the claims appended hereto.
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A guard rail support and assembly is disclosed for use in providing a safe work area for workmen working at dangerous heights, particularly in the construction industry. The guard rail support assembly comprises a plurality of guard rail supports arranged in a spaced fashion and wooden guard rails extending between and attached on either end to each support. Each guard rail support comprises an attachment base having quick fastening means for quick attachment and release of the support to a ground surface of the site under construction, a plurality of rail supports having quick fastening means for quick attachment and release of the wooden guard rails and a fall-protection or tarp tie-off ring. Advantageously, a portable and lightweight guard rail assembly may be constructed with the guard rail supports in an expedient and efficient manner to provide safe, unobstructive protection against falls.
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RELATED APPLICATIONS
This application is a Continuation of U.S. application Ser. No. 09/446,246 filed on Dec. 15, 1999 now U.S. Pat. No. 6,659,158, which was the National Stage of International Application No. PCT/EP98/03773, filed on Jun. 19, 1998.
FIELD OF THE INVENTION
The invention relates to a quick-action rolling shutter door and to modules thereof.
BACKGROUND OF THE INVENTION
Quick-action rolling shutter doors are used for closing openings in the walls of warehouses or factory buildings. Here, it is very important that the quick-action rolling shutter door can be opened and closed fast, only leaving the opening in the wall open for the actual passage of a person or a vehicle there-through. This will, on the one hand, restrict any loss of energy from heated or cooled rooms, and, on the other hand, protect the environment by keeping escaping noise, odors and dust emissions to a minimum.
From practical applications, two types of quick-action rolling shutter door are known. A first type of quick-action rolling shutter door, usually referred to as sectional door, uses rigid door elements which are guided on their sides and, when opened, assume a position parallel to a building wall or ceiling. Said door elements generally include a frame with plural filling inserts of a sandwich construction, similar to the kind used in window or door systems. The K-value of said doors which is between 1.0 to 1.4 can in itself be regarded as good from an energy saving point of view. What is disadvantageous about these doors, however, are their low opening and closing speeds and the high technical effort, amongst other things due to the problems involved in foam-filling the filling inserts with construction material. This construction is not only very problematic when it comes to recycling, but does not afford sufficient protection from burglary, either, since the filling inserts do not offer any resistance.
Another type of quick-action rolling shutter door which is known from practice as the so called hanging or curtain door, uses a thin-walled plastic tarpaulin which is guided on the sides and can be wound up onto a roller. The high opening and closing speeds of this type of quick-action rolling shutter door are obtained at the expense of insufficient thermal insulation, with K-values ranging from 4.0 to 5.75, as well as insufficient safety from burglary.
Both types of quick-action rolling shutter door have disadvantages in relation to heat insulation. The disadvantage of sectional doors in this respect is the formation of cold bridges in the region of the joints interconnecting the individual door elements. The insufficient heat insulation of hanging doors is due to the insufficient insulation properties of the material of the hanging.
Another disadvantage of the prior art quick-action rolling shutter doors is the labor-intensive repair of collision damage. With both types of quick-action rolling shutter door, due to the prior art guiding devices used in them, maintenance work is only possible in the raised, opened state. What makes this shortcoming especially serious is the fact that collisions of vehicles and quick-action rolling shutter door hangings or door elements occur very frequently with quick-action rolling shutter doors. Another disadvantage of the prior art types of quick-action rolling shutter door resides in their insufficient safety from burglary, as already mentioned.
SUMMARY OF THE INVENTION
It is the object of the invention to provide an improved quick-action rolling shutter door with corresponding modules for improving prior art quick-action rolling shutter doors.
This object is solved according to the invention by the features of the claims.
In accordance with claim 1 , the flexible hanging of the quick-action rolling shutter door, which is wound up onto a roller and guided on at least one side by a guiding device, should have at least one thick-walled insulating layer consisting of foamed plastic material. The fact that foamed plastic material is used, which has pores and chambers with small air cushions preventing any heat exchange through the quick-action rolling shutter door hanging, results in good heat and cold insulation. To achieve such insulation does not require a major constructional effort since the quick-action rolling shutter door hanging is flexible and can thus be readily wound up onto a roller. This allows high-speed opening and closing actions. Consequently, there will be no hinges, either, which would require special insulation measures.
The hanging of the quick-action rolling shutter door which constitutes a module for a quick-action rolling shutter door and for which protection is also sought separately, independently of claim 1 , preferably exhibits some reinforcement onto which the thick-walled insulation layer has been laminated. Said reinforcement, which may comprise a fabric or web of steel wires, steel strands, glass or carbon fibres, or cotton, serves as a barrier preventing any cutting through said quick-action rolling shutter door hanging, thus preventing burglary. A particular good cost-effectiveness ratio is obtained when a steel fabric is used for reinforcement.
For facilitating the winding up of the quick-action rolling shutter door hanging, one of its external sides preferably has expansion slots. In the case of a quick-action rolling shutter door hanging with first and second insulation layers, such layers are preferably glued or welded together along contact lines extending transversely to the direction of travel of said quick-action rolling shutter door. Particularly suitable for gluing together insulating layers of polyethylene foam is cyancacrylate.
Another quick-action rolling shutter door module for which independent protection is sought, is the anti-push-up device as claimed in claim 15 . This anti-push-up device, which is provided especially for quick-action rolling shutter doors, is characterized by at least one detent latch which will latch in the guiding device whenever the distance between adjacent track rollers or sliding elements decreases during opening of the quick-action rolling shutter door. The distance between adjacent track rollers or sliding elements will always decrease when the bottom edge of a quick-action rolling shutter door hanging, or of door elements which are slidable relative to each other, is to be lifted. The fact that said at least one detent latch latches in said guiding device will prevent any further lifting of the quick-action rolling shutter door hanging or the door elements in such a case, thus preventing any burglary attempts in this manner. A bracing spring which will force two detent latches apart whenever the quick-action rolling shutter door hanging or the door elements is/are lifted, facilitates the latching process.
Yet another quick-action rolling shutter door module which is very advantageous when used together with a quick-action rolling shutter door hanging of the present invention, is a guiding device for quick-action rolling shutter doors, comprising a guide rail which is essentially U-shaped in cross-section and has a guide space for accommodating track rollers or sliding elements, wherein said guide rail is composed of plural parts. The two legs of the guide rail, which extend essentially in parallel in operation, can be shifted relative to each other, making the guide space freely accessible in its opened state. The fact that the guide space is freely accessible in its opened state allows the maintenance of a quick-action rolling shutter door equipped with such a guiding device in its closed state, which in particular makes an exchange or the cleaning of track rollers or sliding elements of a quick-action rolling shutter door possible. As the quick-action rolling shutter door can be kept closed during maintenance, any energy losses and emissions will be minimal. Moreover, this will facilitate maintenance work since the quick-action rolling shutter hanging and its guiding device are easily accessible.
Another way of minimizing the maintenance and repair work involved in operating a quick-action rolling shutter door is to provide a crash protection device. Such crash protection device for quick-action rolling shutter doors, for which independent protection is also sought, will ensure that the full operativeness of the quick-action rolling shutter door is restored in as short a time as possible after a vehicle has crashed into the hanging or the door elements of the quick-action rolling shutter door. While with quick-action rolling shutter doors of the prior art, parts of the guiding device will become destroyed in a collision, the crash protection device of the invention overcomes this problem in that, in case of a collision with a vehicle, it allows for the releasing of a coupling, thus avoiding the destruction of an element of the guiding device. Preferably, said coupling is designed such that coupling elements which were decoupled or disengaged during the raising of the hanging or door elements of the quick-action rolling shutter door will automatically be coupled or engaged again at funnel-like guide means.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantageous embodiments and further developments of the invention will become apparent from the subclaims as well as the description which follows in which reference is made to the drawings, of which:
FIG. 1 is a view of a first embodiment of a quick-action rolling shutter door according to the invention, with the roller cover removed;
FIG. 2 is a simplified perspective view of the top part of the quick-action rolling shutter door of FIG. 1 ;
FIG. 3 is a cut-off perspective view of a hanging for a quick-action rolling shutter door of FIGS. 1 and 2 ;
FIG. 4 is an enlarged perspective view of a first section of the quick-action rolling shutter door hanging of FIG. 3 ;
FIG. 5 is an enlarged perspective view of a second section of the quick-action rolling shutter door hanging of FIG. 3 ;
FIG. 6 is a guiding device according to the invention for a quick-action rolling shutter door of FIGS. 1 and 2 ;
FIG. 7 is one view of an anti-push-up device according to the invention for a quick-action rolling shutter door of FIGS. 1 and 2 ;
FIG. 8 is a simplified view of a pair of detent latches of the anti-push-up device of FIG. 6 ;
FIG. 8 a is a pair of detent latches for a second embodiment of an anti-push-up device, including a torsion spring for forcing said detent latches apart;
FIG. 9 is one view of a section of a crash protection device according to the invention;
FIG. 10 is a sectional view, taken along lines IX—IX of FIG. 8 , of said crash protection device of FIG. 8 with a quick-action rolling shutter door hanging;
FIG. 11 is a simplified perspective view of a coupling of the crash protection device of FIGS. 8 and 9 ;
FIG. 11 a is a simplified view of another embodiment of a coupling for a crash protection device of FIGS. 8 and 9 ;
FIG. 11 b is a view of the coupling of FIG. 11 a as indicated by arrow XI therein, in the coupled state;
FIG. 12 is a simplified view of a second embodiment of the quick-action rolling shutter door of the invention;
FIG. 13 is a view of a second embodiment of the quick-action rolling shutter door hanging of the invention;
FIG. 14 is a view of the reinforcement of the quick-action rolling shutter door hanging of FIG. 13 ;
FIG. 15 is a sectional view of a variant of the quick-action rolling shutter door hanging of FIG. 13 including expansion slots;
FIG. 16 is a cut-open view of a portion of the quick-action rolling shutter door hanging of the invention including a transverse girder that may be partitioned longitudinally in operation according to yet another embodiment and a longitudinal strip of a reinforcement;
FIG. 17 is a cut-open view of a portion of the quick-action rolling shutter door hanging of the invention including a transverse girder according to yet another embodiment and a longitudinal strap of a reinforcement.
DETAILED DESCRIPTION OF THE INVENTION
The first embodiment of a quick-action rolling shutter door 10 according to the invention, shown in FIGS. 1 to 6 , consists of plural quick-action rolling shutter door modules. A first quick-action rolling shutter door module is the quick-action rolling shutter door hanging 12 which is guided on the side and at the top by a guiding device 14 . Said guiding device 14 includes a roller 16 which can be driven to rotate in either direction by a motor 18 . Said motor 18 is controlled by controlling means 20 which will also process signals from contact rails and light barriers supplied via signal lines 22 .
FIG. 2 shows the top part 24 of the guiding device 14 . It can clearly be seen in this Figure that the guiding device 14 essentially comprises two lateral guide rails 26 , 28 as well as a head beam 30 maintaining the distance between said two guide rails. Extending in parallel to said head beam 30 is a roller 16 supported in roller support means 32 .
Crucial for the quick-action rolling shutter door 10 is the quick-action rolling shutter door hanging 12 , a first embodiment of which is shown in detail in FIGS. 3 to 5 and further embodiments of which are shown in FIGS. 13 to 17 . Like parts are marked with like reference numerals, but increased by 1,000 or 2,000. The quick-action rolling shutter door hanging 12 of the first embodiment illustrated in FIGS. 3 to 5 has a continuous reinforcement 34 of a steel wire fabric, one side of which is laminated with a first insulating layer 36 of a thickness of 25 mm and the other side of which is laminated with a second insulating bayer 38 , likewise 25 mm thick. For use as a burglary-proof door on the outside, a steel fabric is laminated into the foamed material. The steel fabric may be of a thickness of between 0.3 mm to 1 mm. The first and second insulating layers comprise a closed-pore polyurethane foam of a density of 30 kg/m 3 . The first insulating layer is intended to be the external layer and has a smooth fair-faced side 40 which is of the same color as the actual building. The likewise smooth fair-faced side 42 of the insulating layer 38 intended to face inside, by contrast, which may also be customized, is in a glaring color.
The thick first insulating layer, however, may also be structured on the outside, which creates the visual impression of a sectional door.
The quick-action rolling shutter door hanging 1012 partially shown in sectional view in FIG. 13 , whose reinforcement is not shown therein to keep the drawing simple, has two insulating layers 1036 , 1038 , which—as opposed to the quick-action rolling shutter door hanging 12 of the first embodiment—are not glued onto each other over their entire surfaces, but merely along contact or glue lines 1002 . Said insulating layers 1036 , 1038 are made of a cross-linked foamed polyethylene material marked by HT-Troplast AG under the trade name TROCELLEN R under the specification 3015 SWB F4 UV. This cross-linked foamed polyethylene material has a raw density of 33±3 kg/m 3 , a longitudinal tensile strength of 0.42 N/mm 2 , a transverse tensile strength of 0.29 N/mm 2 , a ductile yield, in the transverse and longitudinal directions, of approximately 200 percent, a temperature application range in the bending test of up to minus 40° C., a dimensional stability up to plus 95° C., a thermal conductivity at 30° C. of 0.038 w/m K, and a water vapour diffusion current density of <3 g/m 2 d with a thickness of 10 mm.
Further materials suitable for insulating layers are available from ALVEC under the trade name ALVEOLIT R . The properties of these materials may be noted from the table below:
ISO
Properties
Standard
Unit
TA
TA FR
Raw Density
845
kg/m 3
25
25
Tensile Strength
1926
longitudinal
kPa
280
235
transverse
kPa
180
155
Ductile Yield
1926
longitudinal
%
125
115
transverse
%
105
95
Upsetting hardness
844
Upsetting 10%
kPa
12
13
Upsetting 25%
kPa
32
32
Upsetting 50%
kPa
92
92
Pressure Deformation
1856-C
Remainder, 22 h
strain, 23° C.
Upsetting 25%
0.5 h after strain relieve
%
22
21
24 h after strain relieve
%
13
13
Thermal Conductivity
2581
at 10° C.
W/mK
0.034
0.034
at 40° C.
W/mK
0.038
0.039
Operating Temperature
in-house
° C.
−80/+100
−80/+100
Range
Water Absorption (7 days)
in-house
% v/v
<1
<1
Water Vapour Permeability
1663
g/m 2 × 24 h
3.8 (2 mm)
(Thickness)
μ value (23° C., 0-85% r.F)
1663
5500
Shore Hardness 0/00
in-house
17/33
15/34
Unit
Properties
ISO
Standard
TA FRS
TA FRB
TA FMl
Raw Density
845
kg/m 3
25
25
25
Tensile Strength
1926
longitudinal
kPa
225
235
225
transverse
kPa
140
150
145
Ductile Yield
1926
longitudinal
%
100
110
100
transverse
%
80
100
90
Upsetting Hardness
844
Upsetting 10%
kPa
12
12
12
Upsetting 25%
kPa
31
32
32
Upsetting 50%
kPa
80
95
93
Pressure Deformation
1856-C
Remainder, 22 h
strain, 23° C.,
Upsetting 25%
0.5 h after strain
%
22
21
21
relieve
24 h after strain
%
13
13
14
relieve
Thermal Conductivity
2581
at 10° C.
W/mK
0.034
0.033
0.033
at 40° C.
W/mK
0.039
0/037
0.037
Operating
in-house
° C.
−80/+100
−80/100
−80/+100
Temperature Range
Water Absorption (17
in-house
% v/v
<1
<1
<1
days)
Water Vapour
1663
g/m 2 × 24 h
1.8 (5.5 mm)
Permeability
(Thickness)
μ value (23° C., 0-
1663
4100
85% r.F)
Shore Hardness 0/00
in-house
16/29
18/29
17/27
FIG. 15 shows a variant of the quick-action rolling shutter door hanging 1012 of FIG. 13 . This variant of a quick-action rolling shutter door hanging 2012 has expansion slots 2004 on its external side which expand to form notches 2006 during the winding up of the quick-action rolling shutter door hanging 2012 , thus contributing to a strain reduction within the material of the quick-action rolling shutter door hanging 2012 and facilitating the winding up onto rollers.
FIG. 14 shows a reinforcement 1034 for the quick-action rolling shutter door hanging which comprises first and second transverse girders 1300 , 1302 as well as longitudinal strips 1304 . The first transverse girders 1300 are simple aluminum profiles of rectangular cross-section which extend transversely to the direction of travel of the quick-action rolling shutter door hanging and are connected to longitudinal strips at regular intervals by means of through bolts. The longitudinal strips 1304 are flexible metal strips which may easily be wound up, but present a strong resistance towards being cut by knives or other cutting tools. FIG. 17 shows a first transverse girder 1300 and longitudinal strip 1304 together with first and second insulating layers 1036 , 1038 , respectively.
FIG. 16 shows a portion of a quick-action rolling shutter door hanging 1012 with a second transverse girder 1302 which consists of two parts. Said second transverse girder comprises a first transverse girder part 1306 and a second transverse girder part 1308 , which two parts are slid into each other such that they can be slidingly separated along a parting line 1310 . Said first and second transverse girder parts 1306 , 1308 each have two insertion channels 1312 , 1314 accommodating the insulation layers 1036 , 1038 . For interconnection or, if necessary, for connection to first transverse girders 1300 , longitudinal strips 1304 are again provided. Said longitudinal strips 1304 are bent U-shaped around holding means 1316 so as to ensure a safe connection of said longitudinal strips 1304 to said transverse girder parts 1306 , 1308 via a screwed connection of said longitudinal holding means 1316 . For use of the quick-action rolling shutter door hanging 1012 in an environment where heat or cold insulation is important, the second transverse girders 1302 should be designed such that they will not form cold bridges. To this end, the profiles from which the transverse girder parts 1306 , 1308 are made may be provided with insulating ribs. As an alternative, second transverse girders 1302 need not be provided altogether since, if first transverse girders 1300 are used exclusively, as shown in FIG. 17 , there will not be any cold bridges.
As an alternative to the insulating layer material described, other materials may also be used in the insulating layers, comprising a flexible open- or closed-cell foamed material of a chemically or physically cross-linked type. A closed skin is advantageous. Materials of foamed polyolef ins of a temperature stability up to at least −35° C., preferably −40° C., and a K-value of <2.5 are particularly suited.
Foamed materials which are especially well suited are:
PE—Polyethylene:
Reusable—UV proof—available in any color, behaviour in fire: DIN 4102 B1, B2 class—temperature application range −40° C. up to 105° C. K-value of between 1 and 1.4—raw density of between 30 and 250 kg/m 2 . Foam thickness of between 10 mm and 40 mm for the door insert.
PU—Polyurethane:
Recyclable, UV proof, extremely sound absorbing, temperature stability 40° C. up to, for a short time, 170° C. K-value 1 to 1.4, raw density between 30 and 250 kg/m 2 . Behaviour in fire: DIN 4102 B1, B2 class. Foam thickness of between 10 mm and 40 mm for the door insert.
EPDM—Synthetic Rubber:
Recyclable and suitable for disposal in household rubbish, UV proof, fire behaviour DIN 4102 B1, B2 class. Temperature stability from −57° C. to 150° C. Foam thickness of between 10 mm and 40 mm for the door insert.
PVC—Polyvinylchloride.
For absorbing the wind forces acting on the quick-action rolling shutter door hanging (FIG. 3 ), antibuckling profiles 44 are provided. These profiles 44 extend on either side of the reinforcement 34 transversely to the direction of travel of the door, bridging the distance between the guide rails 26 , 28 of the guiding device 14 , and may also serve as the transverse girders of a reinforcement. Said antibuckling profiles 44 extend essentially Z-shaped and have one leg engaging said reinforcement. Their respective other leg engages the external side of the respective insulating layer 36 , 38 , thus subdividing said insulating layer 36 , 38 into individual portions. Since said insulating layers 36 , 38 are flexible, as is notable from FIG. 3 , and said antibuckling profiles 44 are of low height, the quick-action rolling shutter door hanging 12 of FIGS. 3 to 5 may be wound up onto roller 16 .
In order not only to prevent any strong bending or deflection of the quick-action rolling shutter door hanging 12 , but to ensure a reliable support of the quick-action rolling shutter door hanging 12 at the same time, track roller means 46 are provided at the ends of said antibuckling profiles 44 which are opposite each other, with said reinforcement 34 in-between. Said track roller means 46 —also illustrated in FIG. 6 —includes an axle body 48 on which two roller bodies 52 , spaced from each other by means of a sleeve 50 , are rotatably mounted. One of said roller bodies 52 contacts support screw means 54 provided at one end thereof. The second roller body is supported by a grab body 58 , screwed onto said axle body 48 and including a slot 56 , so as to loosely contact said sleeve so. In this state, said grab body 58 also encompasses ( FIG. 5 ) a leg each of two opposing antibuckling profiles 44 to which it is at the same time glued, soldered or welded, depending on the material of said antibuckling profiles 44 .
FIG. 6 illustrates how said roller bodies 52 , which are supported on their respective axle body 48 and may also be referred to as tandem rollers, are guided in their respective guide rail 26 .
The guide rail 26 shown in FIG. 6 includes a support body 60 made of a rectangular square profile. Mounted on said support body 60 by means of a hinge 62 is a swivelling part 64 made of an equal angle profile. The edge length of said swiveling part 64 is somewhat longer than that of the support body, enabling said swivelling part 64 to encompass said support body 60 , with a reference edge 66 of said swivelling part and a reference surface 68 of said support body 60 being essentially on one plane at the same time so as to define an oblong aperture 70 therebetween for the quick-action rolling shutter door hanging 12 .
In the state illustrated in FIG. 6 , the free leg 72 of the swivelling part 64 extends essentially in parallel to a longitudinal wall 74 of the support body 60 so that these two elements, i.e., the longitudinal wall 74 of said support body 60 and the free leg 72 of said swivelling part 64 , function almost like parallel legs of a U profile. In order to maintain said support body 60 and said swivelling part 64 in this relative position and thus to prevent this constellation from coming apart in operation, a screwed connection 76 is provided which extends through said swivelling part 64 and engages a threaded bore in said support body 60 .
The guide rail shown in FIG. 6 is intended for assembly within a refrigerating chamber. In order to prevent the roller bodies 52 from freezing up and thus blocking, the guide chamber 78 defined by the longitudinal wall 74 and the free leg 72 is lined with heat insulation elements 80 which have at least one heating coil 82 on their internal side for heating said guide chamber 78 . Brush bodies 84 provided on either longitudinal side of said aperture 70 will prevent any excessive heat loss from said guide chamber 78 .
In order to prevent the rolling shutter door hanging from being pushed up, said quick-action rolling shutter door 10 may be equipped with an anti-push-up device 84 . Such an anti-push-up device 84 , which is shown in FIGS. 7 and 8 , includes two detent latches 86 , 88 which are rotatably mounted on the axle body 48 of lower track roller means 46 . In this construction, the centre of gravity of said two detent latches 86 , 88 is above the axis of rotation of said axle body 48 , in an off-centre position. As a consequence, under the influence of gravity, both detent latches 86 , 88 would therefore rotate about the axis of rotation of said axle body 48 in opposite directions, if such movement were not prevented for the moment by a retaining belt 90 . If the rolling shutter door hanging 12 were pushed up, however, the retaining belt 90 , which is suspended from the axle body 48 above the axle body 48 bearing the detent latches 86 , 88 , would become relieved, resulting in said two detent latches 86 , 88 rotating until they are stopped by the walls of the guide chamber 78 of the guide rail 26 .
FIG. 8 a shows a variant of an anti-push-up device in which the detent latches 86 ′, 88 ′ are pre-biased by a twisting spring 89 .
FIGS. 9 to 11 illustrate a crash protection device 92 preventing the destruction of track roller means in the case of a collision of a vehicle with the quick-action rolling shutter door hanging 12 . The crash protection device 92 , which may be provided as an alternative to the anti-push-up device 84 , includes track roller means 94 guiding a coupling 96 . Said coupling 96 includes a clamp roller 98 which is accommodated in a support channel 100 of a clamp body 102 . Said clamp body 102 is screwed to a floor rail 104 forming the bottom end of the quick-action rolling shutter door hanging 12 . In this construction, the support channel 100 of the clamp body 102 is oriented so as to extend transversely to the extension of the quick-action rolling shutter door hanging 102 . A minimum holding force between clamp roller 98 and clamp body 102 is obtained in that clamp roller 98 has a rubber-elastic running surface and in that the support channel 100 within said clamp body 102 is concavely shaped both at the top and at the bottom.
So as to enable the clamp roller 98 to become decoupled from the clamp body 102 in the case of a collision, the quick-action rolling shutter door hanging 12 , in the region of the crash protection device 92 , is cut such that it will not project into the guide rail 26 . In order to safeguard a tight closing nonetheless, a cover 106 is provided where the crash protection device 92 is, which cover 106 is of a design corresponding to the laminated construction of the quick-action rolling shutter door hanging 12 and connects the bottom-most track roller device 94 with the track roller device 108 above it. Besides this cover 106 , coupling belts 110 are provided which keep track roller device 94 and track roller device 108 at a fixed distance from each other.
In order to accomplish a good sealing between said cover 106 and said quick-action rolling shutter door hanging 12 , the opposing edges 112 and 114 of said cover and said quick-action rolling shutter door hanging 12 , respectively, are curved complementary towards each other, leaving merely a small sealing gap 116 between them. Since both the quick-action rolling shutter door hanging 12 and the cover 106 are made of an elastic material, the quick-action rolling shutter door hanging 12 and the cover 106 will overlap. During decoupling of the crash protection device 92 , some material of the quick-action rolling shutter door hanging 12 and of the cover 106 will be compressed, leaving the lower portion of the quick-action rolling shutter door hanging 12 free.
FIGS. 11 a and 11 b illustrate a clamp body 102 ′ for a second embodiment of a coupling for a crash protection device. Said clamp body 102 ′ is in two parts, i.e. it comprises upper and lower clamp body halves 1400 , 1402 which are both inserted in a recession of a profile 1404 extending transversely to the direction of travel of the door. The (common) end 1406 of said upper and lower clamp body halves 1400 , 1402 which faces a clamp roller 98 ′ is shaped like the clamp body 102 of FIGS. 9 to 11 , with the only exception that no wheel-like projection is being encompassed here.
The upper and lower clamp body halves 1400 , 1402 support each other at a contact surface 1408 and each have bevel or chamfered portions on the side opposing the clamp roller so as to leave a free portion 1410 between them, allowing a pincer-like movement of the two clamp body halves 1400 , 1402 towards each other, either to release or to reaccommodate the clamp roller 98 ′. For pre-biasing the two clamp body halves 1400 , 1402 in their holding position, a helical spring 1412 is provided at the end of the clamp body opposing the clamp roller 98 ′, with a pressure load acting on said spring 1412 along its longitudinal axis, said spring 1412 being guided in chambers 1414 , 1416 of the upper or lower clamp body halves 1400 , 1402 , respectively.
The quick-action rolling shutter door 10 shown in FIGS. 1 to 6 can be readily assembled within a very short time according to a scheme known from the furniture industry including assembly instructions in the form of illustrations (FIG. 2 ). The guide rails 26 , 28 and the top 24 , which are manufactured according to specifications of the clear dimensions, are prefabricated in production in such a way that the user will not have to perform major measurements owing to the specified screwed connections and mountings, and that these parts allow easy assembly according to the unitized construction principle. First of all, the guide rails 26 , 28 are laid out on the floor, screwed to transverse girders and mounted in the wall opening. The screwed connections of the roller support means to the shaft, hanging, motor and the transverse girders were already provided by the manufacturer. Using a forklift truck, the user will lift the prefabricated roller support means and insert it in the mountings intended for this purpose. Subsequently, the top part is secured (in position) by means of screws.
It should further be noted that, in view of the bending behaviour of the foamed material and the steel fabric contained therein, the shaft diameter should be 200 mm at least.
A second embodiment of a quick-action rolling shutter door 210 according to the invention is illustrated in FIG. 12 . This quick-action rolling shutter door 210 has a quick-action rolling shutter door hanging 212 which is vertically divided at the centre. The upper end of said hanging 212 extends in a guide rail 226 of a guiding device 214 , and said hanging 212 may be laterally wound up onto a first roller 216 and a second roller 217 . The quick-action rolling shutter door hanging 212 has two mutually complementary magnet rails at its centre which keep the quick-action rolling shutter door hanging 212 together at its centre in its closed state. For increasing safety around the quick-action rolling shutter door 210 , two windows 213 are provided in said quick-action rolling shutter door hanging 212 , which windows 213 are of a transparent plastic material and are welded onto the material of the quick-action rolling shutter door hanging 212 . A quick-action rolling shutter door hanging of this design is also advantageous in a quick-action rolling shutter door of the first embodiment. The quick-action rolling shutter door hanging 212 which is identical in construction to the hanging 12 of the quick-action rolling shutter door 10 of the first embodiment, may readily be provided with windows 213 since its closed-pore insulating layers do not require any sealing or bordering.
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A quick-action rolling shutter door and modules thereof used for closing openings in the walls of warehouses or factory buildings in order to restrict the loss of energy from heated or cooled rooms, and to protect the environment by keeping escaping noise, odors and dust emissions to a minimum. A flexible quick-action rolling shutter door hanging ( 12 ) can be wound up onto a roller, is guided on at least one side by a guiding device, and has at least one thick-walled insulating layer ( 36, 38 ) consisting of plastic foam material.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a Continuation-in-part of Ser. No. 09/573,022, filed May 17, 2000, entitled “Corner Bead Drywall Trim and Method of Manufacture”, issued Oct. 2, 2001, U.S. Pat. No. 6,295,776.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
(Not applicable)
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to drywall construction, and more particularly to an improved corner bead and trim products with paper wings.
(2) Background Information
Current building construction utilizes sheets of drywall, commonly referred to as “wallboard”, to form the surfaces of interior walls of buildings. Drywall, or wallboard, is formed of sheets of plaster which are sheathed in an outer wrapping of heavy construction paper.
In wallboard construction, the joint between adjacent sheets of wallboard is usually covered by a paper tape extending lengthwise along the joint. The conventional drywall tape is provided in narrow elongated strips of porous paper wound into rolls. The drywall tape is applied to the joints, and then covered with wet plaster or “mud”. The plaster is feathered and smoothed along the edges of the tape to conceal the tape edges and form a smooth unmarred surface at the wallboard joints.
It is often necessary to cut the wallboard to form a corner, which thereby exposes the plaster contained between the heavy paper sheets. This exposed plaster tends to crumble unless these edges are protected. To finish exterior corners in wallboard construction, metal corner beads are typically installed. Such corner beads are conventionally formed by roll-forming from an elongated strip of sheet metal, and provide a rounded nose with two mounting flanges extending at substantially right angles from the opposing sides of the nose. These mounting flanges are often knurled or embossed to provide a rough surface so that the joint compound will adhere when the corner is finished.
The corner bead is installed by securing the mounting flanges along the surface of the drywall panels adjacent to the corner by nails or the like. Wet plaster is then smoothed into place to cover the metal flanges, and edges of the plaster are smoothed and feathered to cover and conceal the metal edges.
A second type of corner bead is referred to as a “tape-on” bead. Tape-on corner beads utilize paper wings to secure a metal corner angle in position, rather than using nails or other fasteners. Wet plaster or joint cement for finishing the corner will normally adhere significantly better to the paper cover strip of tape-on beads, than to the exposed metal of conventional nail-on beads. Nail-on beads are also typically more susceptible to developing crack lines along the outer edges of the flanges, than are tape-on beads. In addition, tape-on beads are more tolerant of dimensional and geometric changes in the underlying construction framing than are nail-on beads with their rigid mechanical attachment to the construction framing.
One of the main problems with prior art tape-on bead is the use of standard joint/drywall tape-on the bead. Such drywall tape is very fibrous, which is good for bond strength, but poor for appearance. During the application of joint cement over the tape, to adhere the corner bead to the drywall, fibers will project and protrude with only minimal contact by the application tools. These fibers will ball up during the course of sanding of the joint cement for the final finish, thereby detracting from the finished appearance of the corner.
One method for improving protection against adverse abrasion of this paper strip is disclosed in U.S. Pat. Nos. 5,613,335 and 5,836,122, both to Rennich et al. These patents disclose a paper bead (tape-on bead) utilizing a paper layer which is uniformly impregnated throughout its thickness with latex or similar strengthening compound with a high wet strength so as to make the paper strip resistant to scuffing and abrasion throughout its thickness. This impregnated stock paper would have a high pick it resistance or surface fiber bond, and would effectively inhibit the separation of surface fibers during application on wallboard, thereby providing a good finished appearance in installation. However, the applicants herein have found that paper of this type, which has been impregnated with latex or the like, exhibits poor joint compound bonding properties. Bond Strength Test ASTM C 474 is required by specifications ASTM C 475 and ASTM C 1047 for wallboard accessories manufactured from steel and paper in combination. This ASTM test observes the result of peeling the paper away from a joint compound bond made under controlled conditions.
In addition, it is difficult to apply a uniform layer of joint cement under the paper wings, in order to attach the bead or trim to the drywall. This, in turn, results in the application of either too much or too little “mud”, and affects the appearance of the joint.
BRIEF SUMMARY OF THE INVENTION
It is therefore a general object of the present invention to provide improved tape-on on corner bead and trim with paper wings which exhibits high bond strength.
Yet another object is to provide an improved tape-on corner bead which will firmly bond to the drywall construction, the supporting metal corner angle, as well as the joint cement applied over the top thereof.
A further object of the present invention is to provide a method for constructing tape-on corner bead which permits secure attachment of the corner bead to wallboard.
These and other objects will be apparent to those skilled in the art.
The corner bead of the present invention is of the tape-on type, having an elongated metal core strip with a longitudinal arcuate nose and a pair of flanges extending outwardly from the nose. A strip of paper is bonded to the exterior surface of the core strip, and includes wings which project outwardly beyond the extent of the flanges. The wings have a plurality of dimples projecting from a rearward face.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The preferred embodiment of the invention is illustrated in the accompanying drawings, in which similar or corresponding parts are identified with the same reference numeral throughout the several views, and in which:
FIG. 1 is a perspective view of the corner bead of the present invention exploded away from an exterior corner of wallboard construction;
FIG. 2 is a perspective view of a corner of wallboard construction with the corner bead of the present invention thereon, and covered with joint cement for a finished surface; and
FIG. 3 is an enlarged top view of the corner bead mounted on a corner of wallboard construction.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, a corner bead of the present invention is designated generally at 10 and includes an elongated metal core strip 12 formed with a central arcuate longitudinal channel forming a nose 14 , with flanges 16 and 18 extending outwardly from each edge of the channel of nose 14 at an angle.
Core 12 is preferably a galvanized steel strip having a thickness of approximately 0.014 inches which has been roll-formed. In the preferred embodiment, the flanges are ¾ of an inch in length, measured from nose 14 . The typical core strip nose will have an outside radius of up to about 1.5 inches, and project outwardly from the plane of the flanges approximately 0.033 inches, to provide space to receive joint cement, to cover and “dress” the corner.
In the method of assembly of the corner bead, a continuous steel strip first passes through a preforming roll forming section. The preforming section, by means of progressive contoured rolls, forms the steel core strip 12 into a cross-section that begins to conform to the desired finished shape of the corner bead. This preformed steel strip then progresses into an assembly section.
A continuous length of paper strip 20 enters a paper conditioning section, wherein mechanical abrasion breaks some of the surface bond of the paper fibers and simultaneously, by means of a roller die, forms a plurality of small dimples in designated regions of the paper. In an alternative embodiment, the surface of the paper is not abraded, but a plurality of dimples are formed in designated regions of the paper. The paper strip 20 then progresses to the assembly section for attachment to the preformed core 12 .
In the assembly section, the paper strip 20 is guided through a preheating section that brings the paper to a suitable elevated temperature to improve the subsequent adhesive bonding. It then passes against a slot type hot melt adhesive applicator head, which applies a stripe of adhesive to the paper. The design of the slot head, along with control over the relative travel speed of the paper strip and the rate of flow of adhesive, regulate the location, width and thickness of the adhesive stripe. The heated paper strip 20 with adhesive thereon is then guided into contact with the preformed steel core. The assembly of steel core, adhesive and paper strip then progresses into a finish forming section.
In the finish forming section, the assembly passes through a second series of contoured forming rolls. These rolls form the assembly into the desired finished cross-section section shape of the corner bead, and simultaneously provides the necessary pressure to achieve the bond between the paper strip 20 and steel core 12 . The bonded and formed corner bead then progresses to a cut off section where the corner bead 10 is sheared into the desired finished length.
As shown in the drawings, the preferred embodiment of the invention utilizes a paper cover strip 20 with wings 22 and 24 affixed to flanges 16 and 18 respectively, and extending beyond flanges 16 and 18 . The paper preferably has a thickness of approximately 0.007 inches and will project beyond flanges 16 and 18 approximately ⅝ of an inch. Prior art versions of the invention utilize very small diameters holes that are pierced or cleanly punched through the paper. This improvement presses an indented profile into the paper in such a way that some of the paper fibers are burst to create a rough, fibrous opening, yet leave enough embossed edges to provide a standoff profile. These dimples 26 are arranged in approximately ⅛ inch to {fraction (3/16)} inch spacings. Each dimple 26 is embossed to an initial raise height of approximately 0.007 inches to 0.014 inches. Each dimple 26 is approximately 0.035 inches by 0.035 inches at its base on the raised rearward surface of the paper wing. Dimples 26 may be round, square, oblong, or similar shape.
Preferably, dimples 26 are formed with sufficient die pressure to burst the paper fibers open to a degree that light is visible through the dimple 26 , although subsequent handling may make hanging chad block some of the openings.
A layer of joint cement or “mud” 30 is applied to the wallboard under wings 22 and 24 to adhere the wings 22 and 24 to the wallboard 28 . Dimples 26 act as standoffs, providing a uniform depth of mud 30 along the entire length of wings 22 and 24 , as well as providing anchorage into the joint compound or “mud”. This in turn prevents over application of mud, and improves the overall results. An additional layer, or layers of mud 32 are then applied in a conventional manner to cover the entire paper strip 20 from nose 14 outwardly over wings 22 and 24 , as shown in FIG. 2 . Once coat 32 has dried, the joint cement is sanded and additional layers are applied as necessary for a final finish.
The inventors have found that paper with an off-white tint is preferable, so as to match the color of the drywall facing paper and joint cement. In this way, if a portion of the joint cement is sanded away to reveal the paper strip, the color of the paper strip will closely match the color of the wallboard and will not reveal any stark contrasts.
Whereas the invention has been shown and described in connection with the preferred embodiment thereof, many modifications, substitutions and additions may be made which are within the intended broad scope of the appended claims. More specifically, this invention may be applied to all varieties of drywall accessory or trim, including those types described in ASTM C 1047.
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A corner bead is of the tape-on type, having an elongated metal core strip with a longitudinal arcuate nose and a pair of flanges extending outwardly from the nose at approximately a right angle. A cover strip of paper is bonded to the exterior surface of the core strip, and includes wings which project outwardly beyond the extent of the flanges. The cover strip is formed of a stock paper having high abrasion resistance, tensile strength, and which is dimensionally stable on contact with wet joint compound.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The instant invention relates to supports for installed toilets. In particular, the instant invention relates to adjustable, portable, removable platforms for wall mounted toilets which allow additional weight to be supported. More particularly, the instant invention relates to floor supports for wall mounted toilets in hospitals and other health care facilities, where the toilet may be used by overweight, obese and extremely obese patients.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 11/450,508 filed Jun. 9, 2006 which claims priority to U.S. Provisional Application No. 60/689,323 filed on Jun. 10, 2005, the entire disclosure of which are incorporated by reference and for all purposes as if fully set forth herein.
BACKGROUND OF THE INVENTION
The invention relates to a support platform for wall mounted toilets, particularly to support the additional weight placed on the toilet by overweight, obese or severely obese individuals.
Although there are many types of toilets, those used in hospitals, clinics and other health care facilities, nursing homes and assisted living facilities, weight loss clinics, gyms, office buildings and other related buildings are often wall mounted. Part of the reason for mounting to the wall is to make cleaning easier as this type of toilet leaves a space between the floor and the bottom of the toilet. Frequently, wall mounted toilets are located in bathrooms where a floor drain is available so that the entire floor can be washed and drained easily without having to hold the wash water in a container. Where the toilet is floor mounted, cleanliness at the interface of the toilet and the floor is not assured and bacteria from urine and fecal matter are not always eliminated by normal cleaning procedures. In hospital rooms, clinics, recovery rooms and nursing homes, this is of particular concern as patients may be immune compromised and subject to secondary or hospital acquired infections from bacterial and viral contamination.
Wall mounted toilets are typically rated for a normal sized patient; 350 pounds is a common weight limit for such fixtures. With the increase in obesity in the United States and other nations, there is a high likelihood that an overweight, obese or severely obese individual will use a wall mounted toilet somewhere in the facility. With a limit in the rated weight bearing capacity of the toilet, there is a risk that the toilet mountings will fail and the overweight, obese or severely obese individual will fall. Any fall by such an individual, particularly one where a toilet fixture breaks away from a wall or one where the porcelain breaks, could lead to an injury. Furthermore, there is a risk of damage to the bathroom which can be costly to repair. The issue is of sufficient concern that Harrell and Miller discuss hospital design for bariatric patients and suggest the need for a bariatric toilet seat support (Health Facilities Management, March 2004, pp 34-38).
Current techniques to alleviate this problem in hospitals use wooden supports as a wedge between the wall mounted toilet and the floor. These supports are not easily adjustable. Their composition is not easily cleaned and can become contaminated with microorganisms such as E. coli which is commonly found in bathrooms.
In response to this problem, BAR Industries (Adairsville, Ga.) has developed the SK1000 series toilet support. The support is described in two pending and published US applications, U.S. Ser. No. 11/205,666 to Wright and U.S. Ser. No. 10/701,812 to Wright et al. This support is designed to be mounted using the wall mounts for the toilet and is adjustable using a screw type bumper positioned close to the front of the toilet. It cradles the bottom of the fixture with an arm-like single support and attaches integrally to the wall mounting bolts. The device described in the '666 and '812 applications can be used by each toilet design. Since the BAR Industries toilet support is attached at the wall mounts, it is more difficult to remove or move to a new location. This permanency makes cleaning and repairing the fixture or floor more difficult. It also increases the number of units required by a hospital by reducing the ability to move the fixture to a new bathroom. As the number of units purchased increases, the cost advantage claimed by the manufacturer decreases. Since the SK1000 uses a single bumper style foot, all of the weight of the user is held by the single foot. If the single foot fails under the load (as could occur over time and through exposure to loads), the device will no longer provide support and the toilet could still break away from the wall. Finally, the installation of the SK1000 requires removal of the mounting bolts contained on the toilet. This can cause the toilet to break its seal and can create a leak. These deficiencies make the SK1000 undesirable as a mobile and interchangeable support.
Another company, DB Industries (Little Suamico, Wis.) has developed a Bariatric Toilet Seat Support (BTSS) as described in U.S. Pat. No. 6,889,392 to Karnopp et al and published U.S. application Ser. No. 11/057,793. This support is a four legged stand made of stainless steel which is inserted between the toilet seat and the bowl. It is designed to provide additional weight bearing capacity on the toilet seat itself and not specifically on the fixture. The four legs are adjustable providing for the ability to match any unevenness in the floor. It also provides vertical adjustment with two stainless steel threaded rods with rubber end caps that are fit to the wall behind the toilet. Locking nuts are used at all six adjustable arms or legs. The device is very large and although the manufacturer claims that it takes up little room, it is cumbersome to position, use and maintain. It is also made from a complex series of components leaving multiple opportunities for stress failure. As it is placed between the toilet seat and the bowl, there is a risk that the seat may break under the weight of the bariatric patient. Furthermore, because the unit is positioned underneath the toilet seat and is exposed to the water, there is a higher risk of contamination by fecal matter and/or bacteria. This creates a need for more frequent cleanings than the instant invention. The BTSS is also too large to be heat sterilized in a standard hospital autoclave. Finally, the BTSS does not fit all wall hung toilet models and the company offers customized manufacturing.
Other devices designed for toilets are typically wall mounts that are used at the time of construction. See for example, U.S. Pat. No. 5,107,638 to Unertl which shows a permanent mounting means for a wall mounted water closet fixture. These devices are not specifically designed for bariatric use, but simply as further methods for securing wall mounted elements of the toilet assembly. These devices are permanent attachments to the toilet or its tank and cannot be easily moved. They are ideally used at installation or during renovation of the bathroom and not ideal for use on an existing wall mounted toilet.
BRIEF SUMMARY OF THE INVENTION
In view of the descriptions above and the deficiencies contained therein, the present invention can provide a platform to support wall mounted toilets, so that the weight capacity of the toilet is increased.
The present invention can further provide a removable and portable platform to support wall mounted toilets.
The present invention can also provide adjustment capability to the platform, so that the platform will support a wall mounted toilet independent of the height of the toilet.
The present invention can yet further provide a platform for a wall mounted toilet that is easy to position and adjust and does not require tools to use.
The present invention can embody a platform for wall mounted toilets that can be easily cleaned and sterilized.
The present invention can also provide a platform for wall mounted toilets that is easily transported and lightweight.
Other embodiments, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 shows a perspective view of the toilet support in use with a wall mounted toilet.
FIG. 2 shows a top view of the toilet support.
FIG. 3 shows a front side view of the toilet support.
FIG. 4 shows an oblique view of the toilet support as it is placed under a partial view of a wall mounted toilet.
FIG. 5 shows an oblique view of an alternate embodiment of the toilet support.
FIG. 6 shows a perspective view of an alternate embodiment of the toilet support in use with a wall mounted toilet.
FIG. 7 shows an oblique view of the alternate toilet support as it is placed under a partial view of a wall mounted toilet.
DETAILED DESCRIPTION OF THE INVENTION
Described herein is a bariatric support for a wall mounted toilets that is lightweight, is easily removed for cleaning or transfer to a new bathroom and is adjustable to any wall mounted toilet design. The toilet support can be sterilized chemically using common disinfectants or through heat, steam or high pressure. It is compact in design and can be easily stored in limited spaces. It has a small number of parts and uses high quality interchangeable components.
Referring now to the drawings, in FIG. 1 a front perspective view of the preferred toilet support apparatus as it is placed between the floor 2 and a wall mounted toilet 4 . The lower section 6 of the wall mounted toilet 4 is commonly configured either in a flat or a curved shape. In FIG. 1 , the lower section 6 is flat. Accordingly, the toilet support is shown with a platform 10 having a top surface 11 and a bottom surface 13 spaced by an outside edge 15 having a thickness 17 . The platform 10 also has adjustable base members 9 comprising mounting bolts 12 and feet 16 . In this perspective, only two mounting bolts 12 and feet 16 are shown but four are the preferred number spaced around the corners of the platform 10 . A threaded bore 23 is drilled into the platform 10 and the mounting bolts 12 of the adjustable base members 9 are inserted through the threaded bore 23 . The adjustable base members 9 can be made of any suitable material with a preferred design of stainless steel. The adjustable base members 9 can be adjustable glides or snap lock leveling mounts. The mounting bolts 12 can be of any height with the desirable height sufficient to raise the platform 10 such that it connects the bottom portion of the toilet. Mounting bolts 12 of multiple heights can be used depending on the space between the floor 2 and wall mounted toilet 4 . It is desirable to have at least two inches of each mounting bolt 12 remain above the top surface 11 of the platform 10 . The adjustable base members 9 are arranged around the platform 10 such that any portion of a mounting bolt 12 projecting above the top surface 11 of the platform 10 will not touch any surface of the wall mounted toilet 4 . Each adjustable base member 9 has a weight bearing capacity of at least 250 pounds with a preferred capacity of 500 pounds. The adjustable base members 9 may have greater weight bearing capacity if desired. Adjustable glides or snap lock leveling mounts can be found through multiple sources, one example is the Monroe Company (Auburn Mills, Mich.). The number of adjustable base members 9 is at least four although it can be five or more depending on the design of the toilet support apparatus. A groove 14 is cut into the platform 10 to accommodate a nipple 8 commonly found on the lower section 6 of the wall mounted toilet 4 . The nipple 8 is a common artifact of the molding process. The groove 14 is at least one-eighth inch deep in the platform 10 so that the nipple 8 does not make contact with the platform 10 while the lower section 6 of the wall mounted toilet 4 establishes direct contact with the top surface 11 of the platform 10 . To use the device, the platform 10 is placed under the wall mounted toilet 4 with the groove 14 directly under the nipple 8 . The adjustable base members 9 are adjusted by hand to raise the platform until it makes contact with the lower section 6 of the toilet 4 . Once all adjustable base members 9 have been adjusted and the platform 10 contacts the lower section 6 , the adjustable base members 9 can be adjusted using a wrench to make a firm contact between the platform 10 and the toilet 4 .
In FIG. 2 a top view of the preferred toilet support apparatus is provided. A platform 10 is shown having a top surface 11 and an outside edge 15 with four mounting bolts 12 . The platform 10 is preferably made of aluminum block but can be made from steel, including stainless steel or surgical steel. Other high strength metals that can be sterilized by heat, pressure or chemicals can be used. The platform 10 is at least three quarters of an inch thick and can be of greater thickness depending on the starting material. The mounting bolts 12 are part of the adjustable base members (not shown) which are preferably adjustable glides placed at even intervals near the corners of the platform 10 . Adding at least four mounting bolts 12 allows the force to be distributed among them so each mounting bolt 12 is carrying a portion of the load and not the full force or weight. If a single mounting bolt 12 failed, the remaining adjustable base members will distribute and support the load. The mounting bolts 12 are added by drilling threaded bores (not shown) in the platform 10 to match the diameter of the mounting bolts 12 . The mounting bolts 12 are threaded to accommodate a securing device such as a nut and so they can be inserted into the threaded bores (not shown). The mounting bolts 12 are interchangeable and can be of different thread lengths and total heights depending on the needs of the support and the layout of the bathroom floor. The mounting bolts 12 can have optional flat or Philips head screwdriver notches on their top surface. The groove 14 is cut into the platform 10 to a preferred depth of one quarter inch and a preferred width of two inches. The depth and width of the groove 14 can be varied depending on the dimensions of the wall mounted toilet. The groove 14 extends from the front edge of the platform 10 to a distance of two thirds of the length of the platform 10 . The corners of the platform 10 are preferably rounded to avoid sharp edges. The top and bottom edges of the platform 10 can also be rounded to avoid sharp edges.
In FIG. 3 , more detail is shown through a side view of the toilet support apparatus. The platform 10 and the mounting bolts 12 are shown. A threaded bore 23 is drilled into the platform 10 to provide space for the mounting bolts 12 . Now visible are the adjustable base members 9 comprised of feet 16 connected to the mounting bolts 12 . Each mounting bolt 12 has a top portion 19 extending from the top surface 11 of the platform 10 and a bottom portion 21 extending from the bottom surface 13 . The feet 16 stabilize the toilet support apparatus and provide weight bearing capability. The adjustable base members 9 raise or lower the platform 10 so that the top surface 11 of the platform 10 fits snugly under the wall mounted toilet. Each adjustable base member 9 can be adjusted manually to correct for any slope in the bathroom floor. This is particularly important in hospital bathrooms and nursing home bathrooms where a drain in the floor may exist to allow for easier cleaning. The feet 16 can be made of the same material as the mounting bolts 12 and the platform 10 . Covers or pads 20 made of rubber, Teflon, plastic or another appropriate substance can be added to provide a non-slip and/or non-marring surface if desired. These covers or pads 20 are preferably removable and replaceable although they can be fixed and permanent if made of an appropriate inert substance such as polyethylene or Teflon that is capable of chemical sterilization. The feet 16 can be configured to have covers or pads 20 on none, all or some of the feet 16 as desired.
In an alternate embodiment, a securing member can be added to the mounting bolts 12 . The mounting bolt is then threaded into the threaded bore 23 in the platform 10 so that the securing member sits just below the platform 10 . The securing member is maintained in a loosened position under the platform 10 while the adjustable base member 9 is raised or lowered to fit the platform 10 under the toilet. A wrench can be used to snugly tighten the securing member against the bottom surface 13 of the platform 10 after it has been placed under the wall mounted toilet to provide further security for the platform 10 . In yet another alternate embodiment, securing members can be added above and below the platform 10 on the mounting bolts for further security. The securing members are preferably nuts and can be regular hex nuts or lock nuts of a size that matches the mounting bolts 12 . Washers can be used to further add security between the securing member and the bottom surface 12 of the platform 10 . Both the nut and the washer are made from materials similar to the platform 10 with a preferred embodiment of stainless steel.
In FIG. 4 , a lateral oblique view of the toilet support apparatus is shown as it would appear in use. A partial view of the lower section 6 of a wall mounted toilet 4 with the platform 10 supporting the lower section 6 of the wall mounted toilet 4 is shown. Three adjustable base members 9 with mounting bolts 12 and feet 16 are visible in this view. The adjustable base members 9 are adjusted by rotating them in the threaded bore 23 so that the feet 16 are connected solidly with the floor 2 and the platform 10 is connected firmly with the lower section 6 of the wall mounted toilet 4 . In this view a single wall mount 22 is shown which affixes the toilet 4 to the wall. The toilet support apparatus does not attach to the wall mount 22 of the wall mounted toilet 4 unlike the SK1000 support described above. Furthermore, there is no need for vertical stabilization arms as in the BTSS support described above. The mounting bolts 12 can be of different heights in order to adjust for the height of the wall mounted toilet 4 and for any slope of the floor. In FIG. 4 , covers or pads are not shown but can be used on one or more of the feet 16 .
In FIG. 5 , an alternate version of the toilet support apparatus is shown in a stand alone oblique view. This version supports wall mounted toilets with rounded bottoms. The toilet support apparatus previously described in FIG. 1 through FIG. 4 can be used with a wall mounted toilet that has a rounded lower section but a smaller area of contact between the wall mounted toilet and the toilet support apparatus occurs. The alternate version provides a greater area of contact between the wall mounted toilet and the toilet support apparatus. Two support members 32 are shown with a connecting member 34 . The support members 32 have a front surface 33 and a back surface 35 that are spaced from each other by bottom edges 37 and top edges 39 . The top edges 39 of the support members 32 are curved, exemplarily in a saddle shape, and are configured to cradle the rounded lower section of the wall mounted toilet and provide additional area for the lower section 6 of the wall mounted toilet 4 to contact the toilet support apparatus. The exemplary bottom edges 37 are configured to facilitate welding to the platform 10 , and in the exemplary embodiment both the platform 10 and the bottom edge 37 are accordingly flat. The support members 32 and the connecting member 34 are welded together and are welded to the platform 10 . The support members 32 are of different heights to accommodate the curved shape of a rounded lower section of the wall mounted toilet. The mounting bolts 12 and feet 16 of the adjustable base members 9 are shown and are inserted through the threaded bore 23 in the platform 10 . In the preferred embodiment two support members 32 and a single connecting member 34 are used to add sufficient weight or force bearing capacity. Additional support members 32 and connecting members 34 can be added. The connecting member 34 has a front edge 41 , rear edge 43 , top edge 45 , bottom edge 47 , and two side surfaces 49 where the front edge 41 is connected to a more forwardly disposed (front) vertical support member 32 , the rear edge is connected to a more rearward disposed (rear) vertical support member 32 and the bottom edge 47 is connected to the platform 10 . All connections between the support members 32 , the connecting member 34 and the platform 10 are preferably welds.
In FIG. 6 an alternate version of the toilet support apparatus, as it is used on a rounded bottom, wall mounted toilet, is presented in perspective view. In this example, the wall mounted toilet 4 has a rounded lower section 6 . The platform 10 contains two support members 32 which are welded to the platform 10 with a connecting member 34 welded to the support members 32 and stabilizing them. Adjustable base members 9 inserted through threaded bores 23 in the platform 10 comprise mounting bolts 12 and feet 16 and are shown along with the optional securing member 18 , shown here as adjusting nuts. The feet 16 remain in contact with the floor 2 . To use this version on rounded bottom, wall mounted toilets 4 , the device is placed under the wall mounted toilet and adjusted so the support members 32 are positioned directly under the rounded lower section 6 of the wall mounted toilet 4 . The adjustable base members 9 are then adjusted by hand until the support members 32 cradle the rounded lower section 6 of the wall mounted toilet 4 and then are adjusted using a wrench to create a firm connection. When the optional securing members 18 are nuts they can be adjusted using a wrench until they are firmly positioned under the bottom of the platform 10 .
FIG. 7 shows an oblique view of the alternate version of the toilet support apparatus as it is in use with a partial view of the rounded lower section 6 of a wall mounted toilet. The two support members 32 are shown with the connecting member 34 between the support members 32 . The support members 32 are of different heights to accommodate the curved shape of a rounded lower section 6 of the wall mounted toilet. The mounting bolts 12 and feet 16 of the adjustable base members 9 are shown.
Continuing with the embodiments described above, an alternative can include a wrench mount on the platform and a wrench with the proper span for the mounting bolts and nuts. This provides the user with the ability to place the support quickly and without the need to search for the right tool. The wrench can be of any commercially available type, preferably having a fixed span fitted to the size of the adjustable base member and the optional securing members and more preferably having a ratcheting action due to the confined nature of the space. The wrench and its mount are placed outside of the contact area between the platform and the bottom surface of the wall mounted toilet, preferably along a side of the platform.
In an alternate embodiment, the platform has one or more levels mounted to its top surface including a simple bull's-eye bubble level as is commonly used in construction and on tripod stands. The optional level is used where the floor is determined to be level and a level toilet support is desired. The level or levels are fixed to the top surface of the platform, outside of the contact area between the platform and the bottom surface of the wall mounted toilet.
The toilet support provides additional weight bearing capacity for wall mounted toilets beyond their rated failure point. For many wall mounted toilets, the rated load is between 250 and 350 pounds. When a weight or force greater than this rating is placed on the wall mounted toilet, the toilet may pull away from the wall or crack near the wall mounts, possibly injuring the user and necessitating costly repair or replacement and downtime for the bathroom and/or hospital room. By placing the toilet support properly under the wall mounted toilet, the risk of damage to the toilet is reduced as the force or weight load of the toilet is increased.
Testing of the toilet support with weights has demonstrated that the support can bear a load of well over five hundred pounds, above the normal weight limit of the fixture and well within the weight range for overweight, obese and severely obese persons.
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A support platform for wall mounted toilets is described. The platform attaches easily under the toilet and contains bolts and feet for adjustment. The platform provides support to wall mounted toilets so that persons of weight greater than the rated load of the wall mounted toilet can use the toilet in comfort and safety. It is removable for use in different bathrooms, easily transported and can be sterilized where bacterial or viral contamination is a concern.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to devices and methods for engaging and removing remote tools having threaded portions from a remote location. In particular aspects, the invention relates to devices and methods for removing certain threaded tools from a subterranean wellbore.
2. Description of the Related Art
A number of well tools are employed that are left in the wellbore disconnected from a running or retrieval string. In some cases, these tools are difficult to secure and remove since they present a neck portion that is offset or at an angle with respect to the axis of the wellbore. This generally includes any tool that is left in the wellbore at an angle to the main wellbore axis and is not connected to a running or retrieval string (e.g., directional drilling or driving tools). In addition, some tools require the application of fluid pressure to release them from the wellbore.
SUMMARY OF THE INVENTION
The invention provides devices and methods for removal of a tool from a remote location such as a subterranean wellbore. A retrieval tool is described that generally includes an outer housing, an rotational drive element and an articulated shaft assembly that carries an attachment sub. The attachment sub has a threaded portion that is complimentary to the threaded neck portion of the remote tool to be retrieved. In a described embodiment, the outer housing and rotational drive element are used to locate and guide the attachment sub onto the neck portion of the remote tool so that it can be threadedly attached to the neck portion.
The outer housing includes a locating plate with an opening that is shaped and sized to receive the neck portion of the remote tool. The opening is offset from the central axis of the wellbore and functions to capture the neck portion of the remote tool. In addition, the opening in the locating plate functions to position the attachment sub so that it can be further guided toward the neck portion.
In a described embodiment, a guide sleeve with an enlarged opening radially surrounds the threaded portion of the attachment sub to assist in capture of the neck portion. In the described embodiment, the guide sleeve includes a tapered edge guide portion that assists in guiding the attachment sub toward the neck portion of the remote tool.
Also in described embodiments, a positioning assembly is retained within the inner body and functions to govern angular and lateral orientation of the attachment sub so that it can be readily affixed by threading to the neck portion. In a described embodiment, the positioning assembly includes a number of plates and rings that are in a stacked configuration and retain the attachment sub in a captive arrangement. The plates and rings are able to move laterally with respect to one another, thereby governing orientation of the attachment sub. In described embodiments, the positioning assembly also includes an articulated shaft assembly made up of a set of yokes and shafts to alter orientation of the attachment sub.
In featured embodiments, a clutch assembly operably interconnects the rotational drive member with the outer housing. The clutch assembly functions to release the outer housing from fixed attachment with the rotational drive member and articulated shaft assembly so that the rotational drive assembly will apply torque to the attachment sub following seating of the attachments sub onto the threaded portion of the remote tool. The clutch assembly allows the attachment sub to be threaded onto the neck portion of the remote tool after the neck portion has been captured by the retrieval device. The clutch assembly includes frangible shear members that are broken in order to free the outer body from the inner body and articulated shaft portion. Also in a described embodiment, the clutch assembly includes a key and slot arrangement that allows the outer housing to be carried by the rotational drive member after the shear members are broken.
In described embodiments, the retrieval device includes a fluid conduit that extends through the interior of the rotational drive member, articulated shaft assembly and attachment sub. Preferably, the fluid conduit is operably interconnected with a fluid pump at surface so that fluid pressure may be supplied through the conduit to the remote tool to be retrieved. This features assists in tool removal in instances where application of fluid pressure is used to release the tool within a wellbore from either the wellbore or interconnected tools within the wellbore.
In an exemplary described method of operation, a retrieval device constructed in accordance with the invention is secured to a rotatable running string and disposed within a remote location such as a wellbore which contains the remote tool to be removed. The retrieval device is placed proximate the remote tool. Rotation of the running string will rotate the retrieval device, including the outer housing. As the retrieval device is rotated by the running string, the neck portion of the remote tool becomes aligned with the opening in the locating plate of the retrieval device. The neck portion passes through the locating plate opening and positions the attachment sub in the correct orientation relative to the neck portion. The guide sleeve guides the attachment sub into the thread of the neck portion. The positioning assembly permits the attachment sub to be angled and moved laterally as necessary to be threaded into engagement with the remote tool via rotation of the running string.
Once the attachment sub has been threadedly engaged with the remote tool, the running string, retrieval tool and remote tool are withdrawn from the remote location.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
FIG. 1 is a side, cross-sectional view of a wellbore containing a remote tool to be removed and a retrieval tool constructed in accordance with the present invention.
FIGS. 2A and 2B are an enlarged side, cross-sectional view of the retrieval tool and remote tool of FIG. 1 during running in of the retrieval tool.
FIGS. 3A and 3B are an enlarged side, cross-sectional view of the retrieval tool and remote tool of FIG. 1 during tool orientation.
FIGS. 4A and 4B are an enlarged side, cross-sectional view of the retrieval tool and remote tool of FIG. 1 , now with the locating plate having been landed.
FIGS. 5A and 5B are an enlarged side, cross-sectional view of the retrieval tool and remote tool of FIG. 1 , now with the attachment sub fully engaged with the remote tool.
FIG. 6 is an exploded view of portions of an exemplary positioning assembly used within the retrieval tool shown in FIGS. 2A-2B .
FIG. 7 is an isometric detail depicting the locating plate of the retrieval tool in contact with the neck portion of the remote tool.
FIG. 8 is an isometric detail depicting the locating plate of the retrieval tool in contact with the neck portion of the remote tool and the opening of the locating plate aligned with the neck portion.
FIG. 9 is an exploded, isometric view of portions of an exemplary articulated shaft assembly used within the retrieval tool.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an exemplary wellbore 10 that has been drilled through the earth 12 and has been lined with metallic casing 14 . The wellbore 10 has a central axis, which is illustrated by the dashed line 16 . A remote tool 18 to be removed is located within the wellbore 10 . In the described embodiment, the remote tool 18 is releasably secured either to the wellbore 10 itself or to another tool (not shown) within the wellbore 10 and requires the application of a particular amount of fluid pressure to the upper portion of the remote tool 18 in order to release the remote tool 18 and allow it to be removed from the wellbore 10 . The remote tool 18 has a shoulder 20 with a neck portion 22 that extends axially upwardly from the shoulder 20 . As can be seen in FIG. 2 B, the neck portion 22 has an interior threaded portion 24 , by which the remote tool 18 is secured for removal from the wellbore 10 . It is noted that, in this example, the remote tool 18 has a central axis 26 that is angularly offset from the axis 16 of the wellbore 10 . In addition, in this example, the neck portion 22 is radially or laterally offset from the central axis 16 of the wellbore 10 .
A retrieval tool 28 , which is constructed in accordance with the present invention, is shown disposed within the wellbore 10 by a rotary running string 30 . The running string 30 may be formed of a number of production tubing string sections that are secured together in an end-to-end fashion. Alternatively, the running string 30 may be coiled tubing.
An exemplary retrieval tool 28 in depicted in greater detail in FIGS. 2A-2B and includes a generally bell-shaped outer housing 32 . In the depicted example, the outer housing 32 includes an upper, reduced diameter portion 34 and a lower, enlarged diameter portion 36 . Openings 38 are disposed through the angled shoulder 40 that interconnects the upper portion 34 with the lower portion 36 . The openings 38 allow fluid bypass when running in and help to reduce the overall weight of the retrieval tool 28 . The lower end of the lower portion 36 presents an opening 42 that is closed off by a locating plate 44 . The locating plate 44 includes an elongated opening 46 that is shaped and sized to receive the neck portion 22 of the remote tool 18 . Additionally, in certain embodiments, there is a lateral opening 47 that is formed within the lower portion 36 . The lateral opening 47 provides clearance for interior shaft elements at high angles of deviation and allows access to inner components during assembly, maintenance and operation.
The outer housing 32 is releasably secured by frangible shear members 48 to an articulated shaft assembly, generally shown at 50 . Preferably, the shear members 48 are disposed through the upper, reduced diameter portion 34 of the outer housing 32 . When the shear members 48 are intact, the rotational drive element (described shortly) will transmit torque to the outer housing 32 . The articulated shaft assembly 50 functions to allow lateral and angular movement of an attachment sub 52 within the outer housing 32 . The attachment sub 52 includes a threaded portion 54 that is complimentary to the threaded portion 24 of the remote tool 18 .
The exemplary articulated shaft assembly 50 includes an inner body top sub 56 which is affixed at its lower end to an inner body 58 . A rotational drive element 60 is disposed radially within the inner body top sub 56 . The rotational drive element 60 is rotated by the running string 30 and will transmit torque to other components of the retrieval tool 28 as described herein. It is noted that the shear members 48 interconnect the outer housing 32 to the inner body top sub 56 . Elongated slots 62 are formed within the inner body top sub 56 . A retainer key 64 is disposed within each slot 62 . The retainer keys 64 are secured in place against the rotational drive element 60 by securing plates 66 . When the shear members 48 are used to interconnect the outer housing 32 to the rotational drive element 60 , the retainer keys 64 are located proximate the lower ends of the elongated slots 62 . It should be understood that the retrieval tool 28 features a clutch assembly that includes the shear members 48 , retainer keys 64 and slots 62 . The clutch assembly of the retrieval tool 28 allows the rotational drive element 60 to be selectively released from fixed engagement with the outer housing 32 so that the rotational drive element 60 will thereafter primarily apply torque to the attachment sub 52 to drive it into threaded engagement with the neck portion 22 of the remote tool 18 . The outer housing 32 will still rotate with the inner body 58 and flex joint top sub 60 due to the presence of the retainer keys 64 within slots 62 . However, torque is now applied from the rotational drive element 60 to the attachment sub 52 via the telescopic shaft assembly 72 (described shortly) after the shear members 48 are broken.
The lower end of the rotational drive element 60 is affixed by pins 68 to an upper flex joint yoke 70 . The yoke 70 is affixed to a telescopic shaft assembly 72 also using pins 68 . FIG. 9 is an exploded view that helps illustrate an exemplary connection of the yoke 70 with neighboring components. The shaft assembly 72 is made up of an upper keyed shaft 74 and a lower keyed shaft 76 . The upper keyed shaft 74 receives the lower keyed shaft 76 in a nested configuration, and the two are capable of telescopic movement with respect to each other between extended and retracted positions. The lower shaft 76 is affixed to a lower flex joint yoke 78 , and the lower flex joint yoke 78 is, in turn, interconnected by pins 80 to the attachment sub 52 . Interconnection of the lower flex joint yoke 78 with neighboring components is done in a manner similar to that of the upper yoke 70 . A cylindrical guide sleeve 82 radially surrounds the attachment sub 52 and is attached to it. Preferably, the guide sleeve 82 presents an enlarged lower opening 84 with a tapered edge 86 to serve as a guide portion. It is noted that the lower opening 84 should be substantially aligned with the opening 46 of the locating plate 44 (see FIG. 3B ).
The outer housing 32 defines an interior chamber 88 , and the inner body 58 resides within the chamber 88 . Openings 90 are disposed through the inner body 58 . The openings 90 allow fluid bypass when running in and also help to reduce the weight of the retrieval tool 28 .
In the described embodiment, the inner body 58 also contains a positioning assembly, which is generally indicated at 92 . The positioning assembly 92 is used to angularly and laterally orient the attachment sub 52 to permit it to be aligned with and threadedly affixed to the remote tool 18 . Some portions of the positioning assembly 92 are best understood with further reference to FIG. 6 which shows certain components of the positioning assembly 92 in an exploded view. Generally, the positioning assembly 92 includes a plurality of components that captively retain the attachment sub 52 and which are slidably moveable with respect to one another within the inner body 58 to govern the angular and lateral orientation of the attachment sub 52 . The attachment sub 52 is retained captively within a number of openings that are disposed through these components. The exemplary positioning assembly 92 includes a set down plate 94 that is secured within the inner body 58 . An opening 96 is disposed through the set down plate 94 , and the attachment sub 52 extends through the opening 96 . The opening 96 is elongated and large enough to permit the attachment sub 52 to be moved around within the opening 96 . As can be seen in FIG. 6 , two flanges 98 extend downwardly from the lower side of the set down plate 94 defining a channel 100 between them.
The exemplary positioning assembly 92 also includes a set down ring 102 . The set down ring 102 has an opening 104 , and the attachment sub 52 extends through the opening 104 . The set down ring 102 is shaped and sized to fit within the channel 100 of the set down plate 94 and slide from edge to edge of the set down plate 94 within the channel 100 .
The exemplary positioning assembly 92 also includes a load ring 106 that radially surrounds the attachment sub 52 and is located below the set down ring 102 . In addition, a lower set down ring 108 . The lower set down ring 108 has a central opening 110 through which the attachment sub 52 extends. In addition, the lower set down ring 108 has ridges 112 that project upwardly from the upper surface of the lower set down ring 108 and contact the flat edges of the set down ring 102 .
Finally, the exemplary positioning assembly 92 includes a lifting ring 114 that is secured within the inner body 58 by a securing nut 116 . The attachment sub 52 extends through an opening 118 in the lifting ring 114 .
Fluid is able to pass downwardly through the running string 30 and the retrieval tool 28 . The running string 30 defines a flowbore 120 along its length. The flowbore 120 interconnects with flow opening 122 within rotational drive element 60 and is directed into a flexible fluid conduit 124 . The flexible conduit 124 passes through the upper flex joint yoke 70 , the shaft assembly 72 and the lower flex joint yoke 78 . The conduit then extends to a flow passage 126 that passes through the attachment sub 52 . Thus, fluid may be pumped downwardly from the surface into the flowbore 120 of the running string 30 and it will exit the attachment sub 52 . As a result, fluid pressure may be applied to the remote tool 18 as may be needed to, for example, release the tool 18 from locking interengagement with other tools within the wellbore 10 . Once engaged, fluid pressure can be applied when the remote tool 18 relies on a hydraulic system to release it from the wellbore 10 or from other tools within the wellbore 10 .
In an exemplary method of operation, the retrieval tool 28 is affixed to the running string 30 and disposed into the wellbore 10 , as depicted in FIG. 1 . The retrieval tool 28 is brought into contact with the remote tool 18 . The locating plate 44 of the retrieval tool 28 will contact the neck portion 22 of the remote tool 18 . Typically, the neck portion 22 will not be initially aligned with the opening 46 of the locating plate 44 , as illustrated by FIG. 7 . Because the shear members 48 are intact, rotation of the running string 30 will transmit torque at this point from the rotational drive element 60 to the outer housing 32 , thereby causing the outer housing 32 to rotate with the running string 30 . The running string 30 and affixed retrieval tool 28 are rotated until the opening 46 is aligned with the neck portion 22 (see FIG. 8 ). Once so aligned, the neck portion 22 will enter the opening 46 , as shown in FIG. 3B , preventing further rotation of the outer housing 32 and providing an indication of correct orientation exhibited by an increase in torque. Continuing to lower the running string 30 into the wellbore 10 will bring the neck portion 22 into contact with the tapered edge 86 of the guide sleeve 82 .
As the running string 30 and retrieval tool 28 are further lowered, the guide sleeve 82 and the attachment sub 52 move radially outwardly along the tapered edge 86 , as depicted by FIG. 4B , the guide sleeve 82 functioning to guide the attachment sub 52 into alignment with the neck portion 22 of the remote tool 18 . Once so aligned, further lowering of the running string 30 will bring the locating plate 44 into contact with the shoulder 20 of the remote tool 18 stopping further downward movement of the outer housing 32 and breaking the frangible shear members 48 of the clutch assembly. Once the clutch assembly is disengaged, the rotational drive element 60 is free to move and rotate within the outer housing 32 and further lowering and rotation of the running string 30 will thread the threaded portion 54 of the attachment sub 52 into the threaded portion 24 of the neck portion 22 of the remote tool 18 . Because the frangible shear members 48 have been broken, torque is now transmitted from the rotational drive element 60 to the attachment sub 52 via the articulated shaft assembly 50 rather than to the outer housing 32 .
To aid in the threading operation, angular and lateral orientation of the attachment sub 52 is altered by the articulated shaft assembly 50 as well as governed by the positioning assembly 92 . As the attachment sub 52 is urged into an off-center position by the guiding of guide sleeve 82 , the shaft assembly 72 will pivot upon the upper and lower flex joint yokes 70 , 78 as needed to allow the attachment sub 52 to achieve that position. Also, the shaft members 74 , 76 of the shaft assembly 72 will move telescopically with respect to each other by extending or retracting as needed to accommodate angular or lateral movement of the upper (non-threaded) end of the attachment sub 52 . In addition, the plates 94 , 102 and rings 106 , 108 and 114 of the positioning assembly 92 help orient the attachment sub laterally and angularly to assist with attachment to the remote tool 18 . The attachment sub 52 is held captively within the openings 96 , 104 , 110 and 118 within the plates 94 , 102 and rings 106 , 108 and 114 . Therefore, as these stacked members slide relative to each other, they govern lateral movement of the attachment sub (relative to the central axis 16 ) and, therefore, help it be threaded together with the angled neck portion 22 of the remote tool 18 . This lateral and angular orientation can be seen by comparison of FIG. 3B , which depicts an orientation of the attachment sub 52 that is generally aligned with the central axis 16 , with FIG. 5B , which shows an orientation that departs laterally from the central axis 16 .
Once the remote tool 18 has been affixed to the retrieval tool 28 , fluid pressure may be applied through the running string 30 as required to release the remote tool 18 . The running string 30 , retrieval tool 28 and remote tool 18 can then be removed from the wellbore 10 by pulling upwardly on the running string 30 .
The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to those skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention.
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A retrieval tool and method for retrieving a remote tool with a threaded connection from a remote location. The retrieval tool includes a rotational drive member which rotates an attachment sub having a complimentary threaded portion. An articulated shaft assembly permits the attachment sub to move laterally and angularly with respect to the axis of the rotational drive member. A fluid conduit supplies fluid pressure for releasing the remote tool.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to a motor vehicle door lock system, including a door lock and a outside door handle. In particular, the invention relates to a motor vehicle door lock system whereby the spatial proximity of the hand of the operator with regard to the outside door handle and/or the actual touching of the outside door handle by the operator can be easily detected using a comparatively low power source having excellent response behavior.
[0003] 2. Description of the Related Art
[0004] Electromechanical motor vehicle door lock systems having radio activated remote control but lacking a passive entry function are well known. In these conventional vehicle door lock systems, the operator presses a button on a remote control module, which activates the control electronics by causing the control electronics to pass through its reaction phase immediately. Based upon the distance of the operator when the remote control module button is pressed, the operator reaches the outside door handle on the motor vehicle door with such a long time delay that the reaction phase of the control electronics has long been completed and the motor vehicle lock has been unlocked. By pulling on the outside door handle the operator opens the motor vehicle door, the motor vehicle lock opens either mechanically, whereby the detent pawl is lifted by the motion of the outside door handle, or electromechanically or pneumatically, whereby the outside door handle delivers a control signal to the opening drive to raise the detent pawl.
[0005] Control electronics having a so-called passive entry function, also called an “electronic key”, differs from the above explained conventional electromechanical motor vehicle door lock system in that on the remote control module no manipulation is necessary, therefore a button need not be pressed to unlock the motor vehicle lock when approaching the motor vehicle. Rather, the unlocking of the motor vehicle lock occurs automatically simply when the operator approaches the motor vehicle.
[0006] Accordingly, a passive entry function is defined especially as automatic, vehicle-side data interrogation or identification of an operator-side data medium, transponder or the like in order to ascertain whether an operator approaching the motor vehicle or an operator already engaged in the process of opening the vehicle door is authorized for access. This is generally checked by the corresponding electronics of the motor vehicle. With corresponding authorization of the operator, ordinarily automatic unlocking takes place either by a central interlock system of the door lock of the driver-side door, or at least of the door lock of any door being approached by the operator and any door whose outside handle the operator is touching or activating.
[0007] A motor vehicle door lock system with a passive entry function requires for the control electronics a certain reaction phase or time which is composed of: a starting interval to activate the system as the data medium or remote control module approaches; an authorization check interval to check the operator for his authorization using the coding of signals exchanged between the remote control module and the control electronics; and an actual action interval in which the unlocking of the motor vehicle lock is carried out.
[0008] A corresponding reaction phase is also required when locking the vehicle door lock system, the reaction phase occurring in a manner that is essentially unnoticed by the operator. The length of the reaction phase is approximately more than one hundred milliseconds and is perceived as long as the starting interval is initiated only upon activating the outside door handle. Pulling the outside door handle or the like can take place in a passive entry function under certain circumstances when the reaction phase of the control electronics has not yet been completed. The operator must then pull the door handle a second time; this can be interpreted as a “malfunction”. Since the resulting total time of the reaction phase cannot be shortened as much as desired, attempts have already been made to conceal the delay time.
[0009] Published German Patent Application DE 95 21 024 discloses a motor vehicle door lock system wherein the starting interval and the authorization check interval of the control electronics are shifted into a phase which precedes the actual operation phase which is noticeable to the operator. Accordingly, the remaining time which corresponds to the reaction time of a conventional mechanical motor vehicle door lock system is noticeable to the operator.
[0010] A different approach is to have the starting interval of the control electronics initiated not only when the outside door handle is activated, but also when the hand of an operator approaches the outside door handle. This is accomplished by providing a capacitive proximity sensor on the outside door handle. Published German Patent Applications DE 197 52 974 and DE 196 17 038 each disclose such motor vehicle door lock systems wherein the approach of the hand of the operator is acquired roughly 100-150 ms prior to the hand touching the outside door handle. Consequently, the starting interval of the control electronics, i.e., the “awakening” of the control electronics, begins so far ahead of the actual pulling of the outside door handle that the starting interval and usually the authorization check interval are already completed once the outside door handle is moved by the hand of the operator.
[0011] Because external effects such as rain, snow, dirt and dust greatly change the measured values greatly in capacitive proximity sensors, comparatively high complexity is necessary to ensure proper operation. The use of capacitive proximity sensors in motor vehicle door lock systems is conventional, but entails various difficulties. While the proximity sensors utilize a comparatively high closed-circuit current, it is difficult to set a stable, unequivocal response threshold, and is also expensive. Moreover, due to the use of a comparatively high closed-circuit current, high circuit complexity is necessary, which leads to high costs. Finally, capacitive proximity sensors also emit electromagnetic radiation, which causes interference.
[0012] Based upon the aforementioned difficulties, motor vehicle door lock systems with a passive entry function in which only touching or actuating the outside door handle by the hand of an operator begins the starting interval of the control electronics also have major advantages.
[0013] U.S. Pat. No. 4,868,915 discloses a keyless access system for motor vehicles and includes a passive entry function. The access system has an antenna and an identification means for checking the access authorization of an operator-side data medium if an operator with a data medium is in the monitoring area, and a proximity sensor which activates the access system when an operator is in the monitoring area. While the proximity sensor is preferably a capacitive proximity sensor, magnetic, inductive, acoustic or similar proximity sensors can also be used. One preferred arrangement of the access system and thus also the proximity sensor in the area of the A column or the B column of a motor vehicle is disclosed. Finally it is a type of “antenna system” with wide-area emission.
SUMMARY OF THE INVENTION
[0014] Accordingly, the object of this invention is to overcome the aforementioned disadvantages in devising a motor vehicle door lock system whereby the proximity of the hand of the operator with regards to an outside door handle, and/or the actual touching of the outside door handle by the hand of an operator can be easily detected using a comparatively low power demand and with good response behavior. An aspect of the invention includes a passive entry function of the motor vehicle door lock system can be activated or a starting interval of the control electronics can be initiated. The lock system utilizes ultrasonic waves for the detection of proximity of the hand of an operator with regards to an outside door handle, and/or the touching of the outside door handle by the hand of an operator in the near field.
[0015] In the present invention, “ultrasound” is defined as vibrations or sonic waves with frequencies above the audible range, for example, above approximately 16-20 kHz and preferably up to approximately 8×10 9 Hz. This ensures that the acoustic waves emitted for detection purposes are not audible. Another advantage of the use of ultrasonic waves lies in that at a comparatively low power demand a favorable response behavior can be achieved with respect to the sensing of proximity or contact.
[0016] Another fundamental aspect of this invention is that at least essentially only in the area or in the vicinity of the outside door handle is an ultrasonic field generated. This enables extensive minimization of the power demand, since simply a comparatively small three-dimensional area must be monitored and sufficiently early detection of proximity or contact is still possible.
[0017] In particular, in accordance to the present invention an ultrasonic transducer is provided directly on the outside door handle for emitting and/or acquiring the ultrasonic waves. Here an “ultrasonic transducer” is defined as a component for converting electrical signals into ultrasonic waves or converting ultrasonic waves into electrical signals. “Acquisition” is defined as making available data or measurement signals, the evaluation of which enables detection or sensing of whether the hand of an operator has approached the outside door handle, or is already touching and/or activating the outside door handle. The evaluation can take place especially directly in electronics assigned to the sensor and/or in separate evaluation electronics or the like. This goes without saying for one skilled in the art so that it is not detailed here, since it is essentially irrelevant where the evaluation takes place. However, it is advantageous if the evaluation electronics which make available the corresponding detection signal is already integrated into the outside door handle or the outside door handle arrangement.
[0018] The preferably integrated arrangement of the ultrasonic transducer on the outside door handle enables comparatively simple refitting or introduction in motor vehicles already in production, since simply a correspondingly modified outside door handle with the assigned control and/or evaluation electronics must be used instead of a conventional outside door handle. Approaching the outside door handle and/or touching the outside door handle is preferably detected or acquired by one of the following possibilities or combinations. One simple and economical embodiment calls for the ultrasonic transducer to work both as a sensor and also as a receiver. Especially in pulsed generation of the ultrasonic waves can then the ultrasonic transducer work in the pulse pauses as a receiver. When the ultrasonic waves emitted by the ultrasonic transducer are reflected back by a section of the outside door handle and/or the door area adjacent to the outside door handle, such as the handle well, to the ultrasonic transducer, this can be evaluated in that the hand of the operator or the like does not interrupt the ultrasonic field or the propagation of the ultrasonic waves, therefore there is no proximity. The failure of reflected ultrasonic waves to appear and/or the change of the transit time, because for example the hand of an operator reaching into the ultrasonic field reflects the ultrasonic waves to the ultrasonic transducer, can be detected as proximity and/or contact.
[0019] Optionally, the rate of change of the transit time can be considered. The corresponding applies when ultrasonic waves are reflected back to the ultrasonic transducer solely by an approaching object to be detected, such as the hand of an operator, and not by the outside door hand and/or an adjacent door area. Occurrence of a reflection signal and optionally the change of its transit time then indicate proximity and/or touching. Alternatively or additionally to the ultrasonic transducer operating both as a transmitter and a receiver, there can be an additional ultrasonic transducer for acquiring the emitted ultrasonic waves. The at least two ultrasonic transducers are preferably then located on the outside door handle such that a photoelectric barrier-like ultrasonic field is formed, the interruption of which can be detected as a proximity and/or contact. The sonic propagation between the two ultrasonic transducers however need not run in a straight line. Rather also for example ultrasonic waves reflected on an adjacent door area, such as the handle well, are acquired by the additional ultrasonic transducer. In this case the transmitter and receiver can be located for example nearer to or directly next to one another.
[0020] Depending upon the combination of the aforementioned detection and evaluation possibilities, both proximity and contact can be easily sensed. Differentiation between proximity and contact can be done especially by evaluating transit times and/or the failure of reflection signals to appear. The sensing of proximity and/or touch enables early activation of the passive entry function and initiation of the starting interval of the control electronics. Thus, enough time is gained to unlock the motor vehicle lock for example before the operator in fact actuates the outside door handle to open the corresponding motor vehicle door or the motor vehicle lock.
[0021] The ultrasonic transducer can alternatively be located on a door area adjacent to the outside door handle, such as the handle well. The same applies when using several ultrasonic transducers as well. Thus, especially when this adjacent door area belongs to an outside door handle arrangement which is inserted as a separate part or separate unit into the assigned motor vehicle door, can installation into the motor vehicle door be simplified since the problem of establishing an electrical connection to the ultrasonic transducer in the outside door handle which is conventionally made movable is eliminated. When both proximity and also contact in succession are detected separately, the corresponding functions of the motor vehicle door lock system, the control electronics or for example other electronics of the motor vehicle can be activated in two stages, staggered in time.
[0022] Other aspects, properties, features and advantages of this invention follow from the explanation of preferred embodiments below which are shown in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 shows in a schematic and perspective view a motor vehicle with a vehicle door lock system as claimed in the invention;
[0024] [0024]FIG. 2 shows an outside door handle arrangement in a motor vehicle door lock system as shown in FIG. 1;
[0025] [0025]FIG. 3 shows a schematic plan view of an outside door handle arrangement according to a first embodiment as claimed in the invention;
[0026] [0026]FIG. 4 shows a schematic plan view of an outside door handle arrangement according to a second embodiment as claimed in the invention;
[0027] [0027]FIG. 5 shows a side view of the outside door handle arrangement as shown in FIG. 4; and
[0028] [0028]FIG. 6 shows a schematic plan view of an outside door handle arrangement according to a third embodiment as claimed in the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring now to the drawings, FIG. 1 schematically shows a motor vehicle 1 with a vehicle door lock system 2 having a plurality of vehicle locks 3 for the vehicle doors, the rear hatch and the like, and a hood lock 4 with installation positions. Preferably, each motor vehicle lock 3 can be locked and unlocked by a motor such as an electric motor having a conventional central interlock or a central interlock drive. Each motor vehicle lock 3 may additionally include a motorized opening to lift the detent pawl (not shown) by means of an opening drive (not shown). The locking and unlocking can also be done through the exclusive use of circuitry. In a second embodiment, the motor vehicle locks 3 include an auxiliary closing drive which can be identical to the opening drive or can be separate from it.
[0030] The motor vehicle door lock system 2 is preferably equipped with a passive entry function including a data medium made such as a passive entry chip card or other data medium or transponder 5 which is carried and used as an electronic key by the operator of the vehicle. Thus, data interrogation or identification of the data medium or the transponder 5 can be carried out and the access authorization of the operator can be checked. This may be accomplished by signal waves 6 emitted from the transponder 5 to the motor vehicle driver-side door. With the corresponding access authorization, the motor vehicle locks 3 are unlocked by means of a conventional central interlock system (not shown) or the like. A lock cylinder 7 and a mechanical key 8 is assigned to the motor vehicle lock 3 for use with the driver-side door and the hood lock 4 . Thus, the motor vehicle lock 3 of the driver-side door and hood lock 4 can be mechanically actuated or unlocked in the event of an emergency using the key 8 . In addition, there can be a corresponding emergency unlocking or opening for the other motor vehicle locks 3 .
[0031] As shown in FIG. 1, an outside door handle arrangement 9 is assigned to at least each motor vehicle door lock 3 of the motor vehicle side doors. FIG. 2 shows the outside door handle arrangement 9 of the driver-side door with an integrated lock cylinder 7 . The outside door handle arrangement 9 further includes an outside door handle 10 which is movably supported and interacts with an assigned switching means 11 of the outside door handle arrangement 9 . In operation, when the outside door handle 10 is pulled by the operator, a switching signal is triggered in order to drive an assigned opening drive (not shown) for opening the assigned motor vehicle lock 3 or to lift the detent pawl of the corresponding motor vehicle lock 3 . In a mechanically actuated motor vehicle lock 3 , instead of a switching means 11 there is a conventional transfer mechanism or other actuation detection means. But the switching means 11 can also be omitted when the outside door handle 10 is not movably supported and instead sensing of proximity and contact is accomplished to automatically open the assigned motor vehicle lock 3 . The outside door handle arrangement 9 can additionally include an adjacent door area (not shown).
[0032] [0032]FIG. 3 shows in a schematic overhead view the outside door handle arrangement 9 , which can be made without the lock cylinder 7 . In this embodiment, there is an electrically drivable or operable ultrasonic transducer 12 integrated into the outside door handle 10 . The ultrasonic transducer 12 can produce an ultrasonic field 13 which is emitted as ultrasonic waves 14 , and reflected ultrasonic waves 15 . The ultrasonic transducer 12 works both as a transmitter and a receiver, with the ultrasonic waves 14 preferably being emitted in pulses which pauses the reflected ultrasonic waves 15 being acquired. Accordingly, while only a single ultrasonic transducer 12 is shown, a plurality of ultrasonic transducers 12 which operate in the same manner can be mounted on the outside door handle 10 and/or on an assigned door area.
[0033] [0033]FIGS. 4 and 5 illustrate a second embodiment of the outside door handle arrangement 9 in accordance with the present invention, including a single ultrasonic transducer 12 which works both as the transmitter and receiver, similarly to in the first embodiment. FIG. 6 shows a third embodiment of the outside door handle arrangement 9 in accordance with the present invention, including an additional ultrasonic transducer 16 placed on the outside door handle 10 for use as a receiver for acquiring the ultrasonic waves 14 emitted by the ultrasonic transducer 12 . The ultrasonic transducers 12 , 16 may include a piezoelement comprising a small, economical device having a comparatively lower power demand and available in various suitable embodiments for installation into the outside door handle 10 . In particular, there is essentially a linear sound propagation between the two ultrasonic transducers 12 , 16 operating as the transmitter and receiver. But the ultrasonic transducers 12 , 16 can be arranged in closer spatial proximity to one another for a sonic connection which is not directly linear, but with acquisition of reflected sonic waves. Moreover, the ultrasonic transducers 12 , 16 may be mounted on sections 20 , 21 of the outside door handle 10 at a distance far away as possible from one another in order to enable monitoring of the access space 18 as accurately as possible.
[0034] As shown in FIGS. 3, 4 and 6 , in operation, an ultrasonic field 13 is produced at least temporarily in an access space 18 formed between the outside door handle 10 and the adjacent door panel area 17 . The adjacent door panel area 17 may include a handle well or the like which is inserted or molded into the outside door panel skin. The “access space” is defined as the space into which the hand of an operator ordinarily reaches when activating the outside door handle 10 . To minimize the power demand for the proximity or contact sensing, the ultrasonic field 13 is produced at least essentially solely in the access area 18 . In addition, and as illustrated in FIG. 5, the ultrasonic field may also be produced in the spatial areas 19 surrounding the door handle 10 .
[0035] In the following description, the detection of the proximity of the hand of an operator to the outside door handle 10 and the touching of the outside door handle 10 by the hand of an operator is detailed. For acquisition and evaluation purposes, the motor vehicle lock system includes an evaluation unit including a controller 22 for controlling or driving the ultrasonic transducers 12 , 16 . Optionally, as shown in FIG. 6, there is a second controller 23 . The controllers 22 , 23 are preferably integrated into the outside door handle arrangement 9 , preferably within the outside door handle 10 . Alteratively, the controllers 22 , 23 can be at least partially integrated into an assigned motor vehicle door or into a central motor vehicle controller 24 for the vehicle 1 .
[0036] As shown in FIG. 3, the ultrasonic waves 14 are emitted preferably in pulses transmitted by the ultrasonic transducer 12 . The ultrasonic waves 14 are reflected by a stationary part, such as the outside door handle 10 , towards the ultrasonic transducer 12 which reacquires the reflected ultrasonic waves 15 , especially in the transmission pauses. The direction of primary emission of the ultrasonic waves 14 runs preferably parallel to the lengthwise extension of the outside door handle 10 , and at least essentially parallel to the outside contour of the assigned motor vehicle door panel and especially essentially horizontally as a result of the generally conventional horizontal alignment of the outside door handle 10 . If the hand of an operator is moved into the access space 18 in order to actuate the outside door handle 10 , the ultrasonic field 13 is disturbed or interrupted. The failure of the reflected ultrasonic waves 15 to appear and/or the transit time change of the reflection signal are detected and evaluated as proximity to the outside door handle 10 . In particular, a corresponding signal is output by the controller 22 to the central motor vehicle controller 24 .
[0037] As shown in FIGS. 4 and 5, in the second embodiment, the ultrasonic transducer 12 preferably emits ultrasonic waves in pulses 25 . In contrast to the first embodiment, the pulses are not reflected back to the ultrasonic transducer 12 to any great degree by the outside door handle arrangement 9 or the outside door handle 10 . The direction of primary emission of the pulses 25 relative to the lengthwise extension of the outside door handle arrangement 9 or the outside door handle 10 is slanted both in the vertical and horizontal plane, preferably upwards and towards the motor vehicle 1 . For an access space 18 which is open only to the bottom, the direction of primary emission of the pulses 25 is preferably directed downward instead of upward. Preferably, the direction of primary emission of the pulses 25 therefore has a component or alignment pointed opposite the conventional access motion.
[0038] Only in instances when the hand of an operator is moved into the ultrasonic field 13 , such as the spatial area 19 and/or the access space 18 , does reflection of the ultrasonic waves 15 towards the ultrasonic transducer 12 take place. This event is acquired and detected as proximity or contact with the outside door handle 10 and the transit time of the ultrasonic waves 15 can be considered to differentiate between proximity and contact.
[0039] In the second embodiment, the direction of primary emission of ultrasonic waves 14 from the ultrasonic transducer 12 or the direction of primary extension of the ultrasonic field 13 , can be acquired, detected and evaluated if provisions are made for at least few or essentially no reflections occurring on the outside door handle 10 or other parts of the outside door handle arrangement 9 in its return path back to the ultrasonic transducer 12 . Optionally these reflections can be masked out by choosing a corresponding time window in the evaluation. The system may include a feedback means for controlling at least one of the frequency, pulse length, and amplitude of the transmitted and acquired ultrasonic waves.
[0040] In the third embodiment a more or less photoelectric barrier-like ultrasonic field is produced only in pulses 25 , preferably to minimize the power demand. The ultrasonic transducer 12 emits ultrasonic waves 14 which strike the additional ultrasonic transducer 16 especially directly or optionally after reflection on parts or sections of the outside door handle arrangement 9 and are acquired. If the hand of an operator moves into the access space 18 or into the ultrasonic field 13 , the ultrasonic field 13 between the ultrasonic transducers 12 , 16 is disrupted or completely interrupted. This is acquired and evaluated as proximity to the outside door handle 10 or contact with the outside door handle 10 . Depending upon the execution of the ultrasonic transducer 12 , a hand located in the ultrasonic field 13 can also reflect ultrasonic waves which are acquired and evaluated as proximity or contact back to the ultrasonic transducer 12 . This can take place additionally to the detection of an interruption or of proximity in order to achieve high response reliability.
[0041] The motor vehicle controller 24 preferably has a conventional passive entry function. In particular, to unlock the motor vehicle lock 3 or all motor vehicle locks 3 the motor vehicle controller 24 requires a time reaction phase with a starting interval, authorization check interval and the action interval. When proximity to the outside door handle 10 of any door, or at least the outside door handle 10 of the driver-side door, is sensed or detected, the motor vehicle controller 24 is activated to initiate the starting interval. Alternatively the activation takes place only upon detection or sensing of contact with any outside door handle 10 or the outside door handle 10 of the driver-side door. Early initiation of the starting internal and early checking of the access authorization of the operator who has approached or who is touching the outside door handle 10 are achieved by interrogation or identification of the operator-side data medium or transponder 5 , with the result that the actual activation or pulling of the outside door handle 10 lasts so long that the action interval, generally the lifting of the detent pawl, can proceed seemingly without delay for the operator.
[0042] As already addressed, both proximity sensing and also contact sensing can take place. For example, the evaluation can output a first signal upon detection or sensing of spatial spatial proximity in order to start the passive entry function or the starting interval of the motor vehicle controller 24 . Then, with the corresponding authorization and with a correspondingly time-correlated sensing of contact of the outside door handle 10 the central interlock can be unlocked and/or the assigned motor vehicle lock 3 can open. In the latter case, a switch assigned to the outside door handle 10 or the switching means 11 can be omitted. Then it is not even necessary to make or support the outside door handle 10 or part thereof to be movable.
[0043] The aforementioned measurement or evaluation methods of the preferred embodiments can also be optionally combined with one another. In addition, it should be pointed out that spatial proximity sensing and/or contact sensing can be used also to control other motor vehicle functions and to activate other motor vehicle controls. Preferably to do this the corresponding control signals can be output by the evaluation electronics 22 or other electronics.
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A motor vehicle door lock system whereby at least one of spatial proximity of an operator to the outside door handle and a physical touching of the outside door handle by the operator can be easily detected using a comparatively low power source exhibiting excellent response behavior. One aspect includes a passive entry function of the motor vehicle door lock system can be activated or a starting interval of the control electronics can be initiated. The lock system utilizes ultrasonic waves for the detection of the at least one of spatial proximity of an operator to the outside door handle and a physical touching of the outside door handle by the operator. To sense spatial proximity to the outside door handle and/or touching of the outside door handle at least essentially solely in the access space defined by the outside door handle, an ultrasonic field is produced whereby changes and/or interruptions of the ultrasonic field is detected upon the occurrence of these events.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
[0001] The present invention relates to cladding of roofs and walls of buildings of all kinds, in particular, to a sheet metal cladding panel. The invention further relates to a method for easily attaching the panels to each other to form a sealed cover.
BACKGROUND OF THE INVENTION
[0002] For cladding walls and roofs of buildings, a number of different types of sheet metals panels are available on the market. Many of them have the disadvantages that the mounting of the panels is complicated and time-consuming. This is due to the fact that most known panels require, for their attachment to a substructure, special fastening elements, such as metal strips and fastening clips, which are attached to the substructure with the aid of screws or nails for positioning the panel in relation to the substructure and partly for supporting the panel. Said fastening elements must thus be positioned exactly in relation to the joint between two panels, which requires very accurate measurements for each fastening elements before they can be screwed or nailed in place. When the panel itself is lifted and positioned into its intended location, the fastening elements are folded over a side edge of the panel by hand.
[0003] As one example of a cladding panel, when the next panel is put in place to join the first one, it can have a folded seam gripping over an upstanding side edge of the first panel, whereby the fastening element is folded up and around the folded seam. After this has been done the seaming of the two plates to each other can take place with the aid of a seaming machine. In addition, the known cladding panels, which are mutually joined by seaming, very often require an adaptation of a panel to adjacent panels. This must be performed by cutting away appropriate parts of the sheet panel. This work is time consuming and requires great precision to maintain close fitting and overlapping between the panels to become joined.
[0004] A solution to overcome the listed drawbacks of prior art panels has been disclosed in the patent publication WO 89/05419. In said document, there is presented a sheet metal panel comprising a middle portion between two upwardly folded flanges, of which at least a first one of the upwardly folded flanges has a portion being bent outwardly and downwardly to form a half seam. The second one of the upwardly folded flanges is a single layer sheet metal flange of a height shorter than the height of the first folded flange. According to the arrangement, when two panels are joined alongside each other, the half seam of the first flange of a first panel is positioned over and engaging the second flange, i.e. the single layer sheet metal flange, f of a second panel. The half seam of the first panel can then easily be folded to the sheet metal flange of the second panel to arrive at a sealed folded seam between the two panels. The content of the publication WO 89/05419 is hereby in its entirety incorporated into this description.
[0005] By use of the device presented in WO 89/05419 it is important that, in order to get a complete sealing between the single layer sheet metal flange forming the second flange and the half seam of the first flange. To accomplish this, the cross section height of the second flange preferably reaches up to the inside of the folded half seam. Due to the production processes of the sheet metal panels, it has turned out that during the folding of the panels to establish the second flange, it is difficult to provide said second flange with the correct measures. The tolerance of the height of the second flange can vary up to ±3 mm. A drawback by use of the sheet metal panel presented in said document is that it is a risk of obtaining a non perfect sealing of the seam between the two adjacent flanges of the first and the second panel, when the first and the second flanges are folded together. Moisture could penetrate the seam. A further disadvantage with the prior art panels is that an upstanding side edge of the first panel can be very sharp and thus tear from below the half seam of the adjoining panel covering said sharp edge when the panel are moving in relation to each other.
[0006] Document U.S. Pat. No. 214 027 presents a solution to the stated problem. In said document there is disclosed an elongated sheet metal member forming a web of the panel, upwards folded flanges along the two elongated edges of said web of the panel, a first of said upwards folded flanges being folded outwards and downwards along its upper edge to form a first lap and a second of said upwards folded flanges is folded inwards and downwards along its upper edge to form a half lap. The panel is further provided with a mounting rail along the first flange. An advantage with said invention is that it is easier in the production process to provide the panels with a more exact height of the second flanges of each sheet metal panel. Consequently the second flange of a first panel will always reach up to the inside of the half seam of the second flange of a second panel when the two panels are mounted together alongside of each other. By this a complete seal between the first and the second panels can be provided.
[0007] When a panel of the kind as disclosed in U.S. Pat. No. 214 027 nevertheless has to be cut across its length, where the panel at the cut includes a mounting rail, this could be a tough work as the first flange consists of a double plate layer in the flange and the lap, which makes it very difficult to cut the panel with tools at these locations.
[0008] An object with the present invention is to provide an improvement of the device in relation to prior art and a method for cladding substructures by use of the device
BRIEF DESCRIPTION OF THE INVENTION
[0009] According to one aspect of the present invention there is provided a device characterized in claim 1 .
[0010] According to a second aspect of the invention there is provided a system for use of the device of claim 1 for cladding a roof or a wall of a building according to the independent system claim.
[0011] In a further aspect of the invention a method for cladding a building with the device of claim 1 is presented in the independent method claim.
[0012] Further embodiments are presented in the dependent claims.
[0013] The advantages of the invention related to the different embodiments will be discussed below.
[0014] According to the aspects of the invention the plate of the panel is at the outer one of the double layers of the first flange and the inner one of the double layers of an associated lap provided with slots at regular intervals. The slots are formed as pre-cuts, so that it will be easy to cut the panel at these locations if it is desired to use a shorter panel than the full length pre-fabricated panel.
[0015] Further features of the present invention are disclosed in the subsequent detailed description, which shall be interpreted in combination with the attached drawings. It must be emphasized that the drawings are performed only for the purpose of illustration and shall not limit the invention. The drawings are not performed to scale and shows only conceptual structures and procedures described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 schematically shows a perspective view of the elongated sheet metal panel according to one aspect of the invention.
[0017] FIG. 2 shows in a perspective view the same panel as in FIG. 1 but more from the side of the panel.
[0018] FIGS. 3 a and 3 b show cross sectional views of the panel of FIG. 1 . In FIG. 3 a the view is from the higher located end of an intended location on a building. In FIG. 3 b the view is from the lower located end of an intended location on a building.
[0019] FIGS. 4 a and 4 b shows side views of the panel of FIG. 1 .
[0020] FIG. 5 is a plan view of the panel of FIG. 1 as it is seen from above.
[0021] FIG. 6 shows a schematic view of two sheet metal panels according to an aspect of the invention, wherein the seam joining two adjacent panels is shown in enlargement.
[0022] FIG. 7 is a perspective view of the panel of FIG. 1 from a different angle.
DESCRIPTION OF EMBODIMENTS
[0023] Below, a number of embodiments of the invention are described in support of the enclosed drawings.
[0024] A sheet metal cladding panel ( 1 ) according to an aspect of the invention is illustrated in FIG. 1 . A main portion of the panel 1 is occupied by a surface in the centre part formed by an elongated sheet metal member forming a web 2 of the panel ( 1 ).
[0025] The web 2 of the panel 1 has along its longitudinal edges upwards folded flanges, a first flange 3 and a second flange 4 . Said first flange 3 is in turn along a first ridge 5 folded once again outwards and downwards, as illustrated in FIGS. 1 and 3 , to form a lap 6 . A notch 7 is in this way formed between the first flange 3 and the lap 6 of said first flange 3 . The cross sectional length a of the lap 6 is between 12 mm and 16 mm, in the example preferably around 16 mm. The height of the first flange 3 from the web 2 up to the first ridge 5 is between 30 mm to 50 mm and preferably around 35 mm. Thus, it can be understood that the length a of the lap 6 is approximately half the height of the first flange 3 .
[0026] An object with the panels according to the invention is to clad a substructure by joining panels 1 of the described type along their longitudinal edges such that the second flange 4 of a second panel is inserted into and along said notch 7 of the first flange 3 of the first panel until said second flange 4 fits into said notch 7 . After the insertion of the second panel in this way, the first panel and the second panel are folded together along their united first and second flanges, described in more detail below.
[0027] In a similar way to the described first flange 3 , for each panel 1 , the second flange 4 is along a top line bent inwards and downwards (see FIGS. 1 and 3 ) to form a half lap 8 , thus forming a second ridge 9 at the intersection of the second flange 4 and the half lap 8 . The cross sectional length b of the half lap 8 is in this preferred embodiment around 8 mm, but it is possible to use any length b between 4 mm to 10 mm adapted to the length of the lap 6 of an adjoining panel aimed to cover said half lap 8 . An advantage with the solution of using the half lap 8 of the second flange 4 is that the deviations in the widths of the sheet metals during fabrication of the sheet metals, in comparison to prior art where these deviations appeared as different heights of the second flange 2 of the manufactured panels, are instead when using panel according to the invention established as deviations of the length b of the half lap 2 , which do not cause any inconveniencies or drawbacks with respect to the assembled panels.
[0028] The height of the second flange 4 from the plane of the web 2 up to the top of its second ridge 9 is a little shorter than the height of the first flange 3 up to the top of its ridge 5 . This is due to the fact that the second flange 4 of a second panel shall fit well into the notch 7 of the first flange 3 of the first panel.
[0029] One improvement of the invention in relation to prior art is that the half lap 8 is provided at the production of the panels 1 . As the half lap 8 is folded at a predetermined height h from the bottom of the panel 1 , this is possible to arrange at the manufacturing with a high tolerance compared to the corresponding height of prior art panels, where the lap 8 and the ridge 9 are missing. The plates delivered from a production plant can have differences of their widths as much as up to ±6 mm. These differences can affect the tolerances of the heights of the prior art single metal layer of the second flange 4 .
[0030] By the height, all over this description, is meant the height measured from the underside of the panel, that is from the point where the panel contacts a substructure when being mounted.
[0031] The lap 6 and the half lap 8 of the first 3 and second 4 flanges are at the production process folded downwards to an angle around 45° in relation to the upstanding flange. This inclination downwards in an angle around 45° of the half lap 3 further serves as a water trap, when the panels are used without a finalised folding together of the lap 6 of a first flange of a first panel and a half lap 8 of a second flange of a second panel in cladding a roof or a wall where the angle in relation to the horizontal plane does not require such a finalised folding work.
[0032] Both the first flange 3 and its lap 6 are double-folded. This means that the plate is folded along the lower longitudinal edge 11 of the lap 6 towards the inside of the notch 7 180° back so that the lap 6 is formed as a double layer. At the top of the notch 7 , the plate is folded once again to follow the line of the first flange 3 downwards and thus forming also the first flange 3 into a double layer sheet. In this way all the surfaces of the second flange 3 will have the top surface of the sheet metal from which the panel 1 is produced as outer surfaces. This is important as a protection layer or a coloured surface will be unbroken at the first flange 3 .
[0033] Each panel 1 includes a fastening element 12 for the purpose of fixing the panel to a substructure S to be clad by the panel 1 . The fastening element 12 is a part of and a continuation of the plate which is forming the web 2 , the first flange 3 and the lap 6 , as the plate after being folded back along the inside of the lap 6 and further downwards along the first flange 3 is once again folded outwards from the panel 1 approximately in the plane of the web 2 of the panel 1 to form said fastening element 12 as an extended rim along the side of the panel 1 adjoining the first flange 3 in the plane of the bottom of the panel.
[0034] FIG. 6 illustrates, more in detail, how the fold between a first and a second panel 1 is accomplished. The second flange 4 has been previously inserted into the notch 7 formed between the first flange 3 of the first panel 1 and the lap 6 . Preferably, according to a further aspect of the invention the notch 7 is pre-filled with a sealing agent 10 , such as a grease, a plastic compound or the like. The height of the second ridge 9 should preferably be such that it abuts or nearly touches the innermost part of the notch 7 . The folding to form a seam between the first and the second panel is then performed along the two flanges 3 , 4 . The seam is achieved by folding the lap 6 in and over the edge of the half lap 9 of the second flange 4 . This is possible as the length a of the lap 6 of the first flange 3 is approximately twice the length b of the half lap 9 of the second flange 4 . The folding can be made by means of hand tools or by means of a folding machine. The lap 6 is clamped towards the second flange to form a sealed seam. The sealing agent will thus further spread between the two flanges 3 , 4 . The high tolerance of the height of the second flange 4 will also provide for a secure sealing to make the seam resistant to water and humidity and for avoidance of capillary suction. A further advantage is that the lap 6 encircles the half lap 8 , whereby the stability of the joint between the adjoining panels is improved.
[0035] A further advantage related to the invention is that the second flange 4 being without the half lap 8 would be rather sharp and thus rub against the inside of the notch 7 and could remove a protection layer of the plate in the notch 7 of the adjoining panel, when the panels 1 are moving in relation to each other.
[0036] The material of the panel 1 is a thin sheet of aluminium, copper or a surface-treated steel. The material can as well be a surface-treated sheet of an alloy. The sheet metal member forming the web 2 of the panel 1 does not need to be flat as illustrated in the drawings. Between the flanges 3 and 4 , the web 2 of the flanges can have convex or concave portions or it can have a cross section with ridges. To provide the web of the panel with such ridges or the like could be a measure to obtain higher load carrying properties. Further, if the panels are made for cladding the wall of a building the web 2 of the panels could be provided with embossing or ornamental decorations.
[0037] Further elements of the invention related to embodiments of the dependent claims are discussed in the following paragraphs.
[0038] The fastening element, hereinafter called a mounting rail 12 , is provided with screw holes 13 along the rail. As an example, the screw holes 13 , can be evenly distributed, such as one hole per dm. Preferably, the plate around the screw holes is pressed down to be in the level of the plane of the web 2 of the panel, whereas the edges around the pressed down plate surrounding the screw holes 13 of the mounting rail remain on a higher level, as is illustrated in FIGS. 2 and 6 , to form a frame 14 around the pressed down area of the mounting rail 12 . The neighbouring panel will thus rest on said frame of the mounting rail 12 . In this way the heads of the screws 15 attaching a panel to a substructure S will be sunk in relation to the frame and thus the screw heads will not tear the underside of an neighbouring panel covering the screws 15 , when the panels are moving in relation to each other.
[0039] The mounting rail 12 is not extending along the full length of the first flange 3 . Preferably, the mounting rail 12 is terminated 15 cm from the end which will be mounted as a lower level end of the panel on the substructure S and is further terminated 25 cm from the end which will be mounted as a higher level end of the panel on the substructure S. This design facilitates the work with joining two panels 1 in the longitudinal direction of the panels 1 and further to facilitate the work with the panel, e.g. at the base of a roof and at the roof ridge when cladding a roof with panels. Further, this shortened mounting rail 12 facilitates the work to cut the ends of a panel 1 , when the lengths of the panels have to be adapted to the substructure.
[0040] The height of the second flange 4 from its bottom up to the top of the second ridge 9 formed at an intersection of the second flange 4 and the half lap 8 , is approximately the same as the distance from said mounting rail 12 up to the inside top of the notch 7 formed between the first flange 3 and the lap 6 . If, in a brief example, the height of the first flange 3 of the panels 1 from the bottom of the panel up to the top of the first ridge 5 of said first flange 3 is 35 mm, it would be proper to allow the height of the second flange 4 from bottom side up to the top of the second ridge 9 of the panels to amount to approximately 30 mm or a little less (if the thickness of the plate is 0.5 mm) as 1-2 mm is the approximate thickness of the first ridge 5 and the thickness of the mounting rail 12 with its sunk areas is approximately 1-2 mm. Said dimensions are only given as brief suggestions and should not delimit the invention in this respect in any way.
[0041] When a panel 1 nevertheless has to be cut across its length, where the panel at the cut includes a mounting rail, this could be a tough work, as pointed out previously, as the flange 3 consists of a double plate layer in the flange 3 and the lap 6 , which makes it difficult to cut the panel with tools at these locations. Therefore, according to one aspect of the invention the plate of the panel is at the outer one of the double layers of the first flange 3 and the inner one of the double layers of lap 6 provided with a slot 18 at regular intervals, such as for each 10 cm. The slots 18 are formed as pre-cuts (an illustrated example in FIG. 4 b and a small number of such pre-cuts in FIG. 1 ), so that it will be easy to cut the panel at these locations if it is desired to use a shorter panel than the full length pre-fabricated panel. Said slots 18 start from a short distance above the mounting rail and runs across the outer layer of the double layered first flange 3 and continues across the inner layer of the double layered lap 6 until it almost reaches the edge 11 of the lap 6 . In order to cut a panel across its width, this is easily done along a line running through one of the slots 18 . A pliers or a plate shears is then used to cut across the mounting plate 12 and across the lap 6 and then further on across the panel. This process is greatly facilitated when cutting along one of said slots 18 as the panel is single layered across the whole panel when cut along one of the slots 18 .
[0042] As can be seen in the figures, at one end of the panel 1 , the plate between the first 3 and the second 4 flange is folded downwards and backwards in under the bottom of the web 2 . This folded plate, here called a foot lap 16 of the panel 1 is arranged for grasping and engaging a foot plate along the edge of the roof to be clad by panels or for grasping a corresponding folded plate at the top of a lower panel of a wall to be clad by the panels.
[0043] A further embodiment of the invention is an arrangement for providing leak proof at the joints of two panels at the foot of a roof. The background for this measure is that if a first flange 3 and a second flange 4 are placed abutting each other at the end of the joint, a thin gap will appear between the closely located flanges. This gap can suck water by the aid of capillary forces in between the flanges of the joint and over the time this could cause damages. To prevent this from happening, the first, double layered, flange 3 , according to one example at the intended lower end of the panel 1 , is extended at the first ridge 5 , such that the flange 3 is inclined from the level of the web 2 up to the ridge 5 at an angle around 45° , thus forming a terminating triangular section 17 of the first flange 3 . The flange 3 will thus be drawn out to a sharp point. The purpose is, that after the joining of two panels 1 , the superfluous triangular formed section of the drawn out part of the flange 3 is folded over the right angled end of the second flange 4 of the adjoining panel in the joint, whereby a sealed joint is established, also as seen in the longitudinal direction of the joint. The formed triangular section 17 with the protruding sharp point at the joint also has a purpose to make the joint ugly and thus to automatically force anybody working with the roofing to fold and seal the joint at the terminated end. According to this, the extending triangular formed section will, at the ridge 5 , have a length of approximately the same length as the height of the first flange 3 .
Definitions:
[0044] Up and upwards means in the direction away from a substructure S to be covered by the sheet metal panel.
Down and downwards means in the direction towards the substructure S to be covered by the sheet metal panel.
Outwards means in a lateral direction away from the sheet metal member.
Inwards means in a lateral direction towards the sheet metal member.
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A sheet metal cladding panel for covering roofs and walls of buildings. An elongated sheet metal member forms a web of the panel. The sheet metal member has upwardly folded flanges along two elongated edges of the web of the panel. A first of the upwardly folded flanges is folded outwards and downwards along an upper edge to form a first lap. A second of the upwardly folded flanges is folded inwards and downwards along its upper edge to form a half lap. Also a system and a method for cladding roofs and walls with at least two panels. The panels include pre-cuts at a double-layered first flange.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 12/834,833 filed on Jul. 12, 2010 and titled “HANDRAIL FOR STAIRCASE OR RAMP”.
FIELD OF THE INVENTION
The present invention relates generally to handrails for staircases or ramps, and more particularly to handrails that deter the use of the handrail as a slide.
DESCRIPTION OF THE RELATED ART
Many parks and public areas have staircases or ramps permitting easier navigation from one level to another in the park or public area. Typically, staircases 10 shown in FIG. 1 have handrails 20 on their sides and some in the center as well. Handrails must conform to certain standards so that a person can hold on to them while navigating up or down the stairs. However, handrails have the unintended consequence of providing a convenient track for skateboarders. As shown in FIG. 1 , skateboarders 30 jump their skateboard 40 onto these rails 20 and slide down, possibly damaging the rail or making it unfit for its intended purpose. It would be desirable to curb the actions of skateboarders. Thus, there is a need for a modification of the handrail that would permit people to use it for guiding and stabilizing themselves as they use the staircase or ramp, while at the same time deterring skateboarders from using the handrail.
BRIEF SUMMARY OF THE INVENTION
Embodiments described herein address the aforementioned need. Embodiments modify a conventional handrail in a way that preserves its function, while at the same time preventing or deterring its use by skateboarders.
One embodiment is an improved handrail for a staircase or ramp. The handrail includes an elongated cylinder and riser barriers. The elongated cylinder spans a length of the staircase or ramp is held at a height above the staircase or ramp by external supports. The riser barriers are solely supported by the elongated cylinder at a first set of spaced-apart locations along the elongated cylinder, no location in the second set coinciding with any location in the first set. Each of the riser barriers includes an extender portion and a riser portion, each riser portion being generally vertical and each extender portion being generally horizontal. Each of the extender portions has a length between a proximal end and a distal end, each of the proximal ends having attached thereto an arcuate portion that is adapted and fastened to the curvature of the bottom of the cylinder, and each of the distal ends being fastened to a respective riser portion at a position below the height of the elongated cylinder. The length of each of the extender portion holds a respective riser portion a horizontal distance away from the elongated member to permit passage of a hand along the elongated cylinder. Each of the riser portions has a length that extends above the height of the elongated member so as to deter sliding along the elongated cylinder.
Another embodiment is a plurality of riser barriers for a handrail of a staircase or ramp, where the handrail is an elongated cylinder supported at a height above the staircase or ramp by a plurality of external supports. Each of the riser barriers includes an extender portion and a riser portion. The plurality of riser barriers are solely supported by the elongated cylinder at a first set of spaced-apart locations along the elongated cylinder. The plurality of external supports support the elongated cylinder at a second set of spaced-apart locations along the elongated cylinder, no location in the second set coinciding with any location in the first set, each riser portion being generally vertical and each extender portion being generally horizontal. Each of the extender portions has a length between a proximal end and a distal end, each of the proximal ends having attached thereto an arcuate portion that is adapted and fastened to the curvature of the bottom of the cylinder, and each of the distal ends being fastened to a respective riser portion at a position below the height of the elongated cylinder. The length of each of the extender portion holds a respective riser portion a horizontal distance away from the elongated member to permit passage of a hand along the elongated cylinder. Each of the riser portions has a length that extends above the height of the elongated member so as to deter sliding along the elongated cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
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:
FIG. 1 depicts a skateboarder using the handrail as a slide;
FIG. 2 depicts a staircase employing an embodiment of the present invention;
FIG. 3A depicts a transverse elevational view showing a first embodiment of the present invention;
FIG. 3B depicts a bottom plan view of the embodiment shown in FIG. 3A ;
FIG. 4A depicts a transverse elevational view showing a second embodiment of the present invention;
FIG. 4B depicts a left transverse elevational view of the embodiment shown in FIG. 4A ;
FIG. 5A depicts a transverse elevational view showing a third embodiment of the present invention;
FIG. 5B depicts a right transverse elevational view of the embodiment shown in FIG. 5A ;
FIG. 6A depicts a transverse elevational showing a fourth embodiment of the present invention; and
FIG. 6B depicts a right transverse elevational view of the embodiment shown in FIG. 6A .
DETAILED DESCRIPTION OF THE INVENTION
Embodiments include a modified handrail 100 that prevents a skateboarder from using the handrail. An impediment or barrier is attached that preserves the functionality of the handrail while at the same time deterring its use by the skateboarder.
The embodiment in FIGS. 3A and 3B includes an elongated cylinder 110 , and a riser barrier 120 with extender portion 120 a and a riser portion 120 b . The elongated cylinder 110 spans the distance of the staircase 10 and is held up by vertical supporting members 22 (see FIG. 2 ) whose centers are spaced at approximately 48 inches. The extender portion 120 a of the riser barrier 120 includes an arcuate portion 130 that is fastened to the elongated cylinder 110 using such fastening devices 150 such as bolts or rivets shown in FIG. 3 . The riser portion 120 b has a length that exceeds the thickness of the extender portion 120 a plus the diameter “c” of the elongated cylinder by dimension “a”. In one embodiment, dimension “a” is about 3 inches and dimension “c” is about 1½ inches. The extender portion 120 a has a length that assures the elongated cylinder 110 spaced away from the riser portion 120 b by dimension “b”, which, in one embodiment, is about 1½ inches. Preferably, the riser barrier has ⅛ inch radius at all corners. The dimension “b” is sufficient to permit a user to slide his or her hand along the cylinder without interference, while the dimension “a” is sufficient to deter sliding on the cylinder.
The embodiment 200 in FIG. 4A and FIG. 4B includes an elongated cylinder 110 and an arcuate riser barrier 210 with a proximal end 220 and a distal end 224 . The proximal end 220 is adapted for affixation to the bottom of the elongated cylinder 110 by conforming its curvature approximately to the curvature at the bottom of the elongated cylinder. The proximal end 220 is affixed to the elongated cylinder 110 by means of tack welds 222 at points on either side of the cylinder 110 nearest to the proximal end 220 of the barrier 210 . The arcuate riser barrier 210 extends laterally and rises vertically so that the distal end 224 is spaced horizontally away from the elongated cylinder 110 by dimension “d”, and vertically away by dimension “e”. In one version, dimension “d” is approximately 1½ inches and dimension “e” is approximately 3 inches. As the arcuate riser barrier 210 rises from its proximal end 220 to its distal end, the riser barrier widens and then narrows. The arc-shaped arm has dimension “g” at its widest point and dimension “h” at its distal end. In one embodiment, dimension “g” is about 1½ inches and dimension “h” is about ¾ inches. Dimension “d” is sufficient to permit a user to slide his or her hand along the cylinder without interference while dimension “e” is sufficient to deter sliding on the cylinder.
The embodiment 300 in FIGS. 5A and 5B includes an elongated cylinder 110 , and a riser barrier having extender portion 320 and riser portion 310 . The extender portion 320 is curved downward between the proximal end 330 and the distal end 340 and holds the elongated cylinder 110 away horizontally from the riser portion 310 by dimension “k” and vertically away by dimension “p”, where, in one embodiment, dimension “k” is about 1½ inches and dimension “p” is about 1½ inches. The horizontal separation between the riser portion 310 and cylinder 110 permits the user to slide his/her hand along the cylinder 110 without interference, the downward curve of the extender portion 320 giving added room for the user's hand. The length of the riser portion 310 deters the skateboarder from sliding on the rail. As shown in the figures, the riser portion 310 has a thickness given by dimension “j”, which in one version is about ½ inch and a width given by dimension “n”, which in one version is about 1 inch. The proximal end 330 of the extender portion 320 is generally arc-shaped to conform and attach to the curvature of the elongated cylinder 110 . The distal end 340 of the extender portion 320 includes a generally flat, rectangular vertical portion. The flat, rectangular vertical portion fastens to the riser portion 310 and being wider than the riser portion 310 has a dimension of “m” by which it overlaps on either side the riser portion 310 . In one version, dimension “m” is about ⅜ inch. Any fastening device 350 , such as a bolt or rivet can be used to connect the flat portion of the distal end 340 to the riser portion 310 . The riser portion extends by dimension “q” below the flat portion 340 of the extender portion 320 . In one version, dimension “q” is about ½ inch.
The embodiment 400 in FIGS. 6A and 6B includes an elongated bar 112 and a riser barrier having extender portion 320 and riser portion 310 . The elongated bar 112 is generally rectangular or square in cross-section and may be hollow (shown) or solid. The extender portion 320 of the riser barrier is curved downward between the proximal end 332 and the distal end 340 and holds the elongated bar 112 away horizontally from the riser portion 310 by dimension “k” and vertically away by dimension “p”, where, in one embodiment, dimension “k” is about 1½ inches and dimension “p” is about 1½ inches. The horizontal separation between the riser portion 310 and bar 112 permits the user to slide his/her hand along the bar 112 without interference, the downward curve of the extender portion 320 giving added room for the user's hand. The length of the riser portion 310 deters the skateboarder from sliding on the rail. As shown in the figures, the riser portion 310 has a thickness given by dimension “j”, which in one version is about ½ inch and a width given by dimension “n”, which in one version is about 1 inch. The proximal end 332 of the extender portion 320 is generally flat to conform and attach to the bottom of the bar 112 . The distal end 340 of the extender portion 320 includes a generally flat, rectangular vertical portion. The flat, rectangular vertical portion fastens to the riser portion 310 and being wider than the riser portion 310 has a dimension of “m” by which it overlaps on either side the riser portion 310 . In one version, dimension “m” is about ⅜ inch. Any fastening device 350 , such as a bolt or rivet can be used to connect the flat portion of the distal end 340 to the riser portion 310 . The riser portion extends by dimension “q” below the flat portion 340 of the extender portion 320 . In one version, dimension “q” is about ½ inch.
In all of the above embodiments, the elongated cylinder or bar and riser barrier are fabricated with a material suited for environment in which the staircase or ramp is present. For example, if the staircase or ramp is outside in the elements, the elongated cylinder or bar and riser barrier may be fabricated in steel. Unless specified otherwise, the steel used has a suitable thickness to prevent bending or breakage. Suitable products that can be used for either the cylinder or bar are rectangular, square or round structural steel tubing such as HSS tubing. For round tubing, a length of 1.660×0.140 structural tubing is sufficient. For rectangular tubing, a length of 2×1.5×⅛ inch tubing is sufficient. Suitable products that can be used for the extender portion are brackets, such as the round saddle bracket 1970R, 1978R, 1990R, 1998R, or flat saddle bracket 1970F, 1978F, 1990F, 1998F, manufactured by The Wagner Companies.
Although embodiments have 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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An improved handrail for a staircase or ramp. In one embodiment, the handrail includes an elongated member such as a cylinder or bar that spans the length of the staircase or ramp and a riser barrier. The riser barrier has an extender portion and a riser portion. The extender portion of the riser barrier keeps the elongated member a sufficient distance horizontally from the riser portion that a person can slide his or her hand on the rail without interference. The riser portion projects vertically a sufficient distance above the elongated member to deter sliding down the elongated member. Thus, sliding on the member is deterred, while the function of the cylinder as a handrail is preserved.
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[0001] This application is a Continuation in Part of Ser. No. 13/958,031, filed Aug. 2, 2013.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention is directed to manufacturing of decorative trim such as cornices that provide for detailed woodworking features and architectural structures.
[0004] 2. Description of Prior Art
[0005] Prior art devices of this type have been developed to enable different trim and finish molding venues, see for example U.S. Pat. Nos. 3,956,861, 4,706,431, 5,444,956 and 7,168,474.
[0006] U.S. Pat. No. 3,956,861 discloses a trim arrangement for interior partitions wherein a partition panel has a channel for receiving fasteners and a cover concealment strip which is frictionally inserted therein.
[0007] U.S. Pat. No. 4,706,431 claims a recessed decorative molding for wood paneling having a groove for receiving a decorative strip insert for use in a wood door panel.
[0008] U.S. Pat. No. 5,444,956 is directed to a trim molding with removable insert. A trim molding has an elongated channel into which a backing is positioned with an overlying abutting cut-away insert so as to expose a portion of the locking insert therethrough.
[0009] U.S. Pat. No. 7,168,474 is directed towards a decorative device comprised of modular interchangeable components which has a cornice for crowning an architectural structure with a decorative center piece in the cornice which is applied therein to provide interest.
SUMMARY OF THE INVENTION
[0010] A multi-part decorative trim molding assembly to simulate a hand carved decorative trim piece with relief surfaces. A base molding has a contrasting material upstanding insert in a recessed channel. A U-shaped “tunnel” molding trim having intermediate portions cut-away is inverted and straddles the upstanding insert to provide a true recessed independent composite insert configuration wherein the tunnel molding trim is spaced in relation to the upstanding contrasting material insert within the base molding.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a top plan view of an assembled trim molding of the invention illustrating the multiple insert openings therewithin.
[0012] FIG. 2 is a perspective view of a portion of the assembled molding configuration.
[0013] FIG. 3 is a top plan view of a portion of the insert trim.
[0014] FIG. 4 is a side elevational view thereof.
[0015] FIG. 5 is a bottom plan view thereof.
[0016] FIG. 6 is a partial exploded perspective view of the trim molding assembly of the invention.
[0017] FIG. 7 is a partial perspective view of a base trim of an alternate form of the invention.
[0018] FIG. 8 is a cross-sectional view of an alternate trim molding assembly of the invention.
[0019] FIG. 9 is an exploded cross-sectional view of a second alternate trim molding assembly of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIGS. 1 and 6 of the drawings, the trim molding assembly 10 of the invention can be seen having a base mounting molding 11 , a decorative insert strip 12 and a U-shaped apertured viewing insert 13 . The base receiving mounting molding 11 comprises an integral elongated strip of milled material 14 , in this example preferably wood. The top surface being contoured with a first contoured surface portion 15 extending inwardly from an upstanding perimeter edge 16 . A receiving channel 17 extends longitudinally within defining the inward terminal edge at 18 of the concave surface portion 15 as best seen in FIG. 6 of the drawings.
[0021] An opposite spaced parallel edge at 19 of the channel 17 defines the transverse dimension thereof. An angled top surface portion 14 extends from the terminal edge 19 in a convex surface contour at 20 which transitions into a curvilinear concave surface portion 21 with a rounded over upstanding parallel base perimeter edge portion 22 .
[0022] A flat bottom or back surface 23 interconnects said respective upstanding portions 22 and 16 completing the base receiving mounting molding 11 .
[0023] The decorative channel insert strip 12 can be seen best in FIGS. 1 and 6 of the drawings comprises in this example an elongated cross-sectionally rectangular material having a transverse dimension substantially less than that of the corresponding channel dimension 17 and is positioned midway therein in spaced side to side relation forming corresponding receiving channels 24 A and 24 B.
[0024] The decorative insert molding strip 12 may be of a different material to that of the base 11 , such as a varied wood variety or a contrasting “stain” color.
[0025] Alternately, a veneer overlay 25 can be pre-applied to the exposed upper surface 12 A of the strip 12 by conventional adhesion bonding techniques well know within the art. The veneer overlay 25 may be of any material including wood veneers or other contrasting non-wood materials.
[0026] The key structural element to the trim molding assembly 10 of the invention is the inverted for installation U-shaped insert strip 13 , best seen in FIGS. 5 and 6 of the drawings. The insert strip 13 is, as noted, of a generally inverted U-shaped having oppositely disposed leg portions 13 A and 13 B with an integral interconnecting contoured top 26 therebetween. A plurality of longitudinally spaced view port openings 27 are formed therein extending inwardly from the contoured top 26 to midway in the respective leg portions 13 A and 13 B. The openings 27 define parallel spaced exposed leg edge surfaces 28 A and 28 B with oppositely disposed spaced contoured top exposed edge surfaces 29 A and 29 B.
[0027] The longitudinal length of each of the respective view port openings 27 as illustrated in FIGS. 2 , 3 , 4 and 5 of the drawings is proportional to the intermediate remaining top 26 and leg areas 30 therebetween indicated generally and depending on the design venue of the application chosen which in this example is approximately one-half the length thereof.
[0028] The transverse width of the insert viewing strip 13 is also variable depending on the design requirements of the use application.
[0029] Referring now to FIG. 6 of the drawings, the assembly sequence of the trim molding assembly 10 can be seen wherein the base receiving molding 11 having the recessed channel 17 therein is illustrated with the initial placement of the decorative strip 12 within. The viewing insert 13 is then positioned thereover with the legs 13 A and 13 B registerable with the corresponding defined receiving areas 24 A and 24 B in the channel 17 as the hereinbefore defined by the insert position strip 12 .
[0030] As noted, the decorative strip 12 may have a veneer overlay 25 as illustrated in the assembled molding in FIG. 1 of the drawings and in FIG. 6 of the drawings.
[0031] Referring now to FIG. 7 of the drawings, an alternate form of the invention 31 can be seen wherein a decorative strip 32 is formed integral within a channel 33 in a base molding 34 which may be required in some venues.
[0032] Referring now to FIGS. 8 and 9 of the drawings, multiple alternate trim molding forms can be seen at 35 and 36 wherein a two-part base molding 35 A and 35 B in FIGS. 8 and 36A and 36 B in FIG. 9 of the drawings.
[0033] The base molding 35 A has a receiving area 37 formed therein which allows for the insertion of a decorative strip 38 , such as contrasting material or veneer with a U-shaped apertured viewing insert 39 positioned thereover similar to the strip 13 as set forth and described in the primary form of the invention.
[0034] In this example, an additional base molding portion 35 B is attached to one end of the base molding 35 A by the utilization of an elongated backing strip 40 . Both the base molding 35 A and base molding portion 35 B have attachment channels 41 A and 41 B respectively in their non-viewing reverse surfaces 42 and 42 . The backing strip 40 has oppositely disposed upstanding flanges 42 A and 42 B will, upon assembly, be registerably engaged within the respective attachment channels 41 A and 41 B securing the multiple part molding assembly together.
[0035] A similar assembly can be seen in FIG. 9 of the drawings wherein the base molding 36 has the a two-piece assembly 36 A and 36 B with corresponding attachment channels 43 A and 43 B therein respectively. As described previously, a backing strip 44 having oppositely disposed upstanding engagement flanges 45 A and 45 B is registerable within corresponding aligned elongated receiving channels 46 A and 46 B within the non-viewable sides of the respective two-part molding base as hereinbefore described in spaced aligned relation to one another.
[0036] In this example, an independent U-shaped aperture viewing insert 47 and a decorative insert 48 are held between the respective interengaged molding bases 36 A and 36 B completing the decorative multi-part molding 36 form of the invention.
[0037] It will thus be seen that a new and novel decorative molding with multiple relief insert has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention. Therefore I claim:
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A decorative molding assembly for a variety of surface applications providing a complex molding feature with a machine made single component set composite configured insert. A channel base molding receives a unique configured U-shaped insert forming linear spaced and aligned viewing openings for an underlying contrasting base material achieving a hand crafted detailed look with a single overlying molding tunnel insert combination.
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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 door driving control apparatus for controlling, in a train or the like, the opening/closure driving of a vehicle door that is opened and closed by a motor.
2. Description of the Related Art
In automatic opening/closing doors for getting passengers on/off of trains, automobiles, etc., from the viewpoint of power saving, protection from burning of door driving motors, and prevention of erroneous operation during running, usually each door is driven by supplying electric power to a door driving motor only in opening or closing it and in other situations (the door is closed) the door is locked mechanically by means of a locking device such as a lock pin and no electric power is supplied to the door driving motor.
FIG. 6 shows the configuration of a conventional door driving control apparatus for a railway vehicle. The door driving control apparatus 10 is equipped with an operation instruction computing section 11 , a power conversion section 12 , and a communication interface 14 and is connected to a power source 21 , a linear motor 2 , a position detector 5 which are provided on a vehicle body 20 and a train control apparatus 22 provided in a motorman's cab.
Linear motor 2 , a movable portion of which is connected to a link portion 3 provided on a door 1 , opening/closure-drives the door 1 . The door 1 is provided with a locking device 7 for fixing the door 1 mechanically. The position detector 5 detects a position and a speed of the movable portion of the linear motor 2 and outputs a thus-acquired door position detection value S 1 to the operation instruction computing section 11 .
Among three phase lines (having U, V, and W phases) which connect the power conversion section 12 to the linear motor 2 , output current detectors 4 are connected to the U-phase and W-phase lines, respectively. Output current detection values S 2 obtained by detecting a U-phase current and a W-phase current with the output current detectors 4 are input to the operation instruction computing section 11 .
With the above configuration, when receiving a door operation instruction signal S 3 from the train control apparatus 22 , the operation instruction computing section 11 performs door speed feedback control using the door position detection value Si and the output current detection values S 2 . The power conversion section 12 converts the power from the power source 21 according to this control. The linear motor 2 is supplied with converted power and its driving is thereby controlled. The door 1 is opening/closure-driven as a result of this driving of the linear motor 2 .
Door driving control apparatus 10 for controlling the opening and closing of the door 1 is provided for each door (e.g., each of first to eighth doors) as indicated by reference symbols 10 - 1 to 10 - 8 in FIG. 7 and is connected to the train control apparatus 22 via the communication interface 14 .
As exemplified in FIG. 8 , door installation positions are discriminated from each other by setting addresses A 1 -A 8 for the respective door positions in each car and storing the addresses A 1 -A 8 in the respective door driving control apparatus 10 - 1 to 10 - 8 .
In automatic opening/closing doors for trains, automobiles, etc., when a high pressure is exerted on the door 1 by passengers in a fully jammed car, for example, and the friction of the door 1 is thereby made unduly high or a foreign object is pinched by the door 1 , correct operation of the door 1 is secured by increasing the driving force for the door 1 , opening and closing the door again (i.e., temporarily opening the door 1 being closed and starting a closing operation again after a lapse of a prescribed time with an assumption that a passenger, a bag, or the like has escaped or has been removed) after increasing the driving force for a prescribed time, or performing a like operation. However, when foreign objects are pinched by plural doors 1 , the driving force is increased for all of those doors 1 and hence the total power consumption becomes large.
As shown in FIG. 9 , usually the plural door driving control apparatus 10 - 1 to 10 - 8 of a car are connected to the power source 21 which is provided for the same vehicle body as the door driving control apparatus 10 - 1 to 10 - 8 are provided on, and other apparatus such as an air conditioner 31 and an inverter apparatus for fluorescent lamps are also connected to the power source 21 . Therefore, if the total power consumption becomes large as a result of an increase in the door driving force for plural doors, the voltage of the power source 21 decreases, which may adversely affect the operation of other apparatus in the same car as exemplified by flickering of fluorescent lamps.
Exemplary countermeasures against the above problem are disclosed in JP-A-2005-145240 and JP-A-2005-73381. In JP-A-2005-145240, the fact that high torque is being output for one or some of the doors of the same power supply system is communicated between the door driving control apparatus 10 - 1 to 10 - 8 via the communication interfaces 14 over the inter-car network. Each door driving control apparatus outputs low torque while high torque is being output for another or other doors. In this manner, adjustments are made so that the power consumption of the entire car does not become unduly large.
In JP-A-2005-73381, each of the door driving control apparatus 10 - 1 to 10 - 8 restrict output torque in accordance with its input voltage or input current. In this manner, adjustments are made so that the power consumption of the entire car does not become unduly large.
However, the information that can be communicated over the inter-car network depends on the vehicle type. Therefore, information as to whether high torque is being output may not be available in certain vehicle types, in which case the technique of JP-A-2005-145240 cannot be utilized.
In the technique of JP-A-2005-73381, when an attempt is made to output high torque for all doors, the power supply voltage is lowered and the output torque is thereby restricted. This results in a problem that with restricted output torque the doors may not be operated or locked.
SUMMARY OF THE INVENTION
The present invention has been made to solve the above problems, and an object of the invention is therefore to provide a door driving control apparatus which makes it possible to output high torque for each door and thereby operate it and lock it reliably without reduction in power supply voltage even in the case where information as to whether high torque is being output cannot be communicated between door driving control apparatus.
To attain the above object, the invention provides a door driving control apparatus which drives a door closed by setting door opening/closing drive torque to ordinary torque or high torque when opening/closing driving of plural doors that are driven by respective motors is controlled, comprising setting means for setting a high torque application period for the door so that periods of high-torque closure driving of respective doors or predetermined door groups do not overlap with each other, and instructing means for issuing an instruction to drive the door closed with high torque only during the high torque application period thus set.
With this configuration, when high torque is necessary for plural doors, those doors can be driven open and closed with high torque in such a manner that the periods of high-torque driving of those doors do not overlap with each other even in the case where information as to whether high torque is being output cannot be communicated between the door driving control apparatus. Therefore, the power supply voltage does not decrease due to overlap between periods of high-torque driving and hence each door can be operated with high torque.
In the above door driving control apparatus, the instructing means may be such as to issue, at the end of the high torque application period, an instruction to perform a door re-opening and closing operation.
With this measure, a re-opening and closing operation is performed additionally at the end of a high torque application period in the control that prevents overlap between high-torque driving states of plural doors. Therefore, when foreign objects are pinched by plural doors, the plural doors can be closed with high torque without causing a decrease in power supply voltage and the foreign objects can be removed more properly.
In the above door driving control apparatus, the instructing means may be such as to issue an instruction to perform ordinary door closing driving without employing high torque if a door drive speed exceeds a predetermined speed in the high torque application period.
With this measure, an ordinary closing operation is performed if the door drive speed exceeds the predetermined speed in a high torque application period, that is, if a foreign object is removed during a closing operation of high torque. This dispenses with an unnecessary re-opening and closing operation and hence prevents useless power consumption.
As described above, the invention provides an advantage that high torque can be output for each door and each door can thereby be operated and locked reliably without reduction in power supply voltage even in the case where information as to whether high torque is being output cannot be communicated between door driving control apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show the configuration of a door driving control apparatus for a railway vehicle according to a first embodiment of the present invention.
FIGS. 2A to 2F are a timing chart illustrating opening/closing driving for plural doors of the door driving control apparatus according to the first embodiment.
FIG. 3 is a flowchart of a process where a door large output permission flag is set by an operation instruction computing section of the door driving control apparatus according to the first embodiment.
FIG. 4 is a block diagram showing the configuration of an operation instruction computing section of a door driving control apparatus for a railway vehicle according to a second embodiment of the invention.
FIGS. 5A to 5H are a timing chart illustrating opening/closing driving for plural doors of the door driving control apparatus according to the second embodiment.
FIG. 6 shows the configuration of a conventional door driving control apparatus for a railway vehicle.
FIG. 7 shows how plural conventional door driving control apparatus for a railway vehicle are connected to a train control apparatus via communication lines.
FIG. 8 shows an exemplary manner of assignment of addresses to respective doors that are controlled by the door driving control apparatus.
FIG. 9 shows an exemplary configuration of connections of door driving control apparatus, a power source, and other apparatus of the same car.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be hereinafter described with reference to the drawings.
First Embodiment
FIGS. 1A and 1B show the configuration of a door driving control apparatus for a railway vehicle according to a first embodiment of the invention.
The door driving control apparatus 40 of FIG. 1A is equipped with an operation instruction computing section 41 , a power conversion section 12 , and a communication interface 14 , and is different from the conventional door driving control apparatus 10 of FIG. 6 in that, as shown in FIG. 1B , the operation instruction computing section 41 is equipped with a timer section 43 , a comparison/judgment section 44 , a flag setting section 45 for setting and resetting a door large output permission flag 45 a , and a door opening/closure instructing section 46 .
The timer section 43 starts a timer operation upon reception of a door operation instruction signal S 3 from the train control apparatus 22 . The timer section 43 is configured so as to be cleared if it expires in a state that the door large output permission flag 45 a is set.
An offset value, which is output from the train control apparatus 22 in accordance with a door installation position recognized by a corresponding one of the addresses A 1 -A 8 (see FIG. 8 ), is set in the timer section 43 . The offset value is output when there is no door operation instruction signal S 3 . The offset values serve to deviate output timings of high torque for doors of one car from each other and thereby prevent the doors from causing a heavy load collectively when they are closed. That is, the doors are closed with timings that are deviated from each other in order on a door-by-door basis or a door group basis.
The comparison/judgment section 44 compares a timer measurement time S 5 of the timer section 43 with a preset door large output setting time S 6 and judges whether or not the timer measurement time S 5 is longer than or equal to the preset door large output setting time S 6 .
If the comparison/judgment section 44 judges that the timer measurement time S 5 is not longer than or equal to the preset door large output setting time S 6 , the flag setting section 45 keeps a state that the door large output permission flag 45 a is reset. If the comparison/judgment section 44 judges that the timer measurement time S 5 is longer than or equal to the preset door large output setting time S 6 , the flag setting section 45 sets the door large output permission flag 45 a.
As shown in FIG. 2A , the door large output permission flag 45 a is set at time t 1 . When the timer section 43 expires at time t 3 , the timer section 43 is cleared. As a result, the timer measurement time S 5 becomes shorter than the door large output setting time S 6 and hence the door large output permission flag 45 a is reset immediately at time t 3 .
At this time, if the input of the door operation instruction signal S 3 is continuing, the timer section 43 again starts a timer operation. If it is judged again at time t 4 that the timer measurement time S 5 is longer than or equal to the door large output setting time S 6 , the door large output permission flag 45 a is set and kept set until the timer section 43 expires at time t 6 .
That is, the door large output permission flag 45 a is kept in a reset state during a time width (called “reset time width”) from the start of a timer operation of the timer section 43 to the end of the door large output setting time S 6 , and is rendered in a set state during a time width (called “set time width”) from a time point when the timer measurement time S 5 becomes greater than or equal to the door large output setting time S 6 (i.e., the above-mentioned end of the door large output setting time S 6 ) to a time point when the timer section 43 expires Therefore, the set time width and the reset time width appear repeatedly and alternately. Each of the set time width and the reset time width can be varied by changing the door large output setting time S 6 .
The door opening/closing instructing section 46 outputs a door output instruction value S 7 for opening or closing the door 1 to the power conversion section 12 in response to a door operation instructing signal S 3 as an opening/closure instruction. Furthermore, the door opening/closure instructing section 46 outputs a door output instruction value S 7 for driving the door 1 with high torque to the power conversion section 12 if the door drive speed which can be recognized on the basis of a door position detection value S 1 becomes lower than a prescribed value in a state that the door large output permission flag 45 a is set.
A process that the door large output permission flag 45 a is set by the above-configured operation instruction computing section 41 will be described with reference to a flowchart of FIG. 3 .
First, if it is judged at step ST 1 that no door operation instruction signal S 3 is input to the operation instruction computing section 41 , at step ST 2 offset values which are output from the train control apparatus 22 in accordance with the installation positions of the respective doors 1 are set in the timer sections 43 for the respective doors 1 .
On the other hand, if a door operation instruction signal S 3 is input, the timer section 43 starts a timer operation at step ST 3 .
After the timer operation was started, the comparison/judgment section 44 judges at step ST 4 whether or not a timer measurement time S 5 is longer than or equal to the door large output setting time S 6 . If it is judged that the timer measurement time S 5 is not longer than or equal to the door large output setting time S 6 , at step ST 5 the flag setting section 45 keeps the door large output permission flag 45 a in a reset state.
On the other hand, if it is judged that the timer measurement time S 5 is greater than or equal to the door large output setting time S 6 , at step ST 6 the flag setting section 45 sets the door large output permission flag 45 a . If the timer section 43 expires at step ST 7 , the timer section 43 is cleared at step ST 8 .
Next, an operation that the door 1 is opened or closed after the door large output permission flag 45 a was set in the above-described manner will be described with reference to the timing chart of FIGS. 2A to 2F .
FIGS. 2A to 2F relate to only the first and second doors. More specifically, FIGS. 2A and 2D show how the door large output permission flags 45 a for those doors are set so as not to overlap with each other in time. FIGS. 2C and 2F show how high torque is output while the door large output permission flags 45 a are set as shown in FIGS. 2A and 2D . For comparison with the control according to this embodiment, FIGS. 2B and 2E show how high torque is output in a conventional control.
It is assumed that, as shown in FIGS. 2A and 2D , the door large output permission flag for the first door (first door large output permission flag) 45 a is set during a set time width from time t 1 to t 3 and a set time width from time t 4 to t 6 and the door large output permission flag for the second door (second door large output permission flag) 45 a is set during a set time width from time t 0 to t 1 and a set time width from time t 3 to t 4 .
It is assumed that at time t 0 a door operation instruction value S 3 which is a door closure instruction is input from the train control apparatus 22 to the door opening/closure instructing sections 46 , whereby the first and second doors are subjected to closing operations of ordinary torque (indicated by level “L”).
Also assume that both doors collide with certain foreign objects at time t 2 during the closing operations and the foreign objects are removed and ordinary operations are restored at time t 5 . In the conventional control, as shown in FIGS. 2B and 2E , both doors are subjected to closing operations with high torque (indicated by level “H”) while the foreign objects are kept pinched (from time t 2 to t 5 ). Therefore, in the conventional control, high-torque states of the plural doors overlap with each other in time. A high power is consumed and the power supply voltage of the car concerned thereby decreases during the overlap period.
In contrast, in the embodiment as shown in FIG. 2C , the first door is subjected to a closing operation of high torque only while the door large output permission flag 45 a is set (i.e., from time t 2 to t 3 and from time t 4 to t 5 ). And, as shown in FIG. 2F , the second door is subjected to a closing operation of high torque only during a period from time t 3 to t 4 that does not overlap with the high-torque closing operation periods for the first door. In this manner, the high-torque states of the plural doors do not overlap with each other in time.
As described above, according to the door driving control of the door driving control apparatus 40 according to the first embodiment, when high torque is necessary for plural doors, those doors can be opening/closure-driven with high torque in such a manner that the periods of driving of those doors do not overlap with each other even in the case where information as to whether high torque is being output cannot be communicated between the door driving control apparatus 40 . Therefore, the power supply voltage does not decrease and each door can be operated with high torque.
As a result, unlike in the conventional case, an event can be avoided where the output torque is restricted due to reduction in power supply voltage and doors cannot be operated properly (they are not locked) In other words, the doors can be locked reliably.
Second Embodiment
FIG. 4 is a block diagram showing the configuration of an operation instruction computing section of a door driving control apparatus for a railway vehicle according to a second embodiment of the invention.
The operation instruction computing section instructing means 51 of FIG. 4 is equipped with, in addition to the components 43 - 46 of the operation instruction computing section 41 of FIG. 1B , a speed calculating section 53 , a speed comparison/judgment section 54 , a flag setting section 55 for setting and resetting a door foreign object detection flag 55 a , and a flag status judging section 56 . However, in FIG. 4 , the door opening/closing instructing section of the second embodiment is denoted by reference numeral 57 because as described later its processing is different from the processing of the door opening/closure instructing section 46 shown in FIG. 1 .
The speed calculating section 53 calculates a door speed S 8 on the basis of a door position detection value S 1 .
The speed comparison/judgment section 54 compares the calculated door speed S 8 with a preset threshold speed S 9 , judges whether the calculated door speed S 8 is less than or equal to the threshold speed S 9 , and outputs a judgment result.
If the speed comparison/judgment section 54 judges that the door speed S 8 is less than or equal to the threshold speed S 9 , the flag setting section 55 sets the door foreign object detection flag 55 a.
The flag status judging section 56 judges the set/reset statuses of the door large output permission flag 45 a and the door foreign object detection flag 55 a.
The door opening/closing instructing section 57 outputs a door output instruction value S 7 for closing the door 1 with high torque only if the flag status judging section 56 judges that both of the door large output permission flag 45 a and the door foreign object detection flag 55 a are set. If a transition occurs from a state of both flags 45 a and 55 a being set to a state of the door large output permission flag 45 a being reset, the door opening/closing instructing section 57 outputs a door output instruction value S 7 for causing a re-opening and closing operation in which the door 1 will be opened for a prescribed time and then subjected to an ordinary closing operation (output torque: not high torque) If a transition occurs from a state of both flags 45 a and 55 a being set to a state of the door foreign object detection flag 55 a being reset, the door opening/closure instructing section 57 outputs a door output instruction value S 7 for subjecting the door 1 to an ordinary closing operation.
A re-opening and closing operation which is caused by the above-configured operation instruction computing section 51 when foreign objects are pinched by doors will now be described with reference to a timing chart of FIGS. 5A to 5H .
FIGS. 5A to 5H relate to only the first and second doors. More specifically, FIGS. 5A and 5E show how the door large output permission flags 45 a for those doors are set so as not to overlap with each other in time. FIGS. 5B and 5F show how the door foreign object detection flags 55 a are set. FIGS. 5D and 5H show how high torque is output while the flags 45 a and the flags 55 a are set as shown in FIGS. 5A and 5E and FIGS. 5B and 5F . For comparison with the control according to this embodiment, FIGS. 5C and 5G show how high torque is output in a conventional control.
It is assumed that at time t 0 a door operation instruction value S 3 which is a door closure instruction is input from the train control apparatus 22 to the door opening/closure instructing sections 46 , whereby the first and second doors are subjected to closing operations of ordinary output torque (indicated by level “L”).
Operations to be performed after time t 0 will now be described starting from an operation relating to the first door. If the first door collides with a certain foreign object during the closing operation, the door speed decreases. If the speed comparison/judgment section 54 judges at time t 1 that the door speed S 8 has become less than or equal to the threshold speed S 9 , the flag setting section 55 sets the first door foreign object detection flag 55 a as shown in FIG. 5B .
Then, when the first door large output permission flag 45 a is set at time t 2 as shown in FIG. 5A , the flag status judging section 56 judges that both of the first door large output permission flag 45 a and the first door foreign object detection flag 55 a are set. Receiving this judgment result, the door opening/closing instructing section 57 outputs to the power conversion section 12 a door output instruction value S 7 for closing the first door with high torque. The first door is closed with high torque (indicated by level “H” in FIG. 5D ), which is a foreign object pressing operation.
When the flag status judging section 56 judges at time t 5 that the first door large output permission flag 45 a has made a transition to a reset state (see FIG. 5A ), the door opening/closing instructing section 57 outputs a door output instructing value S 7 for subjecting the first door to a re-opening and closing operation. As a result, as shown in FIG. 5D , the first door is subjected to a re-opening and closing operation including an opening operation from time t 5 to t 6 . The door speed increases during the opening operation. When the speed comparison/judgment section 54 finds the speed increase, the flag setting section 55 resets the first door foreign object detection flag 55 a at time t 5 as shown in FIG.
Then, the first door collides with the foreign object again and the door speed decreases. If the speed comparison/judgment section 54 judges at time t 7 that the door speed S 8 has become lower than or equal to the threshold speed S 9 , the flag setting section 55 sets the first door foreign object detection flag 55 a as shown in FIG. 5B . While the first door large output permission flag 45 a is kept set from time t 9 to t 10 as shown in FIG. 5A , the first door is subjected to a closing operation of high torque in response to a door output instruction value S 7 for closing the first door with high torque (see FIG. 5D ).
Next, an operation relating to the second door will be described. As already described above in the first embodiment, for the second door, as shown in FIG. 5E , the second door large output permission flag 45 a is set in the reset periods of the first door large output permission flag 45 a (see FIG. 5A ) to avoid overlaps.
If the second door collides with a certain foreign object during the closing operation which is performed after time t 0 , the door speed decreases. If the speed comparison/judgment section 54 judges at time t 1 that the door speed S 8 has become lower than or equal to the threshold speed S 9 , the flag setting section 55 sets the second door foreign object detection flag 55 a as shown in FIG. 5F .
At this time, the flag status judging section 56 judges that both of the second door large output permission flag 45 a and the second door foreign object detection flag 55 a are set. Receiving this judgment result, the door opening/closing instructing section 57 outputs a door output instruction value S 7 for closing the second door with high torque. The second door is closed with high torque (indicated by level “H” in FIG. 5H ), which is a foreign object pressing operation.
When the flag status judging section 56 judges at time t 2 (i.e., soon after time t 1 ) that the second door large output permission flag 45 a has made a transition to a reset state (see FIG. 5E ), the door opening/closure instructing section 57 outputs a door output instructing value S 7 for subjecting the second door to a re-opening and closing operation. As a result, as shown in FIG. 5H , the second door is subjected to a re-opening and closing operation including an opening operation from time t 2 to t 3 . The door speed increases during the opening operation When the speed comparison/judgment section 54 finds the speed increase, the flag setting section 55 resets the second door foreign object detection flag 55 a at time t 2 as shown in FIG. 5F .
Then, the second door collides with the foreign object again and the door speed decreases. If the speed comparison/judgment section 54 judges at time t 4 that the door speed S 8 has become lower than or equal to the threshold speed S 9 , the flag setting section 55 sets the second door foreign object detection flag 55 a as shown in FIG. 5F . Assume that the second door large output permission flag 45 a is kept set from time t 5 to t 9 as shown in FIG. 5E and the foreign object is removed and the second door foreign object detection flag 55 a is reset at time t 8 as shown in FIG. 5F .
In this case, the second door is subjected to a closing operation of high torque from the period from time t 5 to t 8 when the flags 45 a and 55 a are set (see FIG. 5H ). At time t 8 , only the second door foreign object detection flag 55 a makes a transition to a reset state and hence the door opening/closure instructing section 57 outputs a door output instruction value S 7 for subjecting the second door to an ordinary closing operation (see FIG. 5H ) The second door is thereby subjected to an ordinary closing operation.
As described above, according to the door driving control of the door driving control apparatus 40 according to the second embodiment, high-torque states of the first and second doors are prevented from overlapping with each other in time. Furthermore, when the door large output permission flag 45 a is reset while the door is subjected to a closing operation of high torque, the closing operation is finished and a re-opening and closing operation is started immediately. When foreign objects are pinched by plural doors, this measure makes it possible to close the plural doors with high torque without decrease in power supply voltage and to remove the foreign objects more properly. If a foreign object is removed during a closing operation of high torque, an ordinary closing operation is performed. This dispenses with an unnecessary re-opening and closing operation and hence prevents useless power consumption.
In the conventional case, as shown in FIGS. 5C and 5G , a high-torque closing operation is performed while the door foreign object detection flag 55 a is set. Therefore, high-torque states of plural doors overlap with each other in time. A high power is consumed and the power supply voltage of the car concerned thereby decreases during the overlap periods.
It should, of course, be appreciated that the invention may be practiced otherwise than as specifically disclosed herein without departing from the scope thereof.
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In controlling, with recognition of their installation positions, the opening/closing driving of plural doors that are driven by respective linear motors, each door is driven closed by switching the door opening/closing drive torque to high torque if the drive speed of the door has become less than or equal to a prescribed speed. In doing so, operation instruction computing sections set high torque application periods for respective doors so that the periods of high-torque closure driving of respective doors or predetermined door groups do not overlap with each other, and issue instructions to drive the doors closed with high torque only during the high torque application periods.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
This invention relates to a building block and more particularly to a modular building block which can be used for constructing various structures such as windows, walls, floors, etc.
In U.S. Pat. No. 3,024,880 there is shown a building panel unit which is constructed of an outer frame 13 with an inner gridwork provided by innerlocking longitudinal and transverse beams 10 and 11. Two sheets 12 of translucent material such as plastic are supported by the gridwork and the frame. In U.S. Pat. No. 3,252,260 lightweight plastic panels 22 and 24 are disclosed. These are assembled together by means of vertical and horizontal inside and outside rectangular bars 60 and 62 which engage outer lateral flanges 40 and 42 of the panels. These bars also provide for connection with additional panel units. Glass panels are described for structural elements in U.S. Pat. Nos. 3,373,538 and 4,628,652. In the '538 patent the glass panels are interconnected by elastic connectors 6 whereas in the '652 patent, glass bodies 1a and 1 b are interconnected by a hard integral foam frame 3.
The prior art does not provide a building block unit which has the versatility of customizing the block for various needs such as insulation properties. Neither does the prior art provide a building block structure wherein the average person can assemble it and put it in place with the use of common tools and materials. The prior art is also deficient in affording a building block of the foregoing type which is modular so that individual units can be easily secured to each other.
It is an object of the invention to provide a building block which can be assembled in a manner to provide a wide variety of insulation capabilities.
It is another object of this invention to provide a building block which can be easily installed.
It is yet another object of the invention to provide a building block of the foregoing type which is modular and can be easily interconnected with other units of the same type.
It is still another object of the invention to provide a building block of the foregoing type which can be easily repaired.
It is an additional object of the invention to provide a modular building block which can be easily assembled either by hand or with automated equipment.
Other objects include a building block which has the versatility for use in constructing a wall, ceiling, floor or window, as well as can be fabricated and repaired with waste material such as scrap glass or plastic.
SUMMARY OF THE INVENTION
The foregoing objects are accomplished and the disadvantages of the prior art are overcome by the present modular building block which includes a first frame member having walls for supporting a first panel member and an inwardly extending surface to prevent passage of the panel member through the first frame member. A second frame member has a projecting wall member constructed and arranged to fit within the first frame member and hold the first panel between the projecting wall member and the inwardly extending surface. The second frame member also has walls for supporting a second panel member and an inwardly extending wall surface to prevent passage of the second panel member through the second frame member. There is also a third frame member having a projecting wall constructed and arranged to fit within the second frame member and hold the second panel between the projecting wall of the third frame and the inwardly extending surface of the second frame. Frictional engagement means are operatively associated with the frame members to hold them together with the panel members sandwiched therebetween.
In a preferred embodiment, the modular block is connected to a second modular block with means operatively associated with the blocks for interconnection.
In one aspect of the invention the second frame member provides a common and multiple frame member for use in constructing a modular block. The projecting wall member of the second frame member is constructed and arranged to fit within the previously described first frame and hold a first panel between the projecting wall member and the first frame. The second frame member is constructed and arranged to receive an additional second frame member opposite the first frame and to hold a second panel member between the two second frame members. Any number of second additional frame members can be interconnected with the outermost second frame member connected to previously described third frame member.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front perspective view of the modular building block of this invention.
FIG. 2 is an assembly view of the modular building block as shown in FIG. 1.
FIG. 3 is a view in vertical section of one of the frame members composing the building block of FIG. 1.
FIG. 4 is a view taken along line 4--4 of FIG. 1 but showing the frame members and the panels separated.
FIG. 5 is a perspective and assembly view of the modular building block illustrating the interconnection of several frame members to form a modular unit as well as the interconnection of the units.
FIG. 6 is a view taken along line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 the modular building block is shown generally at 10 and represents a basic unit structure. It includes a three frame unit with frame member 11 on one side, frame member 12 in the center, and frame member 14 at the other side. These three frame members hold in a sandwich-like effect, two panel members 16 and 17 as best seen in FIG. 2. All three frame members have basically the same geometric configuration and are square in cross section. Frame member 11 includes four wall portions 19-22. The wall portions of frame member 12 are represented by the numerals 23-26, and the wall portions of frame member 14 by the numerals 27-30. Peg-like projecting members 32, 33, 34 and 35 extend from wall portions 19 and 20 of frame member 11 and peg-like members 36, 37, 38 and 39 extend from the wall members 23 and 24 of frame member 12. The purpose of these peg members is to provide a frictional attachment with other modular units such as by fitting into the openings 41 and 42 of a similar frame member 11 and 43 and 44 of a similar frame member 12. It will be recognized that peg members 32, 33, and 36 and 37 will fit into accommodating openings in the bottom of a corresponding frame member such as indicated at 45 in FIG. 3 when another modular block would be placed on top of the block 10 shown in FIG. 1.
An important feature of this invention is the manner in which the frame members 11, 12 and 14 interfit with the panels 16 and 17 therebetween. Referring specifically to FIG. 2 it is seen that there are the projections 46-53 extending from the inside of the wall members 23-26 of frame member 12. These are designed so as to fit in corresponding undercut portions such as 74 and 75 in the frame member 14. These projections, as are the undercuts, are located so as to have maximum engagement when the panel member 16 rests against the inwardly extending wall 80 of the frame member 12 and the inset portion 40 of the frame member 14 presses against the panel 16 while the outer portion 31 of frame member 14 engages the frame 12. This is best seen in conjunction with FIGS. 2 and 4.
In a somewhat similar manner, the panel 17 is retained between frame members 11 and 12. There are the projections 61-68 for fitment into the undercuts such as 72 and 73 in the frame member 12. In this instance there is a projecting wall 78 extending from the frame member 12 for fitment inside the frame member 11 and against the panel 17 so as to sandwich fit the panel between the two frames. The panel 17 is thereby held between the projecting wall 78 and the inset portion 54 extending from the wall members 23-26 of the frame member 11. This is also shown in detail in FIGS. 2 and 4.
The innerfitment between the projections and the indentations on the various frame members is shown in detail in FIG. 4. There it will be seen that the projection 63 on the frame member 11 fits within the undercut 77 in the frame member 12 whereas the projection 48 on the frame member 12 fits within the undercut 76 on the frame member 14. If desired, additional latching can be effected between frame members 14 and 12 such as by the projections 81-84 disposed in the frame members 14 and the undercut members 85-87 on the frame member 12. This is best seen in conjunction with FIGS. 2 and 6.
In the description herein it should be understood that similar components of the described modular blocks are designated by the same number except followed with different letters.
The versatility and modularity of the modular block is exemplified with respect to FIGS. 5 and 6. There it will be seen that several of the frame members such as 12, 12a, and 12b have been interconnected so as to afford placement of several panel members such as 16, 17, 56 and 57 in between to result in a modular unit generally 70. This versatility to sandwich fit a multiplicity of panels is afforded by the frame member 12 which is specifically FIG. 3, and its interconnection with similar frame members 12a and b as shown in FIG. 6. It is seen that frame member 12 not only can receive the frame member 14 on one side, but also can interconnect with a similar frame such as shown as 12a at the opposite side by interfitment of the projecting wall 78 within the frame such as 12a which is afforded by the overhang portion 58a on the frame member 12a. Interlocking would be afforded such as by the undercuts indicated at 72, 73 and 77 on frame member 12, engaging projections 46-53 which would be disposed on frame member 12a. In a similar manner, frame member 12a interfits with frame 12b. Frame 11 is accommodated on frame member 12b in the manner previously described in conjunction with frame members 11 and 12 of modular block 10 as shown in FIG. 2.
As also seen in FIG. 5, the modular block unit 70 with the panel members 12, 12a, and 12b can be positioned to laterally fit into the panel members 12c, 12d, and 12e of the modular block unit generally 60 by means of the lateral projections such as 38 and 39 (See FIG. 2) for fitment into the lateral openings such as 43c, 42c and 43e 42e in the frame members 12c and 12e. It is obvious that not only will the frame members fit together in a lateral manner, but they will also fit together one above the other by means of the upwardly projections such as 37 and 37a-e for fitment into openings in the bottom of similar frame members such as indicated at 45 in FIG. 3.
While not shown in the drawings, adjacent frame members 14 and 14c could be interconnected with the previously described peg and opening arrangement such as shown by the pegs 34 and 35 and the openings 41 and 42 of the frame member 11.
An important feature of this invention is the fact that any number of spaced panels can be employed in a single modular unit. It is well recognized that air is a very good insulator and the more dead air space created between the spaced panels the better the insulation factor. This is provided by the modular block design as seen in FIG. 6.
It will be appreciated that while the previously described interfitment of the various frame members provides a tight seal for the panels in the frame members, if desired, silicone calking material or similar type calking material can be suitably employed. For example it could be placed over the outer surface of the panel 16 adjacent the walls 27-30 as well as inside the frame members and against the adjacent panel surfaces such as over the inset portion 54 of frame member 11 and the inwardly extending wall 80 of frame member 12. In this manner, not only is a tight seal provided, but also repair becomes quite convenient as the frame members can be separated and the panels removed by merely scraping away the calking compound which remains in a semi-solid manner. For a more secure frame structure adhesive could be placed between the frame members.
The frame members of this invention are composed of a polyvinylchloride plastic material available from the B.F. Goodrich Company as No. 85856 or 85890. However, other suitable plastics can be used such as those which are easily injection molded. It will be obvious that any type of panel member can be utilized in conjunction with this invention whether clear glass, plastic, or colored glass or plastic depending on the type of structure desired. A very versatile as well as artistic effect is afforded.
The use of the plastic frame members herein not only afford a snap fitment arrangement which permits disassembly for repair but a construction which is lightweight thus reducing shipping costs. It also permits hand or machine assembly.
The foregoing invention can now be practiced by those skilled in the art. Such skilled persons will know that the invention is not necessarily restricted to the particular embodiments presented herein. The scope of the invention is to be defined by terms of the following claims as given meaning by the preceding description.
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A modular building block wherein a plurality of frame members sandwich fit panels therebetween so as to provide a block with a selective depth and insulation factors. The modular block can be interconnected with other similar blocks to provide any desired structure such as a window, wall or floor. The block is easily assembled yet can be repaired as the frame members can be disassembled and old panels replaced with new ones.
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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 methods of installing foundation systems and particularly to methods of installing foundation systems for modular type construction.
2. Description of the Prior Art
Constructing shelters has been an essential part of human development since the beginning of civilization. In the last century, buildings have been developed beyond the ordinary “stick-frame” construction into new modular designs. Both types of construction, however, use the same types of foundation, which consists of a concrete footing and some type of concrete or block walls. The building is built upon these walls typically by bolting a bottom sill plate to the top of the foundation wall using “J” bolts that have been embedded in the concrete.
Although these walls have been proven to be strong and reliable, they require quite a lot of site preparation, including surveying, grading, excavating, rebar install, setting concrete forms, pouring concrete (or building wall of block), and then back filling around the foundation. Additionally, in many areas, the foundation wall is waterproofed, which adds additional costs and time.
BRIEF DESCRIPTION OF THE INVENTION
The instant invention eliminates all of the problems associated with conventional concrete type foundations. It consists of a modular structure that requires no heavy equipment, a fraction of construction time, minimal site preparation, bagged concrete, and can be easily assembled by a small crew. The foundation system is hurricane proof and tornado proof. It can be assembled and dismantled, for either emergency housing or permanent construction. It allows additions to be added at any time, simply and easily. Moreover, it allows parts of the building to be removed if desired. The foundation system allows an owner or contractor to build it quickly and easily.
The foundation consists of a number of box bar joists that are square units that are assembled based on a grid layout. The box bar joists are supported by foundation steel tube columns that are embedded into the ground. While installing the foundation columns does require bag concrete and crushed rock, no forms or other complex structures are needed for the installation. Once the columns are installed, the box bar joists are installed using a unique leveling system. Once the box bar joists are level and secured to the columns, the foundation is complete. The use of the box bar joists also allows for expansion or contraction as additional box bar joists can easily be added or removed from the foundation. Once the box bar joists are in place, the foundation is ready for building.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a layout grid (LG) used in installing the foundation system.
FIG. 2 is a detail view of a connection node bolt (CNB) in the layout grid (LG) of the foundation system.
FIG. 3 is a detail view of an auger end post and turnbuckle used in the layout grid (LG) of the foundation system.
FIG. 4 is an exploded view of the connection node bolt (CNB) used in the layout grid (LG) of the foundation system.
FIG. 5 is an expanded detail view of the major components used in the foundation system.
FIG. 6 is a top plan view of a portion of the foundation system.
FIG. 7 is a top perspective view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 8 is a front elevation view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 9 is a side elevation view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 10 is a top plan view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 11 is a front elevation view of two box bar joists (BBJ) used in the foundation system.
FIG. 12 is a perspective detail section view of an alignment of 4 box bar joists (BBJ) used in the foundation system.
FIG. 13 is a top perspective view of one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 14 is a bottom perspective view of one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 15 is an enlarged detail view of the leveling toggle bolts (LTB) on one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 16 is an enlarged side view of one of the leveling toggle bolts (LTB) on one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 17 is a perspective view of one of the steel tube columns (STC) used in the foundation system.
FIG. 18 is a side elevation view of one of the steel tube columns (STC) used in the foundation system.
FIG. 19 is a top detail view of one of the steel tube columns (STC) used in the foundation system.
FIG. 20 is a perspective view of the components used as part of the aligning bar connector (ABC) system.
FIG. 21 is a detail perspective view of the various aligning bar connector (ABC) systems.
DETAILED DESCRIPTION OF THE INVENTION
The first step in the construction of the foundation is to prepare the site and lay out the grid. Referring now to FIGS. 1-4 , the grid system 100 is shown. Prior to erecting the grid, it is good practice to ensure the site is surveyed by a licensed surveyor to confirm the location of all property lines. In the preferred embodiment, the best site is one that is nearly flat with no more than a six (6) inch rise (slope) from one side of the building exterior to the other in both directions, ensuring all the foundation poles are the same length; slopes greater than six inches will require longer foundation poles. As an alternative, the site can be graded prior to construction. In the next step, level any grade high points greater than six inches or fill areas lower than six inches with crushed rock or fill material and compact so that the area is reasonably smooth and free from irregular surface changes. Next, install wood stakes at the corners of the exterior walls, tie string between the wood stakes six inches above the construction site high point and ensure it is horizontal with a line level. The string may also be run diagonally to each stake to better view the highpoints of the site and make leveling adjustments accordingly.
Once the site is prepared, the next step is to unroll the site layout grid (LG) in the location where the foundation is to be assembled. The assembled grid is shown in FIG. 1 . The grid is made up of lengths of coated wire rope. In the preferred embodiment, this is stainless steel vinyl coated wire rope, ⅛″ Bare OD, 7/32″ Coated OD. The wire rope is cut into sections and secured to end posts.
The grid may be assembled prior to deployment in the field. Note that for the system, the grid 100 has rows 101 and columns 102 of wire rope to make up the grid. The intersections 103 are fitted with special bolts and other hardware called connection nodes, which ensure that the intersections are properly spaced. The foundation poles are placed at these intersections so it is important to make sure they are properly positioned. Once the site is ready the grid is prepared; stretch the grid so that it is flat on the ground. The grid is anchored at the corners with two augers 104 at each of the corners. The augers are installed twelve (12) inches below grade to ensure the wire is taught, and laid directly on grade.
FIG. 2 shows details of the grid 100 showing one of intersections 103 and the hardware for making up the corners, of the rope grid 100 . Note that the ends of the rope are folded over to make thimbles 105 using clips 106 in the ordinary manner. The thimbles are placed on all lines leading to each auger. At each of the intersections 103 formed by the rows and columns are bolt assemblies 110 that hold the grid together.
FIG. 3 is a detail view of an auger and turnbuckle used in the layout grid (LG) of the foundation system. In this view, the actual attachments are shown. As shown, an auger 104 is shown with a thimble 105 on it. A length of wire rope is run out to a turnbuckle 108 . At the other end of the turnbuckle, the main row of the wire rope is attached. This rope runs the width of the foundation area, where it meets another turnbuckle assembly and another auger. Note the bolt assembly 110 at the intersection.
FIG. 4 is an exploded view of the connection node bolt (CNB) assembly 110 . At the bottom of the assembly is a ¾″-10 hex bolt 111 . This bolt is an ASTM A307 grade A bolts that is zinc plated. Note that it also had two grooves 112 formed in it as shown. These grooves 112 are used to hold the wire ropes that form the grid. The grooves allow the wire ropes 102 and 103 to fit within the bolt to produce a compact assembly. The wire ropes 101 and 102 , with the intersection 103 , are positioned between two flat washers 113 . Above the top washer 113 is a lock washer 114 and hex nut 115 as shown (or hex nylon lock nut replacing lock washer and nut).
As noted, the grid can be assembled prior to field layout. Once the augers are set and the grid stretched on them and properly tightened, the outline of the wire four-foot grid pattern is transferred using white pavement marking paint (or its equivalent) sprayed onto the surface of the ground. Next, orange color marking flags are installed at all connector node bolt (CNB) locations; i.e., at all four-foot wire spacing's. These flags are pushed deep into the soil so each flag is just visible to avoid pulling out the flag during construction. Once the flags are set, the layout grid (LG) can be rolled up and removed as the site is now prepared for the foundation installation.
This system uses rigid box bar joists (BBJ) set on plies. Unlike conventional pile foundations, however, the piles (called steel tube columns (STC) here) are attached to a leveled set of box bar joists (BBJ) before they are cemented into place. To do this, the following components are used, as shown in the following figures.
FIG. 5 is an expanded view of the major components used in the foundation system. FIG. 6 is a top plan view of a portion of the foundation system. At the top of the figure are four box bar joists (BBJ) 10 . Below them are four crawlspace leveling lifts (CLL) 20 . Below them are four columnar supports called steel tube columns (STC) 30 that are shown embedded in the ground 1000 . Note that the steel tube columns (STC) 30 , crawlspace leveling lifts (CLL) 20 and box bar joists (BBJ) 10 are the same for a flat site. The installations directions listed below are for a flat site setup. A sloped site setup is the same except that the steel tube columns (STC) are different lengths to accommodate the uneven ground.
Each of the components is discussed in detail below, along with complete installation details.
FIG. 7 is a top perspective view of one of the box bar joists (BBJ) 10 used in the foundation system. Each BBJ 10 has a top chord 11 that is made up of four pieces of angle iron that are welded together as shown. In the preferred embodiment, each of the top angle iron pieces is a 4″ by 4′ by 0.25″ with two 48″ long and two 40″ long pieces of angle iron. Four ⅞″ inch holes 12 are drilled to receive four ½″-13 bolts 1″ long 12 a , bolt head height is ¼″. The bottom chord 13 of the BBJ 10 is made up of smaller angle iron. In the preferred embodiment, the loner frame is made up of four pieces of 2″ by 2″ by 0.25″ by 40½″ long angle. Additionally, in the preferred embodiment, four ½″-13 studs 14 , 1-inch long are attached as shown to each corner with ¼″ steel plate tabs 14 a . Between the top and bottom chords is a web 15 of #3 rebar, or equivalent, this is welded to the top and bottom chords. Note that the overall height h (see FIGS. 8 and 9 ) of the BBJ 10 can range from 12 to 30 inches. In the example shown the height h is 18 inches.
FIG. 8 is a front elevation view of one of the box bar joists (BBJ) 10 used in the foundation system. FIG. 9 is a side elevation view of one of the box bar joists (BBJ) used in the foundation system. In these views, the top chord 11 , the bottom chord 13 and the web 15 are shown along with the tabs 14 a , studs 14 , ⅞″ hole 12 , and ½″ hex head bolt 12 a . Note here, the height h is also 18″ and overall length of the top chord is 4′ and overall length of the bottom cord is 40½″ (dimensions may vary per structural calculations).
FIG. 10 is a top plan view of one of the box bar joists (BBJ) used in the foundation system. Here, the top chord 11 is shown. Note that the corners 11 a are notched. This is to facilitate the assembly, as discussed below. Note here, that the holes 12 and bolts 12 a are also shown adjacent to the studs 14 and tabs 14 a.
FIG. 11 is a front elevation view of two box bar joists (BBJ) used in the foundation system. Here, two sections of BBJ 10 are shown placed adjacent. This is how the BBJs are aligned during the construction. FIG. 12 is a perspective detail section view of an alignment of four BBJs used in the foundation system. In this view, note how the holes 12 and the studs 14 are aligned. Note too, that the notched corners 11 a come together to form a hole in the center of the assembled BBJs, as shown. This hole is used to secure the aligning bar connectors (ABC), as described below. All BBJs are galvanized and are coated with a bitumen coating.
As discussed above, the BBJs 10 must be arranged and leveled prior to attaching the steel tube columns (STC). To do this, a number of crawlspace leveling lifts (CLLs) 20 are used to support and level the BBJs. Referring now to FIGS. 13-16 , details of the crawlspace leveling lifts (CLLs) 20 are shown. FIG. 13 is a top perspective view of one of the foundation crawlspace leveling lifts (CLL) 20 used in installing the foundation system. FIG. 14 is a bottom perspective view of one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system. Each of the CLLs 20 consists of a base plate 21 that has four spikes 22 attach that extend downwardly from the base plate 21 as shown. Four angle braces 23 extend upward from the base plate (one is placed at each corner of the base plate). The braces 23 are attached to a top plate 24 as shown. Two leveling toggle bolts (LTB) 25 assemblies are attached to the top plate as shown.
FIG. 15 is an enlarged detail view of the leveling toggle bolt assemblies 25 on one of the foundation crawlspace leveling lifts. FIG. 16 is an enlarged side view of one of the leveling toggle bolt assemblies. These assemblies are temporarily installed, as described below, and are used to level the BBJs and to support the BBJs and the STCs while the concrete for the STCs is curing. Each leveling toggle bolt assembly 25 has a long bolt 25 a that is threaded through two nuts 25 b that are welded to the top plate 24 as shown. A leveling nut 25 c welded and fixed to the bolt is provided as a measuring device to move bolt 25 a to the desired height, as discussed below. At the top of each of the toggle bolts 25 a is a “C” holder and toggle clamp 25 d that is riveted (and free turning) to the top of the bolt 25 a . In use, the bottom frame angle of a BBJ is placed in the “C” holder of the toggle bolt and clamped into place. Then, the toggle bolt height can be adjusted as needed, as described in the installation section below. Referring now to FIGS. 17-19 , details of the steel tube columns (STC) 30 are disclosed. FIG. 17 is a top perspective view of one of the steel tube columns (STC) used in the foundation system. FIG. 18 is a side elevation view of one of the steel tube columns (STC) used in the foundation system. Each STC 30 consists of a top cap 31 and a lower column 32 . The top cap gas a 7″ square×¼″ thick flange 33 that is secured to a 6″ long, 2½ inch OD round bar 34 . In the preferred embodiment, the cap is galvanized; the top cap secures the BBJs top chord hex bolt 12 a . Below the cap is a lower column 32 . This column is a 3″ diameter steel tube 35 , 3/16″ thick and is between 6 and 8 feet long. In the preferred embodiment it is galvanized and covered with a bitumen covering. The column has four ¼″×2″×2′ hurricane fins 36 attached as shown. Below the fins, four 2″ shear studs 37 are attached. Two steel angles 38 , 3″×3″×0.25″, 4″ long are attached on opposite sides of the column. These angles have 9/16″ diameter holes 39 drilled in them (see also FIG. 19 ). The angles secure the BBJs stud 14 , tighten with a ½″ hex net and washer.
FIG. 19 is a top detail view of one of the steel tube columns (STC) used in the foundation system. Here, the top cap 31 is shown. Note that the top cap has four 9/16″ perimeter holes 33 a formed in it as shown, and a center hole 33 b that is tapped at 1″-12 NC threads, 2″ deep. The cap 31 is placed into the lower column 32 and is welded to the lower column assembly.
Finally, another temporary component is shown on FIGS. 20 and 21 . FIG. 20 is a perspective view of the components used as part of the aligning bar connector (ABC) system. The aligning bar connectors (ABCs) 40 are made up of ⅛″ steel plates 41 that from a square perimeter and are reinforced by plates 42 that cross in the center as shown. At the four corners are steel tubes 42 , 1½ inch (nominal) milled ID, as shown. Four 1½ inch shoulder bolts 43 are placed in the tubes 42 . In addition, a number of spacers 44 , made from 2″ round stock and having 1½ inch (nominal) milled holes are used to support the ABCs when installed to the steel tube columns (STC) aligning them to the modular grid system.
FIG. 21 is a detail perspective view of various aligning bar connectors (ABC) to be used to align the steel tube columns (STCs). In this view, a single ABC is overlaid with 2 ABCs, followed by three, and so on. The ABCs 40 provide a locking overlay to secure all of the foundation components from above as part of the curing process, as discussed below. In practice, referring to FIG. 6 , the first ABC is placed atop the first BBJ. The four shoulder bolts are then secured to the center holes 33 b on the top caps. Once this is done, the second ABC is secured to the adjacent BBJ. Note that this ABC overlaps the first at one edge. Thus, two of the bolts used in the first installation are removed and then fed through the steel tubes 42 on both of the ABCs. Obviously, spacers 44 are used to support the other end of the second ABC. In a similar manner additional ABCs are installed overlapping them as needed until the entire foundation is covered.
To install the foundation, the following steps are used:
First, set up a laser level at a far corner of the grid that has been laid out as described above. Ensure the laser level is placed in an unobstructed sight line of all marking flags. This corner is opposite of where the first BBJ 10 is to be placed. The start location may be at any corner. In the preferred embodiment, the laser level height is 27″ above grade.
Next, the grid area is inspected to remove debris, vegetation, large rocks and tripping hazards. All paint markings and marking flags are verified as being visible. Note that as described above, the marking flags and paint stripes are on a four (4) foot grid.
Beginning with the first grid square, (opposite diagonal end from laser) auger two rows of STC holes (Depth varies per location). These holes should start at the short length of the building and next row over.
Next, tamp down and compact the exposed earth at the bottom of each hole. Then pour 1 cubic foot of crushed rock into the hole and tamp and compact the rock.
Once the rock has been compacted, place a paver (stone or plastic) cover over each hole. In this example, these holes are called row one (1) and two (2).
Next, place four CLLs 20 in the starting corner of the grid (herein called square # 1 ). As shown in FIG. 6 , place each of the CLLs centered between the holes drilled for the STCs around the perimeter of the first starting corner square # 1 .
Place the perimeter CLLs 20 with the screw hold up toggle lock bracket on the inside of the square (one toggle lock will be unused at the perimeter, as shown in FIG. 6 ).
Note, the bottom plate stakes are not pushed into soil more than an inch at this time. Place a BBJ 10 on the first square CLLs 20 into the channel next to the toggle bolt clamps again as shown in FIG. 6 . Ensure that the CLLs are in a near vertical position. Then, the bottom plate stakes are hammered into the ground.
Next, the leveling/toggle bolts are adjusted (up or down) until the welded leveling nut is centered in the laser level beam. (Note: in the preferred embodiment, the leveling nut is welded to the leveling/toggle bolt.
These steps are repeated for each CCL. When first CCL is level (i.e., when all leveling nuts at the same height), this is the height of all the BBJs 10 used in the system.
Next, after ensuring that the laser level is perfectly level at all times, begin working in the second grid square. As before, the next three CLLs are placed in the adjacent grid square. Similarly, the next BBJ is placed atop the three new CLLs, next to the installed BBJ.
Next, an STC 30 is placed in each of the four holes at square # 1 . (Note: STC may need to be placed earlier, depending on depth of hole from structural analysis). Each STC is raised up and the column cap is bolted to the BBJ hand tight. See FIG. 6 for the position of these components. Next four STC are installed in the grid square # 2 , as before.
Next, an aligning bar connector (ABC) is bolted into the center of each column cap 33 a . See FIG. 6 . Next, the bolts on the column cap are wrench tightened on each BBJ. Then concrete is poured into each STC hole.
The remaining grid squares for the foundation assembly are completed using the same process as in grid squares #1 and #2.
After seven (7) days from the last concrete pour, the CLLs are removed, and earth is pushed back into the holes in eight-inch lifts. Leach lift is compacted. Compact a small amount of earth two inches high around the top of each STC hole.
At this point, the foundation system is complete and ready for building upon.
Note that the ABCs are not removed at this time. They are removed only when floor joists assemblies (FJA not part of this system) are installed. Note: an alternate method of construction uses the floor joists assemblies (FJA) in place of the ABCs.
Finally, a crawlspace vapor barrier may be installed later in the construction process, for example, after installation of roofing.
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 method of installing a modular structure foundation system that requires no heavy equipment, minimal site preparation, and can be easily assembled by a small crew. The foundation consists of a number of box bar joists that are square units which are assembled based on a grid layout. The box bar joists are supported by foundation steel columns that are embedded into the ground. No forms or other complex structures are needed for the installation. Once the columns are installed, the box bar joists are installed using a unique leveling system. Once the box bar joists are level and secured to the columns, the foundation is complete. The use of the box bar joists also allows for expansion or contraction as additional box bar joists can easily be added or removed from the foundation. Once the box bar joists are in place, the foundation is ready for building.
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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 damping apparatus for moving furniture parts, for example for doors, flaps or drawers.
Such damping apparatuses are known in numerous different embodiments. DE 44 09 716 A1 shows an air damper which consists of a piston and a cylinder and whose piston is braked on its plunging into the cylinder by the compressed air in the cylinder, with the escape of the air being largely prevented by a seal through which the piston is moved on plunging into the cylinder. DE 37 29 597 A1 likewise shows a damping apparatus comprising a cylinder and a piston longitudinally displaceably received therein. A spigot is received in the cylinder which has a diameter changing in the longitudinal direction and which is guided in the piston designed as a hollow piston. The air compressed in the cylinder on the insertion of the piston is expanded depending on the position of the piston by the annular gap between the spigot and the bore of the piston.
Damping apparatuses of the kind first mentioned are furthermore known from DE 201 20 112.7. Air dampers are disclosed which have a bore in the jacket wall of the cylinder close to the closed end region, whereby a very good damping effect can be achieved.
If furniture parts are closed with great force or at great speed, the kinetic energy cannot be completely absorbed immediately by the aforesaid dampers on contact with them so that it can occur that the furniture parts jump back before they are pulled into their final closed position by closing apparatuses. A door damping element is known from JP 0020279886 AA which consists of a resilient damping part and an oil damper. The resilient damping part should have the effect that the impact of the door is damped. The remaining kinetic energy should be absorbed by the oil damper.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a damping apparatus of the kind first mentioned which avoids a possible jumping back movement of the furniture parts with a compact construction.
The object is solved by a damping apparatus having the features herein. In accordance with the invention, the damping apparatus has at least two damping stages which have in each case a cylinder having a piston longitudinally displaceable therein and which exert a damping effect of different strength. The braking effect is thus divided into two stages which are designed differently in that they exert braking effects of different strengths on their actuation. Provision can, for example, be made that the braking effect is achieved by two damping stages of which the first damping stage has a comparatively weak spring and the second damping stage has a customary air damper. In such an embodiment, the movement of the furniture part is initially mainly reduced by the force of the spring, while the following damping stage is only partly made use of. The remaining kinetic energy already reduced by the first stage is then completely absorbed by the second damping stage. A progressive braking effect thus results between the two stages, whereby jumping back of the furniture parts is avoided.
The damping apparatus can consist of two damping stages. More than two damping stages can naturally also be realized. The design of the damping apparatus with telescopic cylinders results in a particularly compact aspect of the damping apparatus.
In a preferred aspect of the present invention, the damping apparatus has a multistage, preferably two-stage, telescopic cylinder whose first damping stage has a piston loaded by a spring and received in a telescopic cylinder and whose second damping stage is formed by an air damper. The design of a damping apparatus with multi-stage telescopic cylinders is known, for example, from the already named DE 201 20 112.7 and also from DE 201 17 031.0. Damping apparatuses of this kind are characterized by a very small length or installation depth such that a particularly compact construction can be realized.
An air gap can exist between the piston and the cylinder of the first damping stage such that the braking effect of the first damping stage is essentially brought about by the force of the spring acting on the piston.
In a further aspect of the present invention, provision is made that the cylinder of the first damping stage has a piston fixedly connected to it which has a peripheral seal received in a groove which contacts the wall of the cylinder of the following damping stage in the insertion direction in a sealing manner and which contacts the groove wall in the moving out direction.
Whereas a compression of the air in the cylinder space thus takes place on the insertion movement, and thus the desired damping effect of the air damper is achieved, air can pass between the piston and the cylinder wall on the moving out so that the piston can be moved outward freely and easily.
The sealing is advantageously received in a groove of the piston which is in communication with the inner space of the cylinder of the following damping stage via passages. On the moving out of the piston, air flows through the passages such that, as described above, the piston can be pulled freely outward.
Provision can further be made that the piston of the first damping stage and the piston of the second damping stage each have a cut-out in Which the end regions of the spring of the fist damping stage are received.
In a further aspect of the invention, provision is made that the cylinder of the first damping stage has an annular flange by means of which this is supported in the starting position at a collar of the cylinder of the second damping stage at the front face.
The cylinder of the first damping stage can have an annular flange at which the piston of the first damping stage is supported in the starting position.
In a preferred aspect of the present invention, the last, or in a two-stage design the second, damping stage is formed by an air damper whose cylinder has a bore close to the closed end region in the jacket wall, the diameter of said bore being substantially smaller than that of the cylinder. Reference is made here to DE 201 20 112.7, from which a damping apparatus having a correspondingly arranged bore can be seen.
In a further aspect of the present invention, provision is made that the piston of the first damping stage has a plunger in whose end region a magnet is arranged. This has the effect that the damping apparatus is again moved into its starting position on the opening of the moving furniture part and is then available for a new damping process.
Provision can further be made for a spring to be provided in the last damping stage which is supported on the base of the cylinder of the last damping stage and exerts a return force on the piston of this damping stage. This spring guides the piston of this damping stage back into its starting position.
Provision can be made in this case that the piston of the first damping stage has a plunger in whose end region a buffer is arranged.
It is particularly advantageous for the first damping stage to exert a lower damping action than the second damping stage. Provision can be made for the second damping stage to be designed such that its starting friction is overcome during the actuation of the first damping stage. A gentle transition of the braking effect of the damping stages can thereby be achieved, whereby a springing back of the furniture parts can largely be avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the present invention will be explained in more detail with reference to an embodiment shown in the drawing, in which are shown:
FIG. 1 : a sectional representation through a first embodiment of the damping apparatus in accordance with the invention in its starting position;
FIGS. 2 , 3 : a section through the damping apparatus in accordance with FIG. 1 in a partially and fully inserted position;
FIG. 4 : a section through a further embodiment of the damping apparatus in accordance with the invention in its starting position; and
FIGS. 5-9 : individual parts of the damping apparatus in accordance with FIGS. 1 to 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A damping apparatus 1 in accordance with the invention can be seen from FIG. 1 . This consists of two damping stages of which the first has the cylinder 30 having the piston 32 and the second has the cylinder 20 having the piston 22 .
The piston 32 is guided in a longitudinally displaceable manner in the cylinder 30 of the first damping stage. The piston 32 has a plunger 34 in one piece with it in whose end region the magnet 36 is arranged.
The cylinder 30 has in its end region the piston 22 of the second damping stage, said piston 22 being fixedly connected to said cylinder 30 . The connection can take place, for example, by ultrasonic welding.
The piston 22 is displaceably guided in the cylinder 20 of the second damping stage.
The piston 32 has the cut-out 320 an the piston 22 has the cut-out 220 in which the end regions of the spring 40 of the first damping stage are received.
The piston 32 is supported in its starting position shown in FIG. 1 at the annular collar 302 of the cylinder 30 . Furthermore, the cylinder 30 is supported in the starting position by its annular flange 300 at the collar 200 of the cylinder 20 at the front face, as is shown in FIG. 1 .
The piston 32 is guided in the cylinder 30 such that an air gap remains between the piston 32 and the inner cylinder wall through which the air can flow such that the movement of the piston 32 substantially only takes place against the force of the spring 40 such that the damping characteristic of this first damping stage is quite substantially determined by the spring 40 .
The piston 22 of the second damping stage has the annular groove 24 in which the seal 26 is received. The groove 24 is in communication with the inner space 21 of the cylinder 20 of the second damping stage by means of the passages 28 and 29 .
The end region of the cylinder 20 is closed by the cap 60 which is fixedly connected to the cylinder 20 , for example by ultrasonic welding or by other customary means. The bore 202 , through which air escapes in a controlled manner on the pressing of the piston 22 into the cylinder 20 , whereby the damping action of the second damping stage is effected, is located in the end region of the jacket surfaces of the cylinder 20 .
The function of the damping apparatus shown in FIG. 1 is designed as follows: on the pressing in of the plunger 34 , the spring 40 is first compressed which sets a lower resistance against the impressing force than the second damping stage formed by the air damper. This has the consequence that the piston 32 is moved in the direction of the piston 22 until the end faces of the pistons contact one another, as is shown in FIG. 2 . Part of the movement of the furniture part is absorbed by the pushing in of the piston 32 and the movement energy is reduced accordingly. This is now subsequently taken up by the second damping stage whose function is designed as follows:
Starting from the position shown in FIG. 2 , the cylinder 30 with the piston 22 is now inserted into the cylinder 20 . The air is then compressed in the inner space 21 , whereby the pressure also increases in the passages 28 and 29 as well as in the groove 24 such that the seal 26 is pressed onto the inner wall of the cylinder 20 . This has the consequence that the air can substantially only escape through the bore 202 . The counter force applied by the air results in a further damping of the movement of the furniture part until the cylinder 30 is completely received in the cylinder 20 , as is shown in FIG. 3 .
The damping action of the second damping stage is advantageously designed such that the partial load also acting on the second damping stage during the compression of the spring 40 results in an overcoming of the starting friction. This has the advantage that the second damping stage is set in motion directly after the state shown in FIG. 2 so that a progressive effect of the damping apparatus is achieved and any springing back of the furniture parts can be avoided.
FIG. 4 shows a further embodiment of the damping apparatus in accordance with the invention. The elements shown here substantially correspond to those shown in FIG. 1 . An exception to this is formed by the spring 50 which is supported between the base 60 of the cylinder 20 and the area of the piston 22 of the second damping stage at the front face which faces this. The spring 50 is fixed on the neck 62 of the base 60 . The spring 50 has the effect that a return force is exerted on the piston 22 such that this is pushed back into the position shown in FIG. 4 when no strain is present. The same applies accordingly to the action of the spring 40 on the piston 32 .
In the embodiment shown in FIG. 4 , the end region of the plunger 34 is not fitted with a magnet, but with the buffer 38 .
FIGS. 5 to 9 show individual parts of the aforesaid damping apparatuses in accordance with the present invention. FIG. 5 shows the base 60 of the cylinder 20 which is preferably fixedly connected to this in an air tight manner by ultrasonic welding or also by other connection techniques in order to ensure that the air only escapes through the bore 202 .
FIG. 6 shows the cylinder 20 of the second damping stage with a bore 202 and the collar 200 at the front face which, in the starting position shown in FIG. 1 and in FIG. 4 , holds the annular flange 300 of the cylinder 30 .
FIG. 7 shows the piston 22 with the annular groove 24 and the passages 28 , 29 , with the passages 28 extending radially and the passage 29 extending axially with respect to the cylinder 20 or piston 22 . Furthermore the cut-out 220 can be seen in FIG. 7 which serves the purpose of taking up an end region of the spring 40 whose other end region is received in the cut-out 320 of the piston 32 .
FIG. 8 shows the telescopic cylinder 30 which is received in the cylinder 20 in the inserted state of the damping apparatus, as can be seen from FIG. 3 . The cylinder 30 has the annular flange 300 which contacts the collar 200 of the cylinder 20 at the front face in the starting position. Furthermore, the cylinder 30 has the annular collar 302 which serves the purpose of holding the piston 32 in the starting position in accordance with FIGS. 1 and 4 .
Finally, FIG. 9 shows the piston 32 with the plunger 34 adjoining it in one piece. The cut-out 320 serves the reception of an end region of the spring 40 ; the cut-out of the plunger 34 shown on the right hand side serves the reception of a magnet 36 (see FIG. 1 ) or of the buffer 38 (see FIG. 4 ).
The present embodiments show the second damping stage as an air damper and the first damping stage as a spring-loaded damper. Generally, other embodiments are also conceivable here. For example, the air damper could also be formed by another customary damping device.
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The present invention relates to a damping apparatus for moving furniture parts, for example doors, flaps or drawers. Such a damping apparatus of a compact construction which avoids a possible springing back movement of the furniture parts is provided in accordance with the invention in that the damping apparatus has at least two damping stages each having a cylinder having a piston longitudinally displaceable therein which exert a damping action of different strengths.
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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 in general to a wellbore tool utilized for performing work within a wellbore by converting a chemical pressure source into a force exerted over a distance for operating force actuated downhole tools.
2. Background of the Invention
Prior art wellbore tools have been utilized to provide power for operating and setting downhole tools. One example of such a prior art wellbore tool is a cable conveyed bridge plug for setting within a cased wellbore such as that shown in U.S. Pat. No. 2,637,402, entitled "Pressure Operated Well Apparatus, " invented by R. C. Baker et al., and issued to Baker Oil Tools, Inc. on May 5, 1953. A similar cable conveyed wellbore tool is disclosed in U.S. Pat. No. 2,695,064, entitled "Well Packer Apparatus," invented by T. M. Ragan et al., and issued to Baker Oil Tools, Inc. on Nov. 23, 1954. These patents disclose cable conveyed wellbore tools for setting a bridge plug within a wellbore casing. Both of the cable conveyed wellbore tools include a prior art power charge for providing energy to set the bridge plug within the wellbore casing. These cable conveyed wellbore tools were actuated by the percussion of a firing pin causing a cartridge to explode and ignite the prior art power cartridge, or combustible charge.
Another example of prior art wellbore tool is the wireline conveyed well packer apparatus disclosed in U.S. Pat. No. Re. 25,846, entitled "Well Packer Apparatus," invented by D. G. Campbell, and issued to Baker Oil Tools, Inc. on Apr. 31, 1965. The wireline conveyed well packer apparatus disclosed includes a power charge which is ignited to generate gas for setting the well packer apparatus within a wellbore. The power charge is ignited by passing an electric current down the wireline and exploding an igniter cartridge, which causes a flame to ignite the power charge.
An example of a prior art power charge for use in a wellbore tool to generate gas is a combustion charge disclosed in U.S. Pat. No. 2,640,547, entitled "Gas-Operated Well Apparatus," invented by R. C. Baker et al., and issued to Baker Oil Tools, Inc. on Jun. 2, 1953. The combustion charge is comprised of combustion materials which, when ignited within a wellbore tool disclosed in the patent, will take at least one second for a maximum pressure to be attained within the wellbore tool. This prior art combustion charge includes both a fuel and a self-contained oxygen source. The combustion charge is ignited to generate a pressurized gas which provides a force for setting the gas-operated well apparatus. The combustion charge of the gas-operated well apparatus is ignited by exploding an igniter to start the combustion reaction for burning the combustion charge. The combustion charge, once ignited, burns in a self-sustained combustion reaction to generate the pressurized gas.
Another prior art wellbore tool is the wireline setting tool disclosed in U.S. Pat. No. 2,692,023, entitled "Pressure Operated Subsurface Well Apparatus," invented by M. B. Conrad, and issued to Baker Oil Tools, Inc. on Oct. 19, 1954. The wireline conveyed wellbore tool includes a power charge which is burned in a combustion reaction to generate a pressurized gas. The power charge is ignited by electrically exploding an igniter cartridge which then emits a flame to start the power charge burning. Combustion of the power charge generates pressurized gas having a pressure which provides force for operation of the wireline setting tool to set a downhole tool such as a packer or bridge plug within the wellbore.
Each of the above-referenced patents, U.S. Pat. Nos. 2,640,547, Re. 25,846, 2,695,064, 2,637,402, and 2,692,023, are hereby incorporated by reference as if fully set forth and disclosed herein.
As disclosed in the above-referenced devices, these prior art wellbore tools for converting the chemical components of a power charge into a mechanical force exerted over a distance require at least a separate igniter cartridge for igniting the power charge. Typically, explosive components are used for these prior art igniter materials, such as, for example, gunpowder or lead azide. These types of igniter materials are easily ignited and represent hazards both to operators utilizing these materials in wellbore tools, and to successful completion of wellsite operations. Some of these types of primary ignition or igniter materials are susceptible to ignition from applications of small amounts of electric current, or even discharge of static electricity.
Further, due to the hazards of these igniter materials, special procedures and equipment are required for both transporting and storing prior art igniter materials. Due to the relative ease with which these igniter materials may be ignited, they are typically stored and transported separately from power charge materials to prevent exposure of a large energy source contained within the power charge from such relatively volatile materials included within prior art igniters.
SUMMARY OF THE INVENTION
It is one objective of the present invention to provide a wellbore tool for performing work downhole within a wellbore, the wellbore tool having a power charge for use as a chemical pressure source which is ignited without use of explosive materials.
It is another objective of the present invention to provide a wellbore tool for performing work within a wellbore, the wellbore tool having a power charge which is ignited electrically, without use of explosive materials, to burn in a self-sustained combustion reaction to provide a pressurized gas.
It is yet another objective of the present invention to provide a wellbore tool for use to provide mechanical power for operating a downhole tool, the wellbore tool having an electrical resistance heater for directly initiating a self-sustained combustion reaction for burning a plurality of materials for generating pressurized gas.
It is further another objective of the present invention to provide a wellbore tool for providing a force over a distance to operate a downhole tool, the wellbore tool powered by a self-contained single power cartridge which includes a resistance heater for electrically igniting combustible materials within the power cartridge.
These objectives are achieved as is now described. A wellbore tool is provided to perform work in a wellbore by converting a chemical pressure source into a force exerted over a distance. The wellbore tool includes a pressure chamber, which is sealed by a firing head and contains a power charge having a plurality of chemical components which are burned in a combustion reaction to generate gas. The combustion reaction of the power charge is initiated by a resistance heater which directly initiates the combustion reaction by receiving electrical energy and generating heat. The combustion reaction generates gas within the pressure chamber, the gas having a pressure which pushes a pressure responsive member into movement relative to the pressure chamber for providing a force over a distance to operate a downhole tool.
In the preferred embodiment of the present invention, a wireline conveyed setting tool is provided for converting a self-contained solid propellant into a force extended over a distance for urging a settable wellbore tool into gripping and sealing engagement within a wellbore. The setting tool includes a pressure chamber which is sealed by a firing head and contains a power charge. The power charge includes both the self-contained solid propellant and a resistance heater for igniting the self-contained solid propellant. The resistance heater converts electrical energy into heat for directly initiating a self-sustained combustion reaction in which the solid propellant is burned to generate pressurized gas. The pressurized gas exerts a pressure which pushes against a pressure responsive member to move the pressure responsive member for urging a sleeve to move relative to a mandrel for setting the settable wellbore tool into gripping and sealing engagement within the wellbore.
Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWING
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a partial longitudinal section view of a wellbore depicting a wireline tool string which includes the wireline setting tool of the preferred embodiment of the present invention;
FIG. 2 is a longitudinal section view of a wireline setting tool of the preferred embodiment of the present invention, shown prior to actuation;
FIG. 3 is a longitudinal section view of a portion of a wireline setting tool having a prior art power charge, explosive igniters, firing head, and a pressure chamber; and
FIG. 4 is a longitudinal section view of a portion of a wireline setting tool of the preferred embodiment of the present invention, which includes a pressure chamber, a firing head, and a power charge having a resistance heater.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a partial longitudinal section view depicts a wellbore B having a casing C within which a wireline tool string T is secured to wireline W. An electrical power supply E is schematically shown for providing power to tool string T. Wireline tool string T includes wellbore tool 2 which, in the preferred embodiment of the present invention, is a wireline setting tool. Tool string T further includes a packer P which is releasably secured to wellbore tool 2 for positioning and setting within casing C.
With reference to FIG. 2, a longitudinal section view shows wellbore tool 2 shown prior to actuation. In the preferred embodiment of the present invention, wellbore tool 2 is a wireline setting tool having an elongated tubular body, and including firing head 4 and pressure setting tool 6.
Pressure setting tool 6 includes pressure chamber 8. Pressure chamber 8 includes a manual bleeder valve 10 for selectively bleeding pressure from within pressure chamber 8 after operation of wellbore tool 2. An upper end of pressure chamber 8 threadingly engages firing head 4 and fluid flow therebetween is prevented by seal 12.
Upper cylinder 14 is threadingly coupled to a lower end of pressure chamber 8, and seal 16 prevents fluid flow therebetween. Within upper cylinder 14 is floating piston 18, which is a pressure responsive member. Floating piston 18 is movable within upper cylinder 14 and, during operation of wellbore tool 2, is urged to move downward by gas pressure within pressure chamber 8. Seal 20 prevents fluid flow between an outer circumference of floating piston 18 and an interior diameter of upper cylinder 14.
Cylinder connector 22 is threadingly coupled to a lower end of upper cylinder 14. Seal 24 prevents fluid flow between an outer circumference of an upper end of cylinder connector 22 and an interior of the lower end of upper cylinder 14. Cylindrical connector 22 includes flow port 26 having orifice 28 which substantially measures three-sixteenths of an inch in diameter at an upper end of flow port 26.
Lower cylinder 30 has an upper end which is threadingly coupled to a lower portion of cylindrical connector 22. Seal 32 prevents fluid flow between an outer circumference of the lower end of cylindrical connector 22, and an interior of the upper end of lower cylinder 30.
Secondary piston 34 is disposed interiorly of and is movable within lower cylinder 30. Secondary piston 34 is a second pressure responsive member and is movable within lower cylinder 30. Seal 36 seals between an outer circumference of secondary piston 34 and an interior diameter of lower cylinder 30.
Piston rod 38 is secured to secondary piston 34 by lock pin 40, and is also movable within lower cylinder 30.
Cylinder head 42 is threadingly coupled to the lower end of lower cylinder 30. Seal 44 prevents fluid flow between the outer circumference of cylinder head 42 and the interior diameter of lower cylinder 30. Seal 46 prevents fluid flow between an interior surface of cylinder head 42 and an outer circumference of piston rod 38, which is movable with respect to cylinder head 42 and seal 46.
Mandrel 48 has an upper end which is threadingly secured within cylinder head 42. Set screw 50 prevents rotation of mandrel 48 within cylindrical head 42 after mandrel 48 is threadingly secured within cylindrical head 42. Mandrel 48 includes longitudinally extending slot 52, and longitudinally extending slot 54 which are two diametrically opposed longitudinally extending slots through an outer tubular wall of mandrel 48.
Cross link 56 inserts through longitudinally extending slot 52 and longitudinally extending slot 54, and is movable longitudinally within slots 52 and 54. Cross link 56 further inserts through piston rod 38 and sleeve 58 to couple sleeve 58 to piston rod 38. Cross link retaining ring 60 retains cross link 56 within sleeve 58 to maintain cross link 56 in engagement within sleeve 58 and piston rod 38. Lock screw 62 (not shown) secures cross link retaining ring 60 to sleeve 58.
Sleeve 58 is a driven member which is driven downward by piston rod 38 and cross link 56 when secondary piston 34 is urged into moving downward during operation of wellbore tool 2.
Pressure equalization ports 64 and manual bleeder valve 10 are provided for releasing fluid pressure from within pressure chamber 8, upper cylinder 14, and lower cylinder 30 after operation of wellbore tool 2. Pressure equalization ports 64 are provided at seal 16, seal 24, and seal 44. During disassembly of wellbore tool 2 after operation within wellbore B, thread pressure equalization ports 64 allow release of pressure from within wellbore tool 2 by passing over seal 16, seal 24, and seal 44, respectively, prior to the threaded connections of these seals being completely uncoupled. Thread pressure equalization ports 64 thus allow pressure to be released from the interior of wellbore tool 2 prior to fully uncoupling portions of wellbore tool 2.
Hydraulic fluid 66 is contained between floating piston 18 and secondary piston 34 to provide an intermediate fluidic medium for transferring force between floating piston 18 and secondary piston 34. As shown in FIG. 2, prior to actuating pressure setting tool 6, hydraulic fluid 66 is primarily disposed within upper cylinder 16.
During operation of pressure setting tool 6 to move sleeve 58 with respect to mandrel 48, a gas pressure generated within pressure chamber 8 urges floating piston 18 downward. Downward movement of floating piston 18 presses hydraulic fluid 66 through orifice 28 and flow port 26 to drive secondary piston 34 downward. Movement of secondary piston 34 downward within lower cylinder 30 causes piston rod 38, cross link 56, and sleeve 58 to move downward with respect to lower cylinder 30 and mandrel 48. Firing head 4, pressure chamber 8, upper cylinder 14, cylinder connector 22, lower cylinder 30, cylinder head 42, and mandrel 48 remain stationery as floating piston 18, hydraulic fluid 66, secondary piston 34, piston rod 38, cross link 56, sleeve 58, and cross link retaining ring 60 move within pressure setting tool 6.
Referring now to FIG. 3, a longitudinal section view depicts pressure setting tool 6 used in combination with prior art firing head 68, and prior art power charge 70 within pressure chamber 72. Prior art firing head 68 includes adapter 74, and explosive igniter housing 76. Explosive igniter housing 76 houses primary igniter 78, such as a BP3A primary igniter, and secondary igniter 80. BP3A primary igniters, secondary igniters, and prior art power charges, such as power charge 70, are manufactured by and available from Baker Oil Tools Inc., a division of Baker Hughes Inc., both of Houston, Tex. Both primary igniter 78 and secondary igniter 80 are prior art igniters which include explosive materials for igniting prior art power charge 70.
An upper end of adapter 74 is threaded for connection to a wireline tool string. A lower end of adapter 74 threadingly engages an upper end of pressure chamber 72. Explosive igniter housing 76 is threadingly coupled within the lower end of adapter 74 by a left-hand threaded connection. Seal 82 sealingly engages between an outer circumference of explosive igniter housing 76 and an interior diameter of pressure chamber 72 to prevent fluid flow therebetween. Seal 84 sealingly engages between an outer circumference of explosive igniter housing 76 and an interior diameter of the lower end of adapter 74 to prevent fluid flow therebetween.
Cartridge cap 86 retains primary igniter 78 within an upper end of explosive igniter housing 76. Seal 88 sealingly engages between cartridge cap 88 and primary igniter 78. Secondary igniter 80 is held within explosive igniter housing 76 by snap ring 90 (not shown).
Electrical connector assembly 92 is utilized to electrically connect a wireline, or wireline tool string, to primary igniter 78. Electrical connector assembly 92 includes upper connector pin 93, connector spring 94, and lower connector pin 95. Electrical connector assembly 92 is insulated by insulator sleeve 96 and pin insulator 97 to prevent electrical continuity between adapter 74 and electrical connector assembly 92. Connector lock ring 98 threadingly engages within adapter 74 to hold insulator sleeve 96, pin insulator 97, and electrical connector assembly 92 in place within adapter 74.
Connector spring 94 electrically connects between upper connector pin 93 and lower connector pin 95, and further it urges lower connector pin 95 downward and into contact with the upper end of prior art primary igniter 78.
With reference to FIGS. 1 and 3, prior art power charge 70 is ignited by passing electrical current from an electrical power supply, such power supply E, and through a wireline W to a wireline tool string T, through electrical connector assembly 92, and to primary igniter 78. Primary igniter 78 includes a gunpowder load which is ignited by the electrical current conducted through electrical connector assembly 92. Primary igniter 78 then ignites secondary igniter 80. Secondary igniter 80 generates heat which then ignites prior art power charge 70. Prior art power charge 70 then burns in a self-sustained combustion reaction to generate a gas having a pressure which pushes floating piston 18 downward.
Referring back to FIG. 2, downward movement of floating piston 18 presses hydraulic fluid 66 through orifice 28 and flow port 26 to urge secondary piston 34 downward. Piston rod 38, cross link 56, and sleeve 58 are connected to secondary piston 34. Movement of secondary piston 34 downward urges sleeve 58 to move relative to mandrel 48.
With reference to FIG. 4, a longitudinal section view depicts wellbore tool 100, which is the wireline setting tool of the preferred embodiment of the present invention depicted as wellbore tool 2 in FIG. 1. Wellbore tool 100 includes power charge 102 having resistance heater 104. Wellbore tool 100 further includes pressure setting tool 6 used with pressure chamber 106 and firing head 108. Although pressure chamber 106 is used with firing head 108 in the preferred embodiment of the present invention, in other embodiments of the present invention firing head 108 may be constructed for use with prior art pressure chamber 72 shown in FIG. 3.
Still referring to FIG. 4, in the preferred embodiment of the present invention, firing head 108 includes adapter 110, conductor housing 112, electrical conductor assembly 114, and housing lock ring 116. Conductor housing 112 is threadingly engaged within adapter 110. Seal 118 seals between an outer circumference of conductor housing 112 and an interior diameter of a lower end of adapter 110. A lower end of connector housing 112 includes shoulder 120 and is secured within pressure chamber 106 by housing lock ring 116 threadingly engaging within an upper end of pressure chamber 106. Housing lock ring 116 abuts against shoulder 120 of conductor housing 112 to retain conductor housing 112 within pressure chamber 106. Seal 122 prevents fluid flow between an outer circumference of conductor housing 112 and an interior diameter of pressure chamber 106.
Electrical conductor assembly 114 is electrically insulated within conductor housing 112 by insulator 124, insulator 126, insulator 128, and insulator 130, which are made from polytetrafluoroethylene, which is available from E. I. DuPont De Nemours and Company under the registered trademark TEFLON®. Electrical conductor assembly 114 includes upper conductor pin 132, conductor spring 134, conductor rod 136, and lower conductor pin 138. Conductor spring 134 is compressed so that it presses against upper conductor pin 132 and lower conductor rod 136 to both provide electrical contact therebetween, and to press conductor rod 136 into lower conductor pin 138.
Power lead screw 140 threads into a lower end of lower conductor pin 138. Ground lead screw 142 threads into a lower face of conductor housing 112. Power lead 144 is connected by power lead screw 140 to electrical conductor assembly 114. Ground lead 146 is connected by ground lead screw to conductor housing 112 which provides an electrical ground for completing an electrical circuit from wireline tool string T (shown in FIG. 1), through electrical conductor assembly 114, to resistance heater 104 within power charge 102, and to ground lead 146.
Power charge 102 of the preferred embodiment of the present invention includes resistance heater 104, chemical components 148, and power charge housing 150. Power lead 144 and ground lead 146 extend from resistance heater 104 through a portion of chemical components 148, and through power charge housing 150 to provide an electrical connection for providing power to resistance heater 104. In the preferred embodiment of the present invention, chemical components 148 serve as a propellant which burn to generate a pressurized gas which urges floating piston 18 downwards.
In the preferred embodiment of the present invention, propellant 148 is made of a standard-service, solid propellant mixture which includes, but is not necessarily limited to, a mixture of the following chemical components: potassium perchlorate, gilsonite resin, strontium nitrate, diatomaccous earth, and toluene.
The standard mixture for the preferred embodiment of propellant 148 are the same materials which were utilized in prior art power charge 70. However, in the preferred embodiment of the present invention, propellant 148 in power charge 102 is directly ignited to burn in a combustion reaction by heat from resistance heater 104, rather than being ignited by either a primary or a secondary igniter burning to generate heat for igniting the prior art propellant in prior art power charge 70.
As discussed above, prior art primary igniters, such as primary igniter 78, utilize gunpowder and prior art secondary igniters, such as secondary igniter 80, also utilize an explosive mixture. However, in the preferred embodiment of the present invention, power charge 102 is ignited without use of explosive materials, but rather is directly ignited by heat electrically generated from resistance heater 104. A primary or secondary chemical reaction, such as an explosion, is not utilized.
In the preferred embodiment of the present invention, resistance heater 104 is a 5-watt wire-wound resister which is sealed within chemical components 148 in power charge housing 150. Power charge propellant 148 and resistance heater 104 are packaged into a singular package, or container, power charge housing 150, for storage, transport, and insertion into wellbore tool 100. Propellant 148 is self-contained since it is packaged within the container for power charge 102, which in the preferred embodiment of the present invention is a singular container, power charge housing 150.
Operation of wellbore tool 100 is now discussed with reference to FIGS. 1, 2, and 4. Electrical power is provided from electrical power supply E, through wireline W and to wireline tool string T. Electrical power then passes from wireline tool string T, through electrical conductor assembly 114, power lead screw 140, and power lead 144 to resistance heater 104. The electrical circuit is completed by ground lead 146 which is affixed by ground lead screw 142 to conductor housing 112.
Approximately five to ten times the wattage rating for resistance heater 104 is passed through resistance heater 104. Resistance heater 104 generates heat which then directly ignites chemical components 148, without use of a primary or a secondary igniter, or explosive materials. Ignition of chemical components 148 causes them to burn in a self-sustained combustion reaction and a pressurized gas is generated. The pressure of the pressurized gas then builds within pressure chamber 106 to urge floating piston 18 downward.
Movement of floating piston 18 downward pushes hydraulic fluid 66 through orifice 28 and flow port 26 to push secondary piston 34 downward. Secondary piston 34 is connected to piston rod 38, cross link 56, and sleeve 58. Movement of secondary piston 34 downward within lower cylinder 30 moves sleeve 58 downward with respect to mandrel 48. Relative movement of sleeve 58 with respect to mandrel 48 is applied to a downhole tool, such as packer P, for applying a force over a distance to set packer P within casing C. (Packer P not shown in a set position.)
In the preferred embodiment of the present invention, power charge 102 will burn in a self-sustained chemical reaction, which, in the preferred embodiment of the present invention, is a combustion reaction for generating gas. The combustion reaction of the preferred embodiment is a slow combustion reaction, burning at a rate so that a maximum level of gas pressure within pressure chamber 106 will not be reached before a one second period of time has elapsed. This is to be distinguished from explosive reactions in which explosive material is either detonated, deflagrated, or generally burns with a rate of reaction which takes no more than a time period of several milliseconds to burn the explosive materials.
The preferred embodiment of the present invention offers several advantages over prior art setting tools. Since a primary and secondary igniter are not used within the wellbore tool 100, and thus explosive materials are not used, wellbore tool 100 is safer for operators.
Further, wellbore tool 100 is also safer since more electrical energy is required for powering resistance heater 104 to provide sufficient heat for igniting the power charge in the preferred embodiment of the present invention than was required for igniting prior art primary igniters to initiate combustion of prior art power charges.
Additionally, the wellbore tool of the preferred embodiment utilizes a power charge and power charge ignition system which may be sold and shipped as a single container rather than having three components, a primary igniter, secondary igniter, and a prior art power charge, some of which are shipped as explosive materials rather than flammable solids under United States Department of Transportation shipping regulations.
Although the wellbore tool of the present invention has been described herein embodied as a wireline conveyed setting tool, it may be used in other embodiments, such as, for example, a tubing conveyed wellbore tool, and is not limited to wireline conveyed setting tools, nor tubing conveyed wellbore tools. While the invention has been shown in only one of its forms, it is thus not limited but is susceptible to various changes and modifications without departing from the spirit thereof.
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A wellbore tool is provided to perform work in a wellbore by converting a chemical pressure source into a force exerted over a distance. The wellbore tool includes a pressure chamber sealed by a firing head and containing a power charge which includes a plurality of chemical components which are burned in a combustion reaction to generate gas. The combustion reaction of the power charge is initiated by a resistance heater which directly initiates the combustion reaction by receiving electrical energy and generating heat. The combustion reaction generates gas within the pressure chamber, the gas having a pressure which pushes a pressure responsive member into movement relative to the pressure chamber for providing a force over a distance to operate a downhole tool.
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FIELD OF THE INVENTION
This invention relates to enclosures of the type used in industrial electrical and hydraulic systems and the like, and more particularly to an improved fastener for attaching removable access panels in such enclosures.
BACKGROUND OF THE INVENTION
Control components, wiring, and plumbing in industrial electrical and hydraulic control systems are often mounted in cabinet-like enclosures. Such enclosures typically include a frame having a flange for attachment of one or more removable access panels. Each access panel typically includes a number of quick-release fasteners installed through holes in the panel for attaching the panel to the flange.
Such quick-release fasteners typically include a retaining screw having a shaft section defining an axis. One end of the retaining screw is formed into a head having a larger outer diameter than the shaft of the screw, and including a slot, recess, flats, or knurling so that the screw may be installed and removed by hand or with common hand tools. The opposite panel retaining end of the screw is typically formed to provide male or female screw threads, an L-shaped form, or some other type of quick-attach retainer profile, cooperating with the flange or a mating thread, etc., attached to the flange for securing the access panel to the frame of the enclosure.
The fastener also typically includes a bushing having an outer profile which includes a first section shaped for insertion through a hole in the panel, a shoulder for positioning the bushing in the panel, and a bore extending through the bushing about the axis to receive the shaft with the head of the retaining screw adjacent the shoulder on the outside of the panel, and the opposite panel retaining end on the inside of the panel. The bushing is typically secured within the hole by a C-ring which snaps into a groove of the bushing inside of the panel after the bushing is inserted through the hole. It is common in such fasteners to have the head and panel retaining inner end of the retaining screw larger in diameter than the bore of the bushing, or otherwise configured such that the screw is held captive within the bushing.
In some fasteners, a spring is also provided between the head of the screw and the shoulder of the bushing to facilitate installation and removal of the panel by pulling the panel retaining end of the screw away from the flange after disengagement.
Inherent problems associated with the manufacture and use of prior art quick-release fasteners of the type described above increase the initial and life cycle cost of the fasteners and enclosures in which they are used. Performance and aesthetic desirability of the enclosures is also reduced by the inherent problems associated with the use of the prior art fasteners.
Using C-rings for retaining the fastener in the access panel creates several problems. The initial labor and part cost is increased by the need to stock, handle, and install the separate C-ring. The risk of dropping a C-ring into the enclosure during installation, operation, or maintenance activities is undesirable. There is also an aesthetic problem, in that unless the C-rings clamp the bushing of the fastener tightly against both faces of the panel, the fasteners may rattle when the panel is removed, giving a customer the impression of sloppy workmanship and shoddy design. To alleviate this problem, the bushings can be closely matched to a given panel thickness, but where several different panel thicknesses are used by a manufacturer, perhaps even on the same enclosure, this requires a different fastener configuration for each panel thickness.
Prior quick-release fasteners of the type described above having a head and panel retaining end configured to be larger in diameter or otherwise shaped so as to not slide through the bore of the bushing of the completed fastener are difficult to manufacture. Because neither the head nor panel retaining end of the retaining screw will fit through the bushing, the bushing must be installed on the shaft section of the retaining screw during manufacture prior to forming the head or forming the panel retaining end of the retaining screw. Where the fastener must ultimately be plated, or where a spring is utilized between the head and shoulder of the bushing, the necessity of installing the bushing midway through formation of the screw is highly undesirable.
It is an object of my invention, therefore, to provide an improved enclosure through the use of an improved quick-release fastener for access panels of the enclosure. Other objects of my invention include providing:
(1) a fastener that is more readily manufactured than prior fasteners at a lower cost;
(2) a fastener that is self-retaining;
(3) a fastener that is self-retaining in panels of several different thicknesses;
(4) a fastener in which the component parts can be separately manufactured and subsequently assembled following completion of all manufacturing operations on the various component parts;
(5) a bushing which can be installed on the shaft section of a retaining screw of a fastener following completion of all manufacturing steps for the retaining screw; and
(6) a fastener which can be retrofitted into existing panel and enclosure designs to improve their desirability.
SUMMARY OF THE INVENTION
My invention provides such an improved enclosure and solves the problems defined above through the use of an improved quick-release fastener. According to one aspect of the invention, the improved quick-release fastener includes a bushing having an outer profile including a first section shaped for insertion through a hole in an access panel of an enclosure, a shoulder and a resilient tang axially spaced from the shoulder for retaining the bushing in the panel, and a bore extending through the bushing about an axis for receiving a shaft section of a retaining screw of the quick-release fastener. In preferred embodiments of this aspect of my invention, the tang includes a serrated surface configured to bear against an inner surface of the access panel, with the serrations having notches shaped for receipt of the inner surface of panels of several thicknesses. According to another aspect of my invention, the improved quick-release fastener utilizes a bushing comprised of two segments separable along a plane passing through the axis of the bore of the bushing. In preferred embodiments, the two segments include corresponding male and female alignment formations for aligning the bushing about the bore. In a highly preferred embodiment, the two segments of the bushing are identical.
Other aspects and advantages of my invention will be apparent from a review of the following drawings and detailed description of exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary embodiment of an enclosure according to my invention;
FIGS. 2 and 3 illustrate detailed features of the embodiment of FIG. 1; and
FIGS. 4-6 illustrate alternate embodiments of possible panel retaining ends for a retaining screw in a quick-release fastener according to my invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an exemplary embodiment of an enclosure 10 according to my invention. The enclosure 10 includes a frame 12 having a flange 14 for attachment of a removable panel 16 . The panel 16 includes a hole 18 , and a quick-release fastener 20 retained in the hole 18 , as described in detail below, for attaching the panel 16 to the flange 14 of the enclosure 10 .
The fastener 20 includes a retaining screw 22 having a shaft section 24 defining an axis 26 . The retaining screw 22 includes a head 28 at an outer axial end of the shaft 24 , and an L-shaped opposite inner axial panel retaining end 32 of the shaft section 24 for engaging the flange 14 . The shaft section 24 is located intermediate the head 28 and the latch 32 . The head 28 of the retaining screw 22 includes a slot 30 for receipt of a screwdriver or other such tool for turning the retaining screw 22 . Although FIG. 1 illustrates a slot 30 for receipt of a standard flat-bladed screwdriver, the head 28 of the screw 22 could also be configured to be compatible with other types of installation tools such as Phillips screwdrivers, hex head Allen wrenches, mechanic's wrenches, or even knurled for providing an enhanced finger grip or configured like a thumb screw such that the screw could be turned without the need for a tool.
As shown in FIGS. 1-3, the fastener 20 further includes a bushing 34 having an outer profile including a first section 36 shaped for insertion through the hole 18 in the panel 16 . The bushing 34 includes a shoulder 38 bearing against a first or outer surface 40 of the panel 16 for positioning the bushing 34 in the hole 18 of the panel 16 . The bushing includes a bore 42 extending through the bushing 34 about the axis 26 for receiving the shaft section 24 of the screw 22 , with the head 28 of the screw 22 adjacent the shoulder 38 .
The bushing 34 includes two identical bushing segments 44 separable along a plane 46 passing through the axis 26 of the bore 42 . The bushing segments 44 include corresponding male and female alignment formations in the form of projections and recesses 48 , 50 for aligning the bushing 34 about the bore 42 . The bushing 34 further includes a recess 52 centered on the axis 26 and opening toward the head 28 for receipt of a spring 54 extending from the shoulder 38 toward the head 28 of the screw, for biasing the shaft section 24 of the retaining screw along the axis 26 of the bore 42 in a direction away from the shoulder 38 .
The bushing 34 further includes a pair of resilient tangs 56 , one in each bushing segment 44 . The tangs 56 are axially spaced from the shoulder 38 of the bushing and configured to be resiliently displaced radially inward as the bushing 34 is inserted into the hole 18 of the panel. The tangs 56 include serrations 58 having a plurality of notches 60 shaped for receipt of a second face 62 of the panel 16 . The notches 60 in the serrations 58 of the tangs 56 are shaped such that the bushing 34 can be utilized in panels having several different thicknesses t, with the notches being axially spaced from the shoulder 38 and configured such that for each incremental thickness t, a notch is available for gripping the second or inside face 62 of the panel 16 .
Those having skill in the art will recognize that through use of the split bushing 34 with integral tangs 56 configured to accommodate a number of different panel thicknesses t, my invention provides solutions to the problems detailed above and a number of advantages when used in the manufacture and operation of the type of enclosures described herein. Having the bushing 34 be separable, allows all pieces of the quick-release fastener 20 to be manufactured independent of each other, and brought together only at the assembly stage, thereby eliminating the manufacturing problems inherent in prior quick-release fasteners. The corresponding male and female alignment formations 48 , 50 facilitate assembly and installation. Forming the bushing 34 of two identical segments 44 , reduces manufacturing and inventory costs. The tangs 56 eliminate the need for the separate C-rings utilized in prior quick-release fasteners, thereby reducing both initial assembly and operating cost, and reducing the risk of a C-ring being dropped into the enclosure. The serrations 58 and notches 60 in the tangs 56 , and the overall configuration of the tangs 56 which allows the fastener 20 to be quickly inserted by simply pushing it into the hole 18 in the panel 16 , and to be held fast there in panels of varying thickness to reduce rattling, provides advantages reducing the cost and improving the aesthetic desirability of the enclosure.
Although I have described my invention in terms of various exemplary embodiments thereof, those skilled in the art will recognize that there are a number of variations that can be made without departing from the scope of my invention as defined by the appended claims. For instance, as illustrated in FIGS. 4-6, the inner axial panel retaining end 32 of the shaft section 24 of the retaining screw 22 can be formed into a male thread 64 , or a female thread 66 , or as one part 68 of a quick-attach retainer to mate respectively with a cooperating female thread 65 , male thread 67 , and second part of a quick-attach retainer attached to the flange 14 . It is understood, therefore, that the spirit and scope of the appended claims should not be limited to the specific embodiments described and depicted herein.
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Performance and aesthetic attractiveness of industrial enclosures of the type used to house electrical and hydraulic equipment are enhanced through use of an improved quick-release fastener for attaching removable access panels of such enclosures. The improved fastener includes a split bushing with integral retaining tangs configured for retaining the quick-release fastener in access panels having different thicknesses.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Application No. 61/276,821 filed Sep. 17, 2009
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
BACKGROUND
1. Field of Invention
This invention is related to folding tents and canopies with attached material to lay a beach towel, material or other items on, as well as a carry tote with arm strap to carry the collapsed, folded, and wrapped invention. Specifically to be used on beaches to reduce sun exposure and weather elements while offering material to sit or lay on, as well as an enclosure option it give an appearance of security to its contents. This invention allows a stake like object to pass through a base loop secured to the base of the invention and push into the beach or ground surface. Therefore, the stake secures the invention to the beach or ground surface doing so reduces the likelihood of the invention being moved or blown away by the wind.
2. Prior Art
Standard umbrellas are heavier and long. This makes them more difficult to handle or carry on or off the beach. It can be difficult to stake the umbrella in the sand without it falling down or blowing away. High winds can pull the umbrella out of the sand therefore potentially hitting, damaging, or harming somebody. Standard umbrellas, which are on a pole in the air, do not prevent or reduce sand or other elements from hitting the person lying or sitting under it. Also, on windy days unless weighted down papers will blow or fly away while under a standard umbrella.
Standard canopy tents have small openings. This makes it difficult to place infants or young children in carrying seats through. It is difficult for the baby or toddler to get their diaper or clothes changed or fed through a small opening. Also, the small tent canopies are not secured to the sand therefore can be blown over. As the small tent canopy is completely enclosed there is a reduced amount of airflow through or in the canopy. Although shading the content it may become very warm inside the small tent canopy.
SUMMARY
In accordance, a folding canopy beach tent reduces exposure to sunrays and natural weather elements while providing practical and convenient use of the base (ground cover) material and mesh enclosure. The security of the folding canopy beach tent is set in place by the attached base loops and removable stakes. The folding canopy beach tent is compact when collapsed, folded, and wrapped. Being lightweight makes it convenient and easy to carry with the strap of the carry tote. The draw cord allows the carry tote to remain open or be securely closed. The folding canopy beach tent functions similar to a regular umbrella, tent, and beach towel. It shades or reduces the sunrays on the individuals or items under it. The base (ground cover) material can be used to lay or sit on. The mesh front and sides serve as wind resistance and indirect security of items under it. Meaning, it does not keep people from removing items from beneath the folding canopy beach tent however it makes it more noticeable when somebody other than the owner is trying to remove items from within or under it.
DRAWING
Figures
In the drawings, closely related figures have the same number but different alphabetic suffixes.
FIG. 1A is a perspective view of the rod frame and geometry placement of the joints connecting and at the end of the bottom rods.
FIG. 1B is the angle view of the Part 1 joint.
FIG. 1C is the angle view of the Part 2 joint.
FIG. 1D is the angle view of the dowel.
FIG. 1E is the angle view of the Part 1 joint ( 1 B) and Part 2 ( 1 C) connected together by the dowel ( 1 D).
FIG. 1F illustrates FIG. 1E open and folding.
FIG. 2A is the top view of the front strap used to secure open the folding canopy beach tent.
FIG. 2B is the side view of 2 A.
FIG. 3 is the perspective view of the secure strap for the front mesh.
FIG. 4 is the perspective view of the base loop to secure the folding canopy beach tent.
FIG. 5 is the side view of a stake.
FIG. 6A is a perspective view of the secured open folding canopy beach tent with base (ground cover) material.
FIG. 6B is a right side view of the secured open canopy beach tent with base (ground cover) material.
FIG. 6C is a left side view of the secured open canopy beach tent with base (ground cover) material.
FIG. 6D is the back and side view of the secured open canopy beach tent.
FIG. 7 is the perspective view of the mesh secured inside (under) the front top of the folding canopy beach tent umbrella like material with the secure straps.
FIG. 8A is a perspective view of the front mesh secured to the ground stakes to form an enclosure. Material edging is at the bottom and sides of the folding mesh.
FIG. 8B is a perspective view of the front and right side view of the front and side mesh secured to the ground stakes to form an enclosure. Material edging is at the bottom and sides of the folding mesh.
FIG. 8C is a perspective view of the front and left side view of the front and side mesh secured to the ground stakes to form an enclosure. Material edging is at the bottom and sides of the folding mesh.
FIG. 9A is an illustration of the open folding canopy beach tent rod frame being closed.
FIG. 9B is an illustration of the right and left side rod frames being folded inward (closed).
FIG. 9C is a perspective of the base (ground cover) material wrapped around the folded top and side rod frames.
FIG. 10 is a perspective side view of the carry tote with handle and draw cord used to secure, store, and carry the folding canopy beach tent.
FIG. 11 is a perspective view of the carry tote handle.
FIG. 12 is a perspective view of the draw cord used to open and close the tote carry case.
FIG. 13 is a perspective view of the draw cord lock allows the draw cord to remain open or securely closed.
DRAWINGS - REFERENCE NUMERALS
10
umbrella like UV protected material
12
mesh
14
base (ground cover) material
16
rod
18
Part 1 joint
20
Part 2 joint
22
dowel
24
front strap
26
secure strap
28
joint
30
material edging
32
base loop
34
stake
36
carry tote
38
carry tote handle
40
draw cord
42
cord lock
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described more fully in detail with reference to the accompanying drawings, which the preferred embodiments of the invention are shown. This invention should not, however, be construed as limited to the embodiments set forth herein; rather, they are provided so that this disclosure will be complete and will fully convey the scope of the invention to those skilled in the art.
FIG. 1A is a perspective view of the rod frame and geometry of the joints connecting each rod end. The diameter for the eight side fiberglass rods 16 are ¼″ by 24 and the four top fiberglass rods 16 are ¼″ by 36″ will be given here for purposes of illustration only. It is understood that the rods 16 according to the invention is not limited to a ¼″ by 24 or ¼″ by 36″ fiberglass rods. The rod is made of fiberglass material will be given here for the purpose of illustration. It is understood that the rod according to the invention is not limited to fiberglass material. The top end of each 24″ side rod 16 is connected to each top 36″ rod end 16 by pivoting joints 28 ( FIGS. 1E and 1F ) which allow the rods to pivot to open (outward) and close (inward) ( FIG. 1F ). A single joint 18 is placed on the bottom end of the side 24″ rod 16 ( FIG. 1B ). A dowel 22 ( FIG. 1D ) is placed through the hole of the joint 18 ( FIG. 1B ) to secure the bottom four rods 16 . The four secure base rods 16 each side of frame base can pivot open (upward) and down (collapse). Obviously, those skilled in the art may develop a wide variety of rods, joints, folding joints, pins, fasteners, or other structures that may be used to form the frame and connection and such alternatives are considered within the scope of the present invention.
FIG. 1B is the angled view of the Part 1 joint 18 . In the illustration the joint 18 is cylindrical; however in alternative embodiments it may have other shapes or forms. The internal diameter of 18 is configured to the outside diameter of the rod 16 . To enable the folding canopy beach tent to fold inward and outward the Part 1 joint 18 is adjoined to the Part 2 joint 20 with a dowel 22 ( FIG. 1E ; also illustrated in FIGS. 1A , 9 A, and 9 B). Also, Part 1 joint 18 is used at the end (base) of the rod 16 ( FIG. 1A ). With the connection of the Part 1 joints 18 the folding canopy beach tent rod 16 frame is able to pivot open and collapsed (closed) ( FIG. 1A and FIG. 9A ). The Part 1 joint is made of M90 material will be given here for the purpose of illustration. It is understood that the Part 1 joint according to the invention is not limited to the M90 material. Obviously, those skilled in the art may develop a wide variety of joints; end caps or other structures that may be used to secure the end of the frame, folding ability of the frame and connections and such alternatives are considered within the scope of the present invention.
FIG. 1C is the angle view of the Part 2 joint 20 . The internal diameter of 20 is configured to the outside diameter of the rod 16 . The construction of the base of Part 2 joint allows the Part 1 18 joint to be housed or inserted and secured with a dowel 22 ( FIG. 1E ). The eight secure folding joints 28 (four on each side of the rod 16 frame) ( FIGS. 1E and 1F ) allow the rods 16 to pivot to open (outward) and close (inward) ( FIG. 9A ). The Part 2 joint is made of M90 material will be given here for the purpose of illustration. It is understood that the Part 2 joint according to the invention is not limited to the M90 material. Obviously, those skilled in the art may develop a wide variety of joints; connecting caps or other structures that may be used to create the folding ability of the frame and connection and such alternatives are considered within the scope of the present invention.
FIG. 1D is the angle view of the dowel 22 . The external diameter and length is based on the internal diameter and length of the Part 1 joint 18 and Part 2 joint 20 . The dowel is used to adjoin Part 1 joint 18 and Part 2 joint 20 to create a folding joint 28 ( FIGS. 1E and 1F ). The dowel 22 is also used to adjoin four Part 1 joints 18 to secure the rod 16 frame base and allowing it to pivot open (up) and collapse (close) ( FIGS. 1A and 9A ). The dowel 22 is made of copper material will be given here for the purpose of illustration. It is understood the dowel according to the invention is not limited to copper material. Obviously, those skilled in the art may develop a wide variety of rivets, locks or other structures that may be used to adjoin the Part 1 joints 18 and Part 2 joints 20 and such alternatives are considered within the scope of the present invention.
FIG. 1E is the angle view of Part 1 joint 18 , Part 2 joint 20 , and dowel 22 creates a folding joint 28 . The folding joint 28 is used at the eight top corners of the folding canopy beach tent rod 16 frame. The internal diameter of the folding joint 28 is configured to the outside diameter of the rod 16 . The eight secure folding joints 28 allow the rod 16 frame to pivot to open (outward) and close (inward) ( FIG. 1A and FIG. 9A ). Obviously, those skilled in the art may develop a wide variety of folding joints; connectors or such alternatives are considered within the scope of the present invention.
FIG. 1F illustrates FIG. 1E open and folding.
FIG. 2A is the top view of the front strap 24 used to secure the front of the folding canopy beach tent to the sand or ground. It is constructed of the umbrella like base material ( 14 ). Its top of 24 is sewn to the inside top front of the folding beach canopy tent ( FIGS. 6A thru 6 D). The bottom of 24 has a loop ( FIG. 2B ) sewn enabling the folding canopy beach tent to be secured to the beach or ground with a stake 34 like object ( FIG. 5 ; also illustrated 6 A thru 6 D and 8 B thru 8 C). The front strap is made of umbrella like polyester material will be given here for the purpose of illustration. It is understood that the front strap according to the invention is not limited to the umbrella like polyester material. Obviously, those skilled in the art may utilize a wide variety of fabrics and such alternatives are considered within the scope of the present invention.
FIG. 2B is the side view of the front strap 24 ( FIG. 2A ).
FIG. 3 is the perspective view of the secure strap 26 for the enclosure mesh 12 . The secure strap 26 is located inside the top front of the folding canopy beach tent. The secure strap 26 is made of nylon material will be given here for the purpose of illustration. It is understood the secure strap 26 according to the invention is not limited to nylon material. When the enclosure mesh 12 is rolled up it is secured in place by the secure straps 26 ( FIG. 7 ; also illustrated 6 A thru 6 D). For the purpose of illustration six pairs of secure straps 26 ( FIG. 7 ) are used. It is understood that secure straps 26 according to the invention is not limited to six pairs. Obviously, those skilled in the art may utilize a wide variety of fabrics; materials, fasteners, hooks and such alternatives to secure the enclosure mesh are considered within the scope of the present invention.
FIG. 4 is the perspective view of the base loop 32 to secure the base of the folding canopy beach tent to the sand or ground. The loop is constructed of the umbrella like base material ( 14 ). The base loop is sewn at the base of the folding canopy beach tent. For the purpose of illustration three loops are placed in the back ( FIG. 6D ). For the purpose of illustration one loop is placed on each side of the folding canopy beach tent beside the joined Part 1 joints 18 ( FIG. 6A ). The stake 34 ( FIG. 5 ) is inserted through the base loop 32 securing the folding canopy beach tent to the beach or ground. The base loop 32 is made of umbrella like base polyester material 14 will be given here for the purpose of illustration. It is understood that the base loop 32 according to the invention is not limited to the umbrella like base polyester material 14 . Obviously, those skilled in the art may utilize a wide variety of fabrics, fasteners, hooks, and other structures to secure the invention to the beach or ground surface and such alternatives are considered within the scope of the present invention.
FIG. 5 is a side view of a stake 34 . For the purpose of illustration seven stakes 34 are inserted through the base loops 32 to secure the folding canopy beach tent frame base to the beach or ground ( FIGS. 6A the 6 D and 8 B thru 8 C). The stake 34 is made of ABS material and is 9″ in length will be given here for the purpose of illustration. It is understood that the stake 34 according to the invention is not limited to the ABS material or 9″ length. Obviously, those skilled in the art may utilize a wide variety of stakes, fasteners, and other structures to secure the invention to the beach or ground surface and such alternatives are considered within the scope of the present invention.
FIG. 6A . is a perspective front view of the open folding canopy beach tent. In the illustration the front edge (hangover), top, and right side top edge (hangover) of the invention is covered with umbrella like UV protected material 10 . The umbrella like material is made polyester material with silver undercoating for UV protection will be given here for the purpose of illustration. It is understood that the umbrella like UV protected material 10 according to the invention is not limited to the umbrella like polyester material with silver undercoating for UV protection. The illustration shows the right side mesh 12 . It is understood that the mesh is made of polyester material will be given here for the purpose of illustration only. It is understood that the mesh according to the invention is not limited to the polyester material. The side mesh 12 is sewn or secured to the inside of the umbrella like material 10 side edge (hangover) and side frame rods 16 . In the illustration the side frame rods 16 ( FIG. 1A ), front straps 24 ( FIGS. 2A-2B ), base (ground cover) material 14 , base loops 32 ( FIG. 4 .), and stakes 34 ( FIG. 5 ) are displayed. Obviously, those skilled in the art may utilize a wide variety of fabrics and other materials to cover the rod frame structure of the invention and such alternatives are considered within the scope of the present invention.
FIG. 6B is a perspective right side view of the open folding canopy beach tent. The invention front edge (hangover), top, and right side edge (hangover) around the right side top and back is covered with umbrella like UV protected material 10 . In the illustration the right side of the invention is covered with mesh 12 . The base (ground cover) material 14 is similar to umbrella like material 10 with the option of being non-UV protected. The base (ground cover) material is made of polyester non-UV protected will be given here for the purpose of illustration. It is understood that the base (ground cover) material 14 according to the invention is not limited to the umbrella like polyester non-UV protected material. In the illustration the base (ground cover) material 14 and edging around the right side bottom frame rod 16 is covered with the base (ground covered) material 14 . The side mesh 12 is sewn or secured to the inside of the inside (hangover) of the umbrella like material 10 and base (ground cover) material 14 . In the illustration the side frame rods 16 ( FIG. 1A ), front straps 24 ( FIGS. 2A-2B ), base (ground cover) material 14 , base (ground cover) loops 32 ( FIG. 4 .), and stakes 34 ( FIG. 5 ) are identified. Obviously, those skilled in the art may utilize a wide variety of fabrics and other materials to cover the rod frame structure of the invention and such alternatives are considered within the scope of the present invention.
FIG. 6C is a perspective left side view of the open folding canopy beach tent. In the illustration the front edge (hangover), top, and left side edge (hangover) around the left side top and back is covered with umbrella like UV protected material 10 . In the illustration the left side of the invention is covered with mesh 12 . The base (ground cover) material 14 is similar to umbrella like material 10 with the option of being non-UV protected. In the illustration the base (ground cover) material 14 and edging around the left side frame rod 16 bottom is covered with the base (ground covered) material 14 . The side mesh 12 is sewn or secured to the inside of the inside (hangover) of the umbrella like material 10 and base (ground cover) material 14 . In the illustration the side frame rods 16 ( FIG. 1A ), front straps 24 ( FIGS. 2A-2B ), base (ground cover) material 14 , base (ground cover) loops 32 ( FIG. 4 .), and stakes 34 ( FIG. 5 ) are identified. Obviously, those skilled in the art may utilize a wide variety of fabrics and other materials to cover the rod frame structure of the invention and such alternatives are considered within the scope of the present invention.
FIG. 6D is a perspective back view of the open folding canopy beach tent. In the illustration rod 16 frame side top and side edge rod 16 frame (hangover) is covered with umbrella like UV protected material 10 and the bottom edge rod 16 frame is covered with base (ground cover) material 14 . In the illustration the side of the invention is covered with mesh 12 . The side mesh 12 is sewn or secured to the inside of the inside (hangover) of the umbrella like material 10 and base (ground cover) material 14 . In the illustration the side frame rods 16 ( FIG. 1A ), front straps 24 ( FIG. 2A-2B ), base loops 32 ( FIG. 4 .), and stakes 34 ( FIG. 5 ) are identified. Obviously, those skilled in the art may utilize a wide variety of fabrics and other materials to cover the rod frame structure of the invention and such alternatives are considered within the scope of the present invention.
FIG. 7 is a perspective view of the enclosure mesh 12 rolled up and secured to the inside front top of the folding canopy beach tent. In the illustration six (pairs) secure straps 26 are displayed as securing the enclosure mesh 12 to the inside front top of the folding canopy beach tent. The secure straps 26 are sewn or secured to the inside front top of the folding canopy beach tent. In this illustration six pairs of secure straps 26 are tied to secure the enclosure mesh 12 to the inside top of the canopy folding beach tent. Obviously, those skilled in the art may develop a wide variety of buttons, fasteners, or other structures that may be used to secure the enclosure mesh in place and such alternatives are considered within the scope of the present invention.
FIG. 8A is a perspective front view of the open canopy beach tent displaying the enclosure mesh 12 down. In the illustration the front edge (hangover) and top are covered with umbrella like UV protected material 10 . The top of the enclosure mesh 12 is sewn or secured to the inside top front ( FIG. 7 ) of the folding canopy beach tent. When the secure straps 26 are released the enclosure mesh unrolls to the length to touch the sand or ground surface. The bottom end of the enclosure mesh has material edging 30 sewn or secured around the base to reduce tearing, fraying, and maintain the shape of the enclosure mesh. Obviously, those skilled in the art may utilize a wide variety of fabrics and other materials to cover the rod frame structure, form an enclosure, or create a binding seam of the invention and such alternatives are considered within the scope of the present invention.
FIG. 8B is a perspective front and right view of the open canopy beach tent with the enclosure mesh 12 released and unrolled down. In the illustration the front edge (hangover) and top are covered with umbrella like UV protected material 10 . The top of the enclosure mesh 12 is sewn or secured to the inside top front of the folding canopy beach tent. FIG. 8B is the illustration of FIG. 6B when the secure straps 26 are released the enclosure front and front corners mesh 12 are released and lowered to ground level. The bottom end of the enclosure mesh 12 has material edging 30 sewn or secured around the base to reduce tearing, fraying, and maintain the shape of the enclosure mesh 12 . In the illustration base (ground cover) material 14 , base loops 32 ( FIG. 4 .), and stakes 34 ( FIG. 5 ) are displayed. Obviously, those skilled in the art may utilize a wide variety of fabrics and other materials to cover the rod frame structure, form an enclosure, or create a binding seam of the invention and such alternatives are considered within the scope of the present invention.
FIG. 8C is a perspective front and left view of the open canopy beach tent with the enclosure mesh 12 released and unrolled down. FIG. 8C is the illustration of FIG. 6C when the secure straps 26 are released the enclosure front mesh 12 and front corners mesh 12 are released and lowered to ground level. The bottom end of the enclosure mesh 12 has material edging 30 sewn or secured around the base to reduce tearing, fraying, and maintain the shape of the enclosure mesh. In the illustration base (ground cover) material 14 , base loops 32 ( FIG. 4 .), and stakes 34 ( FIG. 5 ) are displayed. Obviously, those skilled in the art may utilize a wide variety of fabrics and other materials to cover the rod frame structure, form an enclosure, create a binding seam, or securing invention to the beach or ground of the invention and such alternatives are considered within the scope of the present invention.
FIG. 9A is an illustration of the open folding canopy beach tent rod 16 frame being collapsed (closed). FIG. 9A is the illustration of FIG. 1A converting the rod 16 frame structure of the folding canopy beach tent from an open position to a collapsed (closed) position. In the illustration is the base (ground cover) material 14 . Collapsing of the top structure allows the user to sit on the base (ground cover) material 14 while obtaining full sunrays and weather exposure, if so desired.
FIG. 9B is an illustration of the open right and left side rod frames being folded closed (inward). To store the folding canopy beach tent the rod 16 frame is collapsed ( FIG. 9A ). For the purpose of this illustration the two sets of four rod 16 frame sides are folded inward. As the base (ground cover) material 14 is secured to the base (bottom) rod 16 frame the base (ground cover) material 14 will also fold inward.
FIG. 9C is a perspective view of the base (ground cover) material 14 wrapped (rolled) around the collapsed ( FIG. 9A ) and folded ( FIG. 9B ) folding canopy beach tent rod 16 frame. The wrapped folding canopy beach tent is then stored in the carry tote 36 ( FIG. 10 ).
FIG. 10 is a perspective side view of the folding canopy beach tent carry tote 36 . The wrapped folding canopy beach tent ( FIG. 9C ) is stored, secured, and carried in the carry tote 36 . For the purpose if this illustration the carry tote is made of the base (ground cover) material. The width and length dimensions' of the carry tote 36 is calculated on the size of the wrapped folding canopy beach tent. The carry tote 36 has a carry handle 38 ( FIG. 11 ) sewn or secured to a side of the carry tote 36 . To secure the folding canopy beach tent in the carry tote a draw cord 40 ( FIG. 12 ) is sewn in one end of the carry tote 36 . A cord lock 42 ( FIG. 13 ) will be inserted on the draw cord 40 ( FIG. 12 ) enabling the open end of the carry tote 36 to be open or secured closed. Obviously, those skilled in the art may develop a wide variety of carry totes to store, secure, and carry the folding canopy beach tent and such alternatives are considered within the scope of the present invention.
FIG. 11 is a perspective top view of the carry tote handle 38 . The width and length dimensions' of the carry tote handle is calculated on the size of the carry tote ( FIG. 10 ). The carry tote handle 38 is made of polyester material will be given here for the purpose of illustration. It is understood that the carry tote handle according to the invention is not limited to the polyester material. Obviously, those skilled in the art may develop a wide variety of carry totes handles to placed on the carry tote and such alternatives are considered within the scope of the present invention.
FIG. 12 is a perspective top view of the draw cord 40 . The width and length dimensions' of the draw cord is calculated on carry tote's 36 ( FIG. 10 ) open-end diameter. The draw cord 40 is made of polyester material will be given here for the purpose of illustration. It is understood that the draw cord according to the invention is not limited to the polyester material. Obviously, those skilled in the art may develop a wide variety of drawstrings; fasteners, closures and such alternatives are considered within the scope of the present invention.
FIG. 13 is a perspective front view of the cord lock 42 . The width and length dimensions' of the draw lock 42 is calculated on thickness diameter of the draw cord 40 ( FIG. 12 ). The cord lock is made of ABS material will be given here for the purpose of illustration. It is understood that the cord lock 42 according to the invention is not limited to the ABS material. Obviously, those skilled in the art may develop a wide variety of fasteners; locks, closures and such alternatives are considered within the scope of the present invention.
It is understood that the present invention is not limited to the embodiments described above. Variations in the construction of the folding canopy beach tent material, frame, fabric structure supported by the frame may be contemplated by one skilled in the art; without limiting the intended scope of the invention herein disclosed and as defined by the following claims.
ADVANTAGES
The folding canopy beach tent eliminates the need to carry an umbrella when a person carries an umbrella primary to shade their face or shade a baby, toddler, or small child. The folding canopy beach tent eliminates the need to carry a beach towel as it has a material base. When a person is lying under the folding canopy beach tent they are able to see through both sides and the front. The mesh creates a wind resistance enabling items to remain under the folding canopy beach tent without the wind blowing them away. The mesh reduces the sand or particles being blown in the face of the person lying under the folding canopy beach tent.
When items are placed under the folding canopy beach tent and the front mesh is rolled down and attached to the sides it provides a more visual security of property. Meaning, a person would have to actually open the sides of the folding canopy beach tent to have access to the items located under the folding canopy beach tent. The folding canopy beach tent enables parents or guardians easier access to the baby, toddler, or small child to change their diaper, clothes, feed, or attend to their needs. As the folding canopy beach tent is secured by stakes inserted through base loops to the sand or ground reduces the likelihood of it moving or blowing away during high winds.
The folding beach canopy tent purpose is for convenience when going to the beach and other outside events or activities. As it is a two in one it reduces the need take a large umbrella and ground cover. The folding canopy beach tent is lightweight, folds, and is carried in a carry tote that can be opened or securely closed through the use of the draw cord and cord lock. The tote has an arm strap freeing the hands to carry or hold other items. The folding canopy beach tent reduces the sunrays, sand, or wind on the person lying under it.
The folding canopy beach tent creates easier accessibility to the baby, toddler, or small child lying under it. Folding the front mesh down and attaching it to the side mesh reduces the sun rays, sand, and wind on the child, yet enables the child to be easily visibly seen, and is easily assessable to. The raised canopy beach tent allows a baby's carrying seat to fit under the opened folding canopy beach tent. Also, the raised canopy beach tent allows a person to slightly sit up, lean up, or sit in a low to the ground beach like chair to read or write without the wind blowing the papers away.
CONCLUSION, RAMIFICATIONS, AND SCOPE
Accordingly, the reader will see that the folding canopy beach tent serves as a shade, reduction of direct sunrays, while the mesh serves as a wind resistant and reduces elements such as but not limited to sand while under folding canopy beach tent. The wider front gives easier accessibility to a baby, toddler, small child, or items lying under the folding canopy beach tent. When the front mesh is lowered and attached to the side mesh it secures the items from blowing away or being easily picked up by others. Furthermore, the folding canopy beach tent has the additional advantages in that
it can be used by all ages; infants, teenagers, adults, and seniors. it is compact and lightweight to carry. it permits the production in a variety of colors without requiring the manufacturer to use a separate facility for materials. it permits the production in a variety of sizes without requiring the manufacturer to use a separate facility to produce invention. it permits the production in a variety of shapes without the requiring the manufacturer to use a separate facility to produce invention. it is convenient as it does not require accessibility (excluding placing stakes in sand or ground to secure it). It helps to protect the skin from harmful sunrays and weather elements. it makes easier accessibility to fed or change a baby, toddler, or small child. its mesh serves a wind resistant so papers or objects do not easily blow way. its secured in the sand or ground so it will not blow away in high winds. it can serve as a two in one-umbrella and laying on base (ground cover) material (if a beach towel is not had) or a beach towel can be laid on the base (ground cover) material. the folding canopy beach tent base (ground cover) material can be used like a beach towel with or without the canopy open. it enables an individual not to have to sit directly on the surface since a low to the ground beach like chair or other sitting or laying embodiment can fit or be placed under the folding canopy beach tent.
Although the description above contains much specificity these should not be construed as limiting the scope of the embodiment but as merely providing illustrations of some of the presently preferred embodiments. Thus the scope of the embodiment should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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A folding canopy beach tent comprised of lightweight rod structure frame with connecting joints. This structure opens and closes. To closing structure folds down and the rods fold inward making the structure compact. The umbrella and flaccid mesh like material cover the frame structure. The material serves as a protection against sunrays and weather elements. The front flaccid mesh serves as enclosure for the structure. The side flaccid mesh allows airflow, and visibility of surroundings. The dimensions of the folding canopy beach tent provides' enough room to place a child, and other items. Stakes are used to secure the structure to the surface, therefore reducing the likelihood of the wind moving it. The stakes also secure the mesh enclosure when lowered to the ground. The structure's umbrella like material base can be directly sat or laid on. The folded canopy beach tent is carried in a carry tote with strap.
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FIELD OF THE INVENTION
[0001] This invention relates to structures in which a separation in a building, e.g. a floor or wall, is penetrated by “penetrations”, e.g. pipes, electrical conduit, mechanical ventilation or communication wiring within the building. In particular, it relates to a coupling which is installed in place within separations when the structure is being created to allow plastic piping and/or conduit systems to pierce or penetrate fire separations in buildings. More particularly, it relates to cast-in-place couplings that serve as fire stops.
BACKGROUND TO THE INVENTION
[0002] It is well known to provide fire stops for non-metallic pipes and electrical non-metallic conduit that pass through building separations. This is generally achieved through use of fire-activated collars and wraps.
[0003] Both plastic piping and the fire separations travel in both horizontal and vertical directions. Most horizontal floors separations' are constructed with reinforced concrete cast using reusable forms or cast onto metal decks with a steel frame. The vast majority of vertical fire walls are made of concrete block, gypsum wall board with metal or wood framing. This invention relates to providing a plastic fire stop coupling suitable for use with each of such types of penetration locations.
[0004] Firestops act on the basis of the expansion of intumescent materials. When activated the intumescent swells filling the voids in the separation, particularly openings in plastic pipes, by filling or diminishing the diameter of the plastic pipe. The object is to limit the spread of fire to a hourly rating equal to the grade of the surrounding separation.
[0005] In typical cases no allowance is made for movement or lateral shear caused by movement due to floor loading, building creep, seismic activities, and mechanical vibration.
[0006] In some cases firestop devices direct the expanding intumescent inwards using steel housings. These housings are mechanically attached to the fire separation surrounding the pipe. Fire resistant mineral wool and sealant are also used to bring the fire rating of the penetration up to the grade of the separation.
[0007] Another less commonly used device allows an intumescent wrap to be bonded to the exterior of a coupling, installing the coupling at the location where the penetration pierces the separation. Such a system is shown in U.S. Pat. No. 5,634,304. Other patents have issued disclosing the use of intumescents within plastics compositions intended for production of injection molded shapes. Examples are referenced in U.S. Pat. No. 5,934,333 and European applications EP 0 302 987 and EP 0 745 751. What these patents do not disclose is the expansion factor of the intumescent additive. The expansion factor of the intumescent will affect the percent of intumescent needed in the coupling composition in order to close the pipe opening during a fire.
[0008] Non-metallic pipe coupling designs through-out the world bear many similarities. The sockets or receiving portions of the couplings are tapered to allow for snug fits with pipe ends using solvent welding solutions to bond piping effectivity. The solvent weld solution also lubricates the joint to ensure the penetrating pipe end slides into the receiving socket by an appropriate distance.
[0009] Existing couplings are provided with inner end stops to ensure that the pipe does not advance too deeply into the coupling and occupy space designated for the adjoining pipe. Such inner end stops protrude inwardly with an interior dimension no more than the wall thickness of the corresponding pipe. This ensures that the flow of materials within the pipe is not restricted. This end-stop height is normally no more than 6 mm in height. This is usually the bare minimum height required to stop the advancement of the pipe into the coupling.
[0010] Accordingly, one object of this invention is to both provide an end stop within a molded pipe coupling while also providing for an increased thickness of potentially expanding composition to fill the void across the pipe under fire conditions.
[0011] Additionally another object of this invention is to place the greatest volume of intumescent at the underside location of floor applications so that a fire activates the intumescent/composition matrix more promptly.
[0012] In this aspect of the invention, suited for the use and subsequent removal of a forming ring during concrete pouring, an enhanced volume of the coupling material is positioned to be exposed to fire so intumescent materials are activated more efficiently.
[0013] Another object of the invention is to provide a convenient means for positioning cast-in-place couplings within cast building separations.
[0014] In contemporary building techniques based on poured concrete structures, couplings for penetrations are fastened in-place to forms used to cast concrete separations at their destined locations before the concrete is poured. “Coupling” herein includes both actual couplings which are part of conduits and the like, as well as sleeves which provide openings or penetrations through concrete separations through which conduit and the like may pass.
[0015] Mechanical straps and the like have been used to position couplings at their locations before the concrete is poured. In particular, existing systems rely on the use of nails driven into wooden forms to attach couplings to such forms. This creates difficulties after the concrete has set and the forms are to be removed. Often nails are left protruding from the poured concrete with their pointed ends exposed and their head ends deeply embedded. This is not only dangerous but requires considerable labour to remove such nails in a safe manner without damaging the couplings.
[0016] An improved method for fastening couplings in place on concrete forms is required. A further requirement is to provide an efficient manner of sealing the top of the coupling or sleeve from concrete contamination during the concrete pouring process to allow for easy access after the concrete is cured in order to insert the pipe into the coupling or sleeve. This invention addresses these needs.
[0017] The invention in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed with reference to the drawings following hereafter. These embodiments are intended to demonstrate the principle of the invention, and the manner of its implementation. The invention in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this Specification.
SUMMARY OF THE INVENTION
[0018] According to the invention in one aspect, a molded or cast non-metallic coupling of polymeric material is formulated using intumescent additives within the forming material itself. Further, the wall thickness of the coupling in its central portion, between sockets to receive pipe ends, is enhanced over the wall thickness in the socket portions of the coupling. This increased thickness is intended to provide for the presence of sufficient intumescent material to ensure the collapse and sealing of the coupling under fire conditions. The wall thickness of the coupling could be increased over the entire length of the coupling to achieve this fire stopping result. However, it is sufficient to provide only such increased thickness in the central portion of the coupling, between the end stops that are provided to locate the pipe ends, as is required to seal-off the coupling.
[0019] Firestop couplings according to this aspect of the invention incorporate an intumescent additive that forms an integral part of the material of the coupling. Preferably the coupling is made of a material that is compatible with being structurally joined, as by solvent binding or other equivalent, to the piping or conduit system. The coupling may receive its shape by being injected molded, extruded or machined. It may thereby be provided with a central portion wall thickness that is greater than wall thickness of the piping or conduit to which it is coupled. This thickened central wall portion of the coupling may also serve to provide the end stop for the sockets in the coupling.
[0020] The coupling may be fabricated of any suitable material. Preferred materials include injection molded or extruded polyvinylchloride or chlorinated polyvinylchloride. Also suitable are plastics such as ABS, polypropylene, polyethylene and polybutles. These plastics are available in both rigid and flexible forms. Accordingly, a coupling may be made of a composition that will both intumesce on exposure to fire and which exhibits flexibility to reduce stress on the joint between pipe and coupling.
[0021] Preferably the composition of the coupling contains an intumescent additive wherein the intumescent additive is between 5 and 30% by weight of the composition, more preferably between 15 and 25% by weight of the composition, still more preferably between 15 and 20% by weight of the composition. This intumescing additive should preferably provide a volume expansion that is greater than 3 times, more preferably within the range of at least 4 to 6 times. It may also contain a heat activated expanding agent such as fluid or gas containing expanding beads or gas generants wherein the heat activated expanding agent is between 0.5 and 3% by weight of the composition.
[0022] The invention also provides a firestop coupling molded from a flexible matrix to accommodate pipe displacement with respect to the penetration. Further, addition coupling wall thickness containing intumescent material may be provided, sufficient to close a perimeter gap around the outer circumference of the coupling, crushing any loose packing present therein.
[0023] The fire stop coupling of the invention may be provide with at least one tapered receiving end to accommodate solvent welding.
[0024] According to the invention in another aspect, a coupling is provided with a detachable attachment means that is formed integrally with the coupling. Preferably this is in the form of a footing or tab with a hole formed therein that extends laterally from one end of a coupling. Nails, screws or other fastening means pass through the hole to fix the coupling to a form before concrete is cast.
[0025] This tab is joined to the coupling by a break-away connection. Once cast in place, the tab will separate from the coupling under moderate force, allowing nails to be readily removed from the cast structure.
[0026] As an alternate arrangement, the coupling is shaped to receive a fitting that detachably engages with one end of the coupling. A frictional fit is sufficient for these purposes. For this purpose, a generally cylindrical coupling may be provided at one end with an outer surface that is formed, as by inclined e.g. flats or a conical taper, to engage with complementary surfaces on a form-mounted fitting that serves as a detachable attachment means. The fitting is provided with a hole through which a fastener, e.g. a nail or screw, may be placed to attach it to a form. In this case, the fitting will stay with the form when the form is removed from the cast structure. Advantageously, the form may be re-used with the fitting fixed in the same place.
[0027] In either case, any fastener placed through the hole provided on the detachable attachment means will, after the concrete is poured, be barely embedded within the cast concrete. Accordingly, the attachment means can be separated from the coupling and be readily removed from the concrete. Particularly, nails will separate automatically from the concrete when the forms are removed. Thereafter, such nails may readily be removed from the forms by pulling upon their head ends.
[0028] The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 is a schematic side view of a prior art system by which a coupling is fastened to a wooden form panel before the pouring of concrete occurs.
[0030] [0030]FIG. 2 is a schematic side view of a coupling according to the invention provided with an integrally attached, detachable coupling means which is attached to a wooden form panel before the pouring of concrete.
[0031] [0031]FIG. 3 is a schematic side view of a coupling according to the invention provided with a frictionally detachable coupling means, in position, attached to a wooden form panel before the pouring of concrete.
[0032] [0032]FIG. 4 is a perspective view of a coupling with two break-away flanges as in FIG. 2.
[0033] [0033]FIG. 5 is a cross-sectional side view of the coupling of FIG. 4 also showing the internal profile wherein the central wall portion is of greater thickness than the socket walls.
[0034] [0034]FIG. 6 is a cross-sectional side view of the conduit and fitting of FIG. 3 also showing an internal profile as in FIG. 5.
[0035] [0035]FIG. 7 is a cross-section of a prior art pipe coupling.
[0036] [0036]FIG. 8 is a cross-section of a pipe coupling according to the invention.
[0037] [0037]FIG. 9 is a cross-section of a pipe coupling with a frangible diaphragm cast into a concrete wall.
[0038] [0038]FIG. 10 is a cross-section of the coupling of FIG. 9 with the diaphragm and adjacent concrete ruptured to allow entry of a pipe end.
[0039] [0039]FIG. 11 is a cross-section of the coupling of FIG. 8 installed in a penetration with glass fibre packing and a silicone layer end seal.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] A coupling according to one aspect of the invention is depicted in FIGS. 5, 6, 8 - 11 . A cylindrical sleeve 6 has a plain exterior in the shape of a circular cylinder. Internally, sockets 20 have walls of a given thickness. The center portion 21 between the sockets 20 has an increased wall thickness. The thickness of the wall in the center portion 21 , combined with the amount of intumescent material present, and the nature of the composition of the conduit itself, combine to ensure that a sealing collapse will occur under fire conditions. The central portion 21 serves as a stop to limit excessive penetration of pipe ends into the coupling. The sockets 20 are preferable tapered in the known manner to facilitate reception of the pipe ends.
[0041] In FIG. 1 a prior art panel 2 on a form or mold for casting a floor has a coupling 1 mounted thereon by a clamp 3 that has vertical flanges 4 held together by bolts (not shown). The clamp 3 has tabs 5 that extend outwardly to permit fasteners (not shown) to fasten the tabs 5 and clamp 3 to the panel. This prior art clamp 3 ends up being cast in place within the concrete, once concrete is poured over the form panel 2 . Nails are removed from the tabs 5 by pulling on their pointed ends.
[0042] In FIG. 2 a coupling 6 according to the invention has pre-formed break-away tabs 7 attached to the coupling 6 . While two tabs are shown, only at least one tab is required. Both the coupling 6 and tabs 7 may be molded as a unitary part when the coupling is produced from a molded polymer e.g. PVC, with a thin joining portion 8 which can be broken.
[0043] The break-away tabs 7 have holes through which nails 9 are passed to fix the coupling 7 to a form panel 2 . Once the coupling 7 is cast in place, the breakaway tabs 7 will, upon application of a detaching force separate from the coupling 7 and concrete, along with the nails. Mere removal of the form 2 can achieve this result. The tabs 7 can then be readily removed from the forms.
[0044] In FIG. 3 a detachable fitting 10 is in the form of a collar 11 into which the coupling 12 may be detachably engaged. The collar 11 has a circular flange 13 with holes 14 through which fasteners, e.g. nails 9 , may be passed to engage with a panel 2 .
[0045] As shown in FIG. 6, the coupling 12 has tapered flats 15 which engage with tapered side walls 16 within the bore of collar 11 . The shapes of the flats 15 and the tapered side walls 16 are complementary. The taper angle provides a detachable friction engagement.
[0046] After concrete is poured, the fitting 10 can separate with the removal of the panel 2 from the cast concrete (not shown). In this case, the fitting 10 is a reusable device, e.g. for use on a flying form. Conveniently, the fitting 10 is already in place to be used again at a new location.
[0047] While FIG. 6 shows a cylindrical coupling 12 with tapered flats 15 , the outer surface of the coupling may be fully conically tapered to fit into the bore of a fitting 10 of complimentary shape. The requirement is only that the coupling 12 will separate readily from the fitting 10 , once cast in place, while being retained in place prior to the pouring of concrete.
[0048] As shown in FIG. 7, the standard coupling 17 used today has a wall thickness no greater than the pipe 18 itself
[0049] As shown in FIG. 8, the intumescent coupling requires a thicker wall 20 than the pipe 19 for pipes 50 mm and larger in diameter.
[0050] As shown in FIG. 9, the concrete fill is standardly poured over the coupling and forming plywood 21 to allow machine float finishing 23 . The forming retaining ring 22 is fastened to the plywood form 21 . The intumescent-containing coupling has an increased wall thickness 24 at one end that is especially suited in floor applications. This thickened portion has greater exposure to fire and will intumesce more readily. This is further shown in FIG. 20 where, after removal of the forms and retaining ring, the thickened wall 24 has more exposure to fire 27 .
[0051] A frangible diaphragm pre-positioned on the coupling (as by being integrally molded thereon) serves as a knock out plate 25 to hold back concrete 23 during pouring. As shown in FIG. 10, the knock out plate 25 has been removed, leaving an opening for pipes 26 to enter the coupling.
[0052] As shown in FIG. 11 the gap 29 between the coupling and the concrete wall 33 is lightly or minimally filled with glass wool as a packing 36 . This is for positioning purposes. Such packing 36 is not required to be fully fire resistant because the increased wall thickness of the coupling 30 on intumescing will expand to close the gap 29 .
[0053] On the basis of the foregoing arrangement, a new and more convenient system is provided for positioning in cast-in-place couplings.
CONCLUSION
[0054] The foregoing has constituted a description of specific embodiments showing how the invention may be applied and put into use. These embodiments are only exemplary. The invention in its broadest, and more specific aspects, is further described and defined in the claims which now follow.
[0055] These claims, and the language used therein, are to be understood in terms of the variants of the invention which have been described. They are not to be restricted to such variants, but are to be read as covering the full scope of the invention as is implicit within the invention and the disclosure that has been provided herein.
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A cast-in-place coupling ( 6 ) is positioned on concrete forms ( 2 ) by detachable attachment means ( 7, 10 ). The coupling ( 6 ) may have breakaway tabs ( 7 ) or may be frictionally engaged to a fitting ( 10 ) fastened to a form ( 2 ). After concrete is poured the attachment means ( 7, 10 ) is separated from the coupling ( 6 ) with minimum effort and inconvenience. The coupling ( 6 ) itself contains an intumescent which causes the coupling ( 6 ) to convert to a firestop under file conditions.
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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 new and improved window replacement system for use in remodeling existing buildings and the like wherein the old windows have deteriorated and must be replaced.
2. Description of the Prior Art
Many old buildings exist which are structurally sound and which have ideal locations but which are economically disadvantaged because of the deteriorated condition of the windows and the excessive heat losses and undesirable side effects caused thereby. Because of the increasing energy costs, in order to make the remodeling of a building economically feasible, it is desirable to replace old deteriorated windows therein to reduce energy costs.
Specifically, replacement usually begins by removal of the old window sashes while leaving an existing frame of metal or wood and the outer trim in tact. New windows preferably of the double glazed and heat insulating type, are then installed in the window openings and various types of trim members are thereafter secured in place and sealed around between the peripheral edges of a new replacement window frame and the adjacent edges of the old window opening.
Because such a great variety exists in types of windows, trim and frame arrangements in existing buildings sought to be remodeled and updated for energy corrections, an approach to the problem has not been feasible or realized in the prior art. Moreover, the task of installing tight sealing and nice looking trim elements around a newly installed replacement window has been difficult and costly with often times undesirable consequences such as unsightly appearance and weather leakage.
OBJECTS OF THE PRESENT INVENTION
It is an object of the present invention to provide a new and improved replacement window system for use in existing buildings and more particularly, it is an object of the present invention to provide a new and improved replacement window system wherein trim elements are installed around the peripheral edges of the replacement windows before the installation or mounting of these windows in the openings in an existing building from which openings, the old and/or deteriorated windows have been removed.
Another object of the present invention is to provide a new and improved replacement window system of the character described suitable for use wherein old and/or deteriorated window sashes are removed from an existing building leaving an existing outer window frame and trim intact.
It is another object of the invention to provide a new and improved replacement window system of the character described which includes a replacement window with peripheral trim elements attached and sealed therewith adapted to be mounted in a window opening of an existing building structure having outer window frame and/or trim elements therein covered by the new window trim.
Another object of the present invention is to provide a new and improved method of replacing the deteriorated and/or windows in an existing building with new windows having improved operating characteristics.
Yet another object of the present invention is to provide a new and improved replacement window system employing a novel design for trim element which is easily cut to length and installed on a replacement window frame prior to mounting of the interior frame into an existing opening from which a window to be replaced had been removed.
Still another object of the present invention is to provide a new and improved replacement window system wherein the difficulty of sealing between the replacement window trim elements and the existing wall structure is minimized.
Still another object of the present invention is to provide a new and improved replacement window system wherein a replacement window with a peripheral trim is provided to easily fit into an existing window opening to cover the old trim and/or frame elements of a window that has been removed.
Yet another object of the present invention is to provide a new and improved elongated trim element for use with a replacement window adapted to be pivotally interconnected and sealed against an outer edge portion of the window frame.
Still another object of the present invention is to provide a new and improved trim element for use with a replacement window and adapted to seal around and cover an existing frame and/or trim elements left in place in a building wall structure.
Still another object of the present invention is to provide a new and improved elongated trim element which is especially adapted to interfit around the outer periphery of a replacement window frame and which is readily installed to form a complete peripheral trim around the window for sealing between the window and the surround of an existing window opening.
Still another object of the present invention is to provide a new and improved replacement window system wherein a novel mounting support element is included for rapidly installing and securing a replacement window in an existing window opening.
Still another object of the present invention is to provide a new and improved replacement window system of the character described wherein elongated interior trim elements are provided to interfit and trim around the periphery of the replacement window on the interior side thereof.
Still another object of the present invention is to provide a new and improved replacement window system wherein elongated interior trim elements are provided to snappingly interfit with window supporting elements on the interior side of a replacement window mounted in an existing window opening.
Another object of the present invention is to provide a new and improved replacement window system which permits the original window frame and trim to remain in place for aid in support of a replacement window.
BRIEF SUMMARY OF THE INVENTION
The foregoing and other objects and advantages of the present invention are accomplished in an illustrated embodiment comprising a new and improved replacement window system for installing a replacement window in the opening of an existing building wall structure, from which opening an old or deteriorated window has been removed. The new and improved system includes apparatus for trimming around the periphery on the outside of a replacement window and the trim apparatus includes elongated exterior trim elements having a flange adapted to extend outwardly of a side frame member of the window and an integral fascia portion joining the flange and extending between the flange and an adjacent edge of the opening in the wall that the replacement window is to be mounted in. The exterior trim elements are provided with elongated connector means along an inner edge of the flange for providing a continuous pivotal interlock between the side frame member of the replacement window and the trim element.
In accordance with the method of the present invention, the replacement window is initially trimmed before installation with a plurality of elongated exterior trim elements mounted thereon to form a complete trim frame around the periphery of the window. Weathertight sealing is effected between the trim elements and the window before the window with the attached trim is mounted in place in an existing opening of a building wall structure. The installation of the window is rapid and easy by using clip elements on the inside attached between the window frame and the existing frame of the old window that has been removed. A final peripheral seal is then completed around the exterior trim element and the wall finally, interior trim elements are mounted around the periphery of the replacement window after it is secured in position in the window opening.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference should be had to the following detailed description taken in conjunction with the drawings, in which:
FIG. 1 is an outside elevational view of an existing building wall structure having a plurality of window openings therein and illustrating in somewhat animated fashion the method of the present invention wherein a deteriorated and/or old window is removed leaving intact a peripheral frame or trim element followed by the installation of a replacement window and trim system in accordance with the features of the present invention;
FIG. 2 is an enlarged, fragmentary, horizontal cross-sectional view taken substantially along lines 2--2 of FIG. 1;
FIG. 3 is an enlarged, fragmentary, cross-sectional view taken substantially along lines 3--3 of FIG. 1;
FIG. 4 is an enlarged, fragmentary, cross-sectional view similar to FIG. 2 but illustrating in somewhat animated form a pivotal interconnection between a replacement window frame edge and an elongated trim element in accordance with the features of the present invention;
FIG. 5 is a greatly enlarged, fragmentary, horizontal cross-sectional view similar to FIG. 4 but illustrating in enlarged detail the pivotal interlock between the elongated trim element and the window frame member in accordance with the features of the present invention;
FIG. 6 is a fragmentary, enlarged, exploded perspective view of a lower corner portion of the window replacement system of the present invention as seen from the inside;
FIG. 7 is a fragmentary, enlarged, perspective view of a lower corner section of the window replacement system of the present invention as seen while looking outwardly from the inside of a building in which the replacement window and trim system has been installed; and
FIG. 8 is a greatly, enlarged, fragmentary cross-sectional view taken substantially along lines 8--8 of FIG. 7 and illustrating a mounting clip element in a position ready for permanent attachment to the adjacent window frame member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings, in FIG. 1 is illustrated an elevational view of a wall structure of an existing building referred to generally by the numeral 10. The existing wall structure is formed with a plurality of rectangularly shaped window openings 12a, 12b and 12c, respectively, left to right, and the left-hand window opening 12a is illustrated with an old and/or deteriorating, double hung, wood window 14 mounted therein which is to be replaced with a new, preferably heat insulating and modern type, replacement aluminum frame window such as a window 16, shown mounted in the right-hand window opening 12c of the wall.
In accordance with the present invention, an upper and lower sash 14a and 14b of the old deteriorating window 14 are removed for replacement and preferably, the rectangular supporting framework of the old window comprising a pair of vertical jambs 18, an upper header 20 and an outwardly and downwardly sloping lower sill 22 are left intact in place in the window opening. A pair of outside vertical jamb stops 24, a header stop 26 and a pair of outside brick or trim molding elements 28 adjacent the vertical jambs and a header brick molding 30 adjacent the header 20 are also left in place. In addition, a pair of vertical inside, jamb stops 32 and an inside header stop 34 and inside window sill member 36 may also be left intact in place after the old window sashes 14a and 14b have been removed. This arrangement provides for a rapid and fast conversion or remodeling process in that only the window sash and intermediate stops need be removed.
Preferably, the replacement window 16 is of a modern, heat insulating, aluminum frame type adapted to hold a single pane of double thickness insulating glass or one or more removable or openable operating sashes preferably of the type having insulating type glazing. The support frame of the replacement window is of a generally rectangular shape having a width and height dimension slightly less than the distance or width measurement between the opposite jamb stops 24 and a height distance measurement slightly less than the vertical or height distance between the upper header stop 26 and the sill 22 of the old window frame. If the old window frame and trim members are removed along with the old window sashes 14a and 14b, the size of the new replacement window 16 may be increased slightly if desired.
The rectangular frame of the new or replacement window 16 includes a pair of vertical stiles 38 interconnected adjacent the upper and lower ends by a pair of horizontally extending upper and lower rails 40 which are butt fitted against inside flange portions of the vertical stiles as shown. Preferably, both the stiles and the rails are identical in transverse cross-section and are of the heat insulating type including an outer face member 42 of extruded aluminum, an inner face member 44 of substantially identical cross-section and a continuous interconnecting structural insulating strip 46 between the outer and inner face members. The strip of insulating material 46 is of a cross-shaped transverse cross-section in keyed interconnection with opposite facing grooves provided in the metal face members.
The outer face members 42 of the window frame elements include an outer wall 42a and on the inside surface, spaced closely adjacent an outside edge, there is provided an elongated groove 43 which faces and is opposite to a similar groove 45 on an inside face portion 44a of the inner face member 44. The elongated continuous groove 43 provides for a positive, pivotal, interlocking interconnection between the window frame element and an elongated side trim element 50 of generally angle-shaped, transverse cross-section constructed in accordance with the features of the present invention. A pair of side or jamb trim elements 50 are provided on opposite sides of the window 16 and are generally similar in transverse cross-section to an elongated header trim element 60 and a sill trim element 70 which has a slightly different transverse cross-sectional shape.
In accordance with the present invention, the side trim elements 50 are formed of extruded aluminum and are cut to appropriate length to trim the window 16 from stock lengths of extruded material. The jamb trim element includes a flange portion 52 adapted to project outwardly at right angles to the outer wall 42a of the window frame member when the trim element is attached thereto. Along the inner edge, the flange 52 is formed with a continuous elongated grooved out portion 53 having a base wall 52a along the inside edge of the flange 52 at right angles to the main body portion thereof, a wall 52b generally parallel to the main body and an L-shaped rib 52c having a tongue 54 adapted to seat in the groove 43 of the window frame member. A sharp edged rib 56 is provided on the wall section 52a to engage the outer surface of the window frame wall face 42a as shown in FIGS. 4 and 5, when the trim element 50 is pivotally interlocked and removed into place with the flange 52 substantially at right angles to the wall surface 42a of the window frame member.
As best indicated in FIGS. 4 and 5, the side trim elements 50 are cut to length to run past the butt fitted ends of the upper, header trim element 60 and the lower, sill trim element 70 as illustrated. The side trim elements are attached to the stiles of the window frame by first engaging the tongue 54 within the elongated groove 43 and then pivoting the trim element in a counterclockwise direction as shown by the Arrow "A" in FIG. 4 until the main body of the flange 52 is substantially at right angles to the wall face 42a of the window frame member. In this position, the sharp edged tongue 54 stoppingly engages the outer surface of the window frame member 42a and limits further rotation in a counterclockwise direction. Rotation in the opposite clockwise direction, however, is permitted whenever it is desired to disassemble a side trim element 50 from a stile 38 of the window frame. The cooperating tongue 54 and groove 43 provide a continuous elongated, pivotal interconnection between the window frame and trim elements 50 and the rib 56 and wall 42a provide a limit stop as described so that assembly of the trim elements onto the sides of the window frame is easy and rapid.
The side trim elements 50 also include an outer fascia portion 58 at right angles to the flange portion 52 and generally in parallel with the outer surface wall 42a of the window frame. The fascia portions are adapted to bridge the space or opening between the side edge of the adjacent window frame member and the edge of an opening 12a, 12b, and 12c of the building wall and cover over the jamb elements 18, 24 and 28 of the old window frame which have been left in place after removal of the sash 14a and 14b. After a trimmed window 16 is mounted in a opening 12a, 12b, 12c, etc., a gunned-in bead of sealant or caulking material 59 is applied to provide sealing between an outer edge of the side trim element fascia 58 and the adjacent edge of the window opening in the building wall as shown in FIG. 2. This sealing is accomplished almost anytime after the window 16 with the trim element previously attached thereto has been mounted in place in the window opening of the building wall 10.
It should be noted that an inner edge of the fascia 58 projects inwardly toward the center of the window a slight distance beyond the perpendicular face of the flange 52 as shown in FIG. 2 in order to provide a small retaining rib 58a along the inside edge which aids in assembly of the header and sill trim elements 60 and 70 onto the frame of the window 16. It should also be noted that the flange 52 of the side trim elements 50 is coped away at the upper and lower corners at 55 and 57 in order to accommodate the upper brick molding 30 and the lower, existing sill 22 as shown in FIGS. 3 and 6. In addition, a pair of spaced apart holes 52d are drilled at appropriate upper and lower positions adjacent the coped corners to accommodate pairs of self-tapping fasteners 61 which are used for interconnecting the butt fitted ends of the horizontal trim elements 60 and 70 to the periphery of the window frame.
As indicated in FIG. 3, a pair of holes 52d are drilled in the flange 52 of the side trim elements 50 just below the coped out upper corner 55 in order to accommodate a pair of upper screw fasteners 61 while a similar pair of lower holes 52d as shown in FIG. 6, are drilled in the flange just above the upper level of the lower coped out portion 57 to accommodate the shanks of a pair of lower screw fasteners 61 used to attach the lower sill trim element 70 in butt fitted relation between the flanges 52 of the side trim elements 50.
In accordance with the present invention, the elongated, header trim element 60 is generally similar in transverse cross-section to the side trim elements 50 and includes a flange portion 62 adapted to extend outwardly of the outer face 42a of the upper header frame member of the replacement window 16 at right angles thereto. Along an inner edge, the flange portion 62 has a continuous groove 63 generally similar to the groove 53 and the groove is formed by a wall segment 62a parallel of the outer face member 42a, a segment 62b coextensive with the main body of the flange portion and an L-shaped or angular flange 62c having a tongue 64 adapted to inter-fit within the groove 43 on the wall face 42a of the upper header 40 of the frame of the window 16. A sharp edged tongue or stop 66 similar to the tongue 56 projects from the groove wall segment 62a to engage the outer face 42a of the window frame header and provide a pivot limiting stop engagement.
The flange 62a of the header trim element 60 is attached to the header rail 40 of the window frame in a manner similar to the pivotal, interlocking interconnection between the side trim elements 50 and the vertical stiles 38 of the window frame. As viewed in FIG. 3, after the tongue 64 is seated within the groove 43 in the window frame header 38, the header trim element 60 is then pivoted in a counterclockwise direction until the stop surface of a sharp edged tongue 66 engages the outer wall 42a of the window frame header to maintain the flange 62 normal to the wall and limit further rotation. In this position the flange 62 of the header trim element is substantially perpendicular or normal to the outer face of the window frame and transverse to the flanges 52 of the side trim elements 50. The header trim element 60 is cut to butt fitt between opposite facing flanges 52 of the side trim elements 50 and once in position therebetween, it is secured in place by the upper pair of threaded screw fasteners 61 which include threaded shanks driven through the upper pair of holes 52d to extend into a pair of integrally formed screw splines 67 formed on the inside surface of the flange 62.
The header trim element 60 includes an upwardly extending outer fascia portion 68 integrally joined to an outer edge of the flange portion 62 and the flange is formed with a narrow upwardly offset portion 62d for providing a lower drip edge 68a along the lower edge of the fascia 68. It should also be noted that the outer face of the fascia 68 is dimensioned to seat against the inside edge of the ribs 58a on the side trim elements 50.
The sill trim element 70 is substantially similar in transverse cross-section to the header trim element 60 but includes a downwardly and outwardly sloping flange portion 72 with a groove 73 formed by an upwardly extending wall segment 72a, an inwardly extending wall segment 72b, and an upstanding flange 72c completing the pocket which receives a lower edge of the outer face 42 of the lower rail 40 of the window frame. The pocket also includes an upper wall segment comprising a sharp edge tongue or stop 76 and an inside tongue 74 is adapted to pivotally interfit and interconnect the trim element 70 on the lower rail 40 in the groove 43 formed on the inside face of the wall member 42a.
A pair of integrally formed screw splines 77 are formed on the lower portion of the flange 72 for accommodating the threaded shanks of a pair of lower fasteners 61 projecting through the lower set of holes 52d which are provided in the flange 52 of the window side trim elements 50. The lower sill trim element 70 includes an outer fascia 78 parallel of the fascia 58 of the side trim elements 50 and the lower sill fascia is inset just behind the ribs 58a on the side fascia as illustrated.
In accordance with the present invention, the rectangular frame of stiles 38 and rails 40 of the replacement window 16 is dimensioned to fit freely inside the existing wall opening 12a, 12b, 12c, etc. with the trim members of the original window left in place after the old window sashes 14a and 14b have been removed.
In applying the trim elements to the frame of the window 16, the side trim elements 60 are first cut to length to fit within a window openings 12a, 12b, 12c, etc. and are then coped at the upper and lower ends as at 55 and 57. The flanges 52 are drilled with pairs of upper and lower holes 52d to accommodate the screw fasteners 61. The header trim element 60 and the sill trim element 70 are then cut to butt fit between the opposite side faces of the flanges 52 of the side trim element 50 and all of the trim elements are pivotally interconnected in position upon the respective window frame stile and rail members with the respective tongue and ribs 54, 64, 74, etc. engaged in the grooves 43. The respective trim elements are then rocked into final position as shown and the screw fasteners 61 are driven through the openings 52d into the pairs of screw splines 67 and 77 in the header trim element and sill trim element, respectively, and once these screws are driven home, the window frame of the replacement window 16 is provided with a complete and rigidly secured peripheral trim. A gunned-in-place seal of caulking material 80 is provided around the periphery of the window frame at the junction between the wall members 42a and the respective pockets 53, 63 and 73 of the trim elements 50, 60 and 70 attached thereto. When this seal is completed, the trimmed window 16 is ready for mounting and installation in an opening 12a, 12b, 12c, etc. of the existing wall structure 10.
Mounting and installation of a trimmed window 16 is accomplished by means of a plurality of small clip elements 82 which are preferably formed of short lengths cut from a length of extruded aluminum or other metal having the transverse cross-section as shown. The clip elements are attached to the inner face members 44 of the window frame of the replacement window 16 at appropriate intervals along all sides. Each clip element includes a relatively large base portion 82a and a right angle flange 82b having a rib 83 thereon adapted to interlockingly and pivotally engage the grooves 45 on the inner surface of the inside face members 44a of the window frame, as best shown in FIG. 8. After interlocking engagement is made, the clip elements 82 are pivoted in a counterclockwise direction as shown by the Arrow "B" in FIG. 8, until the base 82a is substantially perpendicular or normal to the inside face portion or walls 44a of the window frame. To finally secure the clip elements in place, threaded screw fasteners 85 are tightened and these fasteners extend through threaded openings formed in an intermediate flange 82c provided on the clip elements. Each clip element is formed with a rib 86 adjacent the outer edge of the intermediate flange 82c, and the rib is designed as a stop to bear against the inside face 44a of the window frame when the screws 85 are finally tightened to hold the clip element securely in place. It will thus be seen that the clip elements may be easily and rapidly attached to the inside face members 44 of the replacement window frame at appropriate intervals on the frame members by first seating and interlocking the ribs 83 of the clip elements in the grooves 45 and finally tightening the fasteners 85. When this is accomplished, the base portions 82a of the clip elements project inwardly at right angles to the side faces 44a of the window frame members in precision alignment.
After clip elements 82 have been attached to a trimmed window frame, the unit is bodily lifted into an awaiting opening 12a, 12b, 12c, etc. in the existing building wall 10. When in place, the base portion 82a of the clip elements are seated on shims or mounting block 88 of wood, which shims have been leveled and plumbed to vertical so that the frame of the window 16 will be properly aligned. Wood screws or other suitable fasteners 89 are then driven home through drilled holes in the clip element flanges 82a and suitable clearance holes in the mounting blocks or shims 88 until the threaded shanks are home in the existing window frame trim elements 20, 22 and 18 as illustrated.
This arrangement provides for a secure and rapid means for mounting a trimmed window frame in an existing opening. After the clips are secured in place to hold the window, the final outer caulking seal 59 is applied around the outer edges of the trim element fascia members 58, 68 and 78 to seal the replacement window into the existing building wall structure.
Once this step is completed, the building is closed in against the weather and interior trim stock may be applied to finish the installation procedure. Appropriate lengths of elongated interior trim elements 90 are cut and are snap fitted into the clip elements 82. The elongated trim elements preferably formed of extruded aluminum or other metal are cut to length to fit with the horizontals butt fitted against the flanged portions of the verticals. In general, the interior trim elements are of angular shaped, transverse cross-section and each includes a flange section 90a adapted to extend normal to the inside wall face 44a of the adjacent window frame member. On the free edge of the flange there is provided a wedge shaped rib 91 adapted to snappingly engage and interlock with a similar wedge shaped ridge 87 formed on the clip element flange 82c. The elongated interior trim elements 90 also include an interior fascia portion 90b perpendicular to the flange position 90a and the fascia portion is formed with a pair of spaced apart ribs on the interior surface thereof adapted to sandwich opposite sides of a thin edge portion of the face segment 82a of the clip elements as shown in FIGS. 2 and 3. The flange portion 90a of the interior trim elements is also provided with an integral L-shaped rib 94 having a free edge portion adapted to engage and slide against a rib 82d formed on the intermediate flange 82c of the clip elements. It will thus be seen that once an exteriorly trimmed replacement window 16 having previously had exterior trim elements 50, 60 and 70 attached thereto, is then mounted in a window opening 12a, 12b, 12c etc., and the clip elements 82 are fastened in place by the screws 89 and shims 88, the the elongated, interior trim elements 90 may then be cut to length and snapped in place onto the clip elements 82 by biasing the trim elements toward the clips until the wedge shaped ridges 87 and 91 snap into interlocking engagement.
Although the present invention has been described with reference to a single illustrated embodiment thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this invention.
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A new and improved method and apparatus for replacing old windows in an existing building with new windows and surrounding trim comprises the use of elongated, especially designed trim elements which are cut to length and assembled onto the replacement window frame to trim the periphery thereof. The replacement window frame with the peripheral trim elements bodily attached thereto is then mounted in the opening in the building wall structure to replace an old deteriorated window previously removed therefrom. The novel method of assembly and installation guarantees a good fit between the trim elements and the window frame, and permits the critical seal between the trim elements and the window frame to be formed at a convenient location during the assembly of the trim elements onto the window rather than requiring a trim seal to be effected after the window is installed in the building.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention relates to portable shelters, and more particularly to expandable canopy structure kits.
BACKGROUND OF THE INVENTION
[0002] Portable shelters, in the form of canopy structures, have a wide variety of consumer applications. For example, these structures provide the consumer with affordable shelter for valuable equipment, such as automobiles, boats, recreational vehicles, etc. However, traditional canopy structures come in fixed sizes, forcing the consumer to purchase an assortment of canopy structures suitable for a variety of applications. As such, there is a need for a more flexible canopy structure, in terms of size, that can be assembled from a canopy kit.
SUMMARY
[0003] The present invention provides a method and apparatus for an expandable canopy structure. The expandable canopy structure kit includes a frame structure and at least one cover adapted to fit the frame structure. The frame structure includes at least two side frames, a ridge member, and a plurality of transversely expandable roof members disposed on opposing sides of the ridge member, between the ridge member and the side frames.
[0004] The plurality of transversely expandable roof members includes a plurality of first sections and a plurality of second sections. A canopy of a first width, erected with roof members comprising only the first sections, expands to a canopy of a second width by joining at least one second section end-to-end with each of the plurality of first sections.
[0005] In one embodiment of the present invention, the canopy kit provides at least two covers of different sizes to fit at least two possible frame structure widths. Therefore, each erected frame structure has a separate cover adapted to that frame structure.
[0006] A second embodiment of the canopy kit provides a transversely expandable or convertible cover comprising a first cover of a first width with an expandable center piece. The expandable center piece comprises at least one expansion panel that converts a cover having a first width to a cover having a second width.
BRIEF DESCRIPTION OF DRAWINGS
[0007] [0007]FIG. 1 illustrates a canopy structure.
[0008] [0008]FIG. 2 illustrates an expanded canopy structure.
[0009] [0009]FIG. 3 illustrates a portion of a frame structure corresponding to FIG. 1.
[0010] [0010]FIG. 4 illustrates a portion of a frame structure corresponding to FIG. 2.
[0011] [0011]FIG. 5 is a plan view of an expandable cover for the canopy kit of the present invention.
[0012] [0012]FIG. 6 illustrates the cover of FIG. 5 in an expanded configuration.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0013] The present invention comprises a canopy kit that includes an array of components that can be assembled to form a canopy structure 10 such as shown in FIGS. 1 and 2. More particularly, the canopy kit of the present invention is designed to enable one to erect a canopy structure of one size or a canopy structure of a second size. In the embodiment illustrated herein, the canopy kit is designed such that a canopy of a first width such as shown in FIG. 1 can be assembled and erected, or a canopy of a second width, shown in FIG. 2, can be assembled and erected.
[0014] Basically, the canopy kit includes components to form a frame structure 100 , as seen in FIGS. 3 and 4, and one or more covers that are adapted to fit multi-size frame structures. The components forming the frame structure 100 are of the pipe or tubular type, with the individual components adapted to be joined together in conventional fashion. The frame structure components include a series of components that are adapted to form a pair of side frames indicated generally by the numeral 110 , a ridge member 140 , and a series of roof members 130 . Each roof member 130 includes a series of sections adapted to be joined end to end. In the particular kit disclosed herein, each roof member component of the kit includes a first section 132 and a second section 134 . In the larger canopy version, such as shown in FIG. 2, each roof member 130 includes both first and second sections 132 and 134 joined together. As will be appreciated from subsequent portions of this disclosure, this permits the assembly and erection of a relatively wide canopy structure 10 . If a more narrow canopy is desired, one of the first or second sections 132 or 134 can be eliminated. This will produce a canopy structure 10 such as that shown in FIG. 1.
[0015] Provided in the canopy kit to form the pair of side frames 110 , is a series of support legs 112 and a series of intermediate horizontal sections 114 . As seen in the drawings, the intermediate sections 114 , when the canopy is assembled and erected, extend generally horizontally between the respective support legs 112 . Also, forming a part of the side frames is a series of connecting joints 116 and 118 . Connecting joints 116 are referred to as three-way side connection joints while the other joints 118 are referred to as four-way side connecting joints. Essentially, the connecting joints 116 and 118 interconnect the respective legs 112 with the intermediate sections 114 and the roof members 130 .
[0016] Finally, the frame structure of the canopy includes the ridge member 140 which in turn is made up of series of ridge beams 146 connected together by three-way and four-way connecting joints 142 and 144 . As seen in the drawings, the connecting joints 142 and 144 connect the ridge beam components 146 with the roof members 130 .
[0017] Finally, the kit of the present invention is provided with one or more covers. In the case of one embodiment, the kit is simply provided with two covers 200 , 202 of different sizes. In another embodiment, the kit is provided with an expandable cover 204 that is adapted to fit frame structures 100 of various sizes.
[0018] The frame structure 100 illustrated in FIG. 3 forms a canopy 10 shown in FIG. 1. The expandable frame structure 100 of canopy 10 comprises two side frames 110 , a plurality of roof members 130 , and a ridge member 140 .
[0019] Each side frame 110 comprises support legs 112 , intermediate sections 114 , three-way side connection joints 116 , and four-way side connection joints 118 . Support legs 112 include lower portions that are adapted to be extended into a support surface such as the ground or may be embedded in concrete. A distance generally corresponding to the length of an intermediate section 114 separates each support leg 112 of a side frame 110 .
[0020] The three-way and four-way side connection joints 116 and 118 interconnect the intermediate sections 114 to the support legs 112 such that the intermediate sections 114 are generally perpendicular to the support legs 112 and generally parallel to the underlying ground or support surface. Each side connection joint 116 , 118 comprises at least two perpendicular connecting arms. These generally coplanar connecting arms are arranged in an L-shape in the case of a three-way joint and in a T-shape in the case of a four-way joint. In addition, each side connection joint 116 , 118 comprises a roof connecting arm 120 , generally oriented at an angle less than 90 degrees, relative to the plane of the perpendicular connecting arms. These roof-connecting arms 120 include a port or opening for the roof members 130 .
[0021] The ridge member 140 , which extends generally parallel to the side frames 110 , comprises a plurality of ridge beams 146 disposed between three-way ridge connection joints 142 and four-way ridge connection joints 144 . The length of the ridge member 140 is generally equivalent to the length of the side frames 110 . A frame structure 100 of a first width, shown in FIG. 1, is completed when opposite ends of each first section 132 are inserted between the ridge connection joints 142 , 144 and side frame connection joints 116 , 118 . See FIG. 3.
[0022] [0022]FIG. 4 illustrates an expanded frame structure 100 . Disposing a second section 134 between the first section 132 and the ridge connection joint 142 or 144 of each roof member 130 expands the frame structure to a second width. While this detailed description will focus on expandable canopy kits comprising frame structures 100 that are expandable from one width to a second width, it should be apparent to one skilled in the art that adding more sections to the roof member 130 will further expand the width of the frame structure 100 .
[0023] Once the frame structure 100 is erected, a cover may be secured to the frame structure 100 . In one embodiment, the canopy kit includes two separate covers 200 and 202 manufactured to fit different size different frame structures 100 . FIGS. 1 and 2 illustrate this embodiment. In this embodiment, the respective covers 200 , 202 are sized to fit two different size frame structures 100 . Basically, the frame structures of FIGS. 1 and 2 are of the same length but the width of the canopy structure 10 in FIG. 2 is wider than the width of the canopy structure 10 shown in FIG. 1. Consequently, the two covers 200 and 202 are particularly sized to fit the two different sized frame structures 100 . Details of these cover designs are not dealt with herein because such cover designs are well-known and appreciated by those skilled in the art. For a more complete and unified understanding of the structure and design of such covers, reference is made to U.S. Pat. No. 6,155,280, which is expressly incorporated herein.
[0024] The canopy kit of the present invention includes an alternative cover design which utilizes a single cover that is expandable to fit frame structures of various widths. FIG. 5 illustrates an expandable cover 204 of a first width. The expandable cover 204 comprises a first panel 210 , a second panel 212 , tie cords 218 , and an expansion or insert panel 230 (FIG. 6). A panel fastener such as a zipper 214 connects the first panel 210 with the second panel 212 .
[0025] When the two panels 210 and 212 are connected together, as illustrated in FIG. 5, the formed cover 204 is adapted to fit a frame structure 100 of a first width or size.
[0026] The cover 204 can be converted to a second width. This is illustrated in FIG. 6. To convert the cover 204 shown in FIG. 5 to a second width, the expansion panel 230 is connected between the first and second panels 210 and 212 . The expansion panel 230 includes fasteners for connecting to the panels 210 and 212 . In one embodiment the fasteners comprise zipper assemblies. In one case, the zipper 214 utilized for connecting the two panels 210 and 212 together can be utilized to work in conjunction with zipper halves or components that are formed on each edge of the expansion panel 230 . Alternatively, the zipper halves or components formed on opposite sides of the expansion panel 230 can be adapted to connect to entirely different zipper halves or components formed on the interior edges of the panels 210 and 212 .
[0027] As seen in FIGS. 5 and 6, the expandable cover 204 includes opposed tie cords 218 that extend through closed seams formed on opposite ends of the panels 210 and 212 . When the insert panel 230 is inserted between panels 210 and 212 , it follows that a segment of the tie cord 218 on each end of the cover 204 may be exposed. To enclose the segments of the tie cords 218 that extend between the panels 210 and 212 in the expanded version of the cover 204 , as shown in FIG. 6, the insert or expansion panel 230 is provided with a pair of opposed flaps 234 . The flaps 234 are adapted to fold back and attach to the insert panel 230 at a point inwardly of the tie cords 218 . Thus, when the flaps 234 are so folded and secured, the tie cords 218 extending between the panels 210 and 212 are concealed. To secure the flaps 234 in the folded position, various fasteners may be used. In one embodiment, the fasteners include hook and loop fasteners 235 and 236 as illustrated in FIG. 6.
[0028] Therefore, it is appreciated that the canopy kit of the present invention enables at least two different size canopy structures 10 to be assembled and erected from the components therein. In the case of the embodiment illustrated herein, the size of the canopies are adjustable transversely. That is, the kit can be utilized to assemble and erect canopies of various widths. To accomplish this, the present invention provides a frame structure 100 that includes an expandable roof structure. More particularly, the kit of the present invention provides a plurality of roof members 130 that extend from the respective side frames 110 to the ridge member 140 . In the embodiment illustrated herein, the roof members 130 are said to be expandable. They are expandable in terms of the embodiment disclosed since each roof member 130 includes two separate sections 132 and 134 . The two sections 132 and 134 can be joined together to form an expanded frame structure 100 such as shown in FIGS. 2 and 4. Alternatively, one section of each roof member 130 can be eliminated from the canopy structure 10 and this will form a relatively narrow canopy structure 10 such as shown in FIGS. 1 and 3. It should be understood that there are other structures and designs that can be utilized in lieu of the multi-sectional roof members 130 . For example, each roof member 130 could be expandable through a telescoping structure. In addition, it should also be appreciated that the length of the canopy structure 10 can be extended or retracted by adding or removing ridge members 140 and the corresponding roof members 130 , support legs 112 , and intermediate horizontal sections 114 .
[0029] The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.
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Canopies traditionally come in the form of canopy kits, and once erected, provide portable shelter for property, outdoor parties, etc. However, while canopies are useful in a wide variety of applications, the erected canopy structure is often restricted to a fixed size. The present invention discloses a canopy structure kit for a canopy that is transversely expandable from a first width, typically wide enough for an automobile, to a second width, typically wide enough for two automobiles. The expandable canopy structure kit includes extension members to expand the frame structure, and at least one cover adapted to fit the erected frame structure, whether the frame structure assumes an expanded or unexpanded configuration.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application No. 60/517,131 filed 3 Nov. 2003, which application is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to retractable coverings for architectural openings, and more particularly, magnetic components installed on the coverings and the framework surrounding the architectural openings to hold the coverings in position.
[0004] 2. Background Art
[0005] Retractable coverings for architectural openings, such as window blind assemblies, are known in the art. When a window blind assembly is installed on an open window, wind blowing through the window can cause slats of the blind assembly to swing back and forth. Further, sometimes blind assemblies are installed on doors and will undesirably swing to and from the door when it is opened and closed.
[0006] One way to prevent the slats of the blind assembly from moving relative to the window or door is to secure the bottom slat to the framework surrounding the window or door. Many window blind assemblies currently available, however, do not provide a means for securing the bottom slat to the framework. Some blind assemblies do provide such means, but the assemblies require the user to mechanically latch and unlatch a mechanism which is time consuming and a nuisance.
[0007] It is to overcome these shortcomings in prior art coverings that the present invention was developed.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides a magnetic catch to automatically releasably retain a covering adjacent to an architectural opening. Typically, magnetic components are installed on the covering and the covering is mounted in an architectural framework surrounding the architectural opening. Complementary magnetic components to that installed on the covering are then secured to the framework adjacent to the magnetic components on the covering when the covering is fully extended such that the magnetic components on the covering and the framework attract each other through their respective magnetic forces. The magnetic forces thereby work to releasably hold the covering in the fully extended position.
[0009] In one aspect of the present invention, a combination of a covering for an architectural opening and a framework include in combination: a framework extending at least partially around the architectural opening, a magnetic component secured to the framework at a predetermined location, and a retractable covering adapted to extend across the opening or be retracted adjacent to one side of the opening. The covering includes a rail along one edge thereof adapted to be positioned opposite to the one side edge of the opening when the covering is extended, and the rail has a magnetic component positionable adjacent to the magnetic component on the framework such that the magnetic components will attract each other to releasably retain the rail adjacent to the magnetic component in the framework.
[0010] The features, utilities, and advantages of various embodiments of the invention will be apparent from the following more particular description of embodiments of the invention as illustrated in the accompanying drawings and defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front isometric view of a blind assembly in accordance with the present invention in a retracted position.
[0012] FIG. 2 is a front isometric view of the blind assembly of FIG. 1 in an extended position.
[0013] FIG. 3 is a fragmentary vertical section of a window frame taken along line 3 - 3 of FIG. 1 , depicting one embodiment of a catch bracket mounted on a left side of the window frame adjacent to a lower edge thereof.
[0014] FIG. 4 is a fragmentary vertical section of the blind assembly in an extended and open position taken along line 4 - 4 of FIG. 2 , depicting one embodiment of an end cap on a bottom rail of the blind assembly engaging the catch bracket.
[0015] FIG. 4A is an exploded isometric view of the end cap engaging the bottom rail.
[0016] FIG. 5 is a fragmentary vertical section of the blind assembly in an extended and closed position taken along line 4 - 4 of FIG. 2 , depicting the end cap on the bottom rail of the blind assembly magnetically interacting with the catch bracket.
[0017] FIG. 6 is a fragmentary vertical section of the blind assembly taken along line 6 - 6 of FIG. 4 , depicting the end cap on the bottom rail of the blind assembly magnetically interacting with the catch bracket.
[0018] FIG. 7 is an extended view of FIG. 6 depicting the end caps at both ends of the bottom rail of the blind assembly magnetically interacting with respective catch brackets.
[0019] FIG. 8 is an isometric view depicting the mounting of a catch bracket to the left side of the window frame.
[0020] FIG. 9 is an isometric view of a second side of a catch bracket.
[0021] FIG. 10 is an isometric view of a catch bracket connected with a bracket extension member mounted to a rear side of the window frame.
[0022] FIG. 11 is an exploded isometric view of the catch bracket depicted in FIG. 10 .
[0023] FIG. 12 is an isometric view of the second side of the catch bracket depicted in FIG. 10 .
[0024] FIG. 13 is an isometric of a second embodiment of a catch bracket and end cap for a blind assembly showing a portion of a tubular bottom rail attached to the end cap in dashed lines.
[0025] FIG. 14 is an isometric similar to FIG. 13 with the end cap and catch bracket separated.
[0026] FIG. 15 is an isometric of a fully assembled catch bracket of the embodiment of FIG. 13 .
[0027] FIG. 16 is an exploded isometric of the catch bracket as shown in FIG. 15 .
[0028] FIG. 17 is an enlarged section taken along line 17 - 17 of FIG. 15 .
[0029] FIG. 18 is an isometric of an assembled end cap of the embodiment shown in FIG. 13 .
[0030] FIG. 19 is an exploded isometric similar to FIG. 18 .
[0031] FIG. 20 is an enlarged fragmentary section taken along line 20 - 20 of FIG. 13 .
[0032] FIG. 21 is a front elevation of the catch bracket of FIG. 15 .
[0033] FIG. 22 is a side elevation of the catch bracket of FIG. 21 .
[0034] FIG. 23 is a rear elevation of the catch bracket of FIG. 21 .
[0035] FIG. 24 is an end elevation of the catch bracket of FIG. 23 .
[0036] FIG. 25 is a front side elevation of a closure cap for the magnetic of the catch bracket of FIG. 21 .
[0037] FIG. 26 is a side elevation of the closure cap of FIG. 25 .
[0038] FIG. 27 is a bottom plan view of the closure cap of FIG. 25 .
[0039] FIG. 28 is an enlarged section taken along line 28 - 28 of FIG. 32 .
[0040] FIG. 29 is an enlarged section taken along line 29 - 29 of FIG. 32 .
[0041] FIG. 30 is an isometric of half of a removal housing for the fastener used in the end cap of the embodiment of FIG. 13 .
[0042] FIG. 31 is an isometric of the other half of the housing for the fastener of the end cap of FIG. 13 .
[0043] FIG. 32 is an isometric of the fastener used in the end cap of FIG. 13 with the housing component secured thereon.
[0044] FIG. 33 is an exploded isometric of the fastener and housing shown in FIG. 32 .
DETAILED DESCRIPTION OF THE INVENTION
[0045] Retractable coverings for architectural openings are well known in the art. Various types of such coverings are described in a PCT international patent application identified with publication No. WO 03/008751 A1, which is hereby incorporated in its entirety as if fully disclosed herein. Such coverings are movable between extended and retracted positions and when they include vanes or slats, the vanes or slats are typically additionally movable between open and closed positions. As discussed in more detail below and with reference to the attached Figures, the present invention provides a combination of a retractable covering having magnetic components mounted thereon with a framework for an architectural opening in which the covering is mounted. The framework also has magnetic components mounted thereon with the various magnetic components releasably retaining the covering in an extended position. The magnetic forces therefore help prevent the covering from swinging back and forth when the covering is utilized to cover an open window on a windy day, to hold the covering in position on a swinging door when the door is opened or closed or other such uses.
[0046] FIGS. 1 and 2 show the present invention as applied to a blind assembly 50 installed on a frame 52 surrounding a window 54 . The blind assembly 50 includes a plurality of horizontal slats 56 supported on conventional cord ladders 58 suspended from a control system (not shown) housed inside a rigid slat-shaped head rail 60 as more fully described in the afore-noted PCT patent application. Conventional mounting brackets 62 at both ends of the head rail 60 secure the blind assembly 50 to the frame 52 . The cord ladders 58 provide for pivotal movement of the horizontal slats 56 between open and closed positions. Actuation of the cord ladders also allows the blind assembly to be moved between a retracted position, as shown in FIG. 1 , and an extended position, as shown in FIG. 2 . When the blind assembly is in the extended position, magnetic components 64 (described in more detail below with reference to FIG. 7 ) installed in both ends of a bottom rail 66 of the blind assembly attract magnetic components 64 installed in catch brackets 68 connected with the frame adjacent to the bottom edge of the window. In the extended position, the bottom rail 66 of the blind assembly 50 is releasably held in position adjacent to the frame 52 by the magnetic forces created between the magnetic components. Moving the blind assembly from the extended position simply requires a user to actuate the control system and cord ladder to lift the bottom rail with enough force to overcome the magnetic force between the magnetic components.
[0047] As illustrated in FIGS. 3 and 8 , the catch bracket 68 includes a main body 70 with a first side 72 defining a circular recess 74 located in a forward region 76 for seating a magnetic component 64 , and two mounting holes 78 located in a rearward region 80 . As shown in FIG. 9 , a second side 82 of the main body 70 is generally flat. Referring to FIGS. 3 and 8 , when mounting the catch bracket 68 to the frame 52 , two screws 84 are inserted into the mounting holes 78 of the catch bracket and threadedly engage the frame. As shown, the screws 84 have flat heads and the mounting holes 78 in the catch bracket are beveled to minimize any protrusion of the screw head from the catch bracket when installed. The catch bracket 68 as shown in FIGS. 3 and 8 is mounted to a left side 86 of the frame 52 . As such, the first side 72 faces inwardly toward the blind assembly 50 . The catch bracket 68 installed on a right side 88 of the frame 52 is identical and is inverted to face in the opposite direction.
[0048] Depending on the application, it may be desirable to mount the catch bracket on a rear side 90 of the frame 52 . As shown in FIGS. 10 and 11 , a bracket extension member 92 can be connected with the catch bracket 68 to effectively rotate the location of the mounting holes 78 by ninety degrees. As shown in FIG. 11 , the bracket extension member 92 is L-shaped and is defined by the intersection of a first plate 94 and a second plate 96 . Two mounting holes 78 are located in the first plate 94 , and two posts 98 extend from the second plate 96 . To connect the bracket extension member 92 with the catch bracket 68 , the posts 98 on the bracket extension member are inserted into the mounting holes in the catch bracket. As shown in FIG. 10 , the catch bracket 68 is mounted to the rear side 90 of the frame 52 by inserting screws 84 into the mounting holes 78 in the bracket extension member 92 to threadedly engage the rear side of the frame. FIG. 12 shows an isometric view of the second side 82 of the catch bracket when connected with the bracket extension member.
[0049] As previously mentioned and as shown in more detail in FIGS. 4-7 and 4 A, magnetic components 64 are located in both ends of the bottom rail 66 , which attract the magnetic components 64 located in the catch brackets 68 when the blind assembly 50 is in the extended position of FIG. 2 . As illustrated in FIGS. 4A, 6 and 7 , end caps 100 are installed in both ends of the bottom rail 66 . Each end cap 100 includes an extension wall 102 adapted to be inserted into an open end of the hollow bottom rail 66 . The end cap 100 also defines an end wall 104 to cover the end of the bottom rail 66 , with the end wall having an inner surface 106 with a recess 108 to hold the associated magnetic component 64 . As shown in FIG. 4A , a rear plug 108 and a rear edge portion 110 extend from the inner surface 106 of the end cap 100 . When connecting the end cap 100 to the bottom rail 66 , the end cap engages a longitudinally extending extrusion 112 , which is connected with the bottom rail 66 . The longitudinally extending extrusion 112 defines an extrusion tube 114 , an upwardly facing top channel 116 , a downwardly facing bottom channel 118 , and a rear channel 120 . The upwardly facing top channel 118 and the downwardly facing bottom channel 120 are adapted to receive narrow edges 122 on the bottom rail 66 . The extrusion tube 114 on the longitudinally extending extrusion 112 is adapted to receive the rear plug 108 on the end cap, and the rear channel 120 is adapted to receive the rear end portion 110 of the end cap.
[0050] When the blind assembly is in the extended position, the magnetic components housed in the end caps of the bottom rail are located adjacent to the magnetic components in the catch brackets. Equal magnetic forces pulling in opposite directions on the ends of the bottom rail hold the bottom rail in a centered position in the architectural opening that provides for no contact between the end caps and the catch brackets even though as can be seen in FIG. 6 , even if the magnetic force in one direction was greater than the other so that one end of the bottom rail engaged an associated catch bracket, the blind would shift only minimally and imperceptibly. Also, as shown in FIGS. 4 and 5 , the magnetic forces hold the bottom rail 66 in position, but allows the bottom rail 66 to rotate about the magnetic components 64 as the blind assembly 50 is changed from the open position to the closed position.
[0051] The magnetic components 64 used in the present invention can be of various types. For example, the magnets could be ceramic, iron or steel and could be mounted in both the bottom rail and a catch bracket such that opposite poles of the magnets were positioned adjacent to each other for the desired attraction. Magnets could be installed only in the bottom rail with magnetic components in the form of metallic objects installed in the catch brackets, or the magnets could be installed in the catch brackets with metallic objects installed in the bottom rail. The catch brackets could also be positioned at different locations on the frame to releasably secure the bottom rail of the blind assembly at a different position than a fully extended position. Further, additional magnetic components could be installed in other horizontal slats 56 to cooperate with corresponding additional catch brackets.
[0052] A second embodiment of the present invention is shown in FIGS. 13-33 . In this embodiment, modifications have been made to both the catch bracket and the end cap. The second embodiment is specifically designed for use with a magnet and a metallic object as the magnetic components even though variations thereof would be known to those skilled in the art.
[0053] With reference first to FIGS. 13 and 14 , the catch bracket 124 and end cap 126 (shown mounted in the end of a tubular bottom rail 66 shown in dashed lines) are illustrated interconnected in FIG. 13 and separated in FIG. 14 . The catch bracket is adapted to be mounted in the framework of an architectural structure and includes a magnet 130 which is adapted to attract a metallic fastener 132 anchored in the end cap 126 .
[0054] Looking first at the catch bracket 124 as probably best seen in FIGS. 15-19 , it will be seen to include a main body 134 having a cylindrical seat 136 on a distal end and an integral base 138 extending perpendicularly to the main body at the opposite end. The base has a pair of passages 140 therethrough for receipt of mounting fasteners (not shown) and the main body similarly has a pair of passages 142 therethrough for receipt of fasteners with either set of passages being utilized depending upon the location in which the bracket is mounted in a framework as discussed previously. The cylindrical seat 136 has diametrically opposed slots 144 formed in its outer surface adapted to releasably receive a circular closure cap 146 having diametrically opposed legs 148 with catches 150 on their distal ends adapted to be releasably received in the slots. The catches 150 on the ends of the legs are receivable in a depression 152 at the innermost end of each slot 144 but the catch is designed so that an outward force applied to the closure cap will cause the cap to be released from the cylindrical seat.
[0055] A cavity 154 is defined by the cylindrical seat 136 and the closure cap 146 which is adapted to receive the cylindrical magnet 130 . FIG. 17 shows the magnet seated in the cavity and the closure cap snapped into position on the cylindrical seat. The closure cap also has a pimple 155 at its geometric center which projects axially away from the closure cap for a purpose to be described later. The catch bracket is preferably made of a somewhat rigid material that might flex slightly to desirably attract and removably retain the end cap 126 of the bottom rail of a covering or blind assembly as will become more clear hereafter.
[0056] Referring next to FIGS. 18 and 19 , the end cap 126 is very similar to the previously described end cap 100 in that it includes an extension wall 102 adapted to be inserted into an open end of a hollow bottom rail 66 . The end cap also defines an end wall 104 to cover the end of the bottom rail with the end wall having an inner surface 106 having a cylindrical boss 156 integrally formed thereon with the boss having a circular threaded passage 158 therethrough and a cylindrical recess 160 opening through the end wall 104 as best seen in FIG. 20 . As with the previously described end cap 100 , the end cap 126 also has a rear plug 108 and a rear edge portion 110 extending from the inner surface 106 of the end cap. The cylindrical recess 160 in the boss is adapted to seat the metallic fastener 132 which is threadedly received in the passage 158 through the boss to hold it in position.
[0057] The fastener 132 is best shown in FIG. 20 to comprise a threaded bolt having a crowned head 162 which is confined within a two-piece housing 164 shown best in FIGS. 28-33 . A first half 166 of the housing, as seen in FIG. 30 , is generally semi-cylindrical in configuration having a semi-circular passage 168 through an end wall, a catch arm 170 extending downwardly off one side, and a catch groove 172 formed in the opposite side. The interior of the first half of the housing has a semi-cylindrical recess 174 ( FIG. 20 ) in axial alignment with a second recess 176 which communicates with a semi-circular opening 178 through the opposite end wall. The recesses are identical to similar recesses 180 and 182 , respectively, shown in the second half 184 of the housing shown in FIG. 31 .
[0058] The second half 184 of the housing 164 is also generally semi-cylindrical in configuration having the semi-cylindrical recess 180 and the second axially aligned recess 182 formed therein. A catch arm 186 and a catch groove 188 in opposite sides are also on the second half which are positioned to releasably cooperate with the catch groove 172 and the catch arm 170 , respectively, on the first half 166 of the housing. In other words, when the housing components 166 and 184 are placed in confronting face-to-face relationship so as to form a complete cylinder, the catch arm 186 on the second half releasably engages the catch groove 172 on the first half and the catch arm 170 on the first half releasably engages the catch groove 188 in the second half. Similar to the first half, the second half of the housing has semi-circular passages 190 and 192 through opposite end walls which are axially aligned.
[0059] The second recesses 176 and 182 in the first and second housing components have a curved surface 194 which conforms with the crowned head 162 of the fastener so that when the housing components are secured together, the head of the fastener is seated in the cavity formed by the confronting second recesses as shown in FIG. 28 . Accordingly, when the housing is snapped in place around the head 162 of the fastener, the distal end of the threaded shank 196 of the fastener is positioned to be threadedly received in the boss 156 of the end cap 126 and the fastener can be advanced into the boss until the housing 164 is fully received within the cylindrical recess 160 in the outer wall of the boss.
[0060] Preferably the fastener is rotatable with an Allen wrench so that it has a hexagonal recess 198 in its head. The hexagonal recess opens through the opening in the outer end of the housing and can thereby releasably receive the pimple 155 on the closure cap of the catch bracket. This provides a releasable mechanical interlock between the catch bracket and the end cap which helps to center and retain the magnetic attraction between the magnet and the metallic fastener at a predetermined position.
[0061] The present invention can also be applied to other styles of blind assemblies and covers for architectural openings, and should not be construed to be limited to the embodiments described specifically herein. For example, the present invention is also applicable to blinds having solid slats or vanes or no vanes at all or to blinds having bottom rails that are not necessarily hollow. In addition, the present invention would be applicable to vertical blind arrangements such that a side rail in the vertical blind could be releasably retained adjacent to a side frame member of the architectural opening.
[0062] Although various embodiments of this invention have been described above with a certain degree of particularity or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only of particular embodiments, and not limiting. Changes in detail or structure may be made without departing from the basic elements of the invention as defined in the following claims.
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A magnetic catch is used on coverings for architectural openings to releasably retain the coverings in an extended position and immediately adjacent to the framework of the opening. Magnetic components are installed on the covering and the framework surrounding at least part of the architectural opening. The covering is then placed in a position such that the magnetic components on the covering and the framework are close enough to attract each other through their respective magnetic forces. The magnetic forces work to releasably hold the covering in position relative to the framework.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 15/014,891, entitled “Integrated Fiber Cement and Foam as Insulated Cladding with Enhancements,” filed Feb. 3, 2016, which is a continuation of U.S. patent application Ser. No. 14/390,369, now U.S. Pat. No. 9,260,864, entitled “Integrated Fiber Cement and Foam as Insulated Cladding with Enhancements,” filed Oct. 2, 2014, which is a national phase entry of PCT Application Number PCT/US13/35033, filed Apr. 2, 2013, which claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/619872, filed on Apr. 3, 2012. Each of the applications referenced in this paragraph is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Field
[0003] The present disclosure generally relates to building construction materials and methods, and more particularly relates to composite fiber cement cladding with improved properties and methods of installing such material.
[0004] Description of the Related Art
[0005] The future of building construction is moving towards providing an insulated, energy efficient building envelope. In particular, there is an increasing demand for energy efficient residential and commercial constructions which require walls having greater building insulation ratings. The R-value of building insulation is a measure of its resistance to transferring heat or thermal energy. Greater R-values indicate more effective building insulation. The higher the R-value of the insulation of a building, the easier it is to maintain a temperature differential between the interior and the exterior of the building over an extended period of time. One approach to improving the energy efficiency of a building structure is to add insulation to the exterior walls. Adding additional wall insulation, however, can drive up the cost of construction as it requires additional material and installation labor. Adding additional exterior wall insulation can adversely affect the aesthetics, water management, and other properties of the wall structure assembly, as well as impact the design of other components of the wall.
[0006] Foamed material is one type of material that can be used to insulate building structures. While foamed material has been used as an insulation material in certain building construction, it has not been used as efficiently and effectively as it could be. For example, foam sheathing or backing boards have been placed between the framing and fiber cement exterior sidings of a building structure to provide additional insulation. The foam sheathing or backing boards are typically tacked or fastened to the framing prior to installation of the exterior cladding. To reduce the amount of air exchanged between the inside and the outside of the building structure, the seams of the foam sheathing or backing boards often need to be sealed or taped. As such, the installation of the foam sheathing requires additional processing steps. The foam installation may also create aesthetic issues with the exterior siding, such as causing a wavy appearance as when siding is installed over deformations in the foam where fasteners compress the underlying foam.
[0007] Additionally, in high-wind regions, sidings are frequently blown off walls of building structures. To improve wind resistance, shims are often used to create a uniform and flat surface for attachment of the sidings so as to reduce gaps that could catch the wind. Face nailing instead of blind nailing is also recommended, particularly for fiber cement sidings in regions with high wind speed. However, these existing methods for enhancing wind resistance of sidings require additional material and labor, and can detract from the aesthetics of exterior building structure.
[0008] In view of the foregoing, there is a need for a different building construction material and technique for improving the insulation of building structures and improving the wind resistance of exterior sidings. There is also a need for an improved fiber cement composite insulation building material designed without the shortcomings of existing site assembled systems that incorporate foam as an insulating material.
SUMMARY
[0009] Accordingly, disclosed herein are integrated fiber cement and foam cladding systems that incorporate foam or similar light weight material, such as lightweight mats of fiberglass or rockwool, for improving the insulation capacity of a cladding material. In various embodiments, the integrated fiber cement and foam cladding system is designed to improve existing uses of foam and fiber cement during the construction of a wall or other structure in one or more of the following areas: reduced installation time, increase wind loads, simplified assembly, nail holding ability, resistance to thermal bridging, water management, and transportation. As used herein, the terms “foam” or “foamed material” are broad terms and shall have their ordinary meaning and shall include, but not be limited to polymeric foams, inorganic foams, cementitious foams, glass foams, ceramic foams, metallic foams, aerogels, syntactic foams and the like in a substantially solid state.
[0010] In one application, the integrated fiber cement and foam system of the present disclosure is prefabricated and designed with a structure that has sufficient integrity to sustain its connection with the building frame under high wind loads.
[0011] Accordingly, in one embodiment of the invention, there is provided a prefabricated integrated fiber cement and foam insulation panel comprising: a fiber cement layer having a front side and a back side spaced apart to define an intermediate portion and an edge member extending around the intermediate portion; a foam layer having a front side and a back side spaced apart to define an intermediate portion and an edge member extending around the intermediate portion; and an adhesive layer disposed between the fiber cement layer and the foam layer, said adhesive layer adapted to attach the fiber cement layer to the foam layer.
[0012] In a further embodiment of the invention, the foam layer is configured to facilitate alignment and assembly of multiple panels together. In one implementation, the foam layer is profiled with an interlocking feature such that adjacent foam layers will interlock when the siding panels are installed. This interlocking feature facilitates alignment of the siding panels, inhibits the infiltration of air and water between the panels and also increases wind loads on the structure by improving the resistance of the panels to the effects of strong winds impinging on the wall.
[0013] Accordingly, in a further embodiment of the invention, there is provided an exterior cladding system for building structures. The system comprises a first panel and a second panel, wherein each panel comprises a fiber cement layer and a foam layer, the fiber cement layer of each panel being secured to the respective foam layer, the foam layer of each panel comprises interlocking means. In one embodiment of the invention the interlocking means comprises a receiving channel or mating channel whereby the receiving channel or mating channel of the foam layer of the first panel engages with the receiving channel or mating channel of the foam layer of the second panel when the first and second panel are placed in a contiguous arrangement such that at least a portion of the receiving or mating channel of each of the foam layers abut in an interlocking arrangement.
[0014] In a further embodiment of the invention the fibre cement layer is secured to the foam layer by means of an adhesive layer. It is to be understood that any other suitable type of securing means known to a person skilled in the art could also be used. Preferably the method of securing the fibre cement layer to the foam layer allows for thermal cyclic differential expansion between the fibre cement layer and the foam layer and or any other layers which may be present.
[0015] Accordingly, in a further embodiment of the invention, there is provided an exterior cladding system for building structures. The system comprises a first panel and a second panel, wherein each panel comprises a fiber cement layer and a foam layer, wherein the fiber cement layer of each panel is pre-attached to the respective foam layer by an adhesive selected to accommodate the stresses generated by cyclic differential expansion between the fiber cement layer and the foam layer, wherein the foam layer of the first panel comprises an elongate mating channel defined by two opposing sidewalls formed along a longitudinal edge of the foam layer of the first panel, wherein the foam layer of the second panel comprises an elongate protrusion formed along a longitudinal edge of the foam layer of the second panel, the protrusion on the foam layer of the second panel being configured to be received into the mating channel on the foam layer of the first panel in a manner such that the sidewalls formed on the foam layer of the first panel enclose the protrusion formed on the foam layer of the second panel in a manner such that the foam layer of the first and second panels interlock.
[0016] In a further embodiment of the invention, the fiber cement layer is configured to facilitate alignment and assembly of multiple panels together. In one implementation, the fiber cement layer is profiled with an interlocking feature such that adjacent fiber cement layers will interlock when the siding panels are installed. It is to be understood that in other embodiments of the invention the foam layer of the exterior cladding system can be configured such that the interlocking means is located on any two opposing edges of the foam layer. In an alternative embodiment of the invention the interlocking means can be located on at least two opposing edges of the foam layer.
[0017] Conveniently in a further embodiment of the invention, the foam layer comprises an interlocking feature extending around at least a portion of the edge member to facilitate alignment and assembly of the multiple panels together. In a further embodiment of the invention, the interlocking feature is configured to improve the wind load of the installed prefabricated integrated fiber cement and foam insulation panel. In one embodiment of the invention, the interlocking feature comprises complementary shaped tongue or groove configurations. In a further embodiment of the invention, the foam layer is configured to interlock with adjacent foam layers in a manner such that the integrated fiber cement and foam insulation panels are arranged in a nested configuration.
[0018] In yet another application, the integrated fiber cement and foam system provides foam backed siding planks that provide the functional equivalent of continuous insulation and a thermal break across the framing members. In yet another embodiment, the integrated fiber cement and foam system is configured to form a substantial air seal between the individual components of the system. In yet another arrangement, the integrated fiber cement and foam system provides a foamed back lap or panel siding that allows the installer the flexibility to adjust the joints between individual laps or panels and yet maintain a sealed air barrier. In yet another application, the integrated fiber cement and foam system is designed to aid in the placement of fasteners.
[0019] In yet another arrangement, the integrated fiber cement and foam system is designed with a continuous, uninterrupted drainage plane and can prevent water from being trapped between the foam layer and wall sheathing which normally surrounds the structural support of the building structure. In one embodiment of the invention, either the foam layer or the fiber cement layer is configured with one or more drainage channels to provide a drainage plane. In other implementations, drainage channels are formed either on the interior or exterior surface of the foam layer or within the foam layer itself for effective water management within the wall cavities. In a further embodiment of the invention, a plurality of drainage channels are formed in the foam layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed on at least one of the surfaces of the foam layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed inside the foam layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed on at least one of the surfaces of the fiber cement layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed inside the fiber cement layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention the integrated fiber cement and foam insulation panel, at least one surface of the foam layer is provided with a pattern which provides a series of drainage channels in the integrated fiber cement and foam insulation panel. The pattern can adopt any suitable form, for example, a Chevron pattern or a plurality of repeating emblems or logos. In a further embodiment of the invention the foam layer is porous. Conveniently, the foam layer is sufficiently porous to permit water drainage.
[0020] In a further embodiment of the invention, the integrated fiber cement and foam insulation panel comprises a fiber cement layer and a foam layer, wherein the width of the foam layer is smaller than the width of the fiber cement panel so as to form an overhang on the integrated fiber cement and foam insulation panel.
[0021] In a further embodiment of the invention, the integrated fiber cement and foam insulation panel further comprises a reinforcement mesh layer. In one embodiment of the invention, the integrated fiber cement and foam insulation panel further comprises a reinforcement mesh layer embedded in said foam layer. In a further embodiment of the invention, the integrated fiber cement layer and foam insulation panel further comprises a reinforcement mesh layer intermediate the fiber cement layer and the foam insulation layer. In a further embodiment of the invention, the integrated fiber cement layer and foam insulation panel further comprises a reinforcement mesh layer embedded in the fiber cement layer, intermediate the fibre cement layer and the foam insulation layer. In a further embodiment of the invention, the integrated fiber cement and foam insulation panel further comprises one or more fastening tabs. In a further embodiment, the one or more fastening tabs are disposed between the foam layer and the fiber cement layer. In another embodiment, the one or more fastening tabs are disposed on and/or adjacent to the back side of the foam layer. In a further embodiment, the one or more fastening tabs are attached to the panel in a manner such that a portion of each tab extends outwardly from the lateral edges of the foam layer.
[0022] In an embodiment, a method of installing integrated fiber cement and foam insulation panels on a building structure having a framing comprises the steps of: installing one or more starter strips at the base of a wall of the building to form a plank angle; and installing the fiber cement and foam insulation panels sequentially up the wall. In an embodiment, the method further comprises the steps of crotchedly vertically nesting the fiber cement and foam insulation panels. In an embodiment, the method further comprises the steps of installing an insert behind a butt joint intersection between adjacent fiber cement and foam insulation panels; wherein the insert comprises a foam layer with the same profile as a foam layer in the fiber cement and foam insulation panels as a flashing layer. In a further embodiment, wherein the fiber cement and foam insulation panel comprises one or more fastening tabs, the method further comprises the steps of installing the panels to the framing by attaching the one or more fastening tabs to the framing, wherein the fastening tabs are attached to the fiber cement and foam insulation panels in such a manner that at least a portion of each fastening tab is concealed from view when the panels are installed on the building structure.
[0023] In yet another application, the integrated fiber cement and foam system is configured to be stacked in a manner during transit so as to reduce damage normally sustained by foam materials while in transit.
[0024] In some embodiments, the integrated fiber cement and foam insulation system comprises a prefabricated fiber cement and foam insulation siding panel. The prefabricated panel includes a fiber cement layer and a foam layer attached thereto, preferably by an adhesive. The fiber cement layer can be a panel, a plank, a shingle, a strip, a trim board, or the like. In a further embodiment of the invention the fiber cement and foam insulation siding panel comprises an oriented strand board (OSB), said OSB is attached to the foam layer on the opposing side of the fiber cement layer. Various embodiments of the integrated fiber cement and foam insulation system will be described in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIGS. 1A-1B illustrate an integrated fiber cement foam and insulation siding panel according to one embodiment of the present disclosure.
[0026] FIGS. 2A-2C illustrate an integrated fiber cement foam and insulation siding panel according to another embodiment of the present disclosure.
[0027] FIGS. 3A-3I illustrate embodiments of foam layer profiles that can be incorporated in an integrated fiber cement and foam insulation panel.
[0028] FIGS. 3J-3N illustrate profiles of foam starter strips of various embodiments.
[0029] FIG. 4A-4D illustrates an embodiment of integrated fiber cement and foam insulation panels incorporating drainage features of various embodiments.
[0030] FIG. 5 illustrates an integrated wall assembly according one embodiment of the present disclosure.
[0031] FIG. 6A-6I illustrate various embodiments of an integrated fiber cement and foam insulation panel with integrated fastening tabs.
[0032] FIG. 7 illustrates yet another embodiment of the present disclosure showing a prefabricated integrated fiber cement and foam insulation panel with a backing disposed on the backside of the foam layer.
[0033] FIG. 8 illustrates yet another embodiment of the present disclosure showing an integrated fiber cement and foam insulation system that incorporates a discontinuous layer in the foam backing for acoustic dampening purposes.
[0034] FIG. 9 illustrates an embodiment of the present disclosure showing a fiber cement and foam insulation panel designed for high shear applications.
[0035] FIGS. 10A-10C illustrate embodiments showing two fiber cement and foam insulation panels joined together with a butt joint.
[0036] FIGS. 11A and 11B illustrate certain connection mechanisms that can be used to join adjacent integrated fiber cement and foam panels at a butt joint.
[0037] FIG. 12 depicts a flow diagram of installation of fiber cement and foam insulation plants according to one embodiment.
[0038] FIG. 13 depicts yet another embodiment of an integrated fiber cement and foam insulation panel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0039] References will now be made to the drawings wherein like numerals refer to like parts throughout. FIG. 1A illustrates an integrated fiber cement and foam insulation panel 100 configured for exterior siding applications in accordance with various embodiments of the present disclosure. The panel 100 generally includes a fiber cement layer 102 and a profiled foam layer 104 attached thereto. The fiber cement layer 102 can be in the form of a plank, a siding, a shingle, a strip, a trim board, or various other building components. In a preferred embodiment, the fiber cement layer 102 is configured as a siding used for exterior wall applications. The profiled foam layer 104 can be made of open-celled and/or closed-celled foam or other similar lightweight material with insulating material properties, such as polystyrene foam, mineral based foams, foamed cement or gypsum, phenolic foams, and aerogels. Additionally or alternatively, the profiled foam layer 104 may also comprise mineral fibers or fiberglass, cellulose, polyisocyanurate, polystyrene, polyurethane, cotton fibers, and mineral wool. The profiled foam layer 104 may also include as part of its formulation water repellent agents, fire retarding agents, termiticides, insecticides or repellents, gases that enhance R-value retention, fillers that enhance R-value and the like. In some embodiments, the profiled foam layer 104 may be a composite foam comprised of materials with differential composition, density, compressive strength or fastener holding ability. As shown in FIG. 1A , the profiled foam layer 104 is adhered to an interior surface or backside 105 of the fiber cement layer 102 and extend substantially across the length of the fiber cement layer 102 such that the profiled foam layer can provide continuous insulation and thermal break across between the fiber cement layer and framing members upon installation of the panel 100 . Preferably, the profiled foam layer 104 extends partially across the width of the fiber cement layer 102 so as to leave an overhang portion 108 . The overhang portion 108 is adapted to overlap with adjacent panels when the panels are installed in a nesting configuration. In other embodiments, the profiled foam layer 104 does not extend across the entire length of the fiber cement layer 102 so as to accommodate possible expansion of the foam due to thermal effects upon installation of the panel 100 .
[0040] In various embodiments, a specially formulated adhesive layer 106 is uniformly disposed between the interior surface 105 of the fiber cement layer 102 and the profiled foam layer 104 to form a strong and uniform bond between the foam and the fiber cement across the entire panel 100 . The adhesive layer 106 is preferably formulated to establish an effective chemical and/or mechanical interlocking bond with both the foam and the fiber cement. In one embodiment, the adhesive layer 106 may be made of polyurethane, poly urea or isocyanate based materials. Preferably, the adhesive layer when bonding styrene foam to fiber cement is a high-shear strength adhesive that will not attack or eat away at either the fiber cement or styrene foam. Preferably, the adhesive layer will offer a durable bond between the fiber cement and foam layers in a variety of environmental condition including cold and warm conditions, dry and wet conditions, and freeze-thaw conditions, with salt, and in alkaline solutions, etc. The adhesive layer also preferably maintains its adhesive properties through exposure to many cycles of temperature swings (hot to cold), moisture conditions (wet to dry), and/or freeze-thaw cycles.
[0041] In one embodiment, the adhesive layer can be made of a water based adhesive, solvent based adhesive, and 100% solid. The adhesive layer can be formed in a liquid form, in a paste form, and/or in a solid form as hot melt adhesive. The chemistries can include one and two component polyurethane, one and two part epoxy, polyvinyl acetate, polyolefin, amorphous polyolefin, pressure sensitive polyolefin, poly ethylene vinyl acetate, and/or polyamide. In some embodiments, the adhesive may be a hot melt or reactive hot melt adhesive. In such embodiments, it is preferable that the hot melt adhesive establishes a very quick bond so that the fiber cement product bonded with foam can be moved and stacked in production.
[0042] In a preferred embodiment, the adhesive layer 106 is selected to accommodate the possible stresses generated by cyclic differential expansion between the foam and the fiber cement portions of the integrated fiber cement and foam insulation panel. In various embodiments, the adhesive can be applied onto the fiber cement layer by spraying, roll coating, etc. The adhesive layer 106 may be discontinuous, such as with partial coverage over the portion of the back surface 105 of the fiber cement layer 102 which mates to the profiled foam layer 104 to lead to a material and cost savings. A discontinuous adhesive layer 106 may also facilitate the evaporation of moisture from the interface between the elongate fiber cement layer 102 and the profiled foam layer 104 . In other embodiments, the adhesive layer 106 may be continuous, such as with full coverage over the portion of the back surface 105 of the fiber cement layer 102 which mates to the profiled foam layer 104 .
[0043] In another embodiment, the profiled foam layer 104 may be joined to the fiber cement layer 102 by laminating the profiled foam layer 104 to the interior surface or back face 105 of the fiber cement layer 102 . Lamination may be achieved by mechanical means, by use of adhesives or by forming the foam layer directly on the fiber cement layer either before or after curing of the fiber cement layer by autoclaving, depending on the materials used. In yet another embodiment, the profiled foam layer 104 can be formed by applying a layer of foam generating liquid to the interior surface or back face 105 of the fiber cement layer 102 and allowing the layer of foam generating liquid to expand such that the entire interior surface or back face 105 of the fiber cement layer 102 is substantially covered with foam. In this embodiment, the profiled foam layer 104 may be formed into a predetermined shape and profile after foam generation by use of routing, molding or machining equipment as is known to those skilled in the art. Alternatively, the profiled foam layer 104 may be formed by allowing the layer of foam generating material to expand into a mold or container of a predetermined shape or profile, followed by an operation that releases the foam layer from the mold or container.
[0044] With further reference to FIG. 1A , in various preferred embodiments, the profiled foam layer 104 can include drainage channels 112 extending through the exterior or interior of the foam to provide water drainage. The profiled foam layer 104 can also include profiled opposing longitudinal edges 110 , 111 . The profiled edges 110 , 111 are configured to interlock with corresponding profiled edges on adjacent profiled foam layers to facilitate alignment of the panels 100 during installation. In certain implementations, the interlocking features formed by the edges 110 , 111 of the profiled foam layer 104 are adapted to allow the panels 100 to nest with each other as they are assembled on a wall.
[0045] As described in greater detail below, in some embodiments, the interlocking features are specially configured to interlock in a manner that improves the wind load of the panels. As shown in FIG. 1A , one of the edges 111 of the profiled foam layer 104 is configured with a channel 115 defined by two parallel sidewalls 114 a, 114 b extending longitudinally across the edge 111 . The parallel sidewalls 114 a, 114 b in conjunction with the channel 115 formed in the profiled foam layer 104 interlock and secure the edge 110 of adjacent foam layers so as to improve wind resistance of the panel 100 . The interlocking features can also be adapted to provide an air seal, whether with or without use of sealants such as caulk or tape. In some embodiments, the interlocking feature can also be adapted to meet the requirements for continuous insulation and thermal break across the framing members. In some implementations, the interlocking features are also adapted to provide the installer a means to adjust joint spacing so as to efficiently space panels along the wall to reduce material use and installation labor.
[0046] FIG. 1B illustrates a manner in which a plurality of integrated fiber cement and foam insulation panels 100 a, 100 b can be arranged as assembled on a building frame to form an exterior cladding, such as for exterior siding applications. In various preferred embodiments, the panels 100 a, 100 b are prefabricated so that the installer can simply remove the packaging from each panel and attach the panels to the frame of a building. As shown in FIG. 1B , the panels 100 a, 100 b are positioned in a nesting configuration whereby the profiled edges 110 a , 111 a, 110 b, 111 b of the foam layers 104 a, 104 b interlock the panels so as to provide an air seal without sealer and to facilitate alignment and installation. The panels can be positioned such that the interlocking foam layers can provide continuous insulation and thermal break across the building framing members. As also shown in FIG. 1B , the drainage channels 112 allow water to drain from the interior of the panels 100 a, 100 b. The drainage channels 112 can be formed either on the interior or exterior surface of the foam layer or within the foam layer itself for effective water management within the wall cavities. In one implementation, the profiled foam layer 104 has a thickness of about ¼ inch to 3 inches (0.635 cm to 7.62 cm) and the fiber cement layer 102 has a thickness of about ⅛ inch to 1.25 inches (0.318 cm to 3.175 cm). In one embodiment, the profiled foam layer 104 can have a density of between 1.25 to 2.0, such as 1.25, 1.5, 1.75, or 2.0, and an R value of between R3 and R7, preferably R3, such as R3, R5, and R7.
[0047] With further reference to FIG. 1B , in overlapping siding applications, the parallel side walls 114 a, 114 b on the lower edge 117 a of the profiled foam layer 104 a directly contact and enclose both side surfaces of the upper edge 119 b of the adjacent profiled foam layer 104 b, thus mechanically connecting the profiled foam layers 104 a, 104 b with each other, which in turn improve the wind load of the panels 100 a, 100 b. In one embodiment, both the upper and lower edges 117 a, 117 b, 119 a, 119 b of the profiled foam layers 104 a, 104 b have a sloped profile such that the parallel side walls 114 a, 114 b are not evenly disposed. Preferably, the sidewall 114 b in contact with the fiber cement layer 102 a, 102 b is positioned higher than the sidewall 114 a, 114 b not in direct contact with the fiber cement layer.
[0048] FIG. 2A illustrates an integrated fiber cement foam and insulation panel 200 according to another embodiment of the present disclosure adapted for exterior siding applications in which the sidings are not in a nesting configuration. As shown in FIG. 2A , the panel 200 includes a fiber cement layer 202 and a profiled foam layer 204 attached thereto. The profiled foam layer 204 can be attached to the fiber cement layer 202 by an adhesive layer 206 or can be integrally formed on the fiber cement layer 202 . In this embodiment, the longitudinal edge 209 of the profiled foam layer 204 is substantially flush with the longitudinal edges 207 of the fiber cement layer 202 . As also shown in FIG. 2A , the foam layer 204 has interlocking features 210 , 211 adapted for aligning and coupling adjacent panels 200 during assembly, such as a tongue and groove joint. Additionally, drainage channels 212 can be formed in the foam layer 204 as shown in FIG. 2A . In certain preferred implementations, the thickness of the foam and fiber cement layers can be selected to provide target insulation R values and also allow the panels to be integrated into the building structure without requiring alterations of the wall or framing dimensions of existing building structures. In one implementation, the foam backing 204 has a thickness of about ¼ inch to 3 inches (0.635 cm to 7.62 cm) and the fiber cement layer has a thickness of about ⅛ inch to 1.25 inches (0.318 cm to 3.175 cm). In one embodiment, the foam backing 204 can have a density of between 1.25 to 2.0, such as 1.25, 1.5, 1.75, or 2.0, and can have an R value of between R3 and R7, preferably R3, such as R3, R5, and R7. In one embodiment, siding nails from 6d to 16d can be used, such as 6d, 10d, and 16d.
[0049] FIG. 2B illustrates one embodiment in which integrated fiber cement and foam insulation panels 200 can be arranged when they are assembled on a building frame to form an exterior cladding. As shown in FIG. 2B , the foam layers 204 a, 204 b can include interlocking features 210 ′, 211 ′ such as a tongue and groove, such that the fiber cement layers 202 a, 202 b form a substantially planar exterior surface. In some embodiments, the interlocking features in the foam layers may be formed using the same techniques as for forming drainage channels in a separate step. In addition, in the case of EPS foams, the polystyrene beads may be placed in a mold specifically designed to yield a foam panel having both drainage channels and interlocking features.
[0050] FIG. 2C shows an alternative embodiment in which the integrated fiber cement and foam insulation panels can be arranged when they are assembled on a building frame to form an exterior cladding. As shown in FIG. 2C , the fiber cement layers 202 a, 202 b can include interlocking features 210 ″, 211 ″ such that the fiber cement layers 202 a, 202 b form a substantially planar exterior surface. In the illustrated embodiment in FIG. 2C , the profiled foam layers 204 a, 204 b are configured without interlocking features. It should be appreciated that in various embodiments, either the profiled foam layers 204 a, 204 b and/or the fiber cement layers 202 a, 202 b can have interlocking features 210 , 211 .
[0051] In various embodiments, the fiber cement and foam insulation systems disclosed herein are designed with innovative water management mechanisms and improved ventilation functions to facilitate ventilation and drainage of water and other liquids from the wall cavity. As shown in FIG. 1A , the foam layer 104 may incorporate various drainage channels 112 . The drainage channels are designed to divert water away from the panels so as to prevent water from entering the home, prevent damage to the panels, and prevent the panels from attracting insects.
[0052] FIGS. 3A-3I are schematic illustrations of certain embodiments of the profiled foam layer 104 that is part of the integrated fiber cement foam and insulation panel 100 . In some embodiments, the profiled foam layer 104 has a first face 131 that is configured to be in direct contact with a fiber cement panel and an opposing face 133 that is set at an angle relative to the first face 131 so as to form an inclined surface relative to the fiber cement layer. The inclined surface facilitates mounting of the panels in a nesting configuration. In some other embodiments, the profiled foam layer 104 can be configured to allow stacking of the integrated fiber cement and foam panels during transit so as to reduce damage otherwise normally sustained by foam materials while in transit. As illustrated in FIGS. 3A-3D , the profiled foam layer 104 can include complementary angled edges to facilitate nesting. In one embodiment, an angle 134 measuring about 45 degrees relative to the vertical axis can be formed on the upper edge and a complementary angle 136 measuring about 135 degrees relative to the vertical axis can be formed on the lower edge. In some embodiments, the vertical axis can be the vertical axis of the integrated fiber cement and foam panel when the integrated fiber cement and foam panel is positioned or assembled on a building structure. In some other embodiments, the angles 134 , 136 can be 0 to 90 degrees, 90 degrees to 180 degrees, 0 to 45 degrees, 45 degrees to 90 degrees, 90 degrees to 135 degrees.
[0053] In the embodiment shown in FIG. 3B , side 138 can have a range between 3.5 inches (8.9 cm) to 11 inches (27.9 cm), side 139 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 140 can have a range between 0.0625 inch to 0.375 inch (0.159 cm to 0.95 cm), side 141 can have a range between 0.25 inch to 1.25 inches (0.635 cm to 3.175 cm), side 142 can have a range between 0.0625 inch to 0.375 inch (0.159 cm to 0.95 cm), side 143 can have a range between 0.0625 inch to 0.375 inch (0.159 cm to 0.375 cm), and side 144 can have a range between 0.75 inch to 1.75 inch (1.91 cm to 4.45 cm). Angle 145 can have a range between 30 degrees to 60 degrees, angle 146 can have a range between 30 degrees to 60 degrees, and angle 147 can have a range between 1.5 degrees to 5.0 degrees.
[0054] In the embodiment shown in FIG. 3C , side 148 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 149 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 150 can have a range between 0.0625 inches to 0.375 inches (0.159 cm to 0.95 cm), side 151 can have a range between 0.625 inches to 1.75 inches (1.59 cm to 4.45 cm), and side 152 can have a range between 0.25 inches to 1.25 inches (0.635 cm to 3.175 cm). Angle 153 can have a range between 30° to 60°, angle 154 can have a range between 30° to 60°, and angle 155 can have a range between 1.5° to 5.0°.
[0055] In the embodiment shown in FIG. 3D , side 156 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 167 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 158 can have a range between 0.25 inches to 1.25 inches (0.635 cm to 3.175 cm), and side 159 can have a range between 0.625 inches and 1.75 inches (1.59 cm to 4.45 cm). Angle 160 can have a range between 30° to 60°, angle 161 can have a range between 30° to 60°, and angle 162 can have a range between 1.5° to 5.0°.
[0056] FIGS. 3E-3I depict additional profiles of foam layers that can be part of the integrated fiber cement foam and insulation panel.
[0057] FIGS. 3J-3N depict profiles of foam starter strips that can be placed at the bottom of a wall to start the proper kick out angle for installation of siding going up a wall.
[0058] In the embodiment shown in FIG. 3J , side 163 can have a range between 1.0 inches to 1.5 inches (2.54 cm to 3.81 cm), side 164 can have a range between 0.0625 inches to 1.0 inches (0.16 cm to 2.54 cm), and side 165 can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm). Angle 166 can have a range between 30° to 60° and angle 167 can have a range between 1.5° to 5.0°.
[0059] In the embodiment shown in FIG. 3K , side 168 can have a range between 1.0 inches to 1.5 inches (2.54 cm to 3.81 cm), side 169 can have a range between 0.0625 inches to 1.0 inches, (0.159 cm to 2.54 cm) and side 170 can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm). Angle 171 can have a range between 30° to 60° and angle 172 can have a range between 1.5° to 5.0°.
[0060] In the embodiment shown in FIG. 3L , side 173 can have a range between 1.0 inches to 1.5 inches (0.159 cm to 2.54 cm), side 174 can have a range between 0.0625 inches to 1.0 inches (0.159 cm to 2.54 cm), and side 175 can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm). Angle 176 can have a range between 30° to 60° and angle 177 can have a range between 1.5° to 5.0°.
[0061] In various embodiments, the fiber cement and foam insulation panels disclosed herein are designed with innovative water management mechanisms to facilitate ventilation and drainage of water and other liquids from the wall cavity. With reference to FIGS. 4A-4D , in various embodiments, the drainage channels may take on a variety of patterns including grooves, designs or logos 113 . As depicted in the illustrated embodiments, the drainage channel patterns are formed on the back side of the foam layer 104 . However, it should be appreciated that in various embodiments, the drainage channels 112 and grooves, designs or logos 113 may be formed along any surface of the foam, or in other embodiments, through the thickness of the foam. The drainage channels, can be made by machining or hot wire cutting or a spindle molder with aluminum blades. The channels or features may also be formed using molding techniques such as injection molding. In alternative embodiments, the drainage channels 112 can take the form of an embossed or debossed feature in the form such as an image, symbol, design or logo. In another embodiment, the drainage channels can take the form of chevrons or tread designs. In some embodiments wherein thermoplastic foams, such as polystyrene foams, are used, the drainage channels 112 may be added by machining using a router or grinder or by using a hot wire, water jet cutting or laser cutting means. In the case of thermosetting foams, water channel routing, grinding, or injection molding techniques may be preferred. In yet other embodiments, such as foams made out of expanded polystyrene (EPS), the drainage channels may be incorporated into the mold used to form the foam. In other embodiments, such as foams made out of cut block EPS foam, the porosity of the foam can function as the drainage channels or to improve ventilation. In such embodiments, the foam porosity can be adjusted to allow drainage. As such, the foam according to some embodiments of the present disclosure may not require drainage channels.
[0062] FIG. 5 illustrates an integrated wall assembly 300 according to one embodiment of the present disclosure. The wall assembly 300 can include a sheathing 301 , such as oriented strand board (OSB), and a plurality of prefabricated fiber cement and foam insulation panels 300 a - e mounted to the sheathing 301 . The foam layer 304 on each panel interlocks with the foam layer on adjacent panels such that the fiber cement layers 302 are aligned in a nested configuration. In the embodiment shown in FIG. 5 , water draining channels 312 are formed on the front surface of the foam layer. In some embodiments, the drainage channels 312 can be formed on the back surface of the foam layer 304 , within the interior foam layer, or a combination of the front, back surface and/or interior of the foam layer. In other embodiments, the drainage channels may be formed on the back face of the fiber cement layer 302 . In yet other embodiments, the drainage channels may be formed in both the foam layer and the fiber cement layers. In some implementations, a layer of weather resistant barrier material 313 , such as those marketed under the HardieWrap® brand, can be positioned between the sheathing 301 and the foam layer 304 of the fiber cement and foam insulation panel 300 a - 300 e.
[0063] FIG. 6A illustrates an embodiment of a fiber cement and foam insulation trim corner 400 with an integrated fastening tab 416 . The trim corner 400 with the fastening tab 416 is for use around an outside corner of a building structure. FIG. 6B illustrates an embodiment of a foam insulation panel with an integrated fastening tab for use around an inside corner of a building structure. The fastening tabs 416 are configured for mounting the fiber cement and foam insulation trim corner to the building frame or other support structure without having to attach a fastener through the front face of the fiber cement layer 402 . As such, the fastening tabs 416 can be used so that the fasteners are concealed from view upon installation of the panels. The panels 400 may also be useful in installations where the wall does not include a sheathing to attach the panels. As shown in the illustrated embodiments in FIGS. 6A-6B , in some embodiments, the fastening tabs 416 can have one or more overhanging portions 417 extending outwardly from an edge of the foam layer to fasten to a support structure of a building (e.g., extending from the lateral edges of the foam layer). In one preferred embodiment, the overhanging portions 417 can be between 3-10 inches (7.62 cm-25.4 cm) in length, more preferably approximately 3 inches ( 7 . 62 cm) in length.
[0064] As shown in FIG. 6A and FIG. 6C , in some embodiments, the fastening tabs 416 can be arranged to be disposed between the fiber cement layer 402 and the foam layer 404 . In some embodiments, the fastening tab 416 is generally formed of a strip of metal shaped to follow the contours of the exterior or interior surface of the foam layer 404 .
[0065] With reference to FIGS. 6A-6B , and FIGS. 6D-6F in some embodiments, the fastening tabs 416 can have a one or more recesses or flat tangs or flanges 419 creating a notched or angled profile. The recesses 419 can allow the overhanging portions 417 to be flush with a surface of the foam and/or flush with mating components of the building to fasten to a support structure of the building. Preferably, the recesses 419 are between 0.25″ and 1″ in length. The fastening tabs can be installed in a manner such that at least a portion of each fastening tab is concealed from view when the wall panel 400 is installed on the building. The fastening tabs 416 can include angled or filleted corners 478 with radii between 1/32″ and 1/16″.
[0066] FIGS. 6D-6F illustrate embodiments of fastening tab 416 profiles.
[0067] FIG. 6D illustrates an embodiment of a fastening tab 416 profile for use in a fiber cement and foam insulation board installed around an inside corner. In one implementation, portions 421 a, 421 b of the fastening tabs 416 adjacent the foam layer can be between 3″ to 11.5″ (7.62 cm to 29.21 cm) ( 421 a ) and/or between 4″ to 11.5″ (10.16 cm to 29.21 cm) ( 421 b ), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to 25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″ (0.635 cm) and 1″ (2.54 cm), and the edges 478 can have radii between 1/32″ (0.079 cm) and 1/16″ (0.159 cm), as depicted in FIG. 6D . Such an embodiment can be used for inside corner installations.
[0068] FIG. 6E illustrates an embodiment of a fastening tab 416 profile for use in a fiber cement and foam insulation board installed around an outside corner. In one implementation, portions 421 a, 421 b of the fastening tabs 416 adjacent the foam layer can be between 1.5″ to 10.5″ (3.81 to 26.67 cm) ( 421 a ) and/or between 2″ to 11″ (5.08 cm to 27.94 cm) ( 421 b ), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to 25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″ (0.635 cm) and 1″ (2.54 cm), and the edges 478 can have radii between 1/32″ (0.079 cm) and 1/16″ (0.159 cm), as depicted in FIG. 6E . Such an embodiment can be used for inside corner installations.
[0069] FIG. 6F illustrates another embodiment of a fastening tab 416 profile for use in an integrated fiber cement and foam insulation panel. In one implementation, portions 421 of the fastening tabs 416 adjacent the foam layer can be between 3″ to 10″ (7.62 cm to 25.4 cm), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to 25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″ (0.635 cm) and 1″ (2.54 cm), and the edges 478 can have radii between 1/32″ (0.079 cm) and 1/16″ (0.159 cm) as depicted in FIG. 6F . Such an embodiment can be used for non-corner installations. It should be appreciated that in other embodiments, the length of the portion 421 of the fastening tabs 416 adjacent the foam layer can be sized to any dimensions necessary to match the foam layer length. In one embodiment, the overall thickness of the fastening tab 416 is between 16 to 20 gauge, preferably 18 gauge.
[0070] FIGS. 6G-6I illustrate embodiments of foam profiles for use with fastening tabs in fiber cement and foam insulation panels.
[0071] FIG. 6G illustrates an embodiment of a foam profile for use in an inside corner section of an integrated fiber cement and foam insulation panel with integrated fastening tabs. In such an embodiment, the foam layer 404 can have an “L” shape configuration and can have a side length 479 between 3.5″ to 14″ (8.89 cm to 35.56 cm) and a side length 480 between 3.5″ to 13″ (8.89 cm to 33.02 cm), with thicknesses 481 , 482 between 0.25″ to 1.5″ (0.635 cm to 3.81 cm).
[0072] FIG. 6H illustrates an embodiment of a foam profile for use in an outside corner section of a fiber cement and foam insulation panel with integrated fastening tabs. In such an embodiment, the foam layer 404 can have an “L” shape configuration and can have a side length 483 between 3.5″ to 14″ (8.89 cm to 35.56 cm) and a side length 484 between 1.5″ to 10.5″ (3.81 cm to 26.67 cm) with thicknesses 485 , 486 between 0.25″ to 1.5″ (0.635 cm to 3.81 cm).
[0073] FIG. 6I illustrates an embodiment of a foam profile for use in a fiber cement and foam insulation panel with integrated fastening tabs. In such an embodiment, the foam layer 404 can have a length 488 between 1.5″ to 12″ (3.81 cm to 30.48 cm) with a thickness 487 between 0.25″ to 1.5″ (0.635 cm to 3.81 cm).
[0074] In some embodiments, the fastening tabs 416 can be attached to the panel 400 using one or more connecting elements. The connecting elements can include nails, staples, pins, rivets, screws, anchors, clasps, bolts, bucklers, clips, snaps, and other types of fasteners as in known to those of skill in the art. In yet further embodiments, the foam layer can include one or more recess features (not illustrated) in which the tabs are placed such that the tabs do not extend beyond the back wall of the foam layer. In some embodiments, the recess feature in the foam layer may be formed using the same techniques as for forming drainage channels and/or interlocking features in a separate step. In addition, the recess features may be formed out of a mold specifically designed to yield a foam layer having drainage channels, interlocking features, and recess features. In further embodiments, the fastening tabs 416 can attach the panel 400 to the support structure using at least one connecting element described above.
[0075] FIG. 7 illustrates yet another embodiment of the present disclosure showing a prefabricated panel 600 including a fiber cement layer 602 , a backing 622 and a foam layer 604 disposed therebetween connecting the backing 622 to the fiber cement layer 602 . In some embodiments, the backing 622 preferably made out of OSB and can be laminated to the foam layer 604 . It will be appreciated that the foam layer 604 and/or the fiber cement layer 602 can incorporate various interlocking features to facilitate alignment and sealing of the adjacent layers and drainage channels to facilitate water management.
[0076] FIG. 8 illustrates yet another embodiment of the present disclosure showing an integrated fiber cement and foam insulation panel 700 incorporating a discontinuous layer 724 in the foam layer 704 a, 704 b. The discontinuous layer 724 can provide enhanced acoustic dampening properties, reducing unwanted outside noise and vibrations from entering the building and also reducing interior noises from leaving the building. Such an embodiment can act to give further privacy for occupants inside of the building. In some implementations, the discontinuous layer 724 can be made of a viscoelastic material. Preferably, the discontinuous layer 724 is attached to framing members of the wall to dampen vibrations from the exterior of the building from being transmitted to the interior of the building.
[0077] FIG. 9 illustrates a further embodiment of the present disclosure showing a prefabricated fiber cement and foam insulation panel 800 designed for high shear applications. The panel 800 includes a fiber cement layer 802 , a foam layer 804 , and a mesh 826 disposed therebetween for reinforcement. In some embodiments, the panel 800 can provide sufficient shear strength to eliminate or substantially reduce the need for structural sheathing, such as OSB. In other embodiments, the foam layers may include facing materials such as meshes or non woven sheets to enhance the shear strength of the fiber cement and foam insulation panel 800 . In yet further embodiments, the panel 800 may also incorporate mesh or reinforcing fibers within the body of the foam layer. The panel may include vapor permeable facing materials adjacent the foam layer, including foils or films to reflect heat or heat loss due to air permeability.
[0078] FIGS. 10A-10C illustrate further embodiments of the present disclosure showing two fiber cement and foam insulation panels 900 a, 900 b joined together with a butt joint 926 . The panels include fiber cement layers 902 a, 902 b and profiled foam layers 904 a, 904 b. In this embodiment, the profiled foam layers 904 a, 904 b extend only a partial length of each respective fiber cement layer 902 a, 902 b, thus leaving a space on both ends of each fiber cement layer configured to receive an insert 928 . The insert 928 can be placed at the joint 926 to mitigate water penetration into the wall and allow condensation to drip over the face of the plank below the lap siding. The insert 928 can include a foam layer 932 laminated with a piece of house wrap or flashing 930 . The flashing 930 may be used as a water resistive barrier. The flashing 930 can be constructed to be longer than the foam layer 932 such that when joined together to form the insert 928 , the flashing includes an overhang 931 which extends beyond a length of the foam layer 93 (best depicted in FIG. 10B ). In one preferred embodiment, the foam layer 932 of the insert 928 can have a nominal width of 6 inches (15.24 cm) and the flashing 930 can have an overhang 931 of approximately 1.16 inches (2.95 cm). In one embodiment, the insert 928 can include a foam layer 932 having a profile that matches the profile of the mating foam layers 904 a, 904 b of the adjacent panels 900 a, 900 b.
[0079] FIGS. 11A and 11B are schematic illustrations of certain connection mechanism that can be used to join adjacent integrated fiber cement and foam panels 1100 a , 1100 b at a butt joint. In one embodiment, a recess 1101 a, 1101 b is formed along the lateral edges of each panel 1100 a, 1100 b. Each recess is configured to receive a portion of an insert 1102 a, 1102 b designed to join the two panels. The insert 1102 a, 1102 b can assume a variety of different shapes and configurations. In one embodiment, the insert 1102 b is an elongate planar member that can be made out of foam, fiber cement, or other material. The insert 1102 b can be inserted between the two panels and slidingly engage with the recesses formed on the edge of each panel. In some embodiments, the insert 1102 a is keyed to mate with corresponding patterns in the recess 1101 a, 1101 b so as to interlock and further secure the two panels.
[0080] FIG. 12 depicts a flow diagram of installation 1000 of fiber cement and foam insulation panels on a wall according to one embodiment. The method includes cutting and trimming 1002 starter strips. As described above, starter strips can be used to ensure a consistent plank angle for the integrated panels. The method next includes installing 1004 the starter strips at the base of the wall. Starter strips may be fastened to the wall using one or more fasteners described above (e.g. siding nails from 6d to 16d). The starter strips may be fastened to a sheathing (when present) or directly to the studs of the building. The method further includes cutting and trimming 1006 the integrated fiber cement and foam insulation panels. The method next includes installing 1008 the fiber cement and foam insulation panels to the wall. In some embodiments, as described above, the panels can include interlocking features for nesting or crotchedly connecting the panels. In some embodiments, as described with reference to FIGS. 6A-6I , panels incorporating fastening tabs can be used. As described above, fastening tabs may be useful in installations where the wall does not include a sheathing to attach the panels to conceal the fasteners. The method optionally includes installing 1010 inserts at the butt joints between adjacent panels, as described with reference to FIGS. 10A-10C and 11A-11B . As described above, the inserts can include a flashing to act as a water resistive barrier.
[0081] FIG. 13 illustrates yet another embodiment of an integrated fiber cement and foam insulation panel 1300 . The panel 1300 generally includes two fiber cement layers 1302 a , 1302 b and a profiled foam layer 1304 disposed therebetween. The fiber cement layers 1302 a , 1302 b can be attached to opposing faces of the foam layer 1304 via a suitable adhesive. As shown in FIG. 13 , the thickness of the foam layer 1304 can be substantially greater than the thickness of the fiber cement layers 1302 . In some embodiments, the foam layer 1304 includes profiled edges configured to mate and interlock with corresponding edges on adjacent panels, thereby forming a continuous surface. The panel 1300 is preferably pre-fabricated so that it can be used readily at the construction site.
[0082] The advantages of the prefabricated integrated fiber cement and foam composite insulation panel include a higher R-value fiber cement building material that is easily installed, provides a building envelope that resists penetration from the elements yet can breath and drain water away from the interior, and a faster installation time when a builder decides to use foam insulation on the structure.
[0083] To avoid over-compression and distortion when attaching the integrated fiber cement and foam panels to a wall, the foam preferably has a minimum compressive strength of about 15 psi as determined by ASTM D 6817. In some embodiments, to ensure that the integrated fiber cement and foam system has a minimum wind load resistance of 3.0 kPa ultimate load when tested using an ASTM E 330 vacuum testing apparatus, the minimum compressive strength of the foam is preferably about 15 psi as determined by ASTM 6817. In one embodiment, an integrated fiber cement and foam insulation cladding panel, formed in accordance with the designs disclosed herein, has a wind load of greater than 83 psf, preferably greater than or equal to 94 psf.
[0084] The foregoing description of the preferred embodiments of the present disclosure has shown, described and pointed out the fundamental novel features of the inventions. The various devices, methods, procedures, and techniques described above provide a number of ways to carry out the described embodiments and arrangements. Of course, it is to be understood that not necessarily all features, objectives or advantages described are required and/or achieved in accordance with any particular embodiment described herein. Also, although the invention has been disclosed in the context of certain embodiments, arrangements and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments, combinations, sub-combinations and/or uses and obvious modifications and equivalents thereof. Accordingly, the invention is not intended to be limited by the specific disclosures of the embodiments herein.
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An integrated fiber cement and foam cladding system is provided that incorporates foam or similar light weight material to improve the insulation capacity of the cladding system. The system includes at least a fiber cement layer and a foam layer disposed on the backside of the fiber cement layer. The system improves the R-value of the building, a measure of the building's resistance to transferring heat or thermal energy.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND AND SUMMARY OF THE INVENTION
The invention is directed to a template system for marking rafters for roof construction. Determining the cuts for rafters can be a complicated and time-consuming chore. One problem, for some people, is that it is difficult to visualize a roof pitch and the correct angles for the cuts on the rafters, making layout of the cuts difficult, even after the appropriate angles are determined.
Templates for rafters have been proposed, but tend to be complicated to use, for some cuts requiring several steps of manipulating the template for marking a single cut line. Another problem in the art is including a wide range of roof pitches on a single template, which limits the number of different types of cuts that can be accommodated on the template.
The present invention provides a template system for roof rafters that eliminates problems in the art with a template that is simple to understand and use. The system includes a plurality of templates, each having cut guides corresponding to a single roof pitch.
Each template includes a base portion with a hinged flange. Preferably, the template is formed from a translucent, plastic material with the hinge formed in the plastic material as a living hinge. The flange is pivotable in both a front and a rear direction relative to the base, and can thus be positioned perpendicular to the base from either front or rear. The user can conveniently position the template at either end of a rafter and on either side, simplifying the marking process. Further, the adaptability of the template allows the user to position the template in a way in which visualizing the cut on the rafter is easiest, which both facilitates using the template and reduces the potential for error.
The template is placed on a rafter stock with the flange on the upper surface and the base on the side surface of the rafter. The outer edges of the template define various cuts for marking on the rafter stock, including one edge for a common rafter plumb cut and a second edge for hip and valley rafter plumb and heel cuts.
The template also includes indications for marking the measuring lines of a 2×4 rafter and a 2×6 rafter. A bottom edge of the template includes a "birds mouth" notch for marking the seat and heel cuts for a 2×6 common rafter. A triangular hole in the base has edges defining a seat cut and a heel cut for a common 2×4 rafter.
An indicator line adjacent the notch at the bottom edge defines a seat cut for a 2×6 hip or valley rafter. For ease of marking, a small notch may be provided at the end of the indicator line, or more preferably, a slot may be provided coinciding with the indicator line. Alternatively, the indicator line may be formed as a hinge providing a pivotably wing alongside the notch. The wing includes one edge defining the seat cut edge of the notch, and is positionable parallel with the base for marking the 2×6 common rafter seat cut. The wing is pivotable to perpendicular to the base, so that the hinge line can be used for marking the seat cut for a 2×6 hip or valley rafter.
A second indicator line is provided adjacent the hole for a seat cut for a 2×4 hip or valley rafter. A slot may also be provided coincident with the second indicator line for ease of marking. The second indicator line may also be formed as a hinge to provide a pivotable flap adjacent to the triangular hole, with one edge of the flap forming the edge defining the seat cut for a common 2×4 rafter, and the hinge line defining the seat cut for a 2×4 hip or valley rafter.
A template according to the invention includes a second hinge in the base portion to allow folding the template in half for convenient storage in a tool pouch.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the following detailed description in conjunction with the appended drawings, in which:
FIG. 1 is a top view of a template in accordance with the invention; and
FIG. 2 is a perspective view of the template shown in a marking position on a rafter (shown in ghosted line).
DETAILED DESCRIPTION
FIG. 1 illustrates a template in accordance with the invention shown in a planar configuration. The template is preferably formed from a sheet of translucent or transparent plastic material, which allows viewing the underlying rafter for accuracy in marking. The template includes a base 20 and a flange 22 attached to the base by a longitudinally extending hinge 24. The hinge 24 is conveniently formed as a living hinge by deformation of the plastic sheet material. The hinge 24 forms a longitudinal reference as it is always positioned on a longitudinally extending edge of a rafter.
The hinge 24 allows the flange 22 to be pivoted from the planar position shown in FIG. 1 to a position perpendicular to the base 20, as shown in FIG. 2. The flange 22 can be positioned on a top or bottom surface of a rafter, with the base 20 positioned on the side surface. In FIG. 2, the flange 22 is shown bent toward a rear surface 28 of the template and positioned on the top 12 of the rafter 10. The hinge 24 also advantageously allows the flange 22 to be bent in the opposite direction, that is toward a front surface 26 of the template. The hinge 24 conveniently allows the template to be adapted to the relative positions the user and the rafter are in, that is, the user can be standing at either end of a rafter, and on either side, and can fold and position the template on the rafter in the most convenient position for best seeing where the cut is to be made.
The template includes a plurality of edges oriented relative to the hinge 24 to correspond with various cuts for common, hip, valley, and jack rafters. The various rafters discussed below are understood to have the meanings as generally used in the building art. According to the invention, a template is formed for a single roof pitch for simplicity and ease in using a template. The system according to the invention includes a plurality of templates, each corresponding to a common roof pitch. In addition, the base 20 has a width from the hinge 24 to a bottom edge 30 that can accommodate a 2×4 or a 2×6 rafter. The template can be used for a 2×8 rafter by extending the marking lines for the 2×6 size.
A first end edge 32 of the base 20 is oriented to correspond to a plumb cut made on both ends of a common rafter. A first edge 23 of the flange 22 is oriented for marking the top of the common rafter.
A notch, defined by first notch edge 36 and second notch edge 38, is formed in the bottom edge 30 and provides guides for a seat cut (first edge 36) and heel cut (second edge 38) for a 2×6 common rafter.
The base 20 includes a triangular hole, defined by first edge 40, second edge 42, and bottom edge 44, to provide cutting guides for a seat cut (first edge 40) and heel cut (second edge 42) for a 2×4 rafter. The bottom edge 44 corresponds to a length measuring line for a 2×6 rafter, and a line 46 at the top of the triangular hole indicates the length measuring line for a 2×4 rafter.
A second end edge 50, opposite the first end edge 32, is oriented for the plumb cut and heel cut for hip and valley rafters. Hip and valley rafters are given a plumb cut at both ends, as are common rafters. In addition, however, the top end faces of hip and valley rafters must also be cut at 45° to mate with the ridge board. The valley rafter is typically cut with a bevel to mate with both the main ridge board and a gable or dormer ridge board. A second edge 25 of the flange 22 is at 45° to the longitudinal hinge 24 for marking the face cuts of the ends of the hip and valley rafters.
The template can easily provide the marks for a valley bevel cut without measuring the midpoint of the rafter. The flange 22 is folded in one direction and placed on a valley rafter. Marks are made on the first side (using edge 50) and the top side (using edge 25). The flange is then folded in the opposite direction and positioned on the opposite side of the rafter, and the side mark and an additional top mark are made. The intersection of the top marks shows the leading edge of the bevel.
An indicator line 60 adjacent to the first edge 36 of the notch indicates the seat cut for a 2×6 hip or valley rafter. A mark can be made using the ends of the indicator 60 at the bottom edge and the intersection of the notch edges 36 and 38. Alternatively, a slot can be provided along the indicator line 60 for marking through the template. According to another embodiment, the indicator line 60 can be formed a hinge defining a wing 62 that can be positioned planar for marking the common rafter seat cut with edge 36, or bent upward to allow use of the hinge line 60 for marking the seat cut for the 2×6 hip or valley rafter.
Similarly, a second indicator line 64 is provided adjacent to the first edge 40 of the triangular hole for marking the seat cut for a 2×4 hip or valley rafter. A slot can also be provided along the second indicator line 64 for guiding a marking pencil. Alternatively, the second indicator line 64 can also be formed as a hinge, with an additional cut 66 made from the end of the second indicator line 64 to the bottom edge 44 of the triangular hole, to define a flap 68. The flap 68 can be positioned planar with the base 20 for using the first hole edge 40, or bent up for using the hinge line 64, for marking the desired cut, as explained above.
A second hinge can be formed in the base, conveniently along the measuring line 46, to allow the template to be folded in half for storage in a tool pouch.
The template according to the invention provides a tool that is simple to use, in part because the shape of the template aids in visualizing the cuts to be made. Roof pitch is the ratio of the rise of the roof to the horizontal span, and is typically expressed as inches per one foot of span. This can be difficult to visualize, but by positioning the template with the common rafter plumb edge, first edge 32 vertically, the flange 22 will show the roof pitch. A user with a set of template according to the invention can view a variety of templates to find a desirable roof pitch.
In addition, the template can be used for setting the angle of a miter saw or radial arm saw without the need convert pitch into degrees. As saws do not usually include pitch scales, this function eliminates a step in cutting a rafter with miter or radial arm saws.
The invention has been described in terms of preferred features and embodiments, however, the invention is not intended to be limited to the literal embodiments described herein. Those skilled in the art will understand that changes, variations, and substitutions can be made without departing from the spirit and scope of the following claims.
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A template system for rafters for roof construction includes a plurality of individual templates, each dedicated to a single roof pitch. Each template is formed from a plastic material to have a base and a flange attached to the base by a living hinge formed in the plastic material. The flange allows convenience in positioning the template on a rafter stock in a position best suited to the user's own position. The edges of the template are oriented relative to the hinge to provide marking guides for various cuts for common, valley, hip, and jack rafters.
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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 roofing system for a roof deck which is not steeply inclined, such as is found in commercial, as opposed to residential roofs. More specifically, the fastener-free roofing system of the present invention is directed to the use of a curable adhesive composition which will simply and safely secure roofing insulation to a roof deck without the need for mechanical fasteners.
BACKGROUND OF THE INVENTION
Flat Roofs in General
In the roofing art, and in this specification, "flat roof" refers to a roof having a slope of less than about 25° relative to a horizontal plane. Many such roofs are substantially flat with a slight incline to allow water to run off. Some flat roofs comprise numerous sloping sections which create peaks and valleys, and a water drain is generally located at the bottom of each valley to facilitate water drainage. Flat roofs traditionally comprise three basic components (from top to bottom): (1) a waterproof membrane (top); (2) thermal insulation (middle); and (3) the structural deck (bottom).
The waterproof membrane typically comprises two or more plies of a felt membrane in combination with bitumen (generally coal tar pitch or asphalt). The felt stabilizes and strengthens the bitumen, and distributes contractive tensile stress when the bitumen is cold and glasslike. Alternatively, the membrane can be a polymeric sheet or a series of polymeric sheets adhered together to form seams where they are joined.
The membrane is typically used in combination with metallic and/or nonmetallic flashings which guard against leakage through portions of the membrane which are pierced or terminated, such as at gravel stops, walls, curbs, expansion joints, vents and drains.
Mineral aggregate (normally gravel, crushed rock, or slag) is often spread atop the membrane to hold it down on the roof deck and protect the membrane from wind, rain, solar radiation, and fire. Such aggregate may be unnecessary on smooth-surfaced asphalt roofs having glass-fiber felts.
Conventional membranes cannot resist large movements of the deck, or insulation covering it, and will be punctured by heads of fasteners which protrude above the insulation due to such movements. Membrane puncture (due to fastener heads, foot traffic or the like) and undue membrane shifting or movement (due to foot traffic, wind forces or the like) are primary causes for leaks in flat roofs which have been properly installed.
Roofing Insulation
The second basic component of a flat roof is the roofing insulation installed just beneath the membrane. Insulation may be provided by several materials, such as rigid insulation prefabricated into boards, or poured insulating concrete fills (sometimes topped with another more efficient rigid board insulation).
The roofing insulation preferably has adequate shear strength to distribute tensile stresses in the membrane to prevent it splitting. The insulation should also have adequate compressive strength to withstand traffic, and the impact of hailstones. Furthermore, the insulation should have sufficient adhesive and cohesive strength to resist delamination due to wind uplift forces and the like. Finally, the dimensional stability should be sufficient to withstand thermal and moisture cycles.
The Roof Deck
The final component of a flat roof is the structural deck which lies below the insulation. The roof deck is generally a metal, concrete, gypsum or wood substrate which is generally integral with the building's basic structure upon which substrate the rest of the roof is built up.
Uplift Forces Due to Winds
Forces generated by wind currents are generally much greater at the top of most commercial buildings than they are at ground level, and the taller the building, generally the greater the wind forces upon a roof. Wind uplift pressure can damage a roof or even blow it off, unless it is properly anchored to the building.
Leaks Due to Improper Anchoring of Insulation
However, wind is not the only reason to firmly fasten down a roof. Unanchored insulation boards increase the risk of membrane splitting. Internal stresses produced by thermal and moisture changes in the membrane on a flat roof has a tendency to exert a ratcheting action on poorly anchored insulation. Flexible membrane expands and contracts during thermal cycles, thereby producing a cumulative ratcheting action toward the center of the roof. Over time, this ratcheting action can pull the insulation from the roof's edges, destroying the effectiveness of the edge flashing and of the roof.
Mechanical fasteners can be used to secure the insulation to the roof deck. However, corrosion can be a problem. Although such fasteners can be coated with specialized anti-corrosive metals or polymers, such coatings can be partially removed as the fastener is ratcheted in place due to roof movement. Even a small breach in the coating can be sufficient to allow corrosion to infiltrate the entire fastener. Non-metal fasteners are perhaps possible, but would be very expensive due to the physical properties needed for such a fastener system. Even where the fastener does not corrode, fasteners will generally expand and contract with temperature changes, and holes through which fasteners are driven are therefore prone to enlarge over time, causing the fastener's holding ability to fail, or the fastener to back out through the membrane. Fasteners are also a problem because they provide the opportunity for moisture to penetrate into the insulation.
Any leak in the membrane will generally cause water to flow to a fastener head, since the fasteners generally make indentations in the insulation they are anchoring (indeed, a leak in the membrane will often be near the head of a fastener because the head has punctured the membrane due to a fastener backing out, for example due to foot traffic).
The use of fasteners is also labor intensive and subject to errors of workmen installing insulation on the deck. Eliminating fasteners for the insulation eliminates the possibility they might protrude through the insulation.
SUMMARY OF THE INVENTION
Many failed attempts substantially to satisfy the need for a fastener-free roofing system are of record in the art. The inventors herein have discovered that a surprisingly reliable roofing system may be formulated with an adhesive having desirable penetration and adhesion characteristics and desirably quick curing times.
It is therefore an object of the present invention to provide a fastener-free roofing system which is inexpensive, easy to install and less prone to failure than conventional flat roof systems. Other objects and features of the present invention will become apparent to one of ordinary skill in the art, upon further reading of this specification and subsequent claims.
The preferred roofing system of the present invention can be used with virtually any building having a roof deck which is not steeply inclined. The roofing system comprises a dispersion of a polyol and asphalt, or of a polyisocyanate prepolymer and asphalt as the adhesive which upon curing, secures a roofing panel (preferably of insulation) to a roof deck. Optionally, a vapor barrier can be placed between the roof deck and roofing insulation, and in this embodiment, the roofing adhesive is placed on each side of the vapor barrier.
The adhesive of the present invention can also be used between insulation panels, between an insulation panel and the roofing membrane and also between membrane layers or sections. The adhesive of the present invention is relatively inexpensive, reliable and easy to use.
The roof deck can be metal, wood, concrete, gypsum, or the like. The roofing insulation is preferably a rigid board made from either organic or inorganic materials.
Other curing systems may include epoxy, acrylate, cyanoacrylates, silicone, and silane-hydration-condensation curing systems. The curing system can be a "one-part" or a "two-part" system. The most preferred curing systems are those which cure in about an hour. However, ordinary skill and experimentation might be required to adjust the rate of cure for any particular adhesive system used in an alternative embodiment of the present invention.
The adhesive of the present invention is preferably substantially solvent-free, readily curable at typical ambient temperatures and preferably comprises a one-part dispersion of a polyisocyanate prepolymer and asphalt, or a two-part dispersion of a polyol and asphalt to which an isocyanate is added prior to applying a mixture of the two parts. Either dispersion optionally contains a filler. The preferred curing system is a one-part, isocyanate end-capped polyurethane prepolymer. A critical aspect of the present invention is that the adhesive has wetting and interdiffusion capability and quick cure time.
The most preferred adhesive is a dispersion wherein asphalt which is liquid or semi-liquid at room temperature is suspended within a liquid prepolymer which is substantially solvent-free yet has substantial surface wetting capability. As a result, the liquid prepolymer can substantially wet the surface of the deck and also the surface of the insulation. The bitumen or asphalt particles suspended within the prepolymer droplets will generally not interfere with curing. Furthermore, bitumen and asphalt have some penetration and adhesion properties which might be advantageous. Such surface wetting is possible by applying the prepolymer without a substantial amount of asphalt or solvent carrier; however, such a system is not only uneconomical but also difficult to work with.
The filler referred to above may be calcium carbonate, carbon black, clay, diatomaceous earth, or other commonly used fillers. Preferably such fillers are vigorously mixed into the prepolymer and most preferably suspended within prepolymer droplets. Ordinary skill and experimentation may be necessary to formulate an adhesive containing a filler which is not suspended in the prepolymer. A compatibilizing agent is necessary to obtain the dispersion of asphalt in prepolymer or polyol.
Long cure times are generally disadvantageous, because the roof deck can shift due to wind forces or the like and deck may flex from traffic causing non-contact. Non-solvent adhesive systems of the present invention generally remain tacky and are capable of accommodating shifting, but will then quickly cure. Therefore deck shifts and irregularity are generally less of a problem in obtaining adequate adhesion. For porous insulation, such as fiber insulation, the adhesive must penetrate and anchor itself into the insulation fiber.
The adhesive's filler and/or solvent must not substantially separate from the curing component as the insulation adhesive penetrates into the porous substrate. As the adhesive component cures, the polymer matrix should not be unduly interrupted by filler agglomerations or the like.
The roofing adhesive is preferably temperature insensitive, particularly in the temperature range from about -40° F. (-40° C.) to about 160° F. (70° C.). The optimal coverage rate of the roofing adhesive is preferably about 0.5 to about 2 gals/100 ft 2 (gallons per hundred square feet), more preferably, 0.7 to about 1.5 gals/100 ft 2 .
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a perspective view, with portions cut away, schematically illustrating a roof assembly constructed in accordance with the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The preferred roofing system of the present invention is shown generally at 8 in FIG. 1. Virtually any building having a roof deck (such as the metal deck shown at 10) can embody the present invention. The preferred roofing system comprises the adhesive 12 which secures the roofing insulation to the roof deck. Optionally, a vapor barrier 14 can be placed between the roof deck 10 and roofing insulation 18, and in this embodiment, the roofing adhesive 12 and 12' is placed on each side of the vapor barrier 14. A roofing membrane 20 is adhered to the roofing insulation by conventional means or with the insulation adhesive 12. The insulation adhesive can also be used to adhere insulation panels to one another. Aggregate 22 can be placed upon the membrane as an added protective layer. Finally, flashing members 24, and 26 are used to waterproof the edges of the building.
The Roof Deck
The roof deck 10 is integral with the primary support structure of the building and able to resist gravity loads, lateral loading from wind and seismic forces. Deck 10 is preferably about 18-24 gauge, cold rolled, galvanized steel having ribs 11 which are spaced apart at regular intervals such as about 6 inches on center and preferably define a depth of a few inches or so. Conventional prefabricated decks can also be used. Alternatively, the deck can be wood, gypsum or concrete. The wood sheathing can be sawed lumber or plywood.
If the deck is concrete, it can be lightweight or structural concrete and can be cast in place or precast. A cast in place structural deck is preferably continuous, except where interrupted by an expansion joint or another building component. Gypsum can also be used in the practice of the present invention. A gypsum deck is preferably poured on gypsum formboards spanning flanges of closely spaced steel bulb tees. Such cast in place decks generally present large seamless expanses of roof surface, except where expansion joints are used to impede cracks from thermal contraction or drying shrinkage. The roof deck can also comprise mineralized wood fiber comprising long wood fibers bonded with a mineral or resinous binder and formed under a combination of heat and pressure.
Preferably, the structural framing and deck are sloped to thereby provide an inclined roofing surface. The slope is preferably at least about 1/4th of an inch per foot. Such an incline is generally advantageous, since it will generally facilitate water run off and drainage. Although the present invention will generally work, at least to some degree, with roofs which pond water, such a roofing design is not preferred. Tapered insulation may be used to create a slope.
The insulation 18 of the present invention is preferably a rigid board insulation, either organic or inorganic. The organic insulation includes the various vegetable-fiber boards and foamed plastics. Inorganic insulation includes glass fiber, perlite, and wood fiber board.
The board insulation can be cellular or fibrous. Cellular insulation includes foamed glass and foamed plastics, such as polystyrenes, polyurethanes and polyisocyanates.
Fibrous insulation includes various fiberboards, which can be made of wood, cane, or vegetable fibers. The materials can be impregnated or coated with asphaltic materials to make them more moisture resistant. Fibrous glass insulation consists of nonabsorbent fibers formed into boards with resinous binders and can be surfaced with an organic material, such as paper.
Perlite board contains both inorganic (expanded siliceous volcanic glass) and organic (wood fibers) materials bonded with asphaltic binders.
Composite boards comprise a cellular plastic insulation on top and perlite, fiberglass, or fiberboard laminated on the bottom.
The cohesive strength within the insulation must be at least equal to the required wind uplift resistance designed for the roof system to prevent the insulation from breaking in high winds.
Adhering Insulation To The Roof Deck
To secure the roofing insulation to the roof deck, an appropriate adhesive is necessary. The problem with many decks, particularly steel decks, is that they tend to deflect due to wind, surface traffic or the like. The adhesive 12 used in the present invention preferably has sufficient elasticity to withstand conventional deflections, even by a steel deck, without diminishing the bond strength between the deck and insulation. The adhesive 12 is preferably capable of substantially maintaining adhesive integrity even after normal steel deck deflection, and the adhesive preferably has sufficient elasticity and adhesiveness to diminish dishing or differential deflection due to wind, foot traffic or the like.
Furthermore, the adhesive 12 quickly obtains bond strength. The adhesive preferably provides sufficient adhesion between a roof deck and insulation to withstand about 90 pounds per square foot uplift. Bonding sufficient to withstand 90 pounds per square foot uplift should be obtained within about 24 hours, more preferably 5 hours. In just two hours under favorable conditions (40-80% relative humidity, 18°-23° C.).
Upon full cure, preferably within about 24 hours, the adhesive is preferably able to resist 100 pounds per square foot and more preferably 115 pounds per square foot or more.
The curing system can be one-part or more than one part. The most preferred curing systems are those which gel in about an hour. Where curing substantially occurs within 5 minutes or less, often there is insufficient time for the workers to apply the insulation upon the applied adhesive layer, and if so, the adhesive will cure without adequate bonding to the insulation substrate. However, where substantial curing occurs only after more than about 24 hours, deflections in the roof deck, particularly in a steel roof deck, will often tear the insulation away from the deck prior to full adhesive curing, substantially increasing the possibility of adhesive failure or non-contact and non-penetration into the insulation. Ordinary skill and experimentation might be required to adjust the rate of cure for any particular adhesive system used in an alternative embodiment of the present invention.
The adhesive 12 is preferably substantially solvent-free, readily curable at typical ambient temperatures and relative humidity. The preferred curing system is a one-part, isocyanate based moisture curing system. Other curing systems are also possible, such as two part isocyanate or urethane systems, one or two part epoxide systems, room temperature curable polysulfide systems, silicone, and the like, provided the curing system is capable of providing 90 pounds per square foot uplift resistance in less than about 24 hours. Ordinary skill and experimentation may be necessary in optimizing any alternative curing system used in an alternative embodiment of the present invention.
The most preferred adhesive is substantially solvent-free and has substantial surface wetting capability.
The most preferred method of adhesion is to have an inverse dispersion wherein asphalt, and optionally a filler, is suspended within an organophilic liquid prepolymer. As a result, the liquid prepolymer can substantially wet the surface of the metal.
The most preferred filler is asphalt or bitumen, particularly asphalts or bitumens which are liquid or semi-liquid at room temperature. The bitumen or asphalt particles suspended within the prepolymer droplets will generally not interfere with curing. Furthermore, bitumen and asphalt have some penetration and adhesion properties which might be advantageous. A compatibilizing agent is necessary to obtain an inverse dispersion.
Other fillers might also be used, such as calcium carbonate, clay, diatomaceous earth and the like. Preferably such fillers are vigorously mixed into the prepolymer and most preferably suspended within the prepolymer.
Where dispersion of the filler is not obtained, then the filler can interfere with the prepolymer wetting onto the surface and subsequent cure. Ordinary skill and experimentation therefore may be necessary in formulating any adhesive having a filler which is suspended in the prepolymer.
As mentioned above, solvents are less preferred. Long cure times are generally disadvantageous, because the roof deck can shift due to wind forces or the like and substantially diminish potential adhesion. The non-solvent system of this invention generally remains tacky and capable of accommodating shifting and will then quickly cure.
Adhesion is not only important with respect to the surface coating on the metal deck, it is also important in wetting the surface of the insulation. For porous insulation, such as fiber insulation, or for a porous roof deck, such as concrete or wood, the organophilic adhesive must penetrate and anchor itself into the porous substrate. The amount of penetration to anchor the adhesive into the insulation (and porous roof deck, if used) may have to be determined by routine experimentation.
The adhesive's filler and/or solvent should not substantially separate from the curing component as the insulation adhesive penetrates into the porous substrate. As the adhesive component cures, the polymer matrix should not be unduly interrupted by filler agglomerations or the like.
Before the adhesive can be applied to the roof deck, the surface should be chemically or mechanically cleaned using conventional methods. Also a conventional primer can be used.
The Most Preferred Insulation Adhesive
The preferred insulation adhesive of the present invention comprises a base material (asphalt) component, a liquid prepolymer ("curable") component, and a non-volatile compatibilizer. The base material component is used primarily due to its low cost, although such components may also provide advantageous properties, such as good wetting, reinforcement value and/or waterproof and weather resistance properties. The prepolymer component is primarily present to polymerize within the base material subsequent to application, thereby providing a polymer network within the base material which provides strength and cohesion (the polymer network preferably contains urethane groups or the like which also provide desirable elastomeric properties and chemical bonding to surfaces). The compatibilizer is used to promote intermixing of the prepolymer and the base material and maintain a stable suspension.
The Adhesive's Base Material Component
The base material component can be any substantially non-volatile organic material, such as bitumen, asphalt, tar, substantially non-volatile petroleum based materials, and the like. The asphalt or bitumen component is most preferred and can be any commercially available bitumen material common to the industry. Preferably, the bitumen is substantially free of water and is substantially free of heterocyclic compounds or compounds which have reactive sites which will react with isocyanates.
It has also been found that base materials with low softening points, such as less than about 200° F. and preferably about 120° F. or less, generally work better in the present invention than base material with higher softening points. The lower softening points generally provide easier intermixing with the prepolymer when using the compatibilizer in this invention than base materials with higher softening points.
A plasticizer or other non-reactive diluent is preferably added to the base material to further soften the base material, making it easier to intermix with the prepolymer component.
The base material component can sometimes contain reactive sites which will react with the prepolymer component, such as: thio (--SH) or amino (--NH 2 ) functional groups and the like. Such reactive sites can be detrimental to the preferred embodiment of the present invention, particularly in a one component version of the present invention (one and two component systems are discussed below in the section entitled "Curing").
Therefore to prevent unwanted reaction between these reactive sites and the prepolymer component, the asphalt should first be pretreated with a blocking group, such as a reactive isocyanate (such as a para-toluene-sulfonyl isocyanate or the like), anhydride or carbodiamide. Suitable blocking agents include phthalic anhydride, succinic anhydride, or maleic anhydride. The anhydride will generally also dispose of any water within the base material, and water has been found generally to also be detrimental to the preferred embodiment of the present invention. The preferred amount of blocking group to be added to the asphalt is about 0.0 to about 5 weight percent, although the optimal amount of the blocking group can depend upon the particular end-use of the material and the type of base material, and therefore the blocking agent may have to be determined by ordinary skill and experimentation.
The Adhesive's Prepolymer Component
A second component of the preferred embodiment of the present invention is a liquid curable prepolymer, most preferably a polyisocyanate prepolymer system. This preferred polyisocyanate prepolymer is formed from the reaction of an organic polyisocyanate, preferably a diisocyanate, and an organic polyol. The hydroxyl group of the polyol will react with the isocyanate group of the polyisocyanate, and the resulting addition reaction will link the polyol to the polyisocyanate, creating a urethane at the junction of the previously separate molecules. The basic reaction of the diisocyanate with the hydroxyl is a hydrogen exchange, where the hydrogen of the polyol attaches itself to the carbon of the isocyanate, and conversely, the hydrogen of the isocyanate becomes attached to the hydroxyl oxygen, becoming a urethane.
However, the isocyanate functional groups are preferably in substantial excess, and therefore, the polyol molecules will add to the polyisocyanate molecules until the polyol molecules are substantially or completely depleted, and the resulting (prepolymer) molecules will have unreacted isocyanate functional end groups. The resulting molecules preferably have about 1 to about 10 isocyanate functional groups per molecule.
The prepolymer therefore contains rather large molecules having isocyanate functional end groups. The functional groups will be reaction sites during curing. Curing is discussed below under the section heading "Curing".
Virtually any polyisocyanate can be used, including for example methylene di-para-phenylene isocyanate ("MDI"), toluene diisocyanate, polymethylene-polyphenylene-diisocyanate, isophorone diisocyanate, and mixtures thereof. Triisocyanates and higher polyisocyanates also work well. The most preferred polyisocyanates are aromatic polyisocyanates, such as MDI.
Suitable polyols (for reacting with the polyisocyanate to thereby form the polyisocyanate prepolymer) preferably have urethane or urea forming constituents, such as polyether polyols and less preferably polyester polyols, including diols and triols such as glycerine. However, acrylated polyols do not work well in the present invention. Suitable polyols include ethylene glycol, propylene glycol, diethylene glycol, polybutadiene polyols, polytetrahydrofuran polyols, and polycarbonate polyols, and caprolactone-based polyols. Such polyols can be reacted with an alkylene oxide including ethylene oxide, propylene oxide and butylene oxide for example, to form polyether polyol adducts useful in forming the polyisocyanate prepolymer. The polyol can have a weight average molecular weight ranging from as low as about 250 to about 10,000 or more. Less preferred polyols are polyester polyols, since they have been found to be rather water sensitive and somewhat more temperature sensitive.
The polyisocyanate prepolymer is mixed with one or more non-reactive diluents, preferably plasticizers. These non-reactive diluents advantageously modify (typically decrease) the viscosity of the material. The preferred non-reactive diluents also typically make the end product less temperature sensitive, i.e., more durable when used at temperatures greater than about 150° F. Preferred plasticizers include dibutoxyethyl phthalate ("DBEP"), diisodecyl phthalate ("DIDP"), dibutyl phthalate ("DBP"), butylbenzyl phthalate ("BBP"), dioctyl phthalate ("DOP"), dioctyl sebacate ("DOS"), dioctyl adipate ("DOP") and diethylbutyl sebacate ("DEBS"), dibutoxyethoxyethyl sebacate, dibutoxyethyl sebacate, dibutyl sebacate, dioctyl dodecanedioate, diisooctyl dodecanedioate, dioctyl sebacate, dioctyl sebacate (substituted), triisooctyl trimellitate, trioctyl trimellitate, diisooctyl adipate, dioctyl adipate, dioctyl azelate, long chain alkyl alkylether diester, dialkyl diether glutarate, dibutoxyethoxyethyl glutarate, dibutoxyethyl glutarate, tributyl phosphate, and still bottom phosphate plasticizers. Plasticizers derived from phthalic acid are more preferred, and butylbenzyl phthalate is most preferred. The plasticizer reduces the viscosity of the prepolymer and the asphalt, making them more fluid and therefore somewhat easier to intermix.
The amount of prepolymer used in the present invention should be adequate to provide a coherent, substantially homogeneous mass. Typically this will mean that the prepolymer is present in a weight percentage of about 20-90%, preferably about 50%.
The Adhesive's Compatibilizer Component
The third ingredient of the preferred embodiment of the present invention is a compatibilizer which is defined as any material which will aid in inverting the base material within the liquid prepolymer system, and aid in causing the base material to be dispersed within the liquid prepolymer system. The most preferred compatibilizer is a surfactant-type material, having a substantially non-polar portion and a substantially polar-organic portion. The most preferred compatibilizer comprises a polymer unit, or two such units being either identical or different linked together by an ester, carbon or ether bond, said unit having the following formula:
CH.sub.3 --(C.sub.n H.sub.2n)--R.sub.1
wherein:
n is 4 or more, and
R 1 is COOH, COO - M + , COOR 2 or R 2 , preferably COOR 2 ,
wherein:
M is a metal, preferably zinc, and
R 2 is a substantially saturated organic chain having a backbone substantially comprising carbon-carbon, carbon-oxygen, or carbon-nitrogen linkages, or combinations thereof, wherein the backbone's pendent constituents are either --H or --OH and wherein at least one pendent constituent is --OH. The most preferred compatibilizer is obtained where n is 12 or more, and R 1 is COOR 2 .
The paraffinic portion of the most preferred compatibilizer, CH 3 --(C n H 2n )--, is generally very compatible with the asphalt. In general, the longer the chain, the more compatible the molecule will be with the asphalt, and therefore if the chain is relatively short, more compatibilizer molecules will generally be needed to suspend or invert the base material within the liquid prepolymer.
The semi-polar portion of the most preferred compatibilizer polymer, --R 1 , has been found to be very compatible with polyisocyanate prepolymer, plasticizers, and most additives used in asphalt systems which are substantially non-polar, but have polar-organic portions, such as urethane-type polarity. In the preferred embodiment, the hydroxyl constituent(s) of the semi-polar portion of the polymer is compatible with the urethane linkage of the prepolymer (or any other organic segment having a polarity substantially similar to urethane).
In the preferred embodiment, the hydroxyl group(s) will tend to move to the urethane linkage(s) and will tend to pull the compatibilizer in relative close proximity to the pre-polymer molecule. In addition to the hydroxyl groups, the semi-polar portion of the preferred compatibilizer will also have hydrocarbon groups which are substantially non-polar and which are compatible with the non-polar portion, the asphalt.
As a result, the hydroxyl group will help suspend the urethane or similar type portion of the prepolymer, and the rest of the semi-polar portion of the prepolymer while the paraffinic portion of the compatibilizer will generally help suspend the base component. The compatibilizer lifts the base material and prepolymer into suspension within the prepolymer system, enabling them to be thoroughly and easily intermixed.
Regarding the paraffinic portion of the compatibilizer, the flexibility of the paraffinic chain is important and aids in the compatibilizer's ability to suspend the base component. Therefore any double or triple bonds or the like would be detrimental to the paraffinic portion.
Furthermore, the non-polar character of the paraffinic chain is also very important. Modifications to the paraffinic chain will generally be detrimental to the compatibilizer, if they make the non-polarity less uniform. In general, even slight deviation from a pure paraffinic chain will generally reduce compatibility.
The semi-polar portion of the compatibilizer however can be varied in a number of ways and is more difficult to define. As with the paraffinic portion, chain flexibility is also important. Chain flexibility aids in the compatibilizer's ability to suspend both the prepolymer and the base material.
The preferred prepolymer generally has numerous urethane linkages, as well as urea linkages and other components having some organic polarity. The polarity of the oxygen and nitrogen portions of the polymer backbone generally are very compatible with these portions of the prepolymer. As a result, although the semi-polar portion may be less able to suspend certain (non-polar) portions of the prepolymer due to the presence of oxygen or nitrogen, the increased chain flexibility enhances compatibility and the polarity due to the oxygen and nitrogen aids in suspending other polar portions of the prepolymer.
The ester linkage between the paraffinic portion and semi-polar portion has generally been found to be advantageous, although a precise explanation for this cannot be given. One explanation might be that the ester provides a stiff link between two very flexible portions of the compatibilizer molecule. Since the two portions are intended to suspend two different components, perhaps the ester aids in keeping the two portions separate and interactive with their intended component. Perhaps the relatively high polarity of the ester draws the hydroxy portion (and therefore the prepolymer) into close proximity to the paraffinic portion (and therefore the asphalt), thereby allowing improved intermixing. In any event, ester linkages are preferred within the transition zone between the paraffinic side and semi-polar side but are not preferred as part of either of these two sides. Hence the compatibilizer might be better visualized as having a paraffinic side, a transition portion and semi-polar side.
Fatty acids are relatively inexpensive and relatively plentiful. Numerous fatty acids were researched, and it was found that they generally provide noteworthy compatibility (significantly diminish the need for solvent in mixing base material and prepolymer). Metal salts of these fatty acids were also tried, using metals such as zinc, and the salts also provided noteworthy compatibility.
The fatty acids were then reacted with polyols and compatibility generally increased. Compatibility was best when a diol or polyol, particularly a diol, was used to thereby provide a paraffinic chain attached by an ester linkage to a flexible chain having one or more hydroxyl groups. Compatibility was generally better where only one hydroxyl group existed on the chain, preferably toward the terminal end of the chain.
Fatty acids were reacted with diols, particularly ethylene glycol and propylene glycol. The best compatibility was achieved when reacting stearic acid and propylene glycol to produce propylene glycol monostearate. The polystearate version of this molecule, bis stearyl ester polypropylene diol, also provided excellent compatibility.
Further work was therefore done, and it was found that the paraffinic/semi-polar molecule could be linked with another paraffinic/semi-polar molecule (either the same or different) with an ester, ether or carbon linkage, and the resulting molecule would generally work well as a compatibilizer. However three such molecules linked together generally did not give good compatibility results in the preferred embodiment.
Polyhydric alcohols were researched, particularly triethylene glycol. Triethylene glycol caprate caprylate and triethylene glycol dipelargonate both provided noteworthy compatibility, and it is believed that most alcohols reacted with a fatty acid will provide compatibility, at least to some degree. Polyols with ether groups were reacted with fatty acids and found to also provide exceptional compatibility.
Having read the present disclosure and with knowledge of the numerous compatibilizers described above, the ordinary artisan should easily be able to develop obvious variations of the preferred compatibilizer of this invention. Depending upon the end-use and performance requirements of the end-product, an obvious variation of the preferred embodiment may be more suitable.
For example, the greater the amount of base material to be compatibilized, typically the more important the paraffinic portion of the compatibilizer. Either the paraffinic chain should be very long or a large number of such chains should be present. If a lesser amount of asphalt is used, the optimal compatibilizer may be primarily dependant upon the semi-polar portion of the compatibilizer. If the prepolymer is substantially non-polar, then the semi-polar portion of the compatibilizer should generally be non-polar. If an increased amount of urethane portions are present or if the prepolymer is rather polar, then more hydroxyl groups may be required or more ether linkages to obtain the optimal compatibilizer.
It would be impossible to test and describe all possible variations of the preferred embodiment with respect to all possible base material-prepolymer systems and such has been left to the skills of the ordinary artisan after having read the present specification.
The compatibilizer preferably is present in the range of about 0.01% to about 5% with 0.1% being most preferred (all percentages herein are percentages by weight unless otherwise indicated).
The compatibilizer of this invention substantially diminishes the need for a volatile organic solvent, because the fatty acid derivative (or non-derivative) surprisingly provides sufficient miscibility among the material components to form a flowable, sufficiently intermixed system. The resulting material can be easily blended or mixed and can be pumped and sprayed.
The compatibilizer will not interfere with most chemical reactions commonly used in asphalt systems and can be used in a one-part or a two-part system. Unlike traditional organic solvents which can be an environmental and health hazard, the compatibilizer of the present invention is non-volatile and generally relatively non-toxic in comparison to conventionally known solvent systems.
Curing Of The Adhesive
The polymerization reaction of the isocyanate prepolymer is commonly referred to as "curing". Prior to curing, the mixture is substantially flowable at ambient temperatures, but after curing, the resulting polymer network is a non-flowable, non-moldable elastomeric solid.
Curing creates an adhesive bond between the roof deck and roofing insulation. The roofing insulation adhesive generally provides excellent sealant properties, because the asphalt component will generally penetrate into the roof deck surface, thereby providing the prepolymer with a substantial contacting surface upon which to bond as it cures.
The asphaltic material of the present invention is preferably stored and transported in its uncured state. The mixture is preferably applied and then allowed to cure. Curing can be initiated in a number of ways.
In a one-part system, curing is initiated and propagated by moisture, preferably humidity from the air. As a result, the uncured material is generally transported and stored in a substantially water-free environment. When the material is applied and exposed to ambient conditions, the moisture in the air will react with the prepolymer's isocyanate functional groups, creating an amine (urea) and giving off carbon dioxide as a by-product.
The amine will in turn readily and quickly react with any other isocyanate functional group present. The amine-isocyanate reaction is an addition reaction which links the two prepolymer chains together, creating as disubstituted urea functional group at the connection point of the two prepolymer chains. This curing reaction creates a polymer network within the base material which provides strength, cohesion, adhesion and elastomeric properties.
A plethora of other curing reactions could also be used. A secondary curing agent could be added to the one part system which would also react with moisture to create a reaction product (typically an amine) which would initiate and/or propagate the prepolymer polymerization. Such secondary curing agents are often found to be useful, because the curing reaction does not produce carbon dioxide as a bi-product which may be advantageous for certain applications. Secondary curing agents for one part isocyanate based polymerization reactions are well known in the art, such as oxazolidine or ketimine.
In a two-part system, a curative is mixed into the system just prior to application. In such systems, a large number of acceptable curatives are well known in the industry. Acids, amines, hydroxyl, or virtually any hydrogen or proton donating molecule can be used to initiate and propagate the polymerization of an isocyanate prepolymer.
One-part systems are generally preferred however, because end-users typically find that mixing prior to application is unduly burdensome, particularly if certain mixing equipment is necessary or if the length of time and quality of mixing has a small margin for error.
Regardless of whether a one-part or two-part system is used in the preferred embodiment, a large excess of isocyanate will often also advantageously create a strong cross-linked polymer network, because the urethane or disubstituted urea groups (created at the junction point of two prepolymers) can themselves react with isocyanate to form an allophanate (RNHCOHR'COOR') in the case of a urethane reaction or a substituted biuret (RNHCONR'CONHR") in the case of a disubstituted urea reaction.
Other Additives
Other additives can be added to modify the physical properties of the resulting compound. Optional ingredients which can be used include for example, those catalysts (i.e., imidizole tin or other known metal catalysts), fillers and additives conventionally used in base material isocyanate based polymers, such as antioxidants, protectants and the like. If the curing reaction gives off carbon dioxide (as when water reacts with an isocyanate functional group), an absorbent can be used, such as molecular sieve, to absorb the carbon dioxide, thereby substantially preventing unwanted bubbles or the like which may occur with the evolution of gases during curing.
Preferred fillers would include organoclays, Such fillers preferably comprise platelets having long chain organic compounds bonded to its two faces. When used as a filler and when the system is at rest, the organoclay's long chain components will agglomerate, making the system thick and solid-like. However, when a shearing force is applied, such as when the material is moved and/or applied, the long chain components will disperse, creating an emulsion which will aid in the flow properties of the material (the organo-clay will no longer thicken the material unless or until it once again comes to a rest and the long chain components once again agglomerate). Such fillers allow for easy application, since they do not substantially impede the flow capabilities of the compound while the compound is being applied, and such fillers also thicken the material once it comes to rest, thereby substantially preventing the material from flowing away from the area to which is was applied.
Other possible additives would include those modifiers and additives conventionally used in the formation of natural and synthetic elastomers. Such additives include flame retardants, reinforcements (both particulate and fibrous) heavy and light fillers, UV stabilizers, blowing agents, perfumants, antistats, insecticides, bacteriostats, fungicides, surfactants, and the like. Additionally, it should be recognized that additional conventional elastomers can be included as an ingredient in forming the asphalt material of this invention. Such additional elastomers include for example, polysulfide, EPDM, EPR ethylene, propylene diene monomer, ethylene propylene terpolymer, polychloroprene, polyisobutylene, styrene-butadiene rubber, nitrile rubber, and the like.
The Insulation Adhesive Is Substantially Solvent-free
The resulting material is free of solvent evaporation stress (i.e. cracking, blistering and the like) common to many solvent-based systems. The compatibilizer also surprisingly enhanced the resulting material "green strength"--that is, the ability of the asphalt adhesive to be tacky and to adhere during the transition period between the cured and uncured states. The high green strength of the present adhesive is advantageous, because the adhesive generally can be used without the need for clamps or similar-type devices since the material will adhere and bond virtually on contact. The adherence and bonding will increase as the curing progresses.
Preferred Method of Manufacturing
A one-part system is preferred since it eliminates the need for two-component mixing just prior to application, and the preferred method of manufacturing the one-step system, in which all reference to "parts" refers to "parts by weight" unless otherwise stated, is as follows:
1. The prepolymer is mixed at a slightly elevated temperature (140°190° F.) in a substantially water-free environment and comprises (in parts by weight of final material, not parts by weight of prepolymer material):
a) about 20 to about 75 parts, and most preferably about 34 parts of about 2000 equivalent weight polyol;
b) about 2 to about 15 parts, and most preferably 7 parts non-reactive diluent, preferably plasticizer;
c) about 2 to about 20 parts and most preferably about 7 parts of about 150 equivalent weight diisocyanate; and
d) a trace amount of catalyst (preferably tin) preferably at least about 0.01 parts.
2. The prepolymer preferably comprises about 20 to about 90 parts, preferably about 50 parts of the final material. The prepolymer is set aside and not used until step 10 below.
3. The asphalt component is heated in a substantially water-free environment to its softening point or until it is substantially a fluid. The amount of asphalt is preferably about 10 to about 80 parts, most preferably 38 parts. The asphalt should be continually heated to its softening point in a substantially water-free environment throughout the following manufacturing steps.
4. The non-reactive diluents (most preferably plasticizer(s)) are added to the heated asphalt. The amount of non-reactive diluents is preferably about 2 to about 20 parts, most preferably about 9 parts.
5. The blocking agent, preferably an anhydride, isocyanate or carbodiamide, is added. The preferred amount of blocking agent is about 0.2 to about 5 parts, most preferably about 0.6 parts.
6. The materials are mixed until all materials are dispersed or dissolved.
7. A catalyst is added (preferably tin, imidazole, or other metal catalyst). The preferred amount of catalyst is at least about 0.1 parts per million.
8. Mixing is continued and any desired additives are added (thickeners, thixotropes, antioxidants and protectants). The preferred amount of additives is about 2 to about 25 parts.
9. The compatibilizer is then added. The preferred amount of compatibilizer is at least about 0.01 parts, most preferably about 0.05 parts.
10. The prepolymer is added and the mixing is continued until all materials are dispersed or dissolved.
11. Allow the mixture to cool and store in a substantially water-free environment.
Example 1
1. The prepolymer was mixed at room temperature in a substantially water-free environment and comprises (in parts of final material, not parts of prepolymer material);
a) 34 parts of a 2000 equivalent weight polyether triol;
b) 7 parts butyl benzyl phthalate;
c) 7 parts of diphenyl methane diisocyanate; and,
d) a trace amount of tin catalyst, about 1 ppm.
2. The prepolymer was set aside in a substantially water-free environment and not used until step 10 below.
3. 38 parts of industrial grade asphalt was heated in a substantially water-free environment to its softening point. The asphalt was continually heated and mixed at its softening point in a substantially water-free environment throughout the following manufacturing steps.
4. About 9 parts of butyl benzyl phthalate was added to the heated asphalt.
5. 0.6 parts of maleic anhydride was then added to the heated asphalt.
6. The asphalt mixture was mixed for about 10 minutes until all materials were dispersed or dissolved.
7. A trace amount of tin catalyst was then added, about 0.05 parts, and the asphalt was mixed for about 2 hours.
8. 1 weight part of a precipitated silica thixotrope filler and about 4 parts of a calcium carbonate particle filler was then added.
9. 0.5 parts of propylene glycol monostearate was then added.
10. The asphalt was mixed until all the materials were dispersed or dissolved and then the prepolymer was added and mixed about 30 minutes until all materials are dispersed or dissolved.
11. The final mixture was allowed to cool and was stored in a substantially water-free environment.
The above mixture was tested as an insulation adhesive and found to properly cure overnight to a commercially acceptable elastomer under most common outdoor weather conditions. The overnight relative humidity can be as low as about 30% and the overnight temperature can be as low as about 0° F. and the material will properly cure in about 10 to about 20 hours. At higher temperatures and relative humidities, the material will cure much more quickly.
The cure time can be adjusted by increasing or decreasing the amount of catalyst in the formulation or by adding an intermediate water curing component in place of the catalyst, such as oxazolidine or ketimine. The oxazolidine or ketimine can be added in place of the catalyst in an amount of about 0.1 to about 2 parts, preferably about 0.5.
Upon curing, the resulting product of Example 1 had excellent peel adhesion, tensile adhesion and lap shear. The material was very durable and water and weather resistant.
Alternatively, a two-part adhesive can be manufactured wherein the above material is mixed with an amine or other hydrogen donating compound just prior to application. The amine will react with the prepolymer typically much more readily than will water. As a result, the material will cure much more quickly and will not significantly react with water (and therefore will not significantly give off carbon dioxide as a by-product).
Alternatively, a blocking group can be incorporated onto the isocyanate functional groups so that the material will not react with water. A curative can then be mixed with the material just prior to application which will remove the blocking group and initiate and/or propagate curing.
The chemistry relating to polymerization of isocyanate prepolymers is well developed and a full discussion of one component and two component curing systems would be so voluminous as to be inappropriate in light of the fact that the present invention is not directed to any particular curing system. An exhaustive discussion of curing systems is unnecessary and may obscure the present invention. Such curing systems are readily known or can be readily developed by an ordinary artisan, using routine experimentation and knowledge well known in the art.
The above discussion has been provided to aid in the understanding of the present invention. Details provided above are provided primarily to help the ordinary artisan visualize the preferred embodiment and the innumerable other possible embodiments of this invention, and such details are not intended to create any limitations to this invention. Many improvements and modifications are certainly possible and it would be impossible to explicitly describe every conceivable aspect of the present invention. Therefore, the failure to describe any such aspect is also not intended to create any limitation to the present invention. The limitations of the present invention are defined exclusively in the following claims and nothing within this specification is intended to provide any further limitation thereto.
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The present invention relates to low slope roofing systems, particularly in commercial (as opposed to residential) roofing applications. More specifically, the fastener-free roofing system of the present invention is directed to the use of a curing adhesive composition which will simply and safely secure roofing insulation to a roofing deck without the need for mechanical fasteners.
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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 freestanding cylindrical indicator, which is used, for example, by being placed on a road to separate the passage of vehicles or pedestrians or as a medium for indicating various types of announcements, advertisements and messages.
2. Description of the Related Art
A conventional indicating cylinder used on site of roadwork is, for example, generally corn-shaped made of plastics or the like. Such an indicating cylinder has a certain weight because it is made of a synthetic resin or the like to have a certain thickness. Therefore, the transportation becomes difficult. It also has a disadvantage that it is hard to provide a storage space therefor because it has a certain size.
An indicating cylinder having the aforementioned disadvantage solved is known disclosed in Japanese Registered Utility Model No. 3041934.
The indicating cylinder of the aforementioned prior art has a three-dimensional shape such as a pyramid which is formed by folding a spread cardboard, fixing joined ends by means of rivets and detachably fixing a base thereto by an adhesive agent or the like so as to have a freestanding structure.
The structure as described above, enables the indicating cylinder to be made light in weight and be folded after the assembling. Therefore, it saves labor in transportation and a space for the storage.
In such a foldable indicating cylinder, the indicating cylinder and the base is made of a same cardboard so that the weight can be reduced.
When the indicating cylinder is set up for use outdoors, however, it is necessary to put a weight on the base to prevent it from being tumbled due to strong wind because it is exposed to rain or wind.
There is also a problem that the foldable indicating cylinder becomes unusable because an adhesive agent or the like is used at the fitting portion between the indicating cylinder and the base when the adhesive strength is degraded due to an influence of natural circumstances or adhesion of dust and the like in a long term.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a freestanding cylindrical indicator which can have an indicating body and a supporter securely joined by a simple operation.
Another object of the invention is to provide a freestanding cylindrical indicator which can stably hold the indicating body in an upright position.
The freestanding cylindrical indicator of the present invention comprises a cylindrical indicating body and a supporter for holding the indicating body in an upright position. The indicating body comprises a fitting portion. The supporter comprises an inserting portion, which is joined with the fitting portion.
In the freestanding cylindrical indicator of the present invention, the indicating body in an upright position may be stably mounted on the supporter by joining the fitting portion of the indicating body to that of the supporter.
In the freestanding cylindrical indicator of the present invention, the cylindrical indicating body, for example, may be detachably mounted on the supporter. The indicating body in an upright position can be stably mounted on the supporter by joining the fitting portion of the indicating body with the inserting portion of the supporter.
Furthermore, as an example of the cylindrical indicating body, the freestanding cylindrical indicator of the present invention has a cylindrical body with a cross section elliptic, the top end being smaller than the bottom end and the top end closed.
Bonding a single or two sheets of sheet members forms the cylindrical body. A fitting portion comprised of a hole is formed on the side of the bottom end.
Meanwhile, the supporter for holding the indicating body in an upright position has an elliptic supporting ring in the same shape as the indicating body. The supporting ring is provided with an engaging portion, which is inwardly protruded and opposed to an inserting potion to be fitted into the fitting portion of the cylindrical body.
Moreover, the elliptic supporting ring is pulled over to let through the indicating body from the top side and pushes the cylindrical body in the direction of the minor axis utilizing a tapered surface of the cylindrical body. During the operation, the cylindrical body is forced to expand in the direction of the minor axis by the binding force of the supporting ring, so that the cylindrical body is dented to let the inserting portion into the hole but instantaneously expanded to the direction of the minor axis when the inserting portion of the supporting ring come to the same position as the hole of the cylindrical body.
Therefore, the inserting portion of the supporting ring does not come out of the hole of the cylindrical body.
Furthermore, in order to remove the cylindrical body from the supporting ring, the cylindrical body is pushed to shrink in the direction of the minor axis so as to release the inserting portions from the holes. In this state, moving the supporting ring toward the top end of the cylindrical body enables easy disassembling.
BRIEF DESCRIPTION OF. THE DRAWING
FIG. 1 is a diagonal diagram of a supporter of a freestanding cylindrical indicator according to a first embodiment of the present invention;
FIG. 2 is a diagonal diagram of the freestanding cylindrical indicator according to the first embodiment of the present invention;
FIG. 3 is a diagram to explain the assembling procedure of the freestanding cylindrical indicator according to the first embodiment of the present invention;
FIG. 4 is an explanatory diagram of the action of self-shape retentivity produced when a cylindrical body is mounted on a fitting portion to assemble the freestanding cylindrical indicator according to the first embodiment of the present invention;
FIG. 5 is an explanatory diagram of an example of using a plurality of the freestanding cylindrical indicators connected according to the first embodiment of the present invention;
FIG. 6 is a diagonal diagram of a freestanding cylindrical indicator according to a second embodiment of the present invention;
FIG. 7 is a cross sectional diagram taken along line A—A of FIG. 6;
FIG. 8 is a cross sectional diagram of the principal part showing a modification of a supporter of the freestanding cylindrical indicator according to the second embodiment of the present invention;
FIG. 9 is a diagonal diagram of a freestanding cylindrical indicator according to a third embodiment of the present invention; and
FIG. 10 is a diagonal diagram of a freestanding cylindrical indicator according to a fourth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
Referring to FIG. 1 and FIG. 2, a freestanding cylindrical indicator 1 according to the first embodiment comprises a cylindrical body 3 which is made of, for example, a cardboard sheet S and a supporter 2 which has a relatively heavy structure detachably fitted to the cylindrical body 3 so as to hold it in an upright position.
The supporter 2 comprises, for example, a base 4 which is formed to have a wide rectangular or square shape by bending a steel wire and a supporting ring 7 which is fitted to the top face of the base 4 .
The supporting ring 7 is formed to have an elliptic shape by bending the same steel wire as the base 4 and a pair of interlocking portions 8 a, 8 b are protruded by inwardly bending the two mutually opposing portions in the direction of a minor axis.
Furthermore, the supporting ring 7 has connectors 6 a, 6 b which are bent into an L-shape mounted on the both ends in the longitudinal direction. The supporting ring 7 is mounted on the square base 4 through the connectors 6 a, 6 b by means of welding for example.
On the other hand, the cylindrical body 3 is formed to be a cylindrical body with a bottom having an ellipse cross section by bonding a sheet of long trapezoidal cardboard sheet S whose top end S 1 is shorter than a bottom end S 2 .
The cylindrical body 3 is, for example, made of a sheet of trapezoidal cardboard sheet S. The cardboard sheet S has a folding line marked in a position where the cardboard sheet S is folded into two equal sections in the longitudinal direction. Each section of the cardboard sheet S has the two edges inwardly folded to form flaps except the bottom end S 2 thereof. The cylindrical body 3 is formed by folding the cardboard sheet S along the folding line so as to join the opposing faces together and bond the flaps by an adhesive agent.
The cardboard sheet S has slits 9 a, 9 b formed in the vicinity of the bottom end. The cardboard sheet S has, for example, a red-colored beltlike indicating portion 10 printed on the top end side and an indicating mark 12 on both sides about the middle section. A through hole 11 is formed in the beltlike indicating portion 10 in the vicinity of the top end.
Thus, the cylindrical body 3 is tapered from the bottom end 3 a toward the top end 3 b and the top end 3 b is closed.
On the other hand, the slits 9 a, 9 b formed in the vicinity of the bottom end serve to function as holes crossing the axis of the cylindrical body 3 as shown in FIG. 4 .
A length of the bottom end 3 a of the cylindrical body 3 is determined to be longer than a length 7 a of the supporting ring 7 of the supporter 2 in the direction of the major axis.
When the cylindrical body 3 is inserted into the supporting ring 7 of the supporter 2 as will be described afterward, it is pushed and expanded in the direction of the minor axis by a binding force of the supporting ring 7 . When the outer periphery of the cylindrical body 3 substantially coincides with the inner periphery of the supporting ring 7 , the slits 9 a, 9 b formed in the vicinity of the bottom end face to the pair of interlocking portions 8 a, 8 b of the supporting ring 7 .
Now, an assembling procedure of the freestanding cylindrical indicator 1 according to the first embodiment will be described with reference to FIG. 3 and FIG. 4 .
First, the supporter 2 is lowered to pull over the supporting ring 7 of the supporter 2 to let through the cylindrical body 3 held in an upright position from the top end 3 b as shown in FIG. 3 . By lowering the supporter 2 , the inner periphery of the supporting ring 7 comes in contact with the outer periphery of the cylindrical body 3 . By further lowering the supporter 2 downward, the cylindrical body 3 is pushed and deformed with force to expand applied in the direction of the minor axis by the supporting ring 7 .
Moreover, when the outside shape of the cylindrical body 3 substantially matches with the inside shape of the supporting ring 7 , pushing and lowering the supporter 2 is prevented.
At this point, the pair of interlocking portions 8 a, 8 b of the supporting ring 7 are engaged with the slits 9 a, 9 b in the vicinity of the bottom end of the cylindrical body 3 .
Then, self-shape retentivity of the cylindrical body 3 acts on the inner periphery of the supporting ring 7 .
In other words, the cylindrical body 3 in an elliptic shape has all the outer peripheral surface as the external surface configured of an outward tangent lines (code F in FIG. 4) so that the self-shape retentivity (force to open externally) of the cylindrical body 3 acts on the inner periphery of the supporting ring 7 , and the cylindrical body 3 is mounted on the supporter 2 by being elastically pushed against the inner periphery of the supporting ring 7 of the supporter 2 when the outer peripheral surface of the cylindrical body 3 comes in contact with the inner periphery of the supporting ring 7 . When the cylindrical body 3 is mounted on the supporter 2 , the self-shape retentivity of the cylindrical body 3 produced with the mounting portion is used to keep the engagement of the interlocking portions 8 a, 8 b and the slits 9 a, 9 b, so that the cylindrical body 3 is restricted to moving in the axial direction (vertical direction).
Therefore, even when an external force is inwardly applied to a part of the outer periphery of the cylindrical body 3 , the cylindrical body 3 is stably held on the supporter 2 without easily disengaging the slits 9 a, 9 b from the interlocking portions 8 a, 8 b. Forming the supporting ring 7 in an ellipse shape as shown in the present embodiment improves the discrimination of the indication marks on the cylindrical body 3 from the front and back sides.
Besides, since the cylindrical body 3 is tapered from the bottom end 3 a toward the top end 3 b, in a state that the cylindrical body 3 is contacted to the inside of the supporting ring 7 by pulling over the supporter 2 to let through the cylindrical body 3 from the top end, 3 b, a simple operation of suppressing it in the axial direction enables to engage the interlocking portions 8 a, 8 b of the inner periphery of the supporting ring 7 with the slits 9 a, 9 b and securely mount the cylindrical body 3 on the supporter 2 .
FIG. 5 shows an example of using the freestanding cylindrical indicator 1 according to the first embodiment.
As described above, the cylindrical body 1 has a through hole 11 formed at the top end 3 b. Therefore, when two freestanding cylindrical indicators 1 are, for example, used in a mutually connected state, the through hole 11 is used for letting through and holding a bar 13 so that connecting the freestanding cylindrical indicators 1 enables to simply divide a large area.
In the example of usage described above, the two freestanding cylindrical indicators 1 are connected by one bar 13 . However, a method of connecting them is arbitrary. For example, the bar 3 may be made long so that a plurality of freestanding cylindrical indicators 1 can be connected by means of the bar 13 . The bar 13 may also have a desired length by means of any connecting tool. The connecting tool can be made of a flexible material so that it can be bent at any part of it. It is also possible to have any arrangement by using an L-shaped or U-shaped connecting tool.
Specifically, the connection of the freestanding cylindrical indicators 1 by means of the bar according to the first embodiment can be decided as required depending on application purposes and uses.
According to the first embodiment described above, the cylindrical body 3 is made of a single sheet of cardboard sheet S. However, the cylindrical body may be formed to be a cylindrical body with a bottom having an elliptic cross section by bonding two sheets of long trapezoidal cardboard sheet S whose top end S 1 is shorter than a bottom end S 2 . In this case, for example, it is formed by inwardly folding three edges of each sheet except the bottom end S 2 thereof to form flaps and bond the mutually opposing flaps by an adhesive agent.
The cylindrical body 3 made of the two sheets of cardboard sheet S makes it possible to form an indicator in a large size.
In other words, the cylindrical body 3 made of a single sheet of cardboard sheet S may be hard to form a large indicator because the size of the cylindrical body 3 is limited by a size of cardboard sheet S to be cut out.
Second Embodiment
FIG. 6 and FIG. 7 show a freestanding cylindrical indicator 1 A according to the second embodiment of the present invention.
A supporter 2 of the present embodiment is made of a synthetic resin and has an opening 17 formed on the top for allowing the insertion of a cylindrical body 3 . Inward interlocking portions 16 a, 16 b are integrally formed on the inner periphery of the opening 17 . In the opening 17 , an electric lamp 18 is mounted on the supporter 2 through a fitting member 19 . The interlocking portions 16 a, 16 b used for mounting the cylindrical body 3 may be formed on the supporter 2 which is made of a synthetic resin or the like.
The cylindrical body 3 is made of a member having a light transmission property such as thin paper, e.g., Japanese paper, or a sheet member made of a sheet-like synthetic resin. Therefore, the electric lamp 18 as shown in the Figure is mounted in the cylindrical body 3 to illuminate the whole cylindrical body 3 so that the cylindrical body 3 can be used in the night.
Since the cylindrical body 3 is formed with the top end 3 b closed, uniform light can be obtained owing to diffused reflection of light within the cylindrical body 3 . Accordingly, a light source can be made small. Especially, the effect is remarkable when the sheet member is YUPO (trade name; it is made of polypropylene) manufactured by Oji-Yuka Synthetic Paper Co., Ltd.
The back side of the supporter 3 of the present embodiment as shown in FIG. 7, is provided with a rib 2 a which is used to set a removable weight 30 in an appropriate weight. Thus, the weight 30 is removable so that the cylindrical body 3 is readily carried without the weight 30 , and at the same time the stability of the freestanding cylindrical indicator can be easily enhanced with the weight 30 which applies an appropriate weight to the supporter 2 .
Furthermore, FIG. 8 shows a modification of the supporter 2 .
A chamber 31 is formed within the supporter 2 shown as the Figure. A tap 33 is formed on the top of the chamber 31 and it can be closed by a cap 32 . The chamber 31 has a structure of keeping water, sand or the like within. Therefore, the supporter 2 is provided with an appropriate weight by simply supplying water, sand or the like into the chamber 31 on site so that the stability of the freestanding cylindrical indicator can be easily enhanced. Needless to say, since the supporter 2 becomes light in weight by simply discharging water, sand or the like from the tap 33 , not only can it be carried readily but it is not necessary to separately prepare the weight 30 .
Third Embodiment
FIG. 9 shows a freestanding cylindrical indicator 1 B according to the third embodiment of the present invention.
A cylindrical body 3 A of the freestanding cylindrical indicator 1 B has the same structure as the cylindrical body 3 of the first embodiment. For example, a red-colored beltlike indicating portion 10 is printed on the side of the top end, and an indicating mark 24 on both sides about the middle section of the cylindrical body 3 A.
In the present embodiment, the difference from the first embodiment is that slits 21 a, 21 b engaged with a supporter 22 are formed on both ends of an ellipse of the cylindrical body 3 A turned around by 90 degrees on the outer periphery of the cylindrical body 3 A in the direction of the major axis, while the slits 9 a, 9 b are formed on the cylindrical body 3 in the first embodiment.
Specifically, the supporter 22 of the present embodiment comprises at the upper part a symmetric pair of mountain-like interlocking portions 23 a, 23 b made of a bent steel wire which are inwardly close to each other.
By the configuration as described above, the mountain-like interlocking portions 23 a, 23 b of the supporter 22 are opened against the elasticity to engage with the slits 21 a, 21 b formed on the outer periphery of the cylindrical body 3 A. As a result, the cylindrical body 3 A is suppressed by the elasticity of the interlocking portions 23 a, 23 b and also can be securely engaged by the self-shape retentivity of the cylindrical body 3 A itself together with the elasticity.
Fourth Embodiment
FIG. 10 shows a freestanding cylindrical indicator 1 C according to the fourth embodiment of the present invention. It is to be understood that a part of the configuration identical to that of the configuration of the freestanding cylindrical indicator 1 B of the third embodiment is coded the same, and the detailed descriptions will be omitted.
A cylindrical body 3 B of the freestanding cylindrical indicator 1 C is configured the same as the aforementioned cylindrical body 3 . For example, a red-colored beltlike indicating portion 10 is printed on the side of the top end and an indicating mark 24 on both sides about the middle section.
A supporter 26 of the present embodiment comprises a base 4 , which has a wide rectangular or square shape by bending a steel wire, and a supporting ring 29 formed on the top face of the base 4 .
The supporting ring 29 is formed to be have an elliptic shape by bending the same steel wire as the supporter 26 , and a curved portion having a small radius is formed on both ends of the supporting ring 29 in the direction of the major axis as interlocking portions 29 a, 29 b.
By the configuration as described above, the elliptic supporting ring 29 is set to be in the same direction as the cylindrical body 3 B and let into the elliptic opening formed on the bottom end of the cylindrical body 3 B so as to have the same height as the slits 9 a, 9 b. Then, cylindrical body 3 B is turned by 90 degrees to make the inner wall of the cylindrical body 3 B externally expanded, and the interlocking portions 29 a, 29 b on the both ends of the supporting ring 29 in the major axis are engaged with the slits 9 a, 9 b.
Thus, the cylindrical body 3 B is engaged in a state that it is externally expanded by the interlocking portions 29 a, 29 b and can be securely engaged together with the self-shape retentivity of the cylindrical body 3 B itself.
The embodiments of the present invention are described above with reference to the accompanying drawings. It is to be understood that the specific configurations are not limited to the aforementioned embodiments, and modifications and additions to the present invention may be allowed without deviating from the gist thereof.
For example, the sheet member may be made of other materials such as a cardboard sheet and a synthetic resin sheet. The marks indicated on the cylindrical body are not limited to those described in the embodiments.
The cylindrical body is not limited to being formed by assembling the sheet member. For example, it may also be formed by molding a synthetic resin such as blow molding.
The cylindrical body may not be provided with the through hole 11 shown in the drawings.
The “cylindrical body” described above according to the present invention is tapered with the top end closed but can be a cylinder with a hollow interior.
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A freestanding cylindrical indicator of the present invention comprises a cylindrical indicating body and a supporter for holding the indicating body in an upright position. The indicating body has a fitting portion and the supporter has an inserting portion for joining with the fitting portion. Joining the inserting portion of the supporter with the fitting portion of the indicating body enables to fit the indicating body into the supporter. The freestanding cylindrical indicator is set up for, for example, being placed on a road to separate the passage of vehicles or pedestrians or being used as a medium to indicate various types of announcements, advertisements and messages.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE DISCLOSURE
Field of the Disclosure
[0001] The disclosure relates to containment devices and more particularly pertains to a new containment device for containing an overflowed fluid from a toilet.
SUMMARY OF THE DISCLOSURE
[0002] An embodiment of the disclosure meets the needs presented above by generally comprising a toilet structured to have a bowl. A fitting is coupled to the bowl on the toilet. The fitting is positioned proximate a maximum fill level of the bowl. A bag is coupled to the fitting. The bag may receive a fluid from the fitting if the bowl on the toilet becomes overfilled.
[0003] There has thus been outlined, rather broadly, the more important features of the disclosure 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 additional features of the disclosure that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0004] The objects of the disclosure, along with the various features of novelty which characterize the disclosure, are pointed out with particularity in the claims annexed to and forming a part of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The disclosure will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
[0006] FIG. 1 is a front cutaway view of a overflow containment assembly according to an embodiment of the disclosure.
[0007] FIG. 2 is an exploded perspective view of an embodiment of the disclosure.
[0008] FIG. 3 is a front view of an embodiment of the disclosure.
[0009] FIG. 4 is a cross sectional view taken along line 4 - 4 of FIG. 3 of an embodiment of the disclosure.
[0010] FIG. 5 is an in-use view of an embodiment of the disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] With reference now to the drawings, and in particular to FIGS. 1 through 5 thereof, a new containment device embodying the principles and concepts of an embodiment of the disclosure and generally designated by the reference numeral 10 will be described.
[0012] As best illustrated in FIGS. 1 through 5 , the overflow containment assembly 10 generally comprises a toilet 12 structured to have a bowl 14 . The toilet 12 may be a toilet of any conventional design. A fitting 16 is provided. The fitting 16 has an outer wall 18 extending between each of a first end 20 and a second end 22 of the fitting 16 . The fitting 16 has a tubular shape and the first 20 and second 22 ends of the fitting 16 are open. Additionally, the fitting 16 is substantially hollow.
[0013] An outer surface 24 of the outer wall 18 of the fitting 16 has a first threaded portion 26 extending from the second end 22 of the fitting 16 toward a center 28 of the fitting 16 . The outer surface 24 of the outer wall 18 of the fitting 16 has a second threaded portion 30 extending from the center 28 of the fitting toward the first end 20 of the fitting 16 . The outer surface 24 of the outer wall 18 of the fitting 16 is smooth between the second threaded portion 30 and the first end 20 of the fitting 16 .
[0014] The outer surface 24 of the outer wall 18 of the fitting 16 has a retainer groove 32 extending inwardly therein. The retainer groove 32 extends around an entire circumference of the outer wall 18 of the fitting 16 . Moreover, the retainer groove 32 is positioned between the first end 20 of the fitting 16 and the second threaded portion 30 of the fitting 16 . The fitting 16 extends laterally through an inner 34 and an outer 36 surface of the bowl 14 of the toilet 12 . The fitting 16 is in fluid communication with an interior of the bowl 14 of the toilet 12 .
[0015] A pair of gaskets 38 are provided. The pair of gaskets 38 form a closed loop. Each of the pair of gaskets 38 are positioned around the fitting 16 . The pair of gaskets 38 each abuts an associated one of the inner 34 and outer 36 surfaces of the bowl 14 of the toilet 12 . Additionally, the pair of gaskets 38 forms a fluid impervious seal between the fitting 16 and the bowl 14 of the toilet 12 .
[0016] A pair of washer 40 are provided. The pair of washers 40 forms a closed loop. Each of the pair of washers 40 are positioned around the fitting 16 to abut an associated one of the pair of gaskets 38 . A pair of nuts 42 are provided. Each of the pair of nuts 42 threadably engages an associated one of the first 26 and second 30 threaded portions of the fitting 16 . The pair of nuts 42 each engages an associated one of the pair of washers 40 so the fitting 16 is retained in the bowl 14 of the toilet 12 .
[0017] A bag 44 is provided. The bag 44 is rolled upon itself so the bag 44 forms a spiral shape. Additionally, the bag 44 may be comprised of a fluid impermeable material.
[0018] A retainer 46 has an exterior wall 48 extending between each of a front end 50 and a back end 52 of the retainer 46 . The front 50 and back 52 ends of the retainer 46 are open. Additionally, the retainer 46 is substantially hollow.
[0019] An O-ring 54 is coupled to an inside surface 56 of the exterior wall 48 of the retainer 46 . The O-ring 54 extends around an entire circumference of the retainer 46 . The O-ring 54 is centrally positioned on the retainer 46 . Additionally, the back end 52 of the retainer 46 is coupled to a top end 58 of the bag 44 .
[0020] The retainer 46 engages the first end 20 of the fitting 16 . The O-ring 54 engages the retainer groove 32 in the fitting 16 so the bag 44 is fluidly coupled to the fitting 16 . The bag 44 may receive a fluid 60 from the fitting 16 if the bowl 14 on the toilet 12 becomes overfilled. The bag 44 unrolls as the bag 44 receives the fluid 60 from the fitting 16 . Moreover, the bag 44 is elongated when the bag 44 becomes full of the fluid 60 . The fluid 60 may be water.
[0021] A strainer 62 is provided. The strainer 62 has a finger 64 coupled to and extending forwardly from a washer 66 . The washer 66 forms a closed loop. The finger 64 has a centrally positioned bend. Additionally, the finger 64 has an L-shape. A free end 68 of the finger 64 is directed upwardly from the washer 66 . The strainer 62 is positionable between an associated one of the pair of washers 40 and an associated one of the pair of nuts 42 . The finger 64 prevents debris from entering the fitting 16 .
[0022] In use, the bag 44 receives the fluid 60 from the bowl 14 of the toilet 12 if the toilet 12 overflows. The retainer 46 is removed from the fitting 16 after the bag 44 has become filled with the fluid 60 . The bag 44 is disposed of after the filled bag 44 is removed from the fitting 16 . A replacement bag 44 and retainer 46 are coupled to the fitting 16 after the filled bag 44 is removed.
[0023] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of an embodiment enabled by the disclosure, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by an embodiment of the disclosure.
[0024] Therefore, the foregoing is considered as illustrative only of the principles of the disclosure. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be only one of the elements.
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A overflow containment assembly for containing an overflowed fluid from a toilet includes the toilet structured to have a bowl. A fitting is coupled to the bowl on the toilet. The fitting is positioned proximate a maximum fill level of the bowl. A bag is coupled to the fitting. The bag may receive a fluid from the fitting if the bowl on the toilet becomes overfilled.
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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 an anti-seismic device, designed as a mechanical energy dissipating and load limiting device, of a multidirectional type, which can be used for connecting structural subsystems or for insulating the base portions of structural systems and which is particularly suitable for in cases of significant relative displacements of the connected portions.
BACKGROUND OF THE PRIOR ART
A previous patent application in the name of the same applicant, Italian patent application No. 22114 A/89, filed on Oct. 24, 1989 incorporated herein by reference, illustrates anti-seismic devices using a specifically designed curved element, shown in FIG. 1, having a variable section crescent-moon shaped element having two enlarged portions at the ends through which holes are formed to provide pivoting hinge connections.
When external forces are applied to the enlarged end portions, the crescent moon shaped element undergoes deformation assuming a well defined configuration and the related force-deformation curve is of the conventional elasto-plastic type.
By radially arranging any desired number of the mentioned crescent-moon elements greater than three, for example 3,4,5 . . n of said elements the anti-seismic device shown in the above mentioned patent application No. 22114 A/89 is obtained which can be either of the isotropic multi-directional type or not, depending on the particular arrangement of the dissipating elements which may be equally spaced or clustered in a given direction.
As it is known, the reason for adopting these devices is that seismic forces will produce abrupt displacements of the soil with which are associated great accelerations which, as transmitted through the foundations, will generate inertial forces, because of the comparatively large masses constituting the structural construction of bridges, buildings and the like.
Also known is the fact that, during a seismic event, large amounts of energy are generated, which is propagated through the soil so as to penetrate into the structures.
This energy represents, in actual practice, the main cause of possible damages due to the seismic event.
Furthermore, it is also known that by using suitable uncoupling devices, such as, for example, those disclosed in the above mentioned patent application, suitably arranged, it is possible to reduce the amount of energy which penetrates into the structures, as well as the load and displacements produced.
For example, in the case of bridges and viaducts, elastic devices have been used, which are specifically designed for providing an oscillating system, constituted by the mentioned devices, that is the springs and by the construction to be protected (the mass), which oscillating system has a proper resonance frequency, which can be arranged outside of the area of high energy contents region of the frequency spectrum, which is a characteristic of the seismic events, thus providing a great reduction of the seismic response.
In other words, the seismic energy is reflected by the above mentioned elastic devices, with the exception of that portion which is associated to a frequency equal to or near the resonance frequency.
However, the structure considered as an oscillating system will anyhow tend to accumulate the portion of energy in the mentioned spectrum range so that a dissipating device must be used for dissipating the mentioned energy in the form of heat.
Several physical mechanisms can be used for dissipating this energy and can be classified in several types.
In the present invention the dissipating capacity of soft steel or alloys of like performance where these materials are stressed beyond their yield point, is exploited.
A first phase of proportionality between the forces and deformation is followed by a phase in which there is little dependence of the power on the latter.
Thus, the devices constructed on such a constructional principle can be considered as load limiting devices.
Accordingly, when these devices are introduced into suitable points of the construction, the forces transmitted between the connected elements will be limited to values which can be easily established by a skilled designer.
From a dynamic standpoint, the adoption of horizontal restraining devices having a mainly elasto-plastic behavior, will be the same as introducing in series with a "spring", also an energy "dissipating element" having a comparatively high hysteretic capacity which, by plastic deformations will provide a ductility very favorable for the overall construction.
By means of the mentioned dissipating devices, it will be possible to remarkably reduce the spectral response, during violent seismic events, in terms of the accelerations of the overall constructional system, with a great reduction of the stresses on the supporting structures in particular.
These anti-seismic devices have been frequently used on railroad bridges and road bridges.
A modern trend is that of making these mentioned devices according to increasingly daring solutions so that comparatively larger movements between the supported construction and the supporting elements (columns and shoulders), are obtained.
SUMMARY OF THE INVENTION
Thus, the aim of the present invention is to solve the above mentioned problem, by providing a device which is specifically designed for overcoming all the difficulties related to comparatively small displacements while holding at a minimum the dimensions.
Within the scope of the above mentioned aim, a main object of the present invention is to provide such an anti-seismic device which allows comparatively large movements, without the need of using comparatively larger sized crescent moon elements.
Yet another object of the present invention is to provide such an anti-seismic device which allows to hold very reduced the plan size of the assembly.
Yet another object of the present invention is to provide such an anti-seismic device which can be easily constructed from commercially available elements and materials and which, moreover, is very competitive from a mere economical standpoint.
According to one embodiment the present invention, the above mentioned aim and objects, as well as yet other objects, which will become more apparent hereinafter, are achieved by an anti-seismic device, characterized in that said device comprises at least two curvilinear elements, arranged on overlaying planes, to absorb horizontal displacements without increasing the plan view dimensions of the assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become more evident from the following description of some embodiments which are illustrated, by way of example, but not limitative examples, in the accompanying drawings in which:
FIG. 1 is a top plan view of an energy dissipating element according to the prior art;
FIG. 2 illustrates an S-shape modular element;
FIG. 3 illustrates an anti-seismic device made by superimposing, on different planes, several crescent moon elements;
FIG. 4 illustrates the device shown in FIG. 3, with the addition of a bearing;
FIG. 5 illustrates a device made by coupling several S-shape elements;
FIG. 6 illustrates one of the two supporting plates of the device shown in FIG. 5;
FIGS. 7 to 10 illustrate top plan view of corresponding annular devices;
FIG. 11 illustrates a different arrangement of the device of this invention;
FIG. 12 is an elevational view illustrating two superimposed devices with the configuration of FIG. 7;
FIG. 13 illustrates the overall displacement of the device shown in FIG. 12;
FIG. 14 illustrates a cross-sectional view, substantially taken according to the arrows A/A of FIG. 13;
FIG. 15 illustrates an embodiment of the device comprising an insert between the top plate and bottom plate;
FIG. 16 illustrates an embodiment with a reduced height.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the numeral references in the figures of the above mentioned drawings, an elementary solution for doubling, triplicating, etc., the displacements could be those of superimposing, as shown in FIG. 3, two or more devices as those disclosed in the above mentioned patent application.
The top plan dimensions would be held unchanged, whereas the height would be nearly doubled, which, however, usually is not critical.
A limitation of this solution, which is covered by the present application is self-evident in the case in which it is desired to add to the device a bearing capacity, thereby providing an "insulator" device.
This can be obtained (see FIG. 4) by introducing a bearing apparatus, after having enlarged the central pivot pin (10) and having added two sliding pairs (1) made, by way of a not limitative example, of PTFE, and stainless steel.
With reference to FIG. 4 it should be apparent that, in the presence of an overall sliding displacement (2), an undesired eccentricity e=s/2 of the vertical load on the bearing apparatus will be generated.
A preferred device is that which will be hereinbelow described and which can be called a "radial embodiment".
For making such a device, are used the dissipating elements (15), shown in FIG. 2, to which external forces are applied at the points A and B, whereas the point C is left free.
The elements, shown in FIG. 2, can not operate individually, because of the generation of instability effects, and, accordingly, they can be arranged in arrangements similar to those shown in FIG. 5.
The S-shape element shown in FIG. 2 can be exclusively used in an odd number (3, 5, 7 and so on).
Actually, FIG. 5 illustrates the case in which n=3 and in which the forces are applied to the hinges through pins supported by the two plates (16), like those shown in FIG. 6.
The top plate would be reversed and, in the case being considered, it would be rotated clockwise through 60 degrees, so as to cause the longer pin (17) of a plate to align with the shorter pin of the other plate, as well as the two medium size pins.
Thus, it will be possible to properly assemble the S-shape elements which, because of their thickness will lie on different planes.
The central pin, which is indicated by the reference letter C, is not connected to any external elements and undergoes a displacement corresponding to one half the displacement observed between the points A and B.
In this connection it should be pointed out that, compared with the above mentioned patent application, while the displacements are doubled, the top plan size of the anti-seismic device will remain the same.
As stated, the height size is not a critical parameter.
This embodiment of the dissipating device is very simple construction-wise, of very reduced size and more-over it can be easily constructed.
However, if vertical loads must be simultaneously transmitted, i.e. if a seismic insulator type of device must be constructed, the device will have the same drawbacks as the preceding device.
On the other hand, it is possible to overcome this drawback by adopting the so-called "annular" solution.
For constructing an annular embodiment of the dissipating device, the dissipating elements (4) shown in FIG. 1 must be used.
These dissipating elements (4) will be arranged with an even number (n=4, 6, 8, etc. . . . ), according to FIGS. 7 to 10.
In actual practice, in the case of comparatively large displacements, the number of crescent moon elements to be used for constructing a device will be double, triple, and so on, with respect to that shown in the above mentioned figures, since it will be necessary to use several arrangements in a superimposed relationship.
By way of an illustrative and not limitative example FIG. 12 shows an exploded view of a very simple case of two superimposed patterns, having the configuration herein shown.
FIG. 11 illustrates a case in which the adjoining dissipating elements (1) are connected by discrete pins (21) instead of a single or same pin (20).
Such an arrangement will overcome the drawback of suitably contouring the end portions of the dissipating elements in order to prevent the overlaying arrangement from excessively increasing the height of the assembly.
It should be further pointed out that in each type of arrangement, the overall reaction will be obtained by a vectorial sum of the reactions of the single dissipating elements.
By the same type of dissipating element it will be accordingly possible to obtain by several different arrangements, different stiffness of the elastic and post-elastic branches of the characteristic curve of the overall device.
This latter device, in this illustrative but not limitative embodiment, will comprise a top plate (30), including two pins (31), diametrically arranged, engaging into the holes (B) (FIG. 7) of the dissipating elements while the holes (A) will be engaged by pins (32) encased in congruency plate (33).
The bottom portion of the device is symmetrically repeated and comprises the dissipating elements (2) and bottom plate (34).
The congruency or fitting plate (33) will provide the same function of the pin (C) as that of the radial embodiment.
This plate, similar to the pin, is not directly connected to external elements and will undergo a displacement corresponding to one half of the overall displacement.
In this connection it should be apparent that the overall displacement will correspond to the sum of the displacements which can be obtained by any single arrangements, as clearly shown in FIG. 13.
FIG. 14 illustrates a deformed condition of an arrangement including eight dissipating elements.
With the other geometric characteristics of the dissipating elements being the same, the reaction of the device can be changed by suitably modifying the thickness of said dissipating elements.
It is also possible to change the geometric characteristics, and in particular the thickness exclusively of some elements of the arrangement, thereby providing a different reaction in the different directions.
As clearly shown in FIG. 14, the fitting plate (33) can be designed as a circular crown and in the free central space so provided; it will be possible to insert an element suitable for transmitting vertical loads.
Actually, a main object of the present invention has been that of providing a load dissipating and limiting device also operating as a bearing apparatus, i.e. as previously stated, as an "insulator".
With reference to FIG. 15, in the central portion of the apparatus it will be possible to place insert (4) which couples the top plate (30) to the bottom plate (34) to which the insert is fixed.
The insert on the top face thereof will support a sliding block made of PTFE which, in turn, will slide on a polished stainless steel sheet, connected to the top plate.
Thus, mutual displacements between the two facing components will be afforded.
In this connection, it should be pointed out that the insert can be rigid with the top plate and slide on the lower plate.
Under the bottom plate is arranged a conventional bearing apparatus allowing rotation movements to be easily performed.
In the not limitative example shown in FIG. 15, this bearing apparatus is of a vat type, but it can be constituted by any other suitable type of apparatus.
If the height is a critical factor, the bearing apparatus can be introduced inside the two plates, so as to fully or partially exploit the height of the insert, indicated at (41), as the illustrative and not limitative example of FIG. 16.
The latter solution can involve a greater radial size.
To the foregoing it should be added that the device of this invention can also comprise other means for affixing it temporarily to service loads, such as keys to be broken at a given load, rigid clamping elements coupling the end portions of all the dissipating elements or a portion thereof, or guides, either with or without breaking keys, or plungers or hydraulic members (shock-transmitters) to absorb slow motions (for example thermally generated motions) without stressing the dissipating elements.
Further additional elements can also comprise spacing elements which, as suitably connected to the congruency plate and provided at the other end thereof with sliding blocks made of suitable materials, will prevent the congruency plate from being tilted under a pair of action/reaction horizontal forces laying on different planes.
The invention as disclosed is susceptible to several variations and modifications all of which will come within the scope of the inventive concept.
Moreover, all of the details can be replaced by other technically equivalent elements.
In practicing the invention, the used materials, as well as the contingent size and shapes, can be any, depending on requirements.
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A multidirectional antiseismic device dissipates mechanical energy and limits loads; it can be used to connect structural sub-systems or insulate at the base entire structures, especially in cases involving significant relative displacements between connected structural sub-systems. The multidirectional dissipating device is essentially constituted by pluralities of metallic elements, especially shaped and arranged in specific configurations. Two of these are "radial" configurations whereas a third type is "annular". In each case, the configurations extend between an abutment and anchoring top construction and an abutment and anchoring bottom construction.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit as a continuation-in-part of U.S. application Ser. No. 13/,354,795, filed Jan. 20, 2012, and U.S. Provisional Application No. 61/439,526, filed Feb. 4, 2011, the entire contents of which are hereby incorporated by reference herein in its entirety for all purposes.
BACKGROUND OF THE INVENTION
[0002] This invention relates to handles for doors and, in particular, to a method and apparatus for opening doors without using hands.
DESCRIPTION OF THE PRIOR ART
[0003] Grab-bar handles, as they are termed by the trade, are used on most high-traffic manual door entries. Often a vertical bar is used on the entry pull-side of the door, with a horizontal bar on the exit push-side, but other combinations are also used. These vertical bars are typically 10-12 inches in length, while the horizontal bars are usually about the width of the door. Some bars are rectangular, some are round, and some are custom shaped; yet all have the characteristic that they are easy to see peripherally as the user approaches the door, and they are all easy to grab and use with little chance for sustaining an injury. Although grab-bars and doorknobs both present minimal risk of physical injury, doorknobs present a smaller profile which is often times more difficult for a user to quickly see and grab in fast paced high-traffic situations; thus doorknob profiles, because of their small shape, are seldom, if ever used for this type of application.
[0004] When handles are used rather than those of the grab-bar type, they can be rotatably manipulated to operate a latch mechanism to displace the latch into the door and permit the hinged door to swing open using a minimal amount of pulling force applied to the handle after rotation. Handles of this type are either of a generally sphereical knob type or have an elongated handle where the handle can be rotated in a plane parallel to the adjacent door face. The space between the handle and door face is fixed and such a rigid space could cause injury to a person having their forearm disposed in this space if the door is unexpectedly swung open.
[0005] Opening doors using a hands-free technique is known in the prior art. One reference which illustrates a hands-free door handle is U.S. Pat. No. 2,238,513 issued to Ward and discloses a door handle for hands-free opening of a door latch. The handle comprises a proximal end connected to the door, an elongated rod portion extending parallel to the door and in a direction away from the latch, a hook portion and a distal end orientated to be facing downward. The handle can be displaced along an arc parallel to the door, either upward or downward to release the latch. Ward does not pertain to high-traffic uses since a latch mechanism is operated by the movement of the handle.
[0006] An issue with the use of grab-bar handles is that they can transmit germs left by a previous user to a subsequent user. Grabbing a door handle by a hand can contact the contagion left by previous users. This contact could lead to respiratory infection should the individual subsequently place his hand in close proximity to the nose or mouth before washing his hands or application of a hand sanitizer.
[0007] It is well known that hand washing is the most recommended way of preventing contact of unclean fingers with the eyes, nose and mouth. However, in public situations, it is not possible to promptly wash hands. The U.S. Center for Disease Control and Prevention (CDC) reports that up to 80% of germs are transmitted by the hands, and that doorknobs and grab-bars are one of the worst contributors to this problem.
[0008] A prior art example of a hands-free door application taking into consideration the need for sanitary usage is U.S. Pat. No. 6,289,557 issued to Manson et al. which discloses a sanitary door handle assembly for opening a door. The handle portion is arcuate and having the dished side of the handle generally facing one side of a door. While Mansen et al. discloses a door handle capable of being used hands-free, the technique used to open the door requires the user to position his wrist upon the handle and hand in the space between the handle and door. A sudden jarring of the door from the opposite direction could cause injury. Mansen et al. attempts to address this concern by an embodiment having a spring mechanism 36 to alter the position of the handle relative to the door and free an engaged wrist or forearm if the door is unexpectedly opened.
[0009] Another prior art example is U.S. Pat. 7,810,215 issued to Houis which discloses a sanitary handle for opening a latched door. The handle allows for the cradling of a user's forearm for the user to impart first a downward force to unlock the latch and thereafter a pulling force to swing open the door. The orientation of the Houis handle requires that the user be in a close enough proximity to the door in order to apply a sufficient vertical force to displace the handle. This handle embodiment would not be suitable for high traffic situations.
[0010] Other devices for manual hands-free opening of a door include a product marketed under the trademark SANI-HANDLE. This device comprises a rigid wing extending at an upward angle away from the door. Because of its stationary design, a user slips his forearm into the wing so that the forearm is essentially parallel with the door face. This design requires the user's elbow to be close to the door and thus the user is close as well. This proximity to the door can make a user susceptible to injury particularly if the door is swung open from the opposite side while the user is engaging the device.
[0011] The prior art references discussed above are hereby incorporated by reference.
SUMMARY OF THE INVENTION
[0012] The purpose of my invention is to provide a door opening mechanism which is simple to use, provides reliable and injury-free operation, and allows a user to avoid grabbing a handle may be contaminated with germs.
[0013] I have discovered that a hands-free device for opening a hinged door is safer for the user when a rotatable arm-bar having a bend portion and distal end is presented where the bend portion and distal end can rotate in a plane perpendicular to the door face. If a door is opened unexpectedly as when someone behind the door swings the hinged door unexpectedly towards a user, a forearm will not be caught in the set space between handle and door face; rather my invention allows the handle to rotate and the bend portion and the distal end of the arm-bar changes its positioning relative to the door face. This rotational aspect of my invention thus prevents injury to the forearm or wrist since the limb is not held in a fixed relation to the door as is with the prior art.
[0014] My invention is a door opener assembly to which a hands-free pulling force can be applied to swing open a hinged door and incorporates an arm-bar which can rotate in a direction perpendicular to the adjacent door face. This rotation is from an initial position in front of a hinged door to a position where the distal end of the arm-bar extends beyond the swinging edge of the door. The arm-bar of the door opener assembly is biased to the initial position so that a user can apply a pulling force to the arm-bar and the biasing will cause the arm-bar to return to the initial position afterwards. Biasing of the arm-bar can be accomplished by techniques known to those having ordinary skill in the art.
[0015] My invention is suitable for opening doors used in high-traffic situations without requiring that a hand be placed on a handle. Rather than using a hand and gripping the handle, the swinging arm-bar of my invention permits a user to place either a wrist or forearm on the arm-bar for providing the necessary pulling force to swing the hinged door open.
[0016] This perpendicular rotation of the distal end of the arm-bar relative to the door face in conjunction with the arm-bar biased to an initial position are critical components of my invention. For example, although the Ward reference discloses a rotatable arm-bar which extends past the swinging edge of a hinged door, it is done so along an arc parallel to the door. The distal end of the arm-bar of the present invention by contrast, displaces along an arc perpendicular to the door. This difference allows a user operating my device to open and walk through the door in a continuous movement. Stated differently, the door handle of Ward will extend past the swinging edge before the user can pass by while my invention will have the arm-bar follow the user.
[0017] High-traffic situations are those where the doors will be opened and closed on a frequent basis. Some examples include doors to office buildings, hotels, department stores, medical buildings, public restrooms, etc. My invention can also be used in low-traffic conditions.
[0018] My invention is designed for a user to be able to peripherally recognize and easily engage the arm-bar without having to concentrate and thereafter be able to disengage from contact quickly and easily.
[0019] My door opener assembly comprises a housing which is operatively attached to the face of a hinged door where a pulling force is required to swing the door open; near the distal edge of the door opposite the hinged side. Extending from the housing is an arm-bar having a general hook shape that is rotatably mounted to the housing. The arm-bar can be constructed of any material that is traditionally suited for handle applications. Preferably, the arm-bar is an integral component made of a rigid plastic or metal such as aluminum, brass or stainless steel so a user's wrist/forearm will easily slide off the arm-bar as will be discussed later.
[0020] Preferably, the distal end of the arm-bar is generally pointed in a direction parallel to the adjacent door face when the housing is operatively attached to the door.
[0021] Operative attachment means that the location of the housing to the door is suitable for a human to engage the arm-bar while standing and that the location is close to or at the swinging edge (distal edge) of the door to maximize leverage. Attachment in this manner permits the least amount of opening force to pull the door open. Doors typically used in high-traffic situations are well balanced and minimal pulling force is required to open even though the doors are usually constructed of heavy material. These doors typically incorporate the use of horizontal and/or vertical grab bars. Preferably, the door opener assembly will be located above a vertical grab bar or handle which may be present. Attachment of my door opener assembly to a hinged door can be by any means well known in the art. Some examples of acceptable means for attachment include, but are not limited to, threadable engagement, use of an adhesive, or use of suction cups. Finally, operative attachment means not only that the housing can be attached directly to the frame of the door, but can be attached to an intermediate item, such as a vertical grab bar, which in turn is mounted to the frame of the door.
[0022] The arm-bar extending from the housing has a proximal shank portion extending in a vertical direction parallel to the adjacent door face, a bend portion and a distal end. Rotation of the distal end of the arm-bar occurs along a plane perpendicular to the adjacent face of the door while rotation of the shank portion is about its longitudinal axis.
[0023] The arm-bar is biased into an initial or first position as will be discussed later.
[0024] It is to be understood that when my door opener assembly is properly attached to a hinged door, the rotation of the arm-bar is only in a perpendicular plane relative to the adjacent door face. It is to be further understood that the rotation of the arm-bar in a perpendicular plane does not allow for movement of the arm-bar in any other plane such as the movement allowed for by the spring of the Manson et al reference discussed earlier. In order for the door opener assembly of the present invention to function properly, the arm-bar can not move in a direction other than a plane perpendicular to the adjacent door face. Other such movement would undesirably increase the minimal pulling force required to swing open the hinged door.
[0025] The term “perpendicular plane” refers to the arc traveled by the distal end of the arm-bar once the housing is operatively attached to a door. It is to be understood that installation may not result in an arc in a precisely perpendicular plane, but the term should also include a plane which is substantially perpendicular; in other words, a minor deviation therefrom.
[0026] My invention can utilize an arm-bar configuration where either a user's wrist/forearm is raised into contact with the bend portion from below (designated the ‘n’ configuration) or, more preferably, where the user's wrist/forearm is lowered into contact and positioned upon the bend portion (designated the ‘u’ configuration).
[0027] Other configurations for my arm-bar could be utilized so long as the distal end of the arm-bar is rotatable in a substantially parallel plane relative to ground level once attached to a hinged door.
[0028] In the more preferred ‘u’ configuration, the bend portion has a top surface which has an appropriate surface area that is comfortable for a human to rest his forearm or wrist upon and to thereafter exert upon a small opening force as will be discussed later. If the top surface area of the bend portion were too small, the force applied by the user would be focused on a limited area of the forearm/wrist which could result in discomfort at the site of engagement.
[0029] An important feature of my invention is the ability of the arm-bar to rotate from an initial position, where the distal end is located in front of the door face between the door face and the user as illustrated in FIG. 1 , to a releasing position where the distal end is located beyond the vertical swinging edge of the door as the user's wrist disengages contact with the arm-bar. It should be noted the user can disengage at any point before the releasing position is reached; the releasing position merely refers to the maximum rotation limit of the arm-bar; as illustrated in FIG. 1 , in the clockwise direction. With respect to the maximum clockwise rotation limit, the term “beyond the swinging edge” refers to the distal end of the arm-bar being located further away from the hinged edge of the door than the swinging edge of the hinged door.
[0030] The distal end preferably is of a general knob configuration having an orientation toward the swinging edge of the door as shown in FIG. 3 . This preferred knob configuration is conducive for allowing a human's wrist or forearm to easily slide off the arm-bar without risk of injury or article of clothing becoming snagged.
[0031] In my preferred ‘u’ configuration, when my door opener assembly is operatively attached to a door, the distal end is facing in a general upward direction. Stated another way, the arm-bar has a general hook-shape configuration, except that the bend portion is bent outward as viewed in FIG. 6 .
[0032] In an alternative ‘n’ configuration, the bend portion, after curving upward, then curves downward so the distal end is eventually facing in a general downward direction, preferably 30-60 degrees from horizontal which permits a user to engage the lower surface of the bend portion by raising his forearm/wrist to contact, and then disengaging at any time by lowering his forearm or, if the arm-bar has rotated clockwise to its maximum extent as the user is walking through the door opening, the user's wrist/forearm will disengage as it slides away from contact off the distal end.
[0033] An anticipated use of my invention is on commercial doors which will repetitively open and close in high-traffic pedestrian applications. In a typical commercial setting, individuals will be behind the user and others may be on the opposite side of the door desiring to travel in the opposite direction. To prevent injuries, it is necessary that the user be able to immediately remove his wrist or forearm from contact with the arm-bar without any chance that the wrist or forearm could catch in the device which could cause an arm, shoulder or other injury. By example, for my preferred ‘u’ embodiment, the user can release contact with my arm-bar configured for use by a right hand on a right side door by lifting in the +y direction, sliding over the distal end in a −x direction, sliding across the bend portion in the +z direction or any combination of the above.
[0034] The ability to easily disengage from the arm-bar in various directions as a result of the arm-bar geometry and orientation are safety features of this invention. Rather than relying upon a spring mechanism exemplified by the Manson et al. reference to alter the plane of movement for the handle, my invention relies upon the ample spacing between the door and the distal end of the arm-bar for easy, slidable disengagement of a user's wrist.
[0035] Thus, the design of my arm-bar is sized to permit a user's forearm/wrist to be quickly positioned into contact with the bend portion and after a subsequent opening force is applied, to thereafter slidably disengage from contact with the arm-bar; i.e. the forearm/wrist displaced from the space formed between the distal end, the bend portion and the shank portion of the arm-bar.
[0036] My invention is usable in both high and low traffic door applications. It provides the user with an option. Although the arm-bar can be grabbed by the hand and used to open a door, my invention is directed toward the user positioning the forearm/wrist across the bend portion. For the ‘u’ configuration, the user's wrist/forearm is placed upon the bend portion and gravity along with a slight pulling force is used to swing a door open and avoid hand contact with the arm-bar which may have germs deposited by previous users. For the ‘n’ configuration, the user's wrist/forearm is moved upward into contact with the bend portion and a pulling force is used to swing the door open.
[0037] For the ‘u’ configuration, my arm-bar assembly is positioned at an appropriate height on the door so persons approaching the door assembly can easily lay their wrist or forearm upon the bend portion. In a typical installation, my arm-bar assembly would preferably be positioned upon the door slightly above a vertical grab bar as illustrated in FIG. 9 . Operative attachment of the housing proximate to the vertical swinging edge of the hinged door permits the distal end of the arm-bar to be rotated perpendicular to the adjacent door surface to a position where the distal end is beyond the outer swinging edge of the door.
[0038] The engagement zone, meaning the distal end and bend portion of the arm-bar, is appropriately sized for a user's forearm/wrist to contact i.e., not too thin to cause the user discomfort and not too thick so the user's hand can not rest in the space between the distal end and the shank portion of the arm-bar. In a preferred embodiment, the arm-bar, from its initial position, can easily rotate in either direction to accommodate the user's wrist/forearm as it is placed upon the bend portion. With gravity resting the user's forearm upon the arm-bar with the wrist cradled over the bend portion, the user applies a pulling force upon the arm-bar to swing open the door.
[0039] It is to be understood that the pulling force to open the door is applied by the user's wrist and/or forearm. This pulling force is applied generally to the bend section. As the door swings open, the arm-bar rotates in response to the continued contact of the user with the arm-bar. As this rotational movement occurs and the user continues to walk through the door opening, the wrist/forearm position of the user slidably displaces in a direction toward the user's body and eventually disengaging contact with the arm-bar. Due to the smoothness and design of the arm-bar, there is nothing upon which the user or the user's clothing can catch.
[0040] Since most commercial doors are well-balanced with existing door-closing devices, the weight of the persons arm alone provides much of the force required to open the door. With the weight of the user's arm resting upon the bend portion, for example, ten pounds force downward due to gravity, any pulling force the user exerts toward himself to open the door will be applied to overcome the pull resistance of the door, which in commercial application is typically between 1-7 lbs-force. Thus, the user's arm weight is used as part of the pulling force for the ‘u’ configuration.
[0041] In the preferred arm-bar design, the shank portion of the arm-bar is cylindrical as it extends vertically from the housing and parallel to the adjacent door surface to about the low point of the bend portion. Extending past this point to the distal end, the bend portion gradually becomes more oblong and larger in shape and, bends towards the swinging edge side of the door.
[0042] The preferred knob design helps to spread the weight of the user's wrist and forearm over a larger area of the arm-bar.
[0043] The bend in the arm-bar seen in FIG. 7 towards the swinging edge of the door aids the user's forearm and wrist to slide easily and smoothly while still providing a level of gripping force to control the door.
[0044] Preferably, overall rotational movement of the distal end of the arm-bar is limited to about 160 degrees. Part of this degree of rotation permits a user to pull the door open and begin to walk through the door opening while still in contact with the arm-bar since the arm-bar is rotating clockwise for a door hinged on the right side. A smaller part of the degree of rotation is provided in case, for example, a child's head were to accidentally bump the distal end. For these situations, the arm-bar can preferably rotate up to about 20 degrees from the door face in a counterclockwise direction from the initial position. This rotation ability acts much like a shock absorber to dissipate an impact force.
[0045] After the user releases contact to the arm-bar, it is biased to automatically return to the initial position ready for the next user; typically in less than three seconds. Biasing to the initial position can include the use of stretchable material such as natural rubber, synthetic rubber, or the use of coils, springs, leafs, or mechanical, hydraulic or pneumatic devices.
[0046] However, biasing to the initial position can also use of a plurality of magnets to bias or urge a rotating component to one position. Using magnets as part of my door opener assembly, at least two magnets are positioned within the housing to bias the arm-bar to the initial position; one magnet rotating with the arm-bar and the other stationary with the housing. Small magnets simulate push forces, pull forces and forces to maintain the initial position. In a preferred embodiment, one set of magnet(s) are located in the housing to rotate with the shank portion and at least two sets of magnets are located in the housing which remain stationary. Another embodiment can have two sets of magnets rotating and one set stationary. The dynamics of utilizing magnets can be easily modified and fine-tuned and even drastically changed by varying the number of magnets stacked at each position, slightly changing their relative location(s) or even adding additional magnet positions. In one embodiment, one of the members used for position of the magnets can be adapted with a single arced aperture having a plurality of notches whereby the magnet locations can be easily changed to a different position along the arc.
[0047] Use of magnets has benefits of increased reliability, durability and operational flexibility in accordance with the dynamics of the invention. Since the dynamics enhance the comfort, safety and reliability of use, magnets provide an enormous advantage over extension, compression, torsion or other types of springs which are more prone to premature failure relative to magnet usage.
[0048] The use of the magnets will allow easy compensating adjustments which may be required for different arm weights and material changes, such as for example, use of arm-bars constructed from brass rather than from a lighter thermal-plastic material. This consideration would also apply for versions of my invention for down-sizing the size of the arm-bar and support housing for use in more child friendly applications such as elementary schools.
[0049] A further alternative embodiment would have the arm-bar constructed as a composite with the distal end and a segment of the bend portion constructed of a resilient material such as solid rubber or a polymeric material.
[0050] The aforementioned door opener assembly uses a pulling force to swing a door open. Located on the opposite face of a door to which my door opener assembly is operatively attached can be installed a push door opener assembly the type of which is illustrated in FIGS. 10-12 . The push door opener assembly comprises a housing attached to the door and a shaft extending away upon which a contoured pad is rotatably mounted. The push door opener assembly can be mounted upon the opposite door face and a preferred embodiment permits the contoured pad to be rotated about the attachment axis. Magnets are used for returning the contoured pad to its initial position in a similar way as described for the arm-bar.
[0051] In another application, it may be useful to combine the push and the pull feature on a single door face as illustrated in FIG. 13 . In still another application, the pull assembly could also be used for opening refrigerator doors, including commercial refrigerator doors.
[0052] A final application of my invention can be utilized in embodiments where movement of the arm-bar by application of a hands-free pulling force causes rotation of the arm-bar to unlock a latch bolt and swing open a hinged door. For this embodiment, the rotation of the arm-bar would be operatively connected to the shaft of the latch mechanism for displacing the latch shaft into the door in response to arm-bar rotation.
DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 illustrates a user's initial forearm and wrist placement upon the arm-bar of the door opener assembly.
[0054] FIG. 2 is a perspective view of one embodiment of the door opener assembly.
[0055] FIG. 3 is a top view showing the relation of the door opener assembly to the door and the rotational movement of the arm-bar.
[0056] FIG. 4 is a top view of one embodiment of my door opener assembly.
[0057] FIG. 5 is a top view of the arm-bar.
[0058] FIG. 6 is a side view of the arm-bar.
[0059] FIG. 7 is a front view of the arm-bar.
[0060] FIG. 8 is a cut-away view of the housing and attachment of the arm-bar in the initial position.
[0061] FIG. 9 illustrates a use for my invention in a commercial double-door application.
[0062] FIG. 10 illustrated a contoured push plate located on the door face opposite the arm-bar.
[0063] FIG. 11 is a perspective view of the contoured push plate.
[0064] FIG. 12 is a side view of the push plate.
[0065] FIG. 13 is an embodiment incorporating both the arm-bar and push plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0066] The illustrations provided are not necessarily to scale but are for general informational purposes. FIG. 1 generally illustrates the position of a user's forearm/wrist A in relation to my door opener assembly 10 which is operatively attached to a door D and with arm-bar 14 in the u-configuration.
[0067] Since most high-traffic doors utilize a metal frame and glass, door opener assembly 10 is threadably secured to the door's metal frame in a position above any existing vertical grab bar. It should be noted however, a version of door opener assembly 10 could include suction cups for attachment to a door where the surface of attachment may or may not be a portion of the door's metal frame.
[0068] The movement shown in FIGS. 3 and 4 refer to the movement of an arm-bar attached to a right-side hinged door. The positioning and movement for an arm-bar attached to a left-side hinged door would be the mirror image.
[0069] Referring to FIG. 2 , the door opener assembly 10 is comprised of two subassemblies, the housing 12 and the arm-bar 14 . Arm-bar 14 comprises a shank portion 20 , a bend portion 22 , and a distal end 24 . The distance between the shank portion 20 and distal end 24 generally defining a gap G as illustrated in FIG. 6 .
[0070] Arm-bar 14 is rotatably attached to housing 12 with the rotational movement illustrated in FIG. 3 . The closed position of hinged door D, housing 12 , and the initial position of arm-bar 14 appear in solid line when forearm/wrist A is initially placed upon bend portion 22 . The initial position of arm-bar 14 relative to door D is represented by angle L which is about 40 degrees or about 140 degrees from the swinging edge of the door. In this initial position represented by the solid line in FIG. 4 , arm-bar 14 is rotatable in either clock-wise or counter-clockwise direction. Overall, the rotational movement of arm-bar 14 is represented by angle M and is about 160 degrees. Referring to FIG. 3 , the dashed lines represent positions of hinged door D, housing 12 and arm-bar 14 after opening force F has been applied. As the user begins to walk to and through the door opening, the position of arm-bar 14 rotates toward the swinging edge of door D.
[0071] The counter-clockwise position of arm-bar 14 in dashed line in FIG. 4 represents a possible position if hinged door D is inadvertently bumped by an object such as a child's head. This rotational movement would lessen the force of impact and minimize any injury. Also, this movement is limited to prevent distal end 24 from impacting the door surface if it is accidently displaced counter-clockwise.
[0072] Located within housing 12 is are magnet sets 30 and 34 located within housing 12 which provide a relatively small biasing force is used to urge arm-bar 14 into the initial position. If the correct magnet strength is used, arm-bar 14 will responsively rotate upon application of force F to swing open door D.
[0073] As a consequence, even an impact such as a child's head accidentally bumping arm-bar 14 will not suffer an injury. Also, the enlarged dimensions of distal end 24 serve to prevent injury which may otherwise occur if the end had sharp edges. During the installation process of door opener assembly 10 to door D, maintenance personnel will check to ensure the correct magnet strength is used for the particular type of door. Magnets can be changed by removing the cover to housing 12 and inserting the magnets into appropriately sized apertures (not shown) for receiving the magnets into rotatable block 36 and stationary block 32 . FIG. 8 illustrates the relative position of magnets 30 and 34 . It is to be understood that blocks 32 and 36 are constructed of a non-magnetic material.
[0074] In normal operation, as soon as forearm/wrist A is placed upon bend portion 22 , it exerts a force upon arm-bar 14 caused by its weight. The user thereafter can exert an additional, minimal pulling force F in the direction shown in FIG. 3 to begin swinging open hinged door D. As door D is swung open, the user moves and begins to walk through the door opening. Relative to the user's movement and continued engagement to arm-bar 14 , arm-bar 14 rotates in a clockwise direction up to its maximum rotational extent at which continued user movement through the door opening causes forearm/wrist A to slide in direction R until forearm/wrist A completely disengages from contact with arm-bar 14 .
[0075] Mirror-image designs as illustrated in FIG. 9 are used for adjacent doors (double doors) which are normally used to handle high-traffic situations. It is possible for two persons to simultaneously pull open both doors, although they would have to pay attention not to bump each other. For the situation where a person is exiting via one door and another person is entering thru the other door, there is still adequate room to maneuver.
[0076] My door opener assembly can also be used on a typical aluminum-glass ‘storefront’ door D positioned near or adjacent to the swinging edge. Housing 12 is attached above a vertical grab bar B similar to that illustrated in FIG. 9 which is commonly used currently, so that the person entering the door has the choice of using grab bar B or arm-bar 14 .
[0077] The limits of travel of arm-bar 14 in each direction are limited by stops 16 and 18 within housing 12 as shown in FIG. 8 . Within housing 12 is a U channel 50 having a top section 52 and a bottom section 54 each having a hole having a common axis of symmetry with the other. A shoulder bolt 62 is accepted through the holes in top section 52 and bottom section 54 and threadably secured to threaded hole 60 located at the top of shank portion 20 . The head of shoulder bolt 62 rests upon a thrust bearing (not shown) partially positioned in the annular region of top section 52 to secure arm-bar 14 to housing 12 . A washer bearing (not shown) is positioned in the annular region of bottom section 54 for centering the base of shoulder bolt 62 .
[0078] As illustrated in FIG. 8 , a rotor assembly is provided in housing 12 which include stationary magnets 30 disposed in respective recesses in block 32 and traveling magnet 34 disposed in a recess in rotatable block 36 which is secured to the proximal end of shank portion 20 by screw 38 . A stop pin 40 is also secured to the proximal end 26 of shank portion 20 by screw 42 located on the rotating part of the mechanism makes contact with stops 16 and 18 to define the extent of rotation M of arm-bar 14 . FIG. 4 also shows the extent of travel of rotatable block 36 and traveling magnet 34 in the clockwise direction as 36 ′ and 34 ′ respectively.
[0079] It should be noted that a small space exists between the adjacent faces of block 32 and rotatable block 36 so that rotatable block 36 does not frictionally engage.
[0080] The use of magnets 30 and 34 in housing 12 bias arm-bar 14 into the initial position and provides a smooth continuous rotational movement once the user has placed forearm/wrist A upon arm-bar 14 and begins to exert a pulling force F.
[0081] The exact sequence for rotation of arm-bar 14 and opening of door D depends on the position of the user, their change of position and the movement of their forearm/wrist A.
[0082] If, for example, a person were to stand directly in front of housing 12 , rest forearm/wrist A upon bend portion 22 and exert a pulling force F without moving his feet, arm-bar 14 would first move from its initial position and point at the person, being then approximately perpendicular to the adjacent face of door D. If the user were to take a step directly backward, which would further cause forearm/wrist A to pull on door D, the door would open further and the angle would decrease some and the arm bar would actually rotate toward and then past the swinging edge of the door, as seen by a person standing behind the user. The user could then step to the left to begin their entry thru the door. At this point, if the door opening was sufficiently wide, wrist/forearm A would naturally slide off the smooth arm-bar 14 in direction R as illustrated in FIG. 3 as the user moves further through the door opening.
[0083] The user's engagement of forearm/wrist A to arm-bar 14 can be as short as the time it takes to complete application of opening force F or, the engagement time can be delayed considerably and the person can in essence ‘walk the bar’ i.e. continue engagement to arm-bar 14 until the user is moving through the door opening.
[0084] Another method for opening swinging door D is by a user giving arm-bar 14 a hard yank, causing door D to swing open without moving from their initial position. As the door opens rapidly, the arm-bar 14 will quickly rotate and will again allow the slide release of the user's arm.
[0085] After a person has used the invention a couple of times, the operation becomes smooth, where the user's position and the pull angle are changing continually. Thus, the users arm typically enters and rests in the arm bar as shown in FIG. 1 , and is released typically by the slide action as shown in FIG. 3 .
[0086] In a most preferred embodiment of my invention, the arm-bar has a configuration as shown in FIG. 6 in accordance with the dimensions listed in the following table:
[0000]
TABLE 1
Circumference of Arm-Bar and degrees from Vertical
Section
Circumference (in)
degrees from vertical
A-A
2.945
0-90
B-B
3.14
90-120
C-C
4.28
120-150
D-D
5.12
150-165
[0087] FIGS. 6 and 7 also present additional dimensions W and X where W is about 5.9 inches and X is about 1.8 inches. It should be understood that for doors usable primarily by children, an arm-bar can be designed with smaller measurements than those described above for adults.
[0088] FIGS. 10-13 illustrate embodiments which utilize a push door opener assembly 80 which comprises contoured pad 82 rotatably mounted to mount 84 which is attached to door D. The push door opener assembly 82 can be constructed of any durable material but is preferably constructed of hard plastic, or a metal such as aluminum, brass or stainless steel. Assembly 80 can be mounted upon the door face opposite door opener assembly 10 either directly to the door face or to mounting bar 84 as shown in FIG. 10 or it can be configured to part of the door opener assembly as illustrated in FIG. 13 . It should be noted that contoured pad 82 is weighted so that gravity will assist in returning to its initial position. Also, magnets are also used to assist in biasing in the initial position. Contoured pad 82 can be rotated 360 degrees. Rotation of contoured pad permits a more comfortable engagement since the user, once having their forearm cradled in contoured pad 82 , can rotate to any desired position as illustrated in FIG. 10 .
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A door opener assembly having a rotatable arm-bar for hands-free use by individuals in high-traffic pedestrian conditions. The rotatable arm-bar has a distal knobbed end and allows users to easily position a wrist or forearm within the hook and to move laterally, as the person moves, as the door is opened and thereafter provides a slide-release of the forearm or wrist. The smooth surface and design of the arm-bar allows users to disengage from contact without risk of injury occurring such as from the unexpected opening of the door from the opposite 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 portable arrangement for ensuring privacy during use of a public toilet. The arrangement includes a screen in the form of a generally rectangular or square piece of sheet material with an embedded suction cup or other attachment means at each corner. Secured to the screen is a smaller pouch into which the screen can be folded and secured by a zipper for transport.
The sheet material is dimensioned to extend across the width of the door of a public restroom stall, to cover a substantial part of the vertical gaps, openings, or slots formed between walls of the stall and vertical edges on each side of the door, and to be held in position by adhesion of the suction cups to the walls of the stall, so as to ensure that the occupant of the stall cannot be viewed through the vertical openings by a person standing outside the stall.
2. Description of Related Art
The privacy arrangement of the invention is especially suitable for use by any individual who desires greater privacy than is provided by a typical public restroom stall.
Although individuals may desire additional privacy for a variety of reasons, there is an especially critical need for such additional privacy in the case of individuals who have had abdominal surgery and are required to use a colostomy bag. Use of a colostomy bag entails frontal exposure that can easily be viewed through the gap between the door and walls of the toilet stall, and that can cause the individual to avoid use of public toilets, limiting movement or participation in activities by the individual away from home.
It is known to provide privacy screens for portable bathroom assemblies or urinals of type designed for outdoor activities such as campouts, as disclosed in U.S. Pat. Nos. 5,937,452, 6,374,432, and 7,185,375, but the screens entirely surround the bathroom assembly or urinal, and are not suitable for protecting privacy in a conventional fixed bathroom stall.
It is also known to provide portable screen structures that serve as dressing rooms, the screen structure having a door through which an individual enters, and which either entirely surrounds the individual or encloses three sides of the individual, the fourth side being shielded by a structure or vehicle, to provide privacy when changing clothes, as disclosed in U.S. Pat. Nos. 6,840,254 and 7,464,983. Such structures are too large to be easily carried during everyday activities, and cannot be used to provide privacy in a public bathroom stall.
Finally, it is also known to provide a personal cover that fold into a pouch, as disclosed in U.S. Pat. No. 6,393,637, but the personal cover is in the form of a sleeping bag or poncho, and cannot be used as a privacy screen in a public restroom stall.
Each of the above-described prior art privacy screens is designed to substantially surround a person and/or a bathroom assembly or urinal, and therefore insufficiently portable to carry around during daily activities such as shopping or dining out. Furthermore, none is suitable for ensuring privacy in public bathroom stalls, in which only the gaps between the door and walls of the stall need to be screened.
SUMMARY OF THE INVENTION
It is accordingly an objective of the invention to provide an arrangement for ensuring privacy in public restroom stalls, by ensuring that a user of the stall cannot be seen from outside the stall.
This objective is achieved, in accordance with the principles of a preferred embodiment of the invention, by a privacy arrangement that includes a screen in the form of a generally rectangular or square piece of sheet material with an embedded attachment means at each corner. Secured to the screen is a smaller pouch into which the screen can be folded and secured by a zipper, or other fasteners such as buttons, snaps, or Velcro™, for transport.
The attachment means may be in the form of a suction cup provided at each corner of the sheet material, although those skilled in the art will appreciate that other attachment means may be substituted for one or more of the suction cups, or provided in addition to the suction cups, such as magnets or hooks that engage the tops of the walls and door of the stall.
The sheet material is preferably a lightweight, easily foldable material that is sufficiently opaque as to protect the privacy of a user of the stall when the material is placed over the openings or gaps between the door and walls of the stall, and secured to the stall by the suction cups or other attachment means. Perfect opacity is not necessarily required, so long as the material provides a screening effect that prevents a person outside the stall from recognizing or perceiving activities and persons within the stall. A suitable lightweight and sufficiently opaque material is nylon, although the invention is not to be limited to a particular material.
The dimensions of the sheet material are important in that the material must have sufficient length to extend over the gaps or openings at each side of the bathroom stall door, and sufficient width to cover enough of the length of the gaps or openings to provide a requisite degree of privacy. Exemplary dimensions of the sheet material are 5′×5′, although these dimensions may be varied without departing from the scope of the invention so long as the length is greater than the width of a bathroom stall door and the height is sufficient to prevent viewing by standing, or possibly standing and crouching, persons of different heights. A standard bathroom stall door is 58″ high, but doors are also available in the range from 48″ to 70″ (see, e.g., www.allpartitions.com/doors1.html), while door widths typically range from 20″ to 48″ (the Americans with Disabilities Act (ADA) sets a minimum door opening width of 36″ and stall width of 60″ for stalls accessible to the disabled. Based on these dimensions, the sheet material of the invention should not be limited to 5′×5′, but rather may be varied substantially, so long as the sheet is capable of covering gaps on either side of the stall door and has sufficient height to ensure privacy. For the U.S., a minimum length of greater than 30 inches, and a minimum height of 48 inches, appears to be desirable, though these minimum dimensions may be different in other countries and may also change to meet legal requirements such as changes in the ADA or local rules. Those skilled in the art will appreciate that the screen need not be perfectly rectangular or square so long as it is capable of extending over the width of the door and covering the gaps between the door and the walls of the stall.
According to the preferred embodiment of the invention, the privacy screen includes a pouch into which the screen can be folded when not in use. The pouch is secured to or integrated with the screen so that the pouch is immediately available when stall activities have concluded, at which time the screen can simply be folded and tucked into the pouch. A closure, such as a zipper extending along three edges of the pouch, is provided to secure the screen within the pouch for transport, and a strap may be provided to facilitate carrying. The dimensions of the pouch are selected for portability, for example so that the pouch can be carried in a woman's purse or a jacket pocket. Suitable dimensions are 6″×1.75″×4″, although these dimensions may be varied without departing from the scope of the invention.
In an especially preferred embodiment of the invention, the pouch is formed separately from the panel, and is sewn or stitched to a main panel of the screen. The main panel includes a generally rectangular or square opening that is preferably at or near a center of the main panel, the dimensions of the opening corresponding to dimensions of a side of the pouch. The pouch includes a back panel having dimensions corresponding to the dimensions of the opening, four side panels having a width corresponding to the thickness of the pouch, and a flap having dimensions corresponding to dimensions of the back panel, with one side of the flap being secured to the one of the side panels to form a hinge that allows the flap to be opened and closed. The top edges of the side panels are stitched to the panel along the edges of the opening when the flap is in the open position, so that the opening forms an opening of the pouch, such that the main panel of the screen preventing closure of the pouch. One part of a zipper is included on three edges of the opening and three edges of the flap to enable the flap to be secured to the main panel and thereby close the pouch when the main panel is folded into the pouch. According to this arrangement, the pouch is securely integrated into and inseparable from the main panel, thereby providing a convenient and readily accessible storage space into which the screen can easily be folded when the screen is not in use.
As an optional added feature, the pouch may include an additional pocket and closure for holding keys, money, and the like, eliminating the need for the user to carry a separate purse or wallet in addition to the pouch.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a conventional bathroom stall door, for which the screen of the present invention may be utilized.
FIG. 2 is an isometric view of a privacy screen of a preferred embodiment of the invention.
FIG. 3 shows the privacy screen of FIG. 2 , after being attached to a bathroom stall of the type shown in FIG. 1
FIG. 4 is an isometric view of a pouch and main panel, which are to be assembled together to form a screen according to a preferred embodiment of the invention.
FIG. 5 is an isometric view of the pouch and main panel of FIG. 4 , after assembly to form a privacy screen.
FIG. 6 is an isometric view of the reverse side of the privacy screen of FIG. 4 , illustrating the manner in which the main panel is folded into the pouch after use.
FIG. 7 is an isometric view of the pouch of FIGS. 3-6 , after the main panel has been folded into the pouch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Throughout the following description and drawings, like reference numbers/characters refer to like elements. It should be understood that, although specific exemplary embodiments are discussed herein there is no intent to limit the scope of present invention to such embodiments. To the contrary, it should be understood that the exemplary embodiments discussed herein are for illustrative purposes, and that modified and alternative embodiments may be implemented without departing from the scope of the present invention.
FIG. 1 shows a conventional bathroom stall arrangement of the type typically used in non-residential bathrooms. The illustrated stall arrangement includes stall access door 1 and portions of walls 2 and 3 , all of which are typically made of a metal such as steel, and extend from a few inches above floor 4 to a height sufficient to prevent a person standing on the ground from observing the interior of the stall through the space between the ceiling 5 and the tops of the door 1 and walls 2 , 3 . One side of the door is attached to one of the walls 3 by hinges 6 , and a latch 7 is provided on the opposite side of the door to prevent the door from being opening by pushing on the door 1 from outside the stall.
In order to enable the door 1 to be easily opened and closed, the door 1 is space from the walls 2 , 3 by gaps 8 and 9 on each side of the door. The gaps 8 , 9 may have widths of anywhere from less than a quarter inch to a half inch or more. In general, adequate privacy is provided despite the gaps so long as a person on the outside of the stall is a sufficient distance away from the stall and does not intentionally attempt to view the interior of the stall. Nevertheless, it is often possible to look through the gaps into the stall. This possibility poses a disincentive to use of public restrooms can cause substantial discomfort or stress to individuals using the stall, and particularly individuals who have an enhanced need for privacy, such as colostomy patients.
As shown in FIGS. 2 and 3 , the present invention provides a screen 30 that attaches to the walls 2 , 3 of a stall such as the one illustrated in FIG. 1 , and that covers at least the vertical gaps 8 , 9 between walls 2 , 3 and door 1 . Screen 30 includes a main panel 31 , a pouch 32 attached to the main panel 31 , and means 33 for attaching the panel to walls 2 , 3 such that the screen 30 extends between the walls 2 , 3 and covers both vertical gaps 8 , 9 .
The attachment means 33 may be in the form of suction cups provided at each corner of the sheet material, but is not limited to suction cups. Alternative attachment means include, by way of example and not limitation, hooks that engage the tops of the walls and door of the stall, or magnets sewn into pockets adjacent at least two corners of the screen 30 .
The screen 30 is preferably made of a lightweight, easily foldable sheet material that is sufficiently opaque as to protect the privacy of a user of the stall when the material is placed over the openings or gaps between the door and walls of the stall, and secured to the stall by the suction cups or other attachment means. Perfect opacity is not necessarily required, so long as the material provides a screening effect that prevents a person outside the stall from recognizing or perceiving activities and persons within the stall. A suitable lightweight and sufficiently opaque material is a finely woven nylon mesh, although the invention is not to be limited to a particular material.
The screen 30 must have sufficient length to extend over the vertical gaps 8 , 9 or openings at each side of the bathroom stall door 1 , and sufficient width to prevent persons from peering over or under the screen in order to see into the stall. Exemplary dimensions of the sheet material are 5′×5′, although these dimensions may be varied without departing from the scope of the invention so long as the length is greater than the width of a bathroom stall door, including stall doors for the disabled, which must be wide enough to admit wheelchairs. The vertical extent or height of the screen must be sufficient to prevent viewing by standing, or possibly standing and crouching, persons of different heights. For the U.S., a minimum length of greater than 30 inches, and a minimum height of 48 inches, is preferred, although these minimum dimensions may be different in other countries and may also change to meet legal requirements such as changes in the ADA or local rules.
FIGS. 4-7 show a specific exemplary implementation of the privacy screen of FIGS. 2 and 3 , including details of the construction of the privacy screen 30 and the manner in which a main panel 41 of the privacy screen may be folded into the integral pouch 40 for transport. The pouch 40 is secured to or integrated with the screen 30 so that the pouch is immediately available when stall activities have concluded, at which time the screen can simply be folded and tucked into the pouch. A closure, such as a zipper 42 extending along three edges of the pouch, is provided to secure the screen within the pouch for transport, and a strap 43 may be provided to facilitate carrying. The dimensions of the pouch are selected for portability, for example so that the pouch 40 can be carried in a woman's purse or a jacket pocket. Suitable dimensions are 6″×1.75″×4″, although these dimensions may be varied without departing from the scope of the invention.
As illustrated in FIG. 4 , the pouch 40 is formed separately from the main panel 41 , and is then sewn, stitched, or otherwise attached to the main panel 41 , as illustrated in FIG. 5 . In addition to or instead of stitching, the pouch may be attached by fabric glue, rivets, or any other fastening means. The material of the pouch 40 is preferably the same as that of the main panel 41 , although it is within the scope of the invention to make the pouch of a different material, such as vinyl, cloth, or leather, in order to provide a more attractive carrying case and/or provide environmental protection for the main panel 41 stored inside the pouch.
The main panel 41 includes a rectangular opening 43 that is preferably at or near a center of the main panel, the dimensions of the opening 43 corresponding to dimensions of a back panel 44 of the pouch. As best seen in FIG. 7 , the pouch 40 includes the back panel 44 having dimensions corresponding to the dimensions of the opening 43 , four side panels 45 - 48 having a width corresponding to the thickness of the pouch, and a flap 49 having dimensions corresponding to dimensions of the back panel 44 to form a parallelepiped shaped container, with one side of the flap 49 being secured to the one of the side panels 45 to form a hinge 50 that allows the flap 49 to be opened and closed. The top edges 51 of the side panels are stitched or otherwise attached to the panel along the edges 52 of the opening 43 when the flap 49 is in the open position, so that the opening 43 forms an opening of the pouch, and such that the main panel 41 of the screen prevents closure of the pouch until the main panel has been folded into the pouch. One mating half of zipper 42 is included on three edges of the opening, while the other mating half of zipper 42 extends along the three edges of the opening 43 to enable the 49 flap to be secured to the main panel 41 and thereby close the pouch when the main panel 41 is folded into the pouch 40 .
As an optional added feature, shown in FIG. 7 , the pouch may include an additional pocket 55 for carrying items such as cash, bank cards, keys, and other items that would normally be carried in a purse or wallet. The additional pocket is preferably accessible from outside the pouch when the screen is enclosed within the pouch, and may be secured by a separate closure such as a zipper. The pocket could be sewn into back panel 44 , side panels 45 - 48 , or flap 49 .
FIG. 6 shows the reverse side of the arrangement of FIG. 5 , with arrows 54 indicating in schematic fashion the manner in which the edges of the main panel are folded into the pouch 40 before closure, although it will be appreciated that the main panel 41 may be folded multiple times before being positioned in the pouch. The main panel 41 may include creases (not shown) or other guides to facilitate folding. FIG. 7 shows the pouch 40 after the main panel 41 has been folded into the opening 43 and before the flap 49 has been secured to the pouch by the zipper 42 . It will be appreciated that the zipper 42 , as well as the zipper of the optional pocket 50 , may be replaced by other closure elements, such as buttons, snaps, or Velcro™.
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A portable arrangement is provided for ensuring privacy during use of a public toilet. The arrangement includes a screen in the form of a generally rectangular or square piece of sheet material with an embedded suction cup or other attachment means at each corner. Secured to the screen is a smaller pouch into which the screen can be folded for transport.
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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 field of invention relates to active seismic response control systems for use in structures, and more particularly to active seismic response control systems in which variable resistance connecting devices are provided in frames of structures to interconnect frame bodies and variable stiffness elements, or to interconnect the variable stiffness elements themselves provided in the frame wherein external vibrational forces such as earthquake tremors and wind are controlled by the use of computer technology to reduce the vibrational response of the structure to such external vibrational forces.
2. Description of the Prior Art
Applicants have heretofore proposed various types of active seismic response control systems and variable stiffness structures, each of which has a variable stiffness element in the form of a brace or a wall incorporated in the post and beam frames of a structure. The stiffness of the variable stiffness elements per se and/or the combination of a frame body and variable stiffness elements is varied responsive to analysis of the characteristics of the external vibrational forces by computer means to render the structure non-resonant relative to the external vibrational forces to attain the safety of the structure.
Prior art active seismic response control systems primarily observe and deal with the relationship between the predominant periods of seismic and/or wind vibrations and the natural frequency of the structure. Harmonic resonance of the structure during the predominant periods of external vibrations is avoided by changing the natural frequencies of the structure, thereby attenuating the response of the structure to the external vibrations. However, conventional seismic response control systems do not necessarily provide optimal control in cases where the seismic disturbances have indistinct predominant periods or a plurality of predominant periods.
SUMMARY OF THE INVENTION
The present invention provides an active seismic response control system in which a variable resistance connecting device is interposed between a frame body and a variable stiffness element, or in the variable stiffness element. The system also includes response measuring means, control force determining means, and control command generating means.
The optimal control force u shown in FIG. 5 is determined by computer means according to the construction of the frame F, to which the present invention is applied. By analyzing the relationship between the connecting device and the control force, a command is sent by the computer means to the connecting device to provide a control force appropriate for reducing the response of the frame body to external vibrational forces.
The inventive connecting device is referred to as a cylinder lock 10, FIG. 3, comprising a hydraulic cylinder and a piston rod of a double-rod type reciprocating in the cylinder. The cylinder lock may be connected, for example, between the frame and a variable stiffness element such as a frame cross brace. As shown in FIG. 3, the cylinder lock also includes a high-speed switch valve 15 serving as an orifice in an oil path 14 for interconnecting two oil pressure chambers 13A and 13B located on opposite sides of a piston 12a. The switch valve 15 is actuated to regulate the control force by opening and closing at computer-controlled variable speeds, in response to pulsed signals, as shown in FIG. 4.
When an external vibrational force is impressed on a structure, the responses of the structure frame and related parts are detected by sensors, such as displacement meters, speedometers or accelerometers, serving as the response measuring means. The optimal control force for the frame, for example, is calculated by the control force determining means in a computer program, and then a control command for providing the optimal control force is given to the connecting device by the control command generating means to thereby control the vibration of the structure.
While the above-described system controls the vibration of the structure by varying the control force, in another system the connecting device is used as a variable damping means capable of varying the damping coeffecient of the structure as a means to control the vibration of the structure. In another system, the response to displacement and to acceleration of the structure may be controlled either jointly or severally.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide an active seismic response control system which varies and actively regulates a control force according to a determined response calculated to best protect a structure from external vibrations.
Another object of the present invention is to adjust the connecting condition of a variable resistance connecting device provided between the frame body and the variable stiffness element relative to a disturbance such as a seismic motion, whereby a control force applied to the frame body in the form of a damping force is controlled to reduce the response of the structure.
A further object of the present invention is to analyze the relationship between the control force and the connecting device while calculating an optimal control force by the use of a computer, whereby a feed-back control, which is a function of the response of the structure, is provided to protect the structure from harmful over-response.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view of a frame of a structure showing an application of an active seismic response control system according to the present invention;
FIG. 2 is a flow chart showing a control in accordance with the active seismic response control system of the present invention;
FIG. 3 is a schematic view showing a cylinder lock device serving as a connecting device for use in the active seismic response control system of the present invention;
FIG. 4 is a graph showing the relationship between a pulse signal and the opening and closing of the valve controlling the cylinder lock device of FIG. 3;
FIG. 5 is a schematic elevational view of a braced frame of a structure protected by the present invention;
FIG. 6 is a schematic elevational view of a dynamic model of a frame according to the present invention;
FIG. 7 is a hydraulic circuit diagram showing a specific example of a cylinder lock device for use in the active seismic response control system according to the present invention;
FIGS. 8 through 15 are schematic elevational views showing various positions of variable damping devices applied to the frames of variable damping structures, in accordance with the present invention;
FIG. 16 is an elevational view in section showing a variable damping and variable stiffness structure subjected to bending deformation control;
FIG. 17 is a cross-sectional view taken along the line 17--17 of FIG. 16;
FIG. 18 is a cross-sectional view taken along the line 18--18 of FIG. 16;
FIG. 19 is a schematic elevational view showing the frame of a building to which an embodiment of the present invention shown in FIG. 16 is applied;
FIG. 20 is a plan view showing the building of FIG. 19;
FIG. 21 is a schematic view showing an inventive embodiment of a cylinder lock device serving as a variable damping device according to the present invention;
FIG. 22 is a schematic elevational view showing a building under conditions;
FIG. 23 is a schematic view showing the condition of the inventive cylinder lock device in the building shown in FIG. 22;
FIG. 24 is a schematic elevational view showing the building of FIG. 22 in a low damping condition or under the free condition against earthquake tremors and/or wind;
FIG. 25 is a schematic view showing the condition of the inventive cylinder lock device when the building of FIG. 24 is in a low damping condition or under the free condition;
FIG. 26 is a schematic elevational view showing the building of FIG. 22 in a high damping condition or in a locked condition against earthquake tremors and/or wind; and
FIG. 27 is a schematic view showing the condition of the inventive cylinder lock device when the building is in a high damping condition or in a locked condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter will be described a preferred embodiment of an active seismic response control system according to the present invention.
FIG. 1 schematically shows an application of the active seismic response control system according to the present invention, in which a cylinder lock device 1 is interposed between a frame body 2 consisting of a post 3 and a beam 4 and an inverted V-shaped brace 5 serving as a variable stiffness element incorporated in the frame body 2 on each story. The response (amplitude, speed, and/or acceleration) of a structure subjected to the tremors of an earthquake is sensed by a response sensor 6 installed on the structure, and the optimal response is obtained by a computer 7 to generate a control command. FIG. 2 is a flow chart of the operation of this control system.
More specifically, the control using the cylinder lock device 1 functions as follows:
(1) The relationship between the switch valve 15 and the force impressed on the variable stiffness element 5 is analyzed by the computer 7.
(2) The necessary control force is calculated on the basis of the response condition (displacement x, speed x, and/or acceleration x) of the structure.
(3) Computer 7 commands the switch valve 15 to adjust appropriately to obtain the necessary control force. Switch valve 15 opens and closes an orifice in order to provide a control force proportional to the second power of the relative speed.
(4) The cylinder lock device 1 generates the control force according to the computer command to thereby reduce the response of the structure.
In the case where the cylinder lock device 1 is used, if the direction of the response is the same as that of the optimal control force, the cylinder lock device can apply a control force. If the direction of the response is opposite to that of the optimal control force, the cylinder lock device cannot apply a control force. In the latter case, the control force is controlled to be set to zero (the switch valve is assumed to be fully open). This relationship is represented by a formula where the control is executed on the basis of the speed (x) and the relative speed of the frame body to the brace in the dynamic model as shown in FIG. 6, as follows:
Δx=x.sub.1 -x.sub.2
When the product u·Δx of the relative speed and the optimal control force u is negative, the control is executed by the control force u' which is equal to u. When the product as noted above is positive, the control force u' is assumed to be zero. That is, ##EQU1##
Next will be described an embodiment of a variable damping device serving as the connecting device used in the active seismic response control system according to the present invention.
A preferred embodiment 81 of the invention, schematically shown in FIG. 7, comprises cylinder lock 1; flow regulating valve 92; shut-off valve 92c; solenoid 100; pulse generator 100A; and computer 7. A piston 83 of a double-rod type reciprocating in a cylinder body 82 is provided with left and right oil pressure chambers 86A and 86B located on the left and right sides respectively of the piston 83, and pressurized oil in the left and right oil pressure chambers is adapted to stop or flow for fixing or moving piston 83 leftward or rightward.
In a first preferred embodiment of the invention, the cylinder 82 is connected to the frame body of the structure, and the rod 84 is connected to the variable stiffness element. In a second preferred embodiment of the invention, the rod 84 is connected to the frame body and the cylinder 82 is connected to the variable stiffness element. In a third preferred embodiment of the invention, both the cylinder 82 and the rod 84 may be connected to a variable stiffness element 5. The left and right oil pressure chambers are provided with outflow check valves 88A and 88B, respectively, for blocking the outflow of pressurized oil from the corresponding oil pressure chamber. Inflow check valves 89A and 89B are for blocking the inflow of pressurized oil into the corresponding oil pressure chambers 86A and 86B, respectively. Inflow path 90 interconnects the left and right outflow blocking check valves 88A and 88B, and an outflow path 91 interconnects the left and right inflow blocking check valves 89A and 89B.
A flow regulating valve 92 is provided in the connecting position of the inflow path 90 and the outflow path 91, and is controlled to be opened or closed in response to a pulse signal from a pulse generator 100A connected to the computer 7. The variable damping device 81, when considered conceptually with reference to the schematic showing of the cylinder lock 1 of FIG. 3, provides a variable stiffness device for varying the stiffness of the frame body by controlling the locked condition, in which the flow regulating valve 92 is completely closed, and the free condition, in which the flow regulating valve 92 is completely open. In addition, the various damping coefficients c are obtained by regulating the opening of the flow regulating valve 92 to delicately regulate the connecting conditions between the completely locked condition and the completely free condition of the flow regulating valve. By appropriate regulation, the natural period and the damping constant h of the frame body are varied depending upon the damping coefficient c and the vibrational condition of the frame body. Optionally, the damping force may be used as the control force.
The opening of the flow regulating valve 92 is contemplated in relation to time by regulating the interval of pulse signals provided from the pulse generator 100A. As shown in FIG. 4, various openings and various damping coefficients c, accompanying the change of the opening, are realized by varying the times during which the flow regulating valve 92 is open.
The flow regulating valve 92 comprises a valve body 92a and a change-over valve 92b. The valve body 92a has an inlet port 95 and an outlet port 96 provided on one end of the valve body, a back pressure port 97 provided on the other end of the valve body, and a shut-off valve 92c provided on a bypass flow path 98 providing communication between the back pressure port 97 and the inlet port 95. Shut-off valve 92c is capable of blocking the outflow of pressurized oil toward the back pressure port 97, and is opened and closed in response to a pulse signal provided from the pulse generator 100A upon the reception of a command from the computer 7, thereby controlling the opening and closing of the shut-off valve 92c. An accumulator 99 may be provided on either the inflow path 90 or the outflow path 91 in order to compensate for the volumetric change of fluid caused by temperature fluctuation and to compress the working fluid.
Next will be described the operating condition of the variable damping device 81 in accordance with the present embodiment.
(1) Flow regulating valve 92 is open.
When the shut-off valve 92c is opened, the piston 83 is shifted leftward so that the pressurized oil in the left oil pressure chamber 86A flows through the inflow blocking check valve 89A and the outflow path 91 to lift up the change-over valve 92b. Since the left outflow blocking check valve 88A and the right inflow blocking check valve 89B are closed due to the pressurized oil, the pressurized oil flows from the flow regulating valve 92 through the inflow path 90 and the right outflow blocking check valve 88B. Accordingly, the pressurized oil flows from the left oil pressure chamber 86A to the right oil pressure chamber 86B, thereby causing the piston 83 to shift leftward.
When the piston 83 is shifted to the right, the pressurized oil in the right oil pressure chamber 86B flows through the inflow blocking check valve 89B and the outflow path 91 to lift up the change-over valve 92b. Since the right outflow blocking check valve 88B and the left inflow blocking check valve 89A are pressure closed, the pressurized oil flows from the flow regulating valve 92 through the inflow path 90 and the left outflow blocking check valve 88A. Thus the pressurized oil flows from the right oil pressure chamber 86B to the left oil pressure chamber 86A, thereby causing the piston 83 to shift to the right.
(2) Flow regulating valve is closed.
When the shut-off valve 92c is closed and a leftward external force is applied to the piston 83, the oil pressure in the system is equalized and movement of the piston 83 is blocked. When rightward external force is applied to the piston 83, the movement of the piston 83 is similarly blocked.
FIGS. 8 through 15 show various applications of variable damping cylinder lock devices 1 in operative relation to the frame body 102 of the structure.
In the embodiment shown in FIG. 8, a variable damping cylinder lock device 1 is interposed between a beam 104 and an inverted V-shaped brace 105 serving as the variable stiffness element.
In the embodiment shown in FIG. 9, the variable damping cylinder lock device 1 is interposed between U-shaped braces 111A and 111B vertically projecting from upper and lower beams 104A and 104B to constitute a moment resistance frame serving as the variable stiffness element.
In the embodiment shown in FIG. 10, the variable damping cylinder lock device 1 is interposed between the beam 104A and an earthquake-resisting wall 112 serving as the variable stiffness element.
In the embodiment shown in FIG. 11, the variable damping cylinder lock device 1 is interposed between the foundation 104C and a beam 104B, in combination with laminated rubber base isolation members 113. In this embodiment, the variable damping locking device 1 serves as a damper in the base isolation structure. The variable stiffness element in this embodiment is considered to be the foundation 104C of the structure.
In the embodiment shown in FIG. 12, an X-shaped brace 114 provided in frame body 102 is used as the variable stiffness element, and the variable damping cylinder lock device 1 is horizontally interposed in the center of the X-shaped brace.
The embodiment shown in FIG. 13 is applied to the X-shaped brace 115, similar to the embodiment shown in FIG. 12. In the embodiment shown in FIG. 13, the variable damping cylinder lock device 1 is vertically interposed.
In the embodiment shown in FIG. 14, similar to the embodiment shown in FIG. 10, the variable damping cylinder lock device 1 is secured in an opening 117A above a doorway 117 between beam 104A and wall 116, serving as the variable stiffness element.
In the embodiment shown in FIG. 15, the variable damping cylinder lock device 1 is interposed in the center of an X-shaped brace 118 in a large frame 102A, and intermediate large beams 119A and 119B and the brace 118, which are separated from each other.
FIGS. 16 through 27 show embodiments of the invention in which the active seismic response control systems are applied to structures having large bending deformation, such as high-rise buildings. The vibration of high-rise buildings due to earthquake and wind includes the shearing deformation of the frame caused by bending of posts and beams and by bending deformation of the whole frame caused by axial deformation of the posts. Normally, the vibration of a building consists of the total of the aforementioned two deformations, and the greater the height of a slender building relative to its width, the greater is the bending deformation of the whole frame.
Many conventional variable stiffness structures cope with the vibration of a building by controlling the stiffness of the whole frame on each story, which requires a complicated control to cope with the bending deformation. According to the present embodiment, a rod-like control member extending over at least a plurality of stories is provided along the posts of the multi-storied building, and upper and lower portions of the control member are respectively connected with portions of the building, preferably with the uppermost and lowermost portions thereof. A variable damping device capable of varying the connecting condition is provided on an intermediate portion or an end portion of the control member, so that the stiffness of the building or the damping force is controlled by means of control of the bending deformation against the vibrational disturbance such as earthquake or wind.
Referring to FIGS. 16 through 18, an interior steel round pipe 121 serving as the control member is installed inside a hollow rectangular post 122 of a high-rise building. The inside steel pipe 121 has the uppermost portion rigidly connected to cruciform vertical connecting plates 126A and to a rectangular diaphragm plate 125A. The lowermost portion of pipe 121 is rigidly secured to cruciform vertical connecting plates 126B and to a rectangular diaphragm plate 125B. An axial force of post 122 on the uppermost portion is transmitted to the inside steel pipe 121, while an axial force of the inside steel pipe 121 at its lowermost portion is transmitted to the underground portion 122A of post 122 and to the foundation 104C. The interior steel pipe 121, at the reference story, FIG. 16, is separated away from diaphragms 124 by means of small annular concentric clearance spaces 121A, shown in FIG. 18, so that the interior steel pipe 121 is capable of shifting in the axial direction relative to the diaphragms 124 according to the condition of a cylinder lock device 130 provided beneath the lower portion of the interior steel pipe 121. The remote ends of the cylinder lock device piston rod are marked by numerals 132A and 132B.
FIGS. 19 and 20 show the frame of a building, in which the aforementioned double steel pipe damping system shown in FIG. 16 is applied only to the outer posts 122a provided on the outer periphery of the building. Posts 122a are indicated by solid squares in FIG. 20 and standard posts 122b are indicated by the hollow squares. The cylinder lock devices 130 are installed on the first-story portion of the outer posts 122a.
FIG. 21 is a schematic view showing the cylinder lock device 130 corresponding to that shown in FIG. 3, in which a double-rod piston 132a is inserted into a cylinder 131, and a switch valve 135 is provided on an oil path 134 for interconnecting two oil pressure chambers 133 respectively located on opposite sides of the piston 132a. The damping force varied by controlling the opening of the switch valve 135 in multiple steps. If the opening of the switch valve 135 is selected between the fully opened condition and the fully closed condition, two conditions of the switch valve 135, i.e., free and locked, are realized. However, computer controlled intermediate valve openings are obtainable in which the damping force provides a resistance proportional to the power of the relative speed of the piston 132a to the cylinder 131.
The cylinder lock device 130 is installed beneath steel pipe 121, and connected thereto so that vertical motion of pipe 121 results in the relative displacement of the piston 132a to the cylinder 131 of the cylinder lock device 130.
As described above, in the case where the cylinder lock device 130 is controlled under only two modes, i.e., free and locked conditions, the control to obtain non-resonance of a structure is accomplished substantially the same as in prior art variable stiffness active seismic response control systems by allowing or restraining the reaction of a building frame to external seismic or wind forces. In addition, however, by controlling the switch valve 135 with computer-commanded digital signals, the orifice may be continuously adjusted to provide the proper damping coefficient of the cylinder lock device 130.
Table 1 and FIGS. 22 through 27 summarize the relationship between the deformed condition of the building and the condition of the cylinder lock device 130.
TABLE 1__________________________________________________________________________ earthquake or windload normal low damping coefficient high damping coefficientdevice time or free condition or locked condition__________________________________________________________________________deformed FIG. 22 FIG. 24 FIG. 26conditionof buildingcondition of FIG. 23 FIG. 25 FIG. 27device -- piston moves without much piston moves with much resistance under almost resistance under almost opened condition of switch closed condition of valve switch valveδ -- large smallΔl -- large smallT -- long shortN 0 small largeremarks -- stiffness is soft and stiffness is hard and natural period is long natural period is short under condition that under condition that inside steel pipe is inside steel pipe is hardly effective sufficiently effective__________________________________________________________________________ δ: horizontal displacement (uppermost portion) Δl: expansion and contraction of outer post T: primary natural period of building N: axial force of inside steel pipe
Under conditions of normal vibrational stress, the building is not deformed, as shown in FIG. 22, and it is not necessary to control the switch valve 135 of the cylinder lock device 130, as shown in FIG. 23.
FIG. 24 illustrates a situation in which the structure is subjected to a high vibrational stress and the cylinder lock device 130 is in the fully open mode, as shown in FIG. 25.
The building shown in FIG. 26 is subjected to the same vibrational stresses as the building shown in FIG. 24. However, in this case, the cylinder lock device is in the fully, or substantially fully, closed mode, as shown in FIG. 27. FIGS. 24 and 26 illustrate the two extremes of seismic response control provided by the subject invention, it being understood that the inventive system is also capable of providing computer programmed intermediate responses best suited to protect the building during a specific seismic or wind imposed vibrational stress and strain.
Numerous modifications and variations of the subject invention may occur to those skilled in the art upon a study of this disclosure. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as described in the specification and illustrated in the drawings.
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An active seismic response control system includes a variable damping device provided between posts, beams and braces of a structure, wherein the response of the frame is reduced by controlling the variable damping device when an earthquake or strong wind occurs to give a damping force to the frame. The response of the structure is determined by the steps of judging with a computer the optimal damping force or control force to be applied to the structure on the basis of information obtained from sensors in response to the disturbance, and then controlling the coefficient of damping of the variable damping device.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/560,047, filed Apr. 6, 2004, and Canadian Application No. 2,463,354, filed Apr. 6, 2004, which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a telemetry system, and in particular to a measurement while drilling (MWD) system. More particularly, the present invention relates to a servo-actuator for a downhole mud pulser for sending information from downhole to surface.
BACKGROUND OF THE INVENTION
[0003] The desirability and effectiveness of well logging systems where information is sensed in the well hole and transmitted to the surface through mud pulse telemetry has long been recognized. Mud pulse telemetry systems provide the driller at the surface with means for quickly determining various kinds of downhole information, most particularly information about the location, orientation and direction of the drill string at the bottom of the well in a directional drilling operation. During normal drilling operations, a continuous column of mud is circulating within the drill string from the surface of the well to the drilling bit at the bottom of the well and then back to the surface. Mud pulse telemetry repeatedly restricts the flow of mud to propagate signals through the mud upward to the surface, thereby providing a very fast communication link between the drill bit and the surface. Depending on the type of drilling fluid used, the velocity may vary between approximately 3000 and 5000 feet per second.
[0004] A telemetry system may be lowered on a wireline located within the drill string, but is usually formed as an integral part of a special drill collar inserted into the drill string near the drilling bit. The basic operational concept of mud pulse telemetry is to intermittently restrict the flow of mud as it passes through a downhole telemetry valve, thereby creating a pressure pulse in the mud stream that travels to the surface of the well. The information sensed by instrumentation in the vicinity of the drilling bit is encoded into a digital formatted signal and is transmitted by instructions to pulse the mud by intermittently actuating the telemetry valve, which restricts the mud flow in the drill string, thereby transmitting pulses to the well surface where the pulses are detected and transformed into electrical signals which can be decoded and processed to reveal transmitted information.
[0005] Representative examples of previous mud pulse telemetry systems may be found in U.S. Pat. Nos. 3,949,354; 3,958,217; 4,216,536; 4,401,134; and 4,515,225.
[0006] Representative samples of mud pulse generators may be found in U.S. Pat. Nos. 4,386,422; 4,699,352; 5,103,420; and 5,787,052.
[0007] A telemetry system capable of performing the desired function with minimal control energy is desirable, since the systems are typically powered by finite-storage batteries. One such example is found in U.S. Pat. No. 5,333,686, which describes a mud pulser having a main valve biased against a narrowed portion of the mud flowpath to restrict the flow of mud, with periodic actuation of the main valve to allow mud to temporarily flow freely within the flowpath. The main valve is actuated by a pilot valve that can be moved with minimal force. The pilot valve additionally provides for pressure equalization, thereby increasing the life of downhole batteries.
[0008] Another example of an energy efficient mud pulser is described in U.S. Pat. No. 6,016,288, the mud pulser having a DC motor electrically powered to drive a planetary gear which in turn powers a threaded drive shaft, mounted in a bearing assembly to rotate a ball nut lead screw. The rotating threaded shaft lifts the lead screw, which is attached to the pilot valve.
[0009] Solenoid-type pulser actuators have also been used to actuate the main pulser valve, however, there are many problems with such a system. The use of a spring to bias the solenoid requires the actuator (servo) valve to overcome the force of the spring (about 6 pounds) and of the mud prior to actuating the main valve. A typical solenoid driven actuator valve is capable of exerting only 11 pounds of pressure, leaving only 5 pounds of pressure to actuate the pulser assembly. Under drilling conditions requiring higher than normal mud flow, the limited pressures exerted by the solenoid may be unable to overcome both the pressure of the return spring and the increased pressure of the flowing mud, resulting in a failure to open the servo-valve, resulting in the main valve remaining in a position in which mud flow is not restricted, and therefore failing to communicate useful information to the surface.
[0010] A further problem with the use of a solenoid to actuate the pulser assembly is the limited speed of response and recovery that is typical of solenoid systems. Following application of a current to a solenoid, there is a recovery period during which the magnetic field decays to a point at which it can be overcome by the force of the solenoid's own return spring to close the servo-valve. This delay results in a maximum data rate (pulse width) of approximately 0.8 seconds/pulse, limiting the application of the technology.
[0011] Moreover, the linear alignment of the solenoid must be exactly tuned (i.e. the magnetic shaft must be precisely positioned within the coil) in order to keep the actuator's power characteristics within a reliable operating range. Therefore, inclusion of a solenoid within the tool adds complexity to the process of assembling and repairing the pulser actuator, and impairs the overall operability and reliability of the system.
[0012] Existing tools are also prone to jamming due to accumulation of debris, reducing the range of motion of the pilot valve. Particularly when combined with conditions of high mud flow, the power of the solenoid is unable to clear the jam, and the tool is rendered non-functional. The tool must then be brought to the surface for service.
[0013] Stepper motors have been used in mud pulsing systems, specifically, in negative pulse systems (see for example U.S. Pat. No. 5,115,415). The use of a stepper motor to directly control the main pulse valve, however, requires a large amount of electrical power, possibly requiring a turbine generator to supply adequate power to operate the system for any length of time downhole.
[0014] Repair of previous pursers has been an as yet unresolved difficulty. Typically, the entire tool has been contained within one housing, making access and replacement of small parts difficult and time-consuming. Furthermore, a bellows seal within the servo-poppet has typically been the only barrier between the mud flowing past the pilot valve's poppet and the pressurized oil contained within the servo-valve actuating tool, which is required to equalize the hydrostatic pressure of the downhole mud with the tool's internal spaces. Therefore, in order to dissemble the tool for repair, the bellows seal had to be removed, causing the integrity of the pressurized oil chamber to be lost at each repair.
[0015] Furthermore, a key area of failure of MWD pulser drivers has been the failure of the bellows seal around the servo-valve activating shaft, which separates the drilling mud from the internal oil. In existing systems, the addition of a second seal is not feasible, particularly in servo-drivers in which the servo-valve is closed by a spring due to the limited force which may be exerted by the spring, which is in turn limited by the available force of the solenoid, and cannot overcome the friction or drag of an additional static/dynamic linear seal.
[0016] It remains desirable within the art to provide a pulse generator that has an energy efficiency sufficient to operate reliably and to adapt to a variety of hostile downhole conditions, has reduced susceptibility to jamming by debris, and is simpler to repair than previous systems.
SUMMARY OF THE INVENTION
[0017] It is an object of the present invention to obviate or mitigate at least one disadvantage of previous mud pulsers and pulse generators.
[0018] In a first aspect, the present invention provides a downhole measurement-while-drilling pulser actuator comprising a servo valve movable between an open position which permits mud flow through a servo-orifice and a restricted position which restricts mud flow through the servo-orifice, the servo-valve powered to the open position and powered to the closed position by a reversible electric motor.
[0019] In one embodiment, the servo valve includes a servo-poppet powered by the motor in reciprocating linear movement towards and away from the servo-orifice.
[0020] In a further embodiment, the actuator may include a rotary to linear conversion system for converting rotary motion of the reversible electric motor into linear reciprocating movement of the poppet. The rotary to linear conversion system may include a threaded lead screw held stationary and driven in rotation by a rotary motor. In this embodiment, the lead screw may be threadably attached to a ball nut from which the poppet depends, whereby the rotary motion of the motor causes rotation of the screw to result in driven linear movement of the ball nut and the poppet in either direction.
[0021] In a further embodiment, there is provided a servo-controller for controlling the powering of the servo-valve by the electric motor. The servo-controller may further be capable of sensing the position of the poppet with respect to the servo-orifice, such that the poppet position is sensed when mud flow through the servo-orifice is restricted or unrestricted, and wherein the amount and direction of rotation of the motor from the sensed poppet position is counted and stored by the controller.
[0022] In another embodiment, the sensed position of the orifice restriction is calibrated as the fully closed position of the poppet. The poppet's travel is thereby monitored and controlled during operation to avoid unneeded collision or frictional wear between the poppet and the servo-orifice. The servo controller may sense the position of the poppet by sensing whether movement of the poppet is impeded, and the servo-controller counts the number of rotations of the motor until the poppet is impeded and compares the number of rotations to an expected number of rotations to determine the position of the poppet with respect to the servo-orifice. The expected number of rotations can be preset to allow a predetermined rate of mud flow past the servo-orifice when the poppet is moved away from the servo-orifice by the preset expected number of rotations.
[0023] In a still further embodiment, the servo-controller may include a debris clearing command that is initiated when the number of rotations counted is not equal to the expected number of rotations. The debris clearing command may cause the motor to rapidly reciprocate the poppet to dislodge any debris present between the poppet and the servo-orifice.
[0024] In another embodiment, the attachment between the poppet and the motor comprises a dynamic seal to isolate the motor, rotary to linear conversion system and related drive components from the drilling mud in which the poppet and orifice are immersed when in operation.
[0025] In a further aspect, the present invention provides a method for causing the generation of a mud pulse by a controlled pulser's main pulse valve comprising the steps of: powering a pulser servo-valve in a first direction using a rotary motor such that mud is permitted to flow past a servo-orifice to activate a main mud pulse valve; and powering the servo-valve in a second direction using the rotary motor such that mud flow past the servo-orifice is restricted to deactivate the main mud pulse valve.
[0026] In one embodiment, the method further comprises the step of cutting power to the motor to hold the servo-valve in a particular position within its range of motion to tailor the actuator's effect on the main pulse valve and thereby tailor the pressure and duration characteristics of a mud pulse.
[0027] In another aspect, the invention provides a servo-controller for use with a downhole measurement-while-drilling pulser actuator, the servo-controller comprising a sensor, memory, control circuitry, and an operator interface.
[0028] In one embodiment, the sensor is a mudflow sensor, pressure sensor, temperature sensor, rotation-step counter, position sensor, velocity sensor, current level sensor, battery voltage sensor, timer, or an error monitor.
[0029] In another embodiment, the memory stores time-stamped or counted sensed events together with an event-type indication. The servo-controller may be programmable to cause an action within the actuator responsive to a sensed event, a time, an elapsed time, a series of sensed events, or any combination thereof.
[0030] In a further embodiment, the user interface provides information from memory to the operator, and may allow an operator to alter the programming of the control circuitry. 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
[0031] Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
[0032] FIGS. 1A and B are a longitudinal cross sectional view of the upper and lower portions of an embodiment of the mud pulser during mud flow through the servo orifice; and
[0033] FIGS. 2A and 2B are a longitudinal cross sectional view of the upper and lower portions of an embodiment of the mud pulser during mud flow restriction by the poppet.
DETAILED DESCRIPTION
[0034] The present invention relates to an apparatus and method for actuating a mud pulser telemetry system used during well-drilling operations. The present apparatus allows a servo-valve to be powered both in opening and closing to activate a main mud pulser valve, and does not rely on a solenoid system. The powered opening and closing of the servo-valve results in various functional and economic advantages, including the ability to clear debris from the restricted portion of the mud flowpath, and faster data rates due to elimination of inherent operating delays in the solenoid systems of previous tools, with the end result of providing a pulser driver which consumes a minimal amount of DC power while providing more force with which to drive the servo-valve's poppet in each direction. Therefore, the actuator remains functional at a comprehensive range of downhole drilling conditions.
[0035] Furthermore, in the embodiment shown in the Figures, the present device is designed to have several independent, interconnected housings, and employs a double seal between the oil compartment and the drilling mud, which simplifies assembly and repair of the tool. The assembly/disassembly is simplified to reduce repair turnaround time by using modular components.
[0036] Additionally, the use of a stepper motor, electric load sensors, and control circuitry in a powered-both-directions servo-valve system will allow for self-calibration of the tool and self-diagnosis and error correction unavailable in other systems. In an embodiment of the invention, as shown in FIGS. 1A and 1B , a three-phase stepper rotary motor 1 is monitored and controlled by a servo-controller 10 , the rotary movement of the motor 1 being converted into linear movement of a poppet 21 , thereby opening and closing a servo-valve 20 to actuate a mud pulser main valve (not shown). Communication of information to the well surface is accomplished by encoded signals, which are translated to produce pressure surges in the downward flow of the pressurized mud. It is recognized that although the drilling fluid is generally referred to as mud, other drilling fluids are also suitable for use with the present invention, as is well known in the art.
[0037] With reference to the Figures, the mud pulser actuator is lowered downhole and, in the embodiment shown, generally includes a plurality of serially interconnected housings 2 , 3 , 4 , 5 , 6 , 7 , and 8 , an electrical connector 9 , a servo-controller 10 for controlling the operation of a rotary motor 1 , and a servo-valve assembly 20 that is driven in linear motion by the rotary motor 1 . The servo-valve assembly includes a poppet 21 capable of linear reciprocating movement to and from a seal surface 22 of a servo orifice 23 , thereby opening and closing the servo orifice 23 to allow or prevent the passage of pressurized mud and thereby actuate a pulser (not shown, connected to the lower end 2 a of the lowermost housing 2 ) to generate a pressure pulse for telemetric purposes.
Mechanical System
[0038] A rotary-to-linear coupling system 30 a , 30 b (hereinafter referred to as coupling system 30 ) is used to translate the torque from the rotary motor 1 into linear movement of the servo-valve shaft 24 , which is preferably a series of connected shafts for transferring linear movement from the coupling system 30 to the servo poppet 21 . Preferably, the servo shaft includes a spline shaft 24 a , which passes through a spline coupling 24 b that can be used to prevent rotation of the shaft 24 a when necessary. The coupling system 30 also includes seals which serve to isolate the rotating mechanism from the downhole mud.
[0039] In the embodiment pictured in FIGS. 1A and 1B , the rotary motor 1 , is electrically powered through an electrical connection 9 , by a power source (not shown). When activated, the motor 1 rotates a lead screw 31 that is mounted within a bearing support 32 , causing a ball nut 33 to move threadably along the lead screw 31 . Linear movement of the ball nut 33 results in dependent linear movement of the servo shaft 24 , and servo poppet 21 . When driven in the forward direction, the rotary motor 1 will cause linear movement of the poppet 21 away from the servo-valve seat 22 , to allow passage of pressurized mud through the servo-orifice 23 to activate the main mud pulser valve to close. When the motor 1 drives the lead screw 31 in the reverse direction, poppet 21 is urged towards the seal surface 22 to cover the servo orifice 23 , as shown in FIG. 2B , and mud is therefore prevented from passing through the servo orifice 23 to actuate the mud pulser main valve to open.
[0040] The spline shaft 24 is surrounded by lubricating fluid, which must be pressurized against the downhole hydrostatic pressure. As shown, a pressure compensator in the form of a membrane or bellows 42 allows reservoir fluid to substantially equalize the pressure via a part 43 . The pressure compensator be a membrane, bellows, piston type or other type known in the industry. In addition to a bellows seal 40 , an additional seal 41 may be added to hold oil inside the chamber of the tool, with the bellows seal 40 preventing mud from reaching the additional seal 41 . The dual seal 40 , 41 maintains the integrity of the lubrication chamber during operation and during replacement of the bellows seal 40 during maintenance. The addition of this seal 41 does not negatively impact performance of the actuator due to the improved power characteristics of the system, as will be discussed below.
[0041] In a preferred embodiment, the construction of the device allows most downhole clogs, where debris in the mud may stop the poppet 21 from sealing with the seal surface 22 , to be easily cleared as will be described below, and the serially interconnected housing design allows simple and rapid repair of the tool when necessary.
[0042] The valve assembly 20 is preferably composed of a wear resistant material such as tungsten carbide or ceramic to maximize the efficiency of the tool and to minimize maintenance of the tool, and is preferably replaceable.
Operation
[0043] When restriction of mud flow by the main valve is desired, the rotary motor 1 will be activated by the servo-controller 10 in the forward direction. As shown in FIG. 1B , forward powering of the rotary motor 1 will cause the lead screw 31 to turn in the forward (for example, clockwise) direction, thereby raising the ball nut 33 and lifting the servo poppet 21 from the servo-valve seat 22 . This will allow mud flow to pass unrestricted through the servo-orifice 23 to actuate the main mud pulse valve, restricting mud flow to generate a pulse that is transmitted to the surface. The current-consuming portion of the circuit is then shut down until a further signal is received from the servo-controller 10 . The lack of current to the motor 1 results in the motor 1 being immovable and therefore acting as a brake to prevent further movement of the poppet 21 until further activation of the motor 1 .
[0044] Subsequently, when the servo-controller 10 initiates reverse motion by the motor 1 , the lead screw 31 is rotated in the reverse direction (in the example, counterclockwise) by the motor 1 , causing the ball nut 33 and servo shaft 24 to move towards the servo-valve seat 22 as shown in FIG. 2B . Closure of the servo-valve 20 causes opening of the main mud pulser valve to allow mud to flow unrestricted to the surface. The current-consuming portion of the circuit is then shut down until a further signal is received from the servo-controller 10 . The motor again acts as a brake until further power is applied (by shorting its coils together).
[0045] The lead screw 31 and ball nut 33 may be replaced by an alternate system of rotary to linear conversion, however a lead screw 31 and ball nut 33 are advantageous as they are relatively small in size and may be provided with bearings to provide a low-friction mechanism with high load capacity, durability, and low backlash tolerance. The lead screw 31 may be held in contact with the motor 1 by a bearing support 32 or any other suitable means.
[0046] The presently described system of using a stepper motor 1 to drive a servo-valve has several advantages. The powering of the servo-valve 20 in both directions allows greater direct control of the servo-valve 20 , avoids the previous necessity of using a return spring in the servo assembly, and therefore the energy required is similar to that of the force of the downhole mud flow. This results in an energy efficient system, and results to date indicate that the presently described system can supply a force of 100 pounds of pressure for less energy than previous systems, particularly than those which employ a solenoid activator. Thus, the present system can overcome higher pressures on the poppet valve 21 , allowing the system to clear itself of debris, and permitting use in a wide range of downhole conditions, including conditions of higher pressure and higher volume mud flow, and in conditions when the mud is contaminated or is very dense.
[0047] Use of a rotary motor powering the servo-valve in both directions also allows the system to be more responsive than solenoid systems, resulting in a faster data rate with more accurate or precise pulse-edge timing. Experimental results indicate that data rates of 0.25 seconds/pulse are possible with this system, as compared to 0.8 to 1.5 seconds/pulse in solenoid systems.
Flow Detection & Diagnostic Software
[0048] The servo controller detects the position of the poppet 21 against the servo-valve seal 22 by counting the number of rotations made by the motor until further movement of the poppet is impeded. For example, if the poppet 21 is generally programmed to attain an unseated position that is three forward motor rotations away from the seated position, upon seating activation by the servo-controller 10 , the motor will turn three reverse rotations, at which point further rotation will be impeded due to seating of the poppet 21 on the seal 23 . On unseating activation by the servo controller 10 , the motor will turn three complete forward rotations to return the poppet to its pre-programmed unseated position. Seating can be sensed by an increase in current drawn by the motor, from which a large opposing force (like stopped motion due to valve seating) is inferred. The control circuitry also senses rotation of the motors and can count rotations and direction of rotation.
[0049] Debris may enter the device with the mud, potentially causing jamming of the poppet. The servo controller 10 can be programmed to detect and clear jams from the servo-valve 20 . For example, debris may become lodged at the servo-valve seal 22 , preventing the poppet from fully sealing against the valve seal 22 . In such a situation, the motor would be prevented from completing its three reverse rotations. This is sensed by the servo-controller 10 , which will then attempt to dislodge the debris. The dislodging sequence may include rapid reciprocation of the poppet 21 towards and away from the seal 22 , or may include further reverse rotations on the subsequent reverse rotation. For example, if the motor was able to turn only two reverse rotations, the servo-controller 10 will recognize that the valve did not properly close, and will adjust one or more subsequent forward and/or reverse rotations to ensure that the poppet 21 is able to seat against the valve seal 22 . Similarly, debris may cause the poppet to not fully open, resulting in appropriate corrective action by the servo-controller on the next motor 1 activation. In either case, a processor provides a report of measurements recorded and controls the following cycle of the brushless motor's rotation accordingly.
[0050] The ability to detect and clear most jams within the tool allows a more robust design of the tool in other respects. For example, as the tool can easily clear particulate matter from the servo-valve assembly, the tool can be provided with larger and fewer mud ports, and may include reduced amounts of screening. Screening is susceptible to clogging, and so reducing screening leads to longer mean time between operation failure of the device in-hole; and will reduce the velocity of any mud flow through the tool, reducing wear on the bladder and other parts. Further, the removal of several previously necessary components (such as the return spring, transformer, and solenoid and related electronics) contributes to a tool of smaller size (in both length and diameter) that is more versatile in a variety of situations. For example, embodiments with outside diameter less than 1⅜″ (approaching 1″) or length less than four feet have been achieved, although these dimensions are not by way of limitation, but by example only.
[0051] Custom software also has the ability to track downhole conditions, and also uses a sensor to detect mudflow. When mudflow is detected, a signal is sent to the Directional Module Unit (not shown), to activate the overall system. The system also has the ability to time stamp events such as start or end of mudflow, incomplete cycles or system errors, low voltages, current, and the like, as well as accumulated run-time, number of pulses, number of errors, running totals of rotations or motor pulses. Wires or conductors may also be easily passed by the pulser section to service additional near-bit sensors or other devices. The software that detects the mudflow can be configured for different time delays to enable it to operate under a larger variety of downhole drilling conditions than its predecessors. The mudflow detection capability can also be used to calibrate or confirm the closed position of the poppet.
[0052] In addition, a user may monitor such data as well as any downhole sensors using a user interface attachable to the tool. Such sensors may include pressure or temperature sensors, rotation step-counters, travel or depth sensors, current levels, battery voltage, or timers. The user could monitor each component of the actuator to determine when the tool must be removed from downhole for repair. A user may, in turn, program an activity to cause an action or correction in response to a sensed event.
[0053] The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
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An improved energy efficient intelligent pulser driver used for generating a mud pulse in a MWD (measurement while drilling) application. In the pulser driver, a direct current (DC) powered control circuit activates a three-phase DC brushless motor that operates a servo-valve. Opening of the servo-valve equalizes pressure in a plenum causing the operation of a main valve reducing flow area and causing a pressure spike in the mud column. Closing of the servo-valve creates a reduction in mud pressure that operates the main valve and increases the flow area causing an end to the pressure spike. The servo-valve is powered both in opening and closing operations by the motor.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application is a continuation of U.S. application Ser. No. 07/360,593, filed Jun. 2, 1989, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to the art of gravity conveyors, or chutes, which are often used for dropping trash from tall construction sites, such as buildings, in a controlled manner.
U.S. Pat. No. 4,640,403 to McDermott describes a rectangular-in-cross-section gravity-conveyor chute section having a side opening in a front panel thereof with a rotatable door/ledge assembly mounted thereat. The door/ledge assembly includes a ledge which can be moved between a closed position, flat against the front panel, and a laterally-extending position in which it forms a ledge below the side opening. U.S. Pat. No. D296,834 to McDermott also depicts a gravity-conveyor chute section with a side opening and rotatable door/ledge assembly, but in addition thereto, depicts a bottom, offset, section in FIG. 15 for changing the direction of items falling through a bore of the chute. The offset section disclosed in McDermott U.S. Pat. No. D296,834 includes a vertical upstream portion which is attached to a downstream, offset, portion. In this regard, both the upstream portion and the downstream portion form bores which are serially connected, but the bore of the downstream, offset, portion is at an angle to that of the upstream portion. The reason such an offset assembly is often necessary for a gravity conveyor chute is to discharge materials away from buildings on which the chutes are mounted. Thus, it is an object of this invention to provide an offset assembly for a gravity-conveyor chute which can be mounted at the lower end of the gravity-conveyor chute for discharging materials from the chute away from a building on which the chute is mounted.
A difficulty with most prior-art offset assemblies for gravity-conveyor chutes is that the positions of their downstream openings are fixed relative to vertical bores of the chutes. In this respect, it is not always desirable to have materials exiting from chutes at fixed distances from buildings, but rather, it is desirable to be able to adjust the positions of downstream openings relative to vertical sections of chutes. Therefore, it is an object of this invention to provide an offset assembly for a gravity-conveyor chute for which the position of a downstream opening can be adjusted.
It is a further object of this invention to provide an adjustable offset assembly for a gravity-conveyor chute which is durable, easy to mount, and relatively inexpensive to construct.
Further, it is an object of this invention to provide such an adjustable offset assembly for a gravity-conveyor chute which can be easily adjusted for changing the position of a downstream opening thereof.
SUMMARY
According to principles of this invention, an offset assembly for a gravity-conveyor chute comprises offset upstream and downstream tubes which are hingedly attached to one another in such a manner that a downstream end opening of the offset upstream tube remains aligned with an upstream end opening of the offset downstream tube so that the bores of these two sections are aligned whereby items serially fall through the bores. This allows the lateral position of a downstream end opening of the offset downstream tube to be changed relative to the bore of the offset upstream tube. The upstream end opening of the offset downstream tube is bigger in cross section than the downstream end opening of the offset upstream tube so that the downstream end of the offset upstream tube remains in the upstream end opening of the offset downstream tube while the offset downstream tube is being pivoted. Both the offset upstream tube and the offset downstream tube include engaging hinge members which are laterally, outwardly, spaced from side walls thereof and the downstream end of the offset downstream tube is terminated on a plane at an angle to its axis of elongation. There is a side opening in the offset upstream tube and the offset upstream tube includes a door/ledge assembly. Both offset upstream and downstream tubes are rectangular in cross section.
BRIEF DESCRIPTION THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating principles of the invention in a clear manner.
FIG. 1 is a side view of a building having a gravity conveyor chute mounted thereon with an offset assembly of this invention;
FIG. 2 is a rear isometric view of an offset this invention; and
FIG. 3 is a front exploded isometric view of an offset assembly of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, a gravity conveyor chute 10 is affixed to a building 12 having ledges 14 extending from side openings 28 in sections 15 and 16 and tube 18 of the gravity conveyor chute 10. The sections 15 and 16 are tubularly shaped with a downstream end of the upstream section 15 telescoping into an upstream end of the downstream section 16. The sections 15 and 16 can be basically of a type described in U.S. Pat. No. 4,640,403 to McDermott. However, the tube 18 is part of an offset assembly 20 of this invention. In this respect, the offset assembly 20 comprises an offset upstream tube 18 and an offset downstream tube 22 coupled to the offset upstream tube 18 by means of a hinge assembly 24. The offset assembly 20 is shown in more detail in FIGS. 2 and 3. The offset upstream tube 18 comprises mainly a rectangular-in-cross section tube 26 having a side opening 28 therein with a pivotal ledge 30 and a lockable door 32 mounted at the side opening 28. Both the ledge 30 and the door 32 can be pivoted about hinges approximately at 34 to be in a laterally extended positions or to be in closed positions covering the side opening 28. When the ledge 30 is in a laterally extended position, the door 32 can either be in a closed position, or in a laterally extended position. When the ledge 30 is in a closed position, side supports 36 and 38 slide along side panels 40 and 42 of the tube 26.
The tube 26 is essentially the same as tubes of the upstream sections 15 and 16, with the exception that a downstream end 44 is terminated at an angle of about 60 degrees to an axis of elongation of the tube 26, which means that when the offset upstream tube 18 is approximately in a vertical position as shown in FIG. 1, the downstream end 44 of the tube 26 forms an angle of approximately 30 degrees with a horizontal plane. Welded to the side panels 40 and 42 at the downstream end 44 are offset upstream tube hinge bars 46 and 48 which protrude beyond a front panel 50 at 52 and 54. These hinge bars 46 and 48 are also at a 60 degree angle to the axis of elongation of the tube 26.
The offset downstream tube 22 is constructed of sheet steel panels 56, 58, 60, and 62 arranged to form a rectangular funnel 64 with an upstream open end 66. At a downstream end 68 of the funnel 64 is a short rectangular tube 70, having about the same size as the tube 26, for further guiding material passing through the funnel 64.
As can be seen in FIG. 2, the upstream, open end 66 of the funnel 64 is quite a bit larger than the downstream end 44 of the tube 26 of the offset upstream tube 18. The funnel 64 also includes reenforced hinge bars 72 and 74 welded to outer surfaces of the panels 56 and 60 at the upstream open end 66 to extend beyond the panel 62 at extensions 76 and 78.
The extensions 52, 54, 76 and 78 of the respective hinge bars 46, 48, 72 and 74 all have round holes 80 therein for receiving a round hinge shaft 82 with the hinge extensions 52 and 54 being inside the hinge extensions 76 and 78. The hinge shaft 82 is held in position by a pin or the like. When the hinge extensions 52 and 54 are thusly coupled to the hinge extension 76 and 78, with the offset upstream tube 18 being attached to the building 12 as is shown in FIG. 1, the offset downstream tube 22 can pivot about the shaft 82. The offset downstream tube 22 can be held in a fixed position relative to the offset upstream tube 18 by brackets 84 welded respectively between the sides 40 and 42 of the offset upstream tube 18 and upper surfaces 86 of the hinge bars 72 and 74. In this respect, the brackets 84 could be welded at other places as well in order to achieve a fixed relationship between the offset upstream tube 18 and the offset downstream tube 22.
In operation, the offset upstream tube 18 of the offset assembly 20 is fixedly mounted at the side of the building 12 with its ledge 14 and side opening 28 positioned at a window, door, or other opening, of a lower floor of the building 12. The upstream sections 15, 16 etc. are telescoped sequentially into upstream ends of lower sections with their ledges 14 positioned at openings of respective floors in the building 12. Normally, when it is first mounted, the offset downstream tube 22 of the offset assembly 20 is not coupled to the offset upstream tube 18, but rather is added thereto after the offset upstream tube 18 is in position. In this respect, once the offset upstream tube 18 is in position, the offset downstream tube 22 is positioned so that the hinge extensions 76 and 78 are adjacent outside surfaces of the hinge extensions 52 and 54, with the holes 80 thereof aligned. The hinge shaft 82 is passed through the holes 80 and locked in position by a pin. The offset downstream tube 22 is then pivoted on the shaft 82 until it is in a proper position for guiding materials dropped into the gravity conveyor chute 10 into trucks, trollies, or other containers 88 located on the ground 90. In this respect, it might be desirable to adjust the offset downstream tube 22 to deposit material passing through the gravity conveyor chute 10 at a driveway, or road, where trucks can be positioned. Once the offset downstream tube 22 is in a desirable position, the L brackets 84 are welded between the offset upstream tube 18 and the offset downstream tube 22 to achieve a fixed relationship therebetween. If it is desirable to change this relationship, a welding torch is used to remove the brackets and reposition them at second positions.
The offset assembly 20 is constructed entirely of steel, with the panels of the offset upstream tube 18 and the offset downstream tube 22 being formed sheet steel. It will be appreciated by those of ordinary skill in the art that the panel 62 of the offset downstream tube 22 will receive the full brunt of items falling through the gravity conveyor chute 10 and it is therefore necessary that panel 62 be of a higher gage steel plate than the other panels. In this respect, most of the panels are 3/16 inch thick steel whereas the panel 62 is 1/2 inch steel.
It should be appreciated by those of ordinary skill in the art that the thickened hinged bars 46, 48, 72, and 74 provide a pivotal connection between the offset upstream tube 18 and the offset downstream tube 22 which is laterally spaced from outer surfaces of the tube 26 and the funnel 64 which allows the enlarged upstream open end 66 of the funnel 64 to "swallow" the downstream end 44 of the tube 26 to ensure that a bore 92 of the tube 26 remains in registration with a bore 94 of the funnel 64. Further, by terminating the downstream end 44 of the tube 26 at an approximately 30 degree angle to the horizontal, the offset downstream tube 22 is allowed to be placed at various angles close to 90 degrees with respect to the offset upstream tube 18 while not blocking material passing between the bores 92 and 94, as can be best be seen in FIG. 2. By placing the hinge extensions 52, 54, 76 and 78 on the same side of the offset assembly 20 as the ledge 14 the offset downstream tube 22 is allowed to be adjusted over a wide range to offset material away from a building while maintaining registry between the bores 92 and 94. Further, it should be understood that the offset assembly of this invention is relatively uncomplicated to construct but yet is extremely effective and durable.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
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An offset assembly (20) for a gravity-conveyor chute (10) includes offset upstream and downstream tubes (18 and 22) which are hingedly attached one to the other, with an upstream end opening (66) of the offset downstream tube being significantly larger than outer dimensions of a downstream end (44) of the offset upstream tube. The offset upstream and downstream tubes are rectangular in cross section with each including hinge mounts which extend laterally, outwardly, from outside surfaces of panels thereof. The downstream end of the offset upstream tube terminates in a plane which forms an angle with an axis of elongation of the offset upstream tube. The offset upstream tube has a side opening with a ledge and a door thereat.
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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 in general to window treatments of the venetian blind type, and more particularly, to replaceable ladder cord covers which enable the free alteration of the ornamental appearance of the venetian blind by covering the ladder cords with covers of different decorative designs and/or widths.
Venetian blinds are available in a plurality of shapes and sizes. In all cases, the venetian blind is constructed from a headrail which supports the operating assembly and a plurality of tiltable slats supported from the headrail by at least a pair of spaced apart ladder cords. The ladder cords are connected to a tilting mechanism within the headrail to enable the tilting of the slats to effect light control.
The ladder cords are available in a plurality of widths to provide different looks to the venetian blind. For example, the ladder cords may be in the nature of a single cord, or a wide flat tape ranging anywhere from one quarter to two inches in width. The particular width of the ladder cord must be specified at the time of purchase. Thereafter, the user can no longer alter the appearance of the venetian blind with a ladder cord of different width, without having to purchase an entire new venetian blind. It is therefore desirable to provide the consumer with the ability to alter the appearance of the venetian blind by changing the ladder cords to ones of different widths or those having decorative appearance.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide a venetian blind which enables the user to alter the appearance of the venetian blind through the application of replaceable ladder cord covers.
Another object of the present invention is to provide a replaceable ladder cord cover having different widths and/or decorative appearance.
Another object of the present invention is to provide a replaceable ladder cord cover which is easy to install and remove by the user as desired.
In accordance with one embodiment of the present invention there is provided a blind comprising a headrail, support means extending from the headrail for supporting a plurality of slats, and cover means removably attachable to the support means for concealing a portion thereof, whereby the cover means may be removed and replaced with another one of the cover means.
In accordance with another embodiment of the present invention there is provided a blind comprising a headrail, at least a pair of spaced apart ladder cords extending from the headrail supporting a plurality of slats, each of the ladder cords including at least one elongated vertical member extending along a common side of the blind, and at least a pair of elongated strips removably attachably to a corresponding one of the vertical members, whereby the elongated strips may be removed and replaced with another one of the strips.
In accordance with another embodiment of the present invention there is provided a member removably attachable to the ladder cord of a blind, the member comprising an elongated strip, and at least one fastener for removably attaching the member to the ladder cord, whereby the strip may be removed and replaced with another one of the strips.
In accordance with another embodiment of the present invention there is provided a ladder cord cover removably attachable to the ladder cord of a venetian blind, the cover comprising an elongated flat strip, a plurality of fasteners attached to the strip at spaced apart locations on one common side thereof, the fasteners removably securing the strip to the ladder cord, whereby the strip can be replaced with another one of the strips.
BRIEF DESCRIPTION OF THE DRAWINGS
The above description, as well as further objects, features and advantages of the present invention will be more fully understood with reference to the following detailed description of a venetian blind having replaceable ladder cord covers, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a side elevational view of a venetian blind constructed in accordance with one embodiment of the present invention;
FIG. 2 is a bottom plan view of a venetian blind headrail adapted for accommodating replaceable ladder cord covers;
FIG. 3 is a top plan view of a replaceable ladder cord cover removably attached to a ladder cord in accordance with one embodiment of the present invention;
FIG. 4 is a top plan view of a replaceable ladder cord cover removably attached to a ladder cord in accordance with another embodiment of the present invention;
FIG. 5 is a top plan view of a replaceable ladder cord cover removably attached to a ladder cord in accordance with another embodiment of the present invention;
FIG. 6 is a top plan view of a replaceable ladder cord cover removably attached to a ladder cord in accordance with another embodiment of the present invention;
FIG. 7 is a front elevational view of a replaceable ladder cord cover having a decorative surface in accordance with one embodiment of the present invention;
FIG. 8 is a side elevational view of a venetian blind constructed in accordance with another embodiment of the present invention having replaceable ladder cord covers; and
FIG. 9 is a top plan view of a replaceable ladder cord cover removably attached to a ladder cord in accordance with another embodiment of the present invention;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals represent like elements, there is shown in FIG. 1 a venetian blind constructed in accordance with one embodiment of the present invention and designated generally by reference numeral 100. The venetian blind 100 is constructed from an elongated headrail 102 from which there is suspended one or more spaced apart ladder cords 104 for supporting a plurality of slats 106. An operating assembly 108 is positioned within the headrail 102 for adjusting the orientation of the slats 106, as well as raising and lowering the slats by means of a lift cord 110. The lower ends of the ladder cords 104 and lift cord 110 are attached to a bottom rail 112. The operating assembly 108 may be constructed in a variety of forms, for example, see U.S. application Ser. No. 08/350,316 entitled "Low Profile Venetian Blind", filed on Dec. 2, 1994 and assigned to the same Assignee of the present application.
The ladder cords 104 are constructed from a pair of spaced apart elongated members 114 horizontally interconnected by a plurality of equally spaced apart support members 116. The support members 116 are operative for supporting a respective slat 106 which includes aligned openings (not shown) through which there is threadably received the lift cord 110. Although the members 114 of the ladder cords 104 may be constructed as cord-like members, they may also be constructed as flat tapes of varying width.
As shown in FIG. 2, the headrail 102 is constructed from an elongated body 118 having a bottom wall 120 provided with two spaced apart slots 122 arranged transverse to the longitudinal axis of the headrail. The slots 122 are arranged in alignment with the location of the ladder cords 104. In this regard, the free ends of the ladder cords 104, i.e., the members 114, as well as the lift cord 110, extend through their respectively aligned slot 122 for connection to the operating assembly 108. The other free ends of the ladder cords and lift cords 110 are attached to the bottom rail 112.
The bottom rail 112 is constructed from an elongated planar member 124 from which there downwardly depends a plurality of spaced apart ribs 126 having a curved outer profile. An elongated cover 128 is adapted to be releasably secured over the ribs 126. In this regard, the cover 128 is provided with a curved bottom wall 130 having the same radius as the outer ends of the ribs 126. A pair of spaced apart sidewalls 132 extend upwardly from the bottom wall 130 and are provided with inwardly turned flanges 134. The flanges 134 are adapted to be captured within notches 136 extending along the sides of the planar member 124. Accordingly, the free ends of the ladder cords 104 are secured to the bottom rail by being captured about the outermost ribs 126 by means of the sidewalls 132 of the cover 128 when secured thereon by the flanges 134 being received within the notches 136. The lift cord 110, on the other hand, is threadably received through an opening (not shown) within the planar member 124 and formed with a knot or other suitable means for securing the lift cord thereat.
Referring now to FIGS. 1 and 3-6, various embodiments of a replaceable ladder cord cover will now be described. As shown in FIGS. 1 and 3, the ladder cord cover 138 is constructed as an elongated flat tape extending from within the bottom rail 112 to within the headrail 102. The ladder cord cover 138 can be constructed from a variety of widths to provide the venetian blind 100 with a different ornamental appearance as may be desired by the user. For example, the width of the ladder cord cover 138 may range from one quarter of an inch to two inches or more as may be desired for a particular effect. The ladder cord cover 138 may be constructed from a variety of materials having suitable texture and color to complement the venetian blind 100. For example, the ladder cord cover 138 may be a solid color in the same or contrasting with that of the slats 116. In addition, the ladder cord cover 138 may have a variety of smooth or textured surfaces, weaves and the like to provide a specific ornamental appearance. In addition, the surface of the ladder cord cover 140, as shown in FIG. 6, may be decorated with an infinite number of patterns and/or motifs. As shown, the outer surface 142 is provided with a decorative geometric pattern. However, it is possible to have various motifs such as holidays, seasons, or the like.
The ladder cord cover 138 can be attached to the ladder cords 104 in a variety of manners. For example, as shown in FIG. 3, the ladder cord cover 138 may be provided with a plurality of hooks 140 spaced apart along the longitudinal length thereof. In this regard, each of the hooks 140 is provided with a restricted opening 144 to enable passage of the members 114 of the ladder cords 104 therethrough. As shown in FIG. 4, the ladder cord cover 138 may be attached to the members 114 by means of a Velcro fastener 142. The Velcro fastener 142 is constructed from a male hook member 144 and a female loop member 146. In the embodiment disclosed, the female loop member 146 is attached at spaced apart locations along the longitudinal length of the ladder cord cover 138 facing the ladder cords 104. At corresponding opposing locations, a male hook member 144 is attached to the members 114 of the ladder cords 104. In this manner, the mating of the male hook member 144 with the female loop member 146 will removably attach the ladder cord cover 138 to the ladder cord 104. It is to be understood that in another embodiment, the male hook member 144 may be attached to the ladder cord cover 138, and the female loop member 146 to the ladder cords 104.
As shown in FIG. 5, the Velcro fastener 142 may be constructed as a single elongated member which is releasably attachable to itself. In this regard, one portion of the Velcro fastener will be formed as a male hook member 144, and its opposing portion as a female loop member 146. This arrangement eliminates the necessity of having to secure one of the members 144, 146 to the ladder cords 104. In accordance with another embodiment as shown in FIG. 6, the ladder cord cover 138 may be removably attached to the ladder cord 104 by means of a releasable adhesive 148 disposed therebetween. The releasable adhesive 148 may take the form of adhesive tapes, as well as suitable gelled adhesives which have sufficient tack to adhere, yet enable removal as desired. As shown in FIG. 6, the ladder cord 104 may, in itself, be constructed from a relatively wide elongated member.
Referring once again to FIG. 1, the free ends of the ladder cord cover 138 are secured to the bottom rail in a similar manner as the free ends of the ladder cord 104. In this regard, the ladder cord cover 138 has its free end captured between the outer most rib 126 of the bottom rail 112 and the sidewall 132 of the cover 128. The other free end of the ladder cord cover 138 extends upwardly (see FIG. 2) through an aligned elongated slot 158 within the bottom wall 120 of the headrail 102 thereby hiding the free end. By means of this arrangement, the operation of the venetian blind 100 will not be interfered with by the presence of the ladder cord cover 138. In addition, the ladder cord cover 138 will appear to have been originally installed on the venetian blind 100 to retain the high quality look of the venetian blind.
Referring now to FIG. 8, there is shown another embodiment of a bottom rail 152 in accordance with the present invention. The bottom rail 152 has a reverse profile from the bottom rail 112 as shown in FIG. 1. In this regard, the planar member 154 has a curved profile while the cover 156 has a generally flat bottom wall 158. The sidewalls 160 of the cover 156 have inwardly and downwardly directed flanges 162 to be captured within longitudinally extending corresponding grooves 164 adjacent the lateral edges of the planar member 154. The releasable attachment of the cover 156 to the planar member 154 is operative for attaching both the free ends of the ladder cord 104 and ladder cord cover 138 thereto.
Referring now to FIG. 9, there is disclosed still another embodiment of the present invention. As shown, a ladder cord cover 166 is constructed from a flat elongated strip 168 which can be constructed from a variety of materials, such as paper, plastic, cloth and the like. One surface of the strip 168 is coated with an adhesive layer 170. The exposed surface of the adhesive layer 170 is covered with a release layer 172. The release layer 172 is of the conventional type which enables removal thereof to expose the surface of the adhesive layer 170. Upon removal of the release layer 172, a decorative material 174 may be applied to the strip 168 by the user. In this regard, the decorative material 174 may comprise wallpaper, wrapping paper or any other material desired. Accordingly, the ladder cord cover 166 may be personalized by the user by coordinating with a particular wallpaper, border or the like.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that the embodiments are merely illustrative of the principles and application of the present invention. It is therefore to be understood that numerous modifications may be made to the embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the claims.
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A venetian blind includes replaceable ladder cord covers. The ladder cord covers may be constructed in a variety of widths to achieve an appropriate ornamental appearance, as well as being provided with decorative surfaces having a variety of motifs. The ladder cord covers may be color coordinated with the venetian blind to enhance its aesthetic appeal. The ladder cord covers are formed as elongated strips which are removably attachable by the user to the ladder cords when and as desired.
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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 earthworking apparatus and in particular to cutting bits for installation on the blade portions of such apparatus.
2. Description of the Prior Art
As disclosed in U.S. Pat. No. 2,831,275 of Woodrow P. Kinsey et al, owned by the assignee hereof, it is common to provide cutting bits on the blade portion of earthworking equipment, such as earth-moving scrapers and bulldozers. As disclosed in the Kinsey et al patent, such cutting bits are conventionally arranged to be secured to the outside of the scraper bowl by suitable bolts. Such bits effect a cutting action on the earth as the blade is moved forwardly to insure a clean cut. The use of the bits effectively extends the useful life of the blade by minimizing the erosion and wear of the blade proper so as to minimize expense and time consumption in repairing of the blade as a result of such erosion and wear.
In the Kinsey et al patent, the cutting bits are provided with a second set of cutting edges so that when one edge of the cutting bit becomes worn, the bit may be removed and reversely installed on the opposite wall of the scraper bowl so as to dispose the unused cutting surface forwardly and thereby provide extended useful life of the cutting bits.
In U.S. Pat. No. 3,190,018 of Maclay P. Nelson et al, a reversible bit is disclosed which is mounted on the blade by means entirely rearward of the cutting surfaces of the blade so as to provide protection for the mounting means, such as from impact against soil or rocks engaged by the bit or blade.
SUMMARY OF THE INVENTION
The present invention comprehends an improved form of reversible bit for selective mounting to an earthworking blade, and more specifically, is directed to such a bit for use at the opposite corner portions of the blade.
The invention comprehends the provision of such a reversible end bit defined by a rigid member having a first cutting edge portion, a second cutting edge portion extending transversely to the first cutting edge portion, and a mounting portion included between the cutting edge portions and adapted to be mounted to one corner portion of a blade with the first cutting edge portion in cutting position and to the opposite corner portion of the blade with the second cutting edge portion in cutting position.
More specifically, the rigid member may comprise a triangular member having substantially rectilinear cutting edge portions, with one cutting edge portion extending perpendicular to the other and with the mounting portion of the bit defining a generally triangular mounting portion.
The bit may be made symmetrical about a centerline bisecting the angle defined by the cutting edge portions so that selective rotation of the bit 90° about the apex of the bisecting centerline and triangular mounting portion disposes selectively either of the two cutting edge portions in cutting position when mounted to the opposite corners of the blade.
The cutting edge portions may project forwardly from the flat plane of the mounting portion so as to define mutual strengthening means.
The bit may be mounted to the blade corners by suitable bolts, which, by virtue of the triangular arrangement of the mounting portion may be spaced from the corner tip portions of the blade to provide improved minimum distortion mounting of the bits to the blade.
Thus, the reversible end bit of the present invention is extremely economical of construction while yet providing the highly desirable features discussed above.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein:
FIG. 1 is a fragmentary front elevation of a bulldozer blade having reversible end bits embodying the invention;
FIG. 2 is a view taken along line 2--2 in FIG. 1; and
FIG. 3 is an isometric view of reversible end bits.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the exemplary embodiment of the invention as disclosed in the drawing, an earthworking blade generally designated 10 is shown to comprise a bulldozer blade having opposite end portions 11 and 12, respectively defining corner portions 13 and 14. A conventional elongated bit generally designated 15 may be secured to the mid-portion of the blade by suitable bolts 16.
The present invention is concerned with the provision of improved reversible end bits generally designated 17 amd 18 which, as shown in FIG. 1, are adapted to be mounted to the corner portions 13 and 14 of the blade 10 by suitable bolts 19. Bits 17 and 18 are identical comprising reversible end bits which may be selectively installed on either corner portion 13 or 14. For this purpose, each bit is provided with a first cutting edge portion 20 and a second cutting edge portion 21. As shown in FIG. 1, when the bit is installed on the right-hand corner portion 13, the cutting edge portion 20 is disposed lowermost in cutting position with the cutting edge portion 21 extending upwardly therefrom in a retracted position. When the bit is installed on the lefthand corner portion 14 of the blade, the cutting edge portion 21 is disposed lowermost in the cutting position with the cutting edge portion 20 extending upwardly in a retracted position.
Thus, the end bits may be installed on either end of the bulldozer blade by a simple 90° rotation of the bit.
More specifically, as seen in FIG. 3, each bit is defined by a rigid member having a first cutting edge portion 20 and a second cutting edge portion 21 with a mounting portion 22 included between the cutting edge portions and adapted to be mounted to the blade corner portion, as discussed above. The mounting portion may be provided with a plurality of holes 23 opening forwardly through recess portions 24 for receiving the bolt heads.
The cutting edge portions 20 and 21 may extend forwardly from the flat plane of the mounting portion 22 so as to dispose distal forward cutting edges 20a and 21a, respectively, substantially forwardly of the plane of the mounting portion.
As best seen in FIG. 3, the cutting edges 20a and 21a are inclined to the flat plane of the mounting portion with the maximum spacing thereof forwardly from the plane of the mounting portion being at a juncture 25 of the two cutting edge portions aligned with the apex 26 of the triangular mounting plate 22.
In the illustrated embodiment, the cutting edge portions 20 and 21 are integrally joined at the juncture 25 and are integrally formed with the mounting plate portion 22 to define an integral one-piece bit construction.
The cutting edge portions may define inturned distal ends 27 and 28, respectively, which are turned to extend generally parallel to the other cutting edge portion at the opposite edge of the mounting plate portion 22. As shown, the distal portions 27 and 28 may run into the flat plane of the mounting portion 22.
Each of the cutting edge portions 20 and 21 may comprise generally planar portions along the two sides of the triangular mounting plate 22 extending from the apex 26. The planes of portions 20 and 21 along these edges may be inclined outwardly relative to the mounting plate whereby the bit effectively defines a forwardly widening structure. Thus, the cutting edge portions effectively define reinforcing or strengthening means as well as defining the cutting edges of the bit.
Referring to FIG. 3, the bolt holes 23 may be spaced from the apex 26 to provide an improved mounting of the cutting bits to the blade corner portions 13 and 14. Further, as the triangular arrangement of the mounting plate member provides mounting bolt holes remotely from the lowermost cutting edge, a further improved secure mounting of the end bits to the blade is effected.
In the illustrated embodiment, the end bits are symmetrical about a centerline extending from the apex and bisecting the angle defined by the forwardly projecting cutting portions 20 and 21. Thus, the end bits function identically in their mounting at either end of the cutting blade. Thus, with the triangular arrangement of the present end bits, the mutually interacting support provided by the forwardly projecting cutting edge portions provides a high strength, long life bit construction providing substantial improvement over the bit constructions of the prior art.
Referring to FIG. 2, it may be seen that the extending plates and relieved areas at each end of the blade provide ready access to bolts 19 and facilitate mounting and service of the end bits 17 and 18.
The foregoing disclosure of specific embodiments is illustrative of the broad inventive concepts comprehended by the invention.
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A reversible bit for selective mounting to an earth-moving blade, such as a bulldozer blade, having opposite corner portions. The bit includes transversely extending cutting edge portions and a mounting portion adapted to be selectively mounted to opposite corners of the blade with one or the other of the cutting edge portions suitably disposed in cutting position whereby the bit provides substantially twice the normal life of the conventional blade bit.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an obstacle protection arrangement comprising a deformable spatial structure wherein a dissipation of energy is brought about during a deformation resulting from a collision with a moving object (a road vehicle), which arrangement is composed of a series of segments which are interconnected--in the anticipated direction of motion--and which are each comprised of at least one gate-shaped support member standing on the ground and positioned transversely to said direction, as well as of a box-like structure fastened thereto and internally provided with deformation elements, a flank member being affixed on both sides of each segment.
2. Description of the Prior Art
A specific embodiment of such an arrangement is known from U.S. Pat. Nos. 3,982,734 and 3,944,187. The main purpose is to protect solitary obstacles by roadsides in such a manner that vehicles that have moved off the roadway are prevented from coming into contact with such obstacles. It occurs not infrequently that such solitary obstacles are located in the pointed area of road exits or in the continuous shoulder along the roadway.
The protection of an obstacle may be achieved in two ways. In the event of a collision occurring on the nose portion of the obstacle protector means, the vehicle is to be stopped prior to touching the obstacle to be protected. If a collision occurs with the flank of the obstacle protector means, the travelling direction of the vehicle must be changed so as to guide it past the obstacle. In both such cases the occupants of the vehicle should not be exposed to intolerably high decelerations.
In practice obstacle protectors are known to exist which offer none or unsuitable flank protection. Also, several types of obstacle protection arrangements often require an elaborate foundation and anchoring. In addition, various types of known obstacle protectors either do not correctly function in an optimum fashion in the event of a head-on collision when its parallel structure is altered into a V-shape, for example, when placed in a gore area.
SUMMARY OF THE INVENTION
The object of the invention is to provide an improved arrangement which can be used in a V-form for a pointed area at an exit, but also in a parallel form in the shoulder along the roadway. In addition, it is an object of the invention to provide an arrangement which is adaptable to the local conditions and which affords easy mounting and whose cost is relatively low. These and other objects are attained according to the invention by using an obstacle protector means which--as viewed in the intended direction of traffic motion--has its rear support member fastened to a foundation, the front support member being located in a horizontal guideway allowing displacement in the direction of motion only, whilst the segments are rigidly coupled to one another, so that the whole arrangement behaves like a rigid girder.
These features lead to a construction of an obstacle protector means which affords a high degree of rigidity against bending both in a horizontal and in a vertical plane so that two points of foundation are sufficient. The obstacle protector means is composed of a number of standard units or segments, which makes it possible to adapt the obstacle protector to the local situation in terms of absorbing capacity. The degree of energy absorption may be adapted to the local conditions as anticipated by varying, in addition to having the choice of number of segments, the dimensions and compositions of the material of the deformation elements disposed within the box-like structure, as well. In this manner it is possible to assemble successive types of obstacle protectors as a function of the mass and speed of the passing vehicles. Due to the construction with segments, a damaged obstacle protector means according to the invention has a decided residual value, since the parts that have been slightly damaged or have remained undamaged can be used again. The V-shaped embodiment as used in a pointed area may, in the presence of a guide rail construction, be linked up thereto via one or both of the flank members.
In the event of a collision with the nose portion, the segments are successively compressed, starting with the nose segment. Such compression of segments is possible because the flank members when being displaced can pass one another and the box-like structure can be compressed. The deformation of the box-like structure in particular provides the greatest absorption of the kinetic energy of the vehicle.
A most efficient solution for providing for an appropriate energy-absorbing capacity of the box-like structure is obtained by providing the box-like structure with crumpling or ripple tubes which absorb the major portion of the energy in a collision. If needs be, it is possible to increase the deformation resistance of the successive segments--as viewed in the direction of motion--by using more ripple tubes.
In order that the ripple tubes may function without disturbances occurring, the top and bottom side of the box-like structure are beaded a little outwardly, at least one rod being disposed between these expanded areas. This form of construction is also favorable when transporting the individual box-like structures, and prevents damage due to vandalism. According to a particular embodiment, each segment is provided with flank members provided with longitudinal undulations engaging one another. Such members extend on both extremities past the respective segment so that there is an overlapping with neighboring flank members, in which case the connection of the adjoining segments is also carried through by means of at least one double-angled strip forming a connection with the support member. The strip affords a change in the mutual position on the one hand, but no substantial change in the angle of the flank extremities since an extra flange part forms a guide when the flank members are sliding past each other. This is important because upon impact, the divergence of the flank member should not result in the occurrence of laterally directed spearheads formed by the extremities of the flank members.
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims.
Other claims and many of the attendant advantages will be more readily appreciated as the same becomes better understood by reference to the following detailed description and considered in connection with the accompanying drawings in which like reference symbols designate like parts throughout the figures.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a diverging obstacle protector means to be used for the protection of an obstacle in a pointed area;
FIG. 2 is a side view of the arrangement according to FIG. 1;
FIG. 3 is a top view similar to FIG. 1 of an obstacle protector means having a parallel form as is to be used for the shoulder along the roadway;
FIG. 4 is a side view of the arrangement according to FIG. 3;
FIG. 5 is a top view of an alternative form of the arrangement shown in FIGS. 1 and 2;
FIG. 6 shows, on an enlarged scale, a detail of the arrangement as per FIG. 1;
FIG. 7 is a sectional view taken along line VII--VII in FIG. 6;
FIGS. 8a and 8b provide a perspective view and a front view, respectively, of a nose segment of the obstacle protector means according to the invention;
FIG. 9 is a perspective view of the box-like structure of FIG. 6 with edge faces being partially cut out,
FIGS. 10-12 show the double-angled strip of the obstacle protector means of the invention;
FIGS. 13 and 14 illustrate two situations arising in the event of a collision;
FIG. 15 shows a construction enabling the absorption of occurrent tensile forces into a flank member of the alternative form of the embodiment as per FIG. 5;
FIGS. 16a, 16b, 16c provide three views of a nose segment; and
FIGS. 17a and 17b show the results of an eccentric impact upon the nose segment.
DESCRIPTION OF PREFERRED EMBODIMENTS
As can be seen best in the FIGS. 1, 2 and 3, the obstacle protector means is comprised of a series of interconnected segments A provided with a nose segment A'. Each segment is composed of a U-shaped support member G disposed transversely to the direction of motion X and provided for fastening an internal box-like structure N thereto. The support members G are slidably or rollably supported on the ground, such as by rollers R, with the exception of the rearmost segment which is attached to a fixed foundation L. Also, tie members V which are to absorb the longitudinal forces occurring in the associated guide rail construction are attached to the foundation L. The nose segment A' is provided with a guide member H, as shown in FIG. 2, which prevents displacement in any direction other than the direction of travel X (see FIGS. 8a and b).
Each segment is provided on both sides with a flank member C which is connected to the associated support member G via an angled strip D. The shape and function of these strips D are illustrated in FIGS. 10-12. On the bending lines of the strip it is possible to provide weakened sections, for instance bore holes. These strips afford a shifting of successive flank members C past one another during a collision. The support members G move along thus causing a certain degree of transversely directed deflection to occur so that no wedging action takes place. The flank members C will not diverge sidewardly, which is also in the interest of preventing damage to vehicles of third parties or injury to the latter.
FIG. 9 clearly shows that each box-like structure N is provided with crumpling or ripple tubes B. The purpose of these tubes is to absorb the major portion of the kinetic energy of the colliding vehicle. In addition, the box-like structure N imparts stability to the entire structure, specifically, at the occurence of lateral forces (see FIGS. 13 and 14). The box-like structure N facilitates transport and assembly of the obstacle protector means.
The construction of the nose segment A' is best apparent from the FIGS. 8a, 8b, 16a, 16b and 16c. There is an arcuate nose apron C' which may be regarded as a complement to the flank members C ending in each segment A. A support member G' cooperates on its lower side with a foundation guide member H. Inside the nose apron C' there are provided several straight thin plates U (see FIGS. 16a, 16b and 16c). This enables the nose segment at the beginning of the collision to adopt the shape and/or deformation of the vehicle in a manner so that the deformative force of the nose segment is lower than the threshold value of the ripple tubes. This causes the deforming of the first box-like structure to be introduced in a proper manner (FIGS. 17a and 17b).
The functioning of the obstacle protector means is dependent upon the manner in which the collision with the structure proceeds. In a collision a distinction may be made between a head-on collision and a lateral collision. A head-on collision may be still further differentiated into a centric, an eccentric and an angular collision. In the event of a centric collision, first the nose apron C' of the structure will deform. Thereupon, the support member G' will start sliding freely with its feet in the foundation guide member H, and the two flank members C will be pushed backwards. Simultaneously, the first box-like structure will be compressed. The subsequent segments A will be compressed in succession. The number thereof depends upon the magnitude of the quantity of kinetic energy to be dissipated.
The deceleration of the vehicle is determined by:
(a) the ripple resistance of the ripple tubes;
(b) the acceleration of masses (segments A and A' and flank members C);
(c) several other resistance factors such as:
the deforming resistance of the nose segment A',
the mutual friction of the flank members C,
the rolling and sliding resistance of the support members G and
the resistance factors of the vehicle itself.
Due to the influence of the mass inertia and occurent frictions in the structure, the segments will deform one by one. The plates P 1 and P 2 of the box-like structure N are so designed during a head-on collision the upper plate P 1 can freely bend upwards and the lower plate P 2 can freely bend downwards (see FIG. 9). Such upward and downward bending quality is important so as to prevent the tubes from being struck by the lower plate P 2 or upper plate P 1 during impact. In order to ensure this shape, the box N is internally provided with spacer means S. The lower and upper plates P 2 and P 1 , respectively, can absorb tensile forces in the event of a lateral collision. The spacer means S are also advantageous in preventing damage due to vandalism committed by passersby climbing upon the obstacle protector means. The ripple tubes B in the box N are centered and fixedly secured on the frontal face of the box N by means of spiders M. On the back side they are confined in apertures 20 provided in the back plate Q of the box N. By premounting the ripple tubes B, errors are avoided when assembling the structure.
The support members G FIGS. 1 and 3 are so designed as to afford easy and safe mounting of the boxes N through bolt holes 21 on the upper and lower sides, see FIG. 9. The wheels R on the legs of the support members G ensure a smooth displacement of the support members in the longitudinal direction of the structure.
The flank members C have a length of more than twice the length of one segment. They overlap each other, via FIGS. 6, 11 and 12 by means of a guide flange E (see FIGS. 1 and 7), mounted on or formed integrally with the back side of the top of each flange member C and disposed over the next flank member. The flank members C can slide passing one another without there being the danger of a secondary collision of the guide retainer E with the flank member of the following segment, because they have already passed one another in the original position. The advantage of a great length of overlapping is that it increases the lateral and vertical stability of the whole structure.
The flank members C are connected to the support members G by means of angled strips D (FIGS. 10-12). The strips D afford the flank members C a certain amount of movability with respect to the support member(s) G. This is necessary because in the event of a head-on collision and the successive telescoping of segments:
a. the angle formed by the flank members C with respect to the support members G may change;
b. the distance of the flank members C to the support members G may change; and
c. the flank members C must obtain some freedom so as to reduce the influence of mass inertia on the forces in the structure and on the deceleration of the vehicle.
In addition, in the event of a lateral collision:
d. the strips D provide an extra braking path and the flank members C undergo a smooth deformation.
As a result of the form of the angled strips N the movements in the horizontal plane as described can be realized while ensuring sufficient rigidity in the vertical direction. A proper vertical position of the support members G is a condition for the intended behavior of the box-like structure N.
Eccentric head-on collisions are understood to be those collisions in which the longitudinal axis of the vehicle runs parallel to but spaced from the longitudinal axis of the structure. In an angular head-on collision, the longitudinal axis of the vehicle forms an angle with the longitudinal axis of the structure.
If the vehicle strikes the obstacle protector means eccentrically or at an angle, the nose apron A' is intended to be deformed in such a way that the vehicle is not thrown back. To this end the nose apron A is provided with straight thin plates U (FIGS. 1 and 8a). Relative to their points of fastening, the plates U are capable of absorbing tension but no pressure. As a result, the nose segment will be inclined to hold the vehicle. (see FIGS. 17a and 17b).
If, in an eccentric or angular collision, the displacement in longitudinal direction is so large that the support member G' leaves the foundation guide member H, the whole obstacle protector structure is to be regarded as a projecting girder with respect to the supporting foundation L (see FIG. 13). The box-like structure N can absorb this force couple.
Another type of collision is a lateral collision. These collisions concern impacts of collision upon the flank of the obstacle protector means. In such an event the whole obstacle protector means forms a beam having as points of support the ground rail H and the supporting foundation L. The upper and lower plates P 1 and P 2 of the box N act, in the tension zone, as tension absorbers. The ripple tubes B act, in the pressure zone, as pressure absorbers (see FIG. 14). The foregoing describes the obstacle protector means having a box-like structure. This box-like structure N is an essential element for increasing the stability of the structure. An alternative form of embodiment for obtaining the stability is attained by replacing the box-like structure N by two crossed tension rod members F. (see FIG. 5). This alternative embodiment essentially functions in a manner identical with that of the form of embodiment having the box-like structure N. This form of construction with tension rod members likewise can be realized in a V-form and a parallel form.
The construction of the segments of this alternative embodiment is as follows. Between the support members G there are provided individual tubes B, whereupon parallel adjustment is effected by means of the tension rod members F. In the event of a lateral collision the compressive forces are again absorbed by the tubes B. Tensile forces are absorbed by the tension rod members F and the flank members C. For this purpose the flank members C have been internally provided with members J to prevent shifting under tension during lateral collision (FIG. 15). The members J are secured to opposed ends to the spaced flank members C by welds W to resist movement of the flank members C in a tension direction T. For the purpose of increasing the stability the crossed tension rod members may be connected together in the center.
Although the present invention has been shown and described in connection with preferred embodiments thereof, it will be apparent to those skilled in the art that many variations and modifications may be made without departing from the invention in its broader aspects. It is therefore intended to have the appended claims cover all such variations and modifications as all are within the true spirit and scope of the invention.
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An obstacle protection arrangement composed of a series of interconnected deformable segments, each comprising a U-shaped support member and a box structure containing crumpling tubes. Both sides of the arrangement are formed by overlapping flank members such that during a front collision there will be dissipation of energy by deformation of the segments, whereas during a side collision the arrangement behaves like a rigid girder.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The invention relates to a status indicator for a lock adopted for use on padlocks, locking devices or structural objects and particularly to a lock that has two locking units that function independently to execute locking and unlocking operations.
BACKGROUND OF THE INVENTION
[0002] A lock is a widely used to guard articles that have obvious or potential security concern and to protect the articles. For instance, a padlock may be used to lock the zipper of luggage to prevent unauthorized opening.
[0003] Due to security concerns, nowadays airports have very strict standards for luggage inspection. To luggage having security concern, mandatory inspection of unfolding luggage could take place. For luggage that has been locked, the lock has to be broken. After inspection, the lock is damaged and not usable again. As a result, the damaged lock can no longer provide protection after the inspection has finished.
[0004] To remedy the problem of lock damage during security inspection, a lock equipped with two locking units has been developed. For instance, Travel Sentry™ Co. of U.S.A. introduces a number of locks for this purpose. They mainly have one set of locks to allow users to lock and unlock during use, and another set of locks for use during inspection. Hence the inspection people can perform routine security inspection through a normal unlocking procedure to open the lock, and close the lock after the inspection is finished. Therefore the lock may be prevented from damaging, and the luggage can have proper protection after inspection.
[0005] However, the locks mentioned above still have a drawback, namely after the security inspection of the luggage has finished and the lock is closed again, there is no indication to show that lock has been unlocked.
SUMMARY OF THE INVENTION
[0006] In view of the aforesaid problem, the primary object of the present invention is to provide a lock that has two locking units functioning independently so that users can recognize which locking unit has been unlocked.
[0007] In order to achieve the foregoing object, the invention provides a status indicator for a lock with two locking units that has a window on the surface of a lock body and an indicator in the lock that has different indication positions switchable to the window once a locking unit has been unlocked, so that users can see the indicator through the window to identify the locking unit that has been unlocked.
[0008] The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of the invention;
[0010] FIG. 2 is a plane view of the invention;
[0011] FIG. 3 is a fragmentary schematic view of an embodiment of the invention;
[0012] FIGS. 4 and 5 are schematic views of the invention in operating conditions;
[0013] FIG. 6 is a fragmentary perspective view of the invention;
[0014] FIGS. 7A and 7B are schematic views of the invention in operating conditions;
[0015] FIGS. 8A and 8B are fragmentary schematic views of embodiment variations and operating conditions of the invention;
[0016] FIG. 9 is an exploded view of another embodiment of the invention;
[0017] FIGS. 10A and 10B are schematic views of another embodiment of the invention in operating conditions;
[0018] FIGS. 11A and 11B are schematic views of another embodiment of the invention in operating conditions; and
[0019] FIG. 12 is a fragmentary schematic view of an embodiment variation of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to FIG. 1 , the lock 1 according to the invention includes a body 10 and a shackle 20 for coupling a targeted object. The body 10 has a window 100 on the surface to indicate conditions.
[0021] Referring to FIG. 2 , the body 10 contains two locking units 13 and 14 , an indicator 11 and a brake bolt 12 . The two locking units are named a first locking unit 13 and a second locking unit 14 hereinafter to facilitate discussion.
[0022] The indicator 11 has one or more identified notations 111 and 112 that may be, but is not limited to, graphics, characters, color patches and combinations thereof that are distinguishable and may be differentiated visually. The identified notations may be formed on the indicator 11 by, but is not limited to, printing, carving, painting, sticking paper, and the like. In addition, the indicator 11 is coupled with a returning elastic element 113 (such as a compression spring) which has one end pressing the body 10 , to allow the indicator 11 at a first indication position as shown in the drawing in normal condition.
[0023] The brake bolt 12 aims to generate a latch function. It is coupled with a ramming elastic element 121 which has one end pressing the body 10 to push the brake bolt 12 in contact with the indicator 11 in normal condition and latche the indicator 11 .
[0024] As shown in the drawings, the brake bolt 12 has a one-way retaining section 122 . The indicator 11 has a means mating the one-way retaining section 122 , such as an extending sloped member 114 , or a notch 115 shown in FIG. 3 . Therefore, the one-way retaining section 122 can latch the sloped member 114 or notch 115 to anchor the indicator 11 on the first indication position.
[0025] The first locking unit 13 is movable under operation. It has a locking position (referring to FIG. 2 ) relative to the body 10 and an unlocking position (referring to FIG. 4 ). The first locking unit 13 includes a cylinder 131 , which has a concave head 133 extended from a shaft 132 . Referring to FIG. 4 , the locking state between the body 10 and the cylinder 131 may be released by inserting a key K into a key way of the cylinder 131 , so that the cylinder 131 may be sunk axially, to disengage the turning restriction formed between the concave head 133 and the shackle 20 . The shackle 20 may be turned outwards relative to the body 10 about another leg. In addition, while the cylinder 131 is moved, the concave head 133 is driven simultaneously to move the indicator 11 from the first indication position to a second indication position shown in the drawings. The brake bolt 12 retracts and returns again to form a latch condition with the indicator 11 to keep the indicator 11 at the anchor position. When the cylinder 131 is returned to the locking state through operation of the key K, the indicator 11 remains at the second indication position. Therefore, with the indicator 11 driven one-way by the first locking unit 13 . Changing of the second identified notation 112 from the first identified notation 111 corresponding to the window 100 may recognize its position.
[0026] The second locking unit 14 may also be switched between an unlocking state and a locking state through operation. In this embodiment, the second locking unit 14 includes, but is not limited to, a combination lock, which has a dial wheel 141 . The second locking unit 14 also can lock one leg of the shackle 20 . The shackle 20 is inhibited from axial movement when the second locking unit 14 is in the locking state, and the shackle 20 has another leg extended in the concave head 133 .
[0027] When the second locking unit 14 is switched to the unlocking state through operation, the shackle 20 is in the condition shown in FIG. 5 , and moved axially relative to body 10 for a selected distance. During the axial movement, or by adding an extra operation, the brake bolt 12 is driven to release the latch condition on the indicator 11 so that the indicator 11 returns from the second indication position to the first indication position, and the notation corresponding to the window 100 is changed from the second identified notation 112 to the first identified notation 111 .
[0028] Refer to FIG. 6 for the brake bolt 12 releasing the latch condition on the indicator 11 after the shackle 20 has driven the brake bolt 12 . The shackle 20 has a lug 21 . When the second locking unit 14 has released the locking state on the shackle 20 , the shackle 20 may be moved axially to release the turning restriction on the concave head 133 . Referring to FIGS. 7 and 8 , then the shackle 20 may be turned and the lug 21 pushes a bucking portion 123 on the brake bolt 12 to move the brake bolt 12 in a direction, to release the latch condition on the indicator 11 .
[0029] Referring to FIGS. 8A and 8B , the lug 21 mates the bucking portion 123 in shape and position. While the shackle 20 is moved axially, the lug 21 pushes the bucking portion 123 on a sloped surface to release the latching of the brake bolt 12 .
[0030] As previously discussed, while the indicator 11 has been moved to the second indication position through the latching of the brake bolt 12 , the indicator 11 can return to the first indication position again only through the unlocking operation of the second locking unit 14 . Hence by seeing different identified notations 111 and 112 through the window 100 , a use condition of the lock may be recognized.
[0031] Refer to FIGS. 9, 10A and 10 B for another embodiment of the invention. It differs from the previous embodiment, in which the indicator 11 a is moved by turning to switch the first indication position and the second indication position.
[0032] The concave head 133 a of the first locking unit 13 a has a notch 134 a , which enables the key K to drive the concave head 133 a by turning the cylinder 131 a so that the notch 134 a may be switched to turn the shackle 20 a at an unlocked position. Namely, the first locking unit 13 a is moved to an unlocked position (referring to FIG. 1A ) and locked position (referring to FIG. 19B ) by turning.
[0033] As shown in the drawings, the indicator 11 a has identified notations 111 a and 112 a , and a dial hole 113 a in the axial direction, to enable the indicator 11 a to run through the dial hole 113 a and couple on the shaft 132 a . Moreover, the indicator 11 a is coupled with a returning elastic element 114 a , which may be, but is not limited to, a torsion spring. In addition, the indicator 11 a has a first latch notch 115 a and a second latch notch 116 a on the periphery, to engage with the brake bolt 12 a when the indicator 11 a is moved to the first indication position and the second indication position, to maintain the indicator 11 a in a stationary condition.
[0034] By means of the construction set forth above, when the first locking unit 13 a is turned from a locked position shown in FIG. 11A to an unlocked position shown in FIG. 11B , the indicator 11 a also is pushed by a picking bar 1321 a , extended radially from the shaft 132 a and moved from the first indication position to the second indication position. When the first locking unit 13 a returns to the first indication position through operation, the indicator 11 a still remains at the second indication position. The brake bolt 12 a can only release the latch condition on the indicator 11 a through the unlocking operation of the second locking unit 14 . Likewise, the indicator 11 a returns to the first indication position.
[0035] Refer to FIG. 12 for another latch operation of the brake bolt 12 . Instead of driving the indicator 11 by the shackle 20 to release the latch condition, the brake bolt 12 is coupled with a brake knob 30 which may receive a force to drive the brake bolt 12 and release the latch condition on the indicator 11 and allow the indicator 11 to return to the first indication position.
[0036] While the preferred embodiments of the invention have been set forth for the purpose of disclosure, modifications of the disclosed embodiments of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments, which do not depart from the spirit and scope of the invention.
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A status indicator for a lock includes two locking units that operate independently, to execute locking and unlocking operations. The lock has a body, which contains an indicator and a brake bolt. The indicator is latched by the brake bolt to remain at a selected indication position. When one locking unit executes the unlocking operation, the indicator is driven concurrently to switch to another indication position corresponding to a window, and is latched by the brake bolt without returning. The brake bolt can only release the latch condition on the indicator through the unlocking operation of another locking unit. Likewise, the indicator returns to the original indication position. Thus through the window formed on the body surface, the indication position of the indicator may be recognized.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] This invention relates to a system and method for sensing and storing force and torque data on a downhole tool in a downhole oil and gas recovery system.
[0002] Many tools are inserted downhole in a wellbore in an oil and gas recovery system to perform various functions in the recovery process. After many of these tools have been inserted downhole, they require the application of weight and/or torque to operate. For example, in order to “set” a typical downhole retrievable packer, the pipe, or workstring connected to the packer, must be picked up, rotated, and then set back down. After it is set in this manner, the packer is subjected to various other forces such as hydraulic forces, as well as forces caused by thermal expansion and contraction that occur during a cementing or stimulation treatment. Since these forces may change the setting force on the packer and may otherwise adversely affect its operation, it is important that the forces be sensed and their values either stored or transmitted to the surface in real time so as to permit remedial action.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] [0003]FIG. 1 is an elevational view of a downhole tool including an embodiment of a system according to the invention.
[0004] [0004]FIG. 2 is a partial schematic, enlarged, side view of a mandrel of the downhole tool of FIG. 1.
[0005] [0005]FIG. 3 is a cross-sectional view taken along the line 3 - 3 of FIG. 2.
[0006] [0006]FIG. 4 is a partial schematic, enlarged, view of the opposite side of the mandrel of FIG. 2.
[0007] FIGS. 5 - 7 are views similar to those of FIGS. 2 - 4 , respectively, but depicting the mandrel rotated ninety degrees from the positions of FIGS. 2 - 4 , respectively.
[0008] [0008]FIGS. 8 and 9 are electrical circuits employed in the above system.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1, a tubular mandrel is shown in general by the reference number 10 and forms part of a workstring that is inserted downhole in a wellbore, or the like. A retrievable packer 12 , or other downhole tool, is located immediately below the mandrel 10 with the corresponding ends of the mandrel 10 and the packer 12 being connected in any conventional manner. It will be assumed that, when inserted downhole and set, the packer 12 , and therefore the mandrel 10 , will be subjected to the forces discussed above. The mandrel 10 is thus a load-bearing member of the packer 12 subject to the forces experienced by the packer 12 when it is connected in the workstring. It is understood that other downhole tools (not shown) can also be connected in the workstring.
[0010] A series of batteries 14 are angularly spaced in openings formed inside mandrel 10 and are attached to the mandrel 10 in any conventional manner. A printed circuit board 16 is mounted to the outer surface of the mandrel 10 in any conventional manner and is connected to the batteries 14 for receiving electrical power. An outer tubular case 18 extends over the mandrel 10 and the circuit board 16 . It is understood that one or more seal rings can be provided between the case 18 and the mandrel 10 .
[0011] A plurality of strain sensors are located on the outer surface of the mandrel 10 and between the mandrel 10 and the case 18 . The sensors are not shown in FIG. 1 due to scale limitations, but are shown in detail in FIGS. 2 - 4 . In particular, a pair of axially-spaced sensors 20 and 22 (FIG. 2) are mounted to an exterior surface area of the mandrel 10 , and an additional pair of axially-spaced sensors 24 and 26 (FIG. 4) are mounted to an exterior surface area of the mandrel 10 which is diametrically opposite the first-mentioned surface area. The axes of the sensors 20 and 24 extend parallel to the axis of the mandrel 10 and the axes of the sensors 22 and 26 extend perpendicular to the axis of the mandrel 10 .
[0012] As better shown in FIGS. 5 and 6, a pair of axially-spaced sensors 30 and 32 are mounted to an exterior surface area of the mandrel 10 and are angularly displaced approximately ninety degrees from the sensors 20 and 22 and from the sensors 24 and 26 . Also, as shown in FIGS. 6 and 7, a pair of axially-spaced sensors 34 and 36 are mounted to an exterior surface area of the mandrel 10 diametrically opposite the sensors 30 and 32 , and therefore also approximately ninety degrees from the sensors 20 and 22 and from the sensors 24 and 26 . The respective axes of the sensors 30 , 32 , 34 , and 36 extend at an angle to the longitudinal axis of the mandrel 10 , which, in the example shown, is approximately forty-five degrees. The sensor 30 extends perpendicular to the sensor 32 and the sensor 34 extends perpendicular to the sensor 36 .
[0013] Each sensor 20 , 22 , 24 , 26 , 30 , 32 , 34 , and 36 can be in the form of a metal foil strain gauge whose resistance varies in response to various forces applied thereto, in a conventional manner.
[0014] The disposition of the axes of the sensors 20 and 24 parallel to the axis of the mandrel 10 , and the disposition of the axes of the sensors 22 and 26 perpendicular to the axis of the mandrel 10 enables the sensors 20 , 22 , 24 , and 26 to respond to axial compression and tension along the mandrel 10 . Also, the angular disposition of the sensors 30 , 32 , 34 , and 36 enable them to respond to torsional forces on the mandrel 10 .
[0015] The sensors 20 , 22 , 24 , and 26 are connected in an electrical circuit, shown in general by the reference numeral 40 in FIG. 8, which is configured in a conventional Wheatstone bridge configuration. The respective outputs of the sensors 20 , 22 , 24 , and 26 of the circuit of FIG. 8, are related to the applied tensile and compression loads on the mandrel 10 according to the following:
V o V ≈ FP ( 1 + v ) × 10 3 2 EA
[0016] whereby:
[0017] V o is the output voltage from the bridge 40
[0018] V is the excitation voltage to the bridge 40
[0019] v is Poisson's ratio
[0020] P is the applied load
[0021] F is a gauge factor for the strain gauge (usually =2)
[0022] E is Young's modulus of the mandrel 10 material
[0023] and
[0024] A is the cross sectional area of the mandrel 10 .
[0025] When the circuit 40 is provided with excitation voltage to the sensors 20 , 22 , 24 , and 26 , the measured output voltage is representative of the applied tension and compression to the mandrel 10 . In the event the mandrel 10 is subject to bending or torsional forces, the strains due to bending and torsion applied to the sensors 20 and 24 and to the sensors 22 and 26 cancel, thus rendering the circuit 40 insensitive to these forces. Also, the circuit 40 is insensitive to any changes in temperature since any temperature dependent changes in the resistance of the sensors 20 , 22 , 24 , and 26 are cancelled.
[0026] The sensors 30 , 32 , 34 , and 36 are connected in an electrical circuit, shown in general by the reference numeral 42 in FIG. 6 which is also configured in a conventional Whetstone bridge configuration. The respective outputs of the sensors 30 , 32 , 34 , and 36 of the circuit of FIG. 9, are related to the applied torsional loads on the mandrel 10 according to the following:
V V o = 2 FTR π E ( R 4 - r 4 ) ( 1 + v )
[0027] whereby, in addition to the variables defined above:
[0028] T is the applied torque
[0029] R is the outside radius of the mandrel 10
[0030] r is the inside radius of the mandrel 10 .
[0031] When the circuit 42 is provided with excitation voltage to the sensors 30 , 32 , 34 , and 36 , measurement of the output voltage is representative of the applied torsion to the mandrel 10 . Due to the angular disposition of the axes of the sensors 30 , 32 , 34 , and 36 relative to the axes of the mandrel 10 , and the design of the circuit 42 , the circuit 42 is insensitive to bending, tensile loads, and compressive loads on the mandrel 10 . Also, the circuit 42 is insensitive to any changes in temperature since any changes to the sensors 30 , 32 , 34 , and 36 corresponding to axial load, bending, or temperature effects are cancelled.
[0032] It is understood that the circuit board 16 can include hardware and software to provide excitation voltage to circuits 40 and 42 , convert the measured output voltages to digital form, and store the measurements at predetermined intervals into nonvolatile memory. In addition the circuit board 16 can include recording devices that record the compression, tension, and torsion applied to the mandrel 10 as a function of time; as well as a telemetry system to transmit the measured output voltages corresponding to the measured values of forces on the mandrel 10 to the surface in real time for further processing.
[0033] It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the particular type and relative orientation of the sensors can be varied within the scope of the invention. Also, one or more sensors can be utilized for the purpose of sensing only tension, only compression, or only torque on the mandrel 10 , or any combination thereof. Further, the mandrel 10 can be located in a different location in the workstring relative to the packer 12 than described above, and can be located relative to other tools in the workstring so that the forces on the latter tools can be measured. Moreover, the angle that the axes of the sensors extend to the longitudinal axis of the mandrel 10 can be varied, and the above equations would be varied accordingly.
[0034] Although only one exemplary embodiment of this invention has been described in detail above, those skilled in the art will readily appreciate that many other modifications are possible without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
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A system and method for sensing at least one force on a downhole tool connected in a workstring, according to which a mandrel is connected in the workstring and is subjected to the force. Two or more sensors sense axial or torsional force on the mandrel and are connected in an electrical circuit to convert the sensed force to an output signal.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
SUMMARY OF THE INVENTION
a. Field of Invention
The present invention relates to the field of structural panels useful in the construction of pressure bearing or containing tunnels, shafts, shoring and retaining walls.
More particularly, the present invention relates to corrugated structural panels useful in the construction of pressure bearing or containing tunnels, shoring and retaining walls.
Yet more particularly, the present invention relates to corrugated structural panels constructed of fiber reinforced plastic, which panels are useful in the construction of pressure bearing or containing tunnels, shoring and retaining walls.
b. Background of the Invention
A substantial need exists for lightweight, strong (structurally efficient) structural panels which may be used in the construction of pressure bearing or containing tunnels, shoring and walls.
An additional need exists for such above-described structural panels which may be stored compactly when not in use.
A further need exists for structural panels which fulfill the above-described needs and, further, are non-metallic.
Accordingly, it is a primary object of this invention to provide a structural panel suitable for use in construction of pressure bearing or containing tunnels, shoring, and retaining walls.
It is another object of this invention to provide a structural panel which is lightweight and strong (having a high structural efficiency) and may be used in the construction of pressure bearing or containing tunnels, shoring and retaining walls.
It is yet another object of this invention to provide a structural panel which fulfills the above-stated objects and is, further, designed such that a plurality of said structural panels may be compactly stored when not in use.
It is a further and final object of this invention to provide a structural panel which fulfills all of the above-stated objects and is, further, itself constructed of non-metallic materials.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical elevation of a singly corrugated version of the invention.
FIG. 2 is an end view of a singly corrugated version of the invention.
FIG. 3. is a lateral view of a singly corrugated version of the invention.
FIG. 4 is a sectional view of a singly corrugated version of the invention taken along the line 4--4.
FIG. 5 is a sectional view of a singly corrugated version of the invention taken along the line 5--5.
FIG. 6 is an end view of a closed polygon constructed by connection of four of the panels comprising the invention.
FIG. 7 is a perspective view of a tunnel segment constructed of closed polygonals formed by connection of multi-corrugated panels comprising the invention.
FIG. 8 is a perspective view of one end of a single corrugation providing a fastener pocket or void.
DESCRIPTION OF PREFERRED EMBODIMENT
As seen in FIG. 1, the instant invention is a structural panel (10) which is corrugated. The corrugation form used is that of the folded plate type. The structural panel (10) shown in FIGS. 1 through 5 has, for simplicity, but a single corrugation while in practice, a multiplicity of corrugations may be constructed into a single structural panel (10) as seen in FIG. 7.
A structural panel (10) having a single corrugation, as in FIGS. 1 through 5, will be described because the unique design of the singly corrugated panel is simply repeated for construction of a structural panel (10) having multiple corrugations.
The elements of a singly corrugated structural panel (10) are an outer flange (1), inner flanges (2 and 3), webs (8 and 9), triangular prisms (6 and 7), and bearing flanges (4 and 5).
The shape of a single corrugation of a structural panel (10) is clearly shown in FIG. 5 wherein the ridge of such corrugation is the outer flange (1), the grooves or bottom folds of the corrugation are the inner flanges (2 and 3), and the walls of the corrugation are the webs (8 and 9).
Each corrugation within the structural panel (10) of the instant invention is, however, ended in a unique fashion. The end of each corrugation is connected, perhaps integrally, to a triangular prism (6 or 7) element referred to herein as a triangular prism (6 or 7). The external shape, but not necessarily the internal construction, of said triangular prism (6 or 7) element is that of a solid formed by linearly connecting all points between two triangles coplanar with the webs (8 and 9). The triangular prism (6 or 7) element is located at the end of each corrugation within the structural panel (10) transversely to the longitudinal axis of the corrugation. Said triangular prism (6 or 7) serves to transmit the forces from the corrugation to the bearing flange (4 or 5). Both bending and axial forces are transmitted by the triangular prism (6 or 7) to the bearing flange (4 or 5) from the corrugation.
The bearing flange (4 or 5) is integral to one of the three faces of the triangular prism (6 or 7, respectively). One edge of each bearing flange (4 or 5) is connected to the inner flanges (2 and 3). The bearing flanges (4 and 5) form the supporting edges of the structural panel (10) and each bearing flange (4 or 5) lies in a plane inclined to the longitudinal axis of the structural panel (10) thereby providing a bearing surface which in the preferred embodiment is normal, but need not be, to the vector resultant of the summation of the reactive forces.
The two inner flanges (2 and 3) are coplanar and they have parallel longitudinal axis. The outer flange (1) is in a plane parallel to the two inner flanges (2 and 3) and has a longitudinal axis parallel to the longitudinal axis of the inner flanges (2 and 3).
The two triangular prisms (6 and 7) are parallel to one another, but transverse to the longitudinal axis of the outer flange (1) and thus to the longitudinal axis of the corrugation. The two bearing flanges (4 and 5) have their long axes parallel to one another and to the axes of the triangular prisms (6 and 7). The long axes of the two bearing flanges (4 and 5) are perpendicular to the longitudinal axes of the inner flanges (2 and 3), to the longitudinal axis of the outer flange (1), and to the longitudinal axes of the webs (8 and 9).
The webs (8 and 9) serve to connect the long edges of the outer flange (1) to the long edges of the inner flanges (2 and 3) and serve, additionally, to carry shear loads perpendicular to the longitudinal axis of the corrugation. The webs (8 and 9) are non-parallel in the preferred embodiment and angle inwardly from the long edges of the inner flanges (2 and 3) to the long edges of the outer flange (1) toward one another.
In the preferred embodiment, the structural panel (10) is constructed of fiber reinforced plastic which provides a lightweight material which may be fiber reinforced at various points or locations throughout the structural panel (10) to provide needed strength and force bearing characteristics for particular applications. However, the design of the instant structural panel (10) is such that it may be usefully constructed of various other metallic and non-metallic materials.
The corrugated shape of the structural panel (10) is, in the preferred embodiment, such that multiple panels may be stacked by laying each panel flat upon the preceding panel and aligning the corrugations of each succeeding panel to overlay the corrugations of the preceding panel.
The design of the corrugation of the structural panel (10) provides for certain specific desirable characteristics. The outer flange (1) in combination with the inner flanges (2 and 3) provides high resistance to bending moments induced by loading that is perpendicular to the longitudinal axis of the corrugation. Bending moments created by forces acting normal to and inwardly upon the plane of the outer flange (1) are resisted by compressive forces induced in the outer flange (1) and tensile forces induced in the two inner flanges (2 and 3). Reversed bending moments are resisted by tensile forces induced in the outer flange (1) and compressive forces induced in the inner flanges (2 and 3).
The unique design of the corrugation end sections provides certain additional desirable characteristics. Each corrugation end section comprises a triangular prism element (6 or 7), which is transverse to the longitudinal axis of the corrugation. The triangular prism element (6 or 7) efficiently collects stresses (compression, tension and shear) from the flanges and webs of the corrugation and transmits said stresses to the bearing flange (4 or 5) outwardly facing surface which comprises the load bearing edge of the structural panel (10).
As shown in FIG. 8, one or more fastener pockets or voids (20) may exist within the triangular prism element (6 or 7) to accommodate fastener (21) ends. Said fastener pocket or void (20) within the triangular prism element (6 or 7) may be open to anyone or more or none of the triangular prism element (6 or 7) faces adjacent to the triangular prism element (6 or 7) face which is integral to the bearing flange (4 or 5). An aperture (22) through the bearing flange (4 or 5) allows a fastener (21) shaft to protrude from the fastener pocket or void (20) internal to the triangular prism to a supporting connection outside the structural panel (10). Likewise said supporting connection may comprise an aperture (22) in the bearing flange (4 or 5) of an adjacent structural panel (10) which provides fastener pockets or voids (20) to accommodate fastener (21) ends.
This invention has been described in terms of single preferred embodiment, however numerous embodiments are possible without departing from the essential characteristics thereof. Accordingly, the description has been illustrative and not restrictive as the scope of the invention is defined by the appended claims, not by the description preceding them, and all changes and modifications that fall within the stated claims or form their functional equivalents are intended to be embraced by the claims.
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An improvement in corrugated structural panels, useful in the construction of tunnels, shoring, and other pressure bearing or containing structures, wherein the improvement comprises the utilization of a prism element transverse to the longitudinal axis of the corrugation in the design of the end sections of each corrugation within the panel thereby providing means to collect shear, bending and axial stresses from the corrugated panel and transmit them to the panel's supporting edge.
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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 apparatus and method for use in supporting masonry lintels and, more particularly it is directed to a system for adjustably supporting a spine to be concealed within the lintel. In its more specific aspects, the invention is concerned with such a support system which enables the use of a concealed support, maintains the standard grout width and accommodates various widths of masonry and various tolerances, without requiring a precisely pre-constructed lintel support for each job.
It is well known in the art to use supports for masonry lintels. Most of these supports, however, are disposed beneath the lintel and, accordingly, exposed to view. See, e.g., U.S. Pat. Nos. 4,020,612, 4,202,143, 4,757,656, 5,465,558 and the exposed roof truss of U.S. Pat. No. 5,218,801. It is also known to reinforce brick walls supported on piers through means of internal reinforcing elements which extend longitudinally through a passage therefor in the wall so that the elements are concealed, as may be seen from U.S. Pat. No. 5,893,254.
The prior art concealed lintel system of HALFEN Anchoring Systems employs a steel spine that spans the opening being arched and rests on bearing plates at each end. Cored bricks are suspended from the spine through means of “horseshoe” plates that hang on the spine at every third brick joint and stitching rods which extend through openings in the plates and the bricks. During the course of construction, the bricks are supported on a framework and the openings in the bricks and plates, with the rods extending therethrough are packed with mortar. Grout is placed between the bricks, with the result that the spine support is totally concealed. The bearing plates supporting the spine on the piers are welded to the spine and grouted into place on the piers.
The present invention is an improvement over the concealed lintel system of HALFEN in that the bearing plates at either end of the spine are adjustable to accommodate various size and tolerance masonry units and maintain a standard grout width. As a result, the spine of the present invention does not need to be custom designed and fabricated for each project, as was necessary with the welded spine and support plate construction of the prior art HALFEN System.
SUMMARY OF THE INVENTION
The apparatus of the invention is for use in combination with a lintel support comprising a first spine member extending between piers disposed to either side of an area to be arched and support plates mounted on the spine member to suspend cored bricks from the member through means of stitching rods extending through apertures in the plates and bricks. The improvement of the inventive apparatus comprises separate bearing plates on each of the piers to support the spine member, and attachment means to selectively secure the spine member to the bearing plates at different positions of adjustment relative to the plates. Multiple spine embodiments of the invention further include means connecting the spines to the bearing plates which provide for selective adjustment of the relative spacing between the spines. The inventive apparatus may also provide adjustable intermediate supports to suspend the spines from support structure disposed between the piers.
In the method of the invention, a spine member to be concealed within a masonry lintel rests on support structure disposed to one end of the lintel. The method provides an adjustable support between the structure and the spine member to accommodate adjustment of the spine member relative to the structure. The support is adjusted to dispose the spine member in a desired condition of adjustment relative to the structure and then secured to maintain the desired condition of adjustment.
A principal object of the invention is to provide a concealed support system for a masonry lintel which will accommodate last minute adjustments and allow for variations in the sizes of the bricks used to construct the lintel. Another general and related object is to provide an adjustable support system for a concealed masonry lintel which allows adjustments for as built variations in the masonry. These and other objects of the invention will become more apparent when viewed in light of the following detailed description in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a pair of concealed support spines for a masonry lintel wherein the ends of the spines are supported on piers through means of the apparatus and method of the present invention, with bricks shown in phantom supported on horseshoe plates carried by the spines;
FIG. 2 is a perspective view, with parts thereof broken away, illustrating the detail of the spines and associated horseshoe plates and bricks of FIG. 1 ;
FIG. 3 is a cross-sectional elevational view illustrating a first embodiment of the adjustable intermediate support of the invention;
FIG. 4 a is a perspective view illustrating a horseshoe plate designed to be hung from one side of a support spine;
FIG. 4 b is a perspective view of the horseshoe plate of FIG. 4 a , shown hung from a spine member, with bricks suspended therefrom by stitching rods;
FIG. 5 is a cross-sectional elevational view of a second embodiment of the adjustable intermediate support of the invention;
FIG. 6 is a perspective view, with parts thereof broken away, illustrating an embodiment wherein the support of the invention accommodates two spine members, each of which supports a separate horseshoe plate;
FIG. 7 is a cross-sectional elevational view, with parts thereof broken away, illustrating a third embodiment of the adjustable intermediate support of the invention;
FIG. 8 is a cross-sectional elevational view, with parts thereof broken away, illustrating a modification of the third embodiment intermediate support of FIG. 7 ;
FIG. 9 is a cross-sectional elevational view, with parts thereof broken away, illustrating a fourth embodiment of the adjustable intermediate support of the invention;
FIG. 10 is an elevational view, with parts thereof shown in section, illustrating a first embodiment of the bearing plate construction of the invention;
FIG. 11 is an elevational view, with parts thereof shown in section, illustrating a second embodiment of the bearing plate construction of the invention;
FIG. 12 is an elevational view, with parts thereof shown in section, illustrating a third embodiment of the bearing plate construction of the invention;
FIG. 13 is an elevational view, with parts thereof shown in section, illustrating a fourth embodiment of the bearing plate construction of the invention;
FIG. 14 is side-elevational view, illustrating the bearing plate construction of the present invention supporting a generally rectilinear spine; and
FIG. 15 is a side-elevational view similar to FIG. 14 , illustrating the bearing plate construction of the present invention supporting a rectilinear spine with an intermediate support.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a concealed lintel system of the HALFEN type embodying the adjustable support system of the present invention. As there seen, piers P are disposed to either side of an area A to be arched. A pair of spine members S span the area A and are supported at their ends on the piers P. The spine members carry a horseshoe plates H which, in turn, carry cored bricks B through stitching rods 10 which extend through openings 12 in the bricks and openings 14 in the plates. The plates are formed with U-shaped slots 16 which engage over the spine members S. The openings 14 in the plates are disposed both to the outside and to the inside of the spines. The outside openings support bricks B to the outside of the spines. The inside openings supports bricks intermediate to spines. In a typical embodiment, the spines are fabricated from three-eighths inch steel plate, the horseshoe plates are fabricated of three-sixteenth thick plate and the stitching rods are fabricated of one-quarter inch diameter bar. The plate and bar elements are ideally either fabricated of a corrosion resistant steel, or hot-dipped galvanized steel. The stitching rod openings in the horseshoe plates P are of a elongate configuration and ideally correspond with at least two cored openings in the bricks.
In the course of constructing a lintel the bricks are positioned as shown in FIG. 1 , with the horseshoe plates at three brick intervals, and the stitching rods are threaded through the openings in the plates and bricks. The openings in the bricks are packed with mortar around the stitching rods. The horseshoe plates are received in the grouting space between each third brick and the bricks are assembled so that a uniform grout space is provided therebetween. The grout space is filled with mortar. The bricks are supported on a form work (not illustrated) until such time as the mortar has sufficient strength to support the load of the bricks. After the form work is removed, the lintel is cleaned of excess mortar and the joints are pointed.
FIG. 1 illustrates a first embodiment of the inventive spine support system wherein angles 18 are disposed on the piers P to either side of each of the spines S. Each angle comprises a bearing plate portion 20 resting on top of the pier and an upright portion 22 extending vertically therefrom in generally parallel relationship to the spine member which it supports. (This arrangement may be seen in more detail in FIG. 10. )
Lower bolts 24 extend slidably through complimental openings therefor in the upright portions and through enlarged openings 26 in the spine members S. Elongate upper bolts 28 also extend through complimental openings therefor in the upright portions 20 and through enlarged openings 30 in the spine members S. The bolts 28 also span the space between the spine members S and, together with nuts 32 threadably received thereon serve as means to adjust the spacing of the spine members relative to one another. Vertical and horizontal adjustment of the support angles 18 relative to the spine members S is provided through means of the enlarged openings 26 and 30 in the spine members and the smaller diameter of the bolts 24 and 28 extending therethrough. In the course of such adjustments, the nuts on the bolts 24 and 28 are initially left in a loose condition so that the position of the angles 18 relative to the spines may be adjusted to position the bearing plate portions firmly on the piers. Once so adjusted, nuts 34 on the bolts 24 are tightened to clamp the spine members S between the upright portions 22 . The inside nuts 32 on the elongate bolt 28 are then adjusted to provide the desired spacing of the spine members S and the outside bolts 32 are then tightened into place to both fix this condition of adjustment and further clamp the spine members S between the upright portions 22 . The clamping action of the bolts functions to force the upright portions 22 into secure frictional engagement with the spine members S, thus selectively establishing a secure adjusted condition between the angles 18 and the spine members. Once fully adjusted and clamped, the bearing plate portions of the angles 18 are mortared into place on the piers.
The adjustable intermediate support shown in FIG. 3 is secured to an I-beam 34 fixed above the area being arched. The first component of the adjustable intermediate support comprises a T-shaped or angle-shaped member 36 clamped to the I-beam. Clamping is provided by bolts 38 which extend through the T-shaped member, clamp elements 40 slidably received on the bolts, and nuts 42 threadably engaged with the bolts above the clamp elements 40 . In the course of adjustment, the nuts are initially loosened to enable the clamp elements to slide on the I-beam, and once the desired condition of adjustment is achieved, the bolts are tightened to secure the T-shape member in place. Links 44 extend between the member 36 and the spine members S to suspend and lend intermediate support to the spine members. The ends of the links are hooked through apertures provided therefor in the member 36 and the spine members S. Turnbuckles 46 provide for select adjustment of the length of the links.
The horseshoe plate of FIG. 4A , designated H 1 , is designed for the construction of a lintel having a single brick width, as might be used for creating the appearance of a brick arch on the opening in a preexisting wall. It comprises a main plate portion 48 having oblong stitching rod openings 50 extending therethrough and a hanger plate 52 welded in normal relationship to the plate 48 for hooking over a spine member, as seen in FIG. 4 B. The ends of the spine member would be supported on piers, or other support structure, through means of the adjustable support structure of the present invention, for example the first embodiment structure previously described with respect to FIGS. 1 and 10 .
The adjustable intermediate support of FIG. 5 may be used with a single thickness brick lintel, such as that shown in FIGS. 4A and 4B . It is of a construction similar to that of FIG. 3 in that it includes an I-beam 34 , a T-shaped member 36 and bolted clamp elements 40 . The T-shaped member, however, is asymmetrical relative to the I-beam and extends to one side thereof to support an elongate vertically extending bolt 54 . The bolt 54 supports the spine member S through means of an angle 56 welded to the spine member. Nuts 58 are threadably engaged on the bolt 54 to either side of the horizontal flanges of the T-shaped member 36 and the angle. These nuts are selectively adjusted and tightened into place to adjust the length of the FIG. 5 support.
The modified arrangement of FIG. 6 differs from that of FIGS. 1 and 2 in that the spine members S are spaced apart by a greater distance and a separate horseshoe plate H 3 is provided on each spine member. This arrangement accommodates different proportions and combinations of bricks intermediate to spine members. The adjustable supports of the present invention enable the spacing of the spine members to be adjusted to compliment such differences, while maintaining uniform grout width.
The third embodiment adjustable intermediate support shown in FIG. 7 corresponds to the first embodiment shown in FIG. 3 , except that it is the greater width to accommodate wider spacing of the spine members and the separate horseshoe plates of FIG. 6 . Accordingly, the elements of the FIG. 7 intermediate support are designated by numerals corresponding to those used for the like elements of the FIG. 3 embodiment. Like the FIG. 3 embodiment, the FIG. 7 embodiment provides for adjustment of the intermediate support both longitudinally and vertically, relative to the fixed I-beam 34 .
The modification of the third embodiment intermediate support shown in FIG. 8 differs from that of FIG. 7 only in the construction of the T-shaped member, designated 36 A and the clamp elements which secure the member 36 A to the I-beam 34 . The top of the T-shape member 36 A is formed with what is known as a HALPEN channel for slidably receipt of special bolts 38 A which carry washer like clamp elements 40 A and threadably receive clamping nuts 42 A. When the nuts 42 A are loosened, the bolts 38 A may be slid over the flange of the I-beam 34 to enable the T-shaped member to be adjusted in position relative to the I-beam both longitudinally and transversely. Once in the desired position of adjustment, tightening of the nuts 42 A serves to fix the position of the T-shaped member 36 A relative to the I-beam.
The fourth embodiment intermediate support of FIG. 9 differs from the first embodiment of FIG. 3 only in the construction of the clamp used to secure the intermediate support to the I-beam 34 . In the FIG. 9 embodiment, the clamp comprises angle-shaped members 58 engaged over the lower flange of the I-beam, which members have intermediate L-shaped extensions 60 welded thereto and extending downwardly therefrom. The extensions are adjustably secured together by a threaded rod 62 extending therethrough and nuts threadably engaged with the rod to either side of each of the extensions. The nuts are adjusted and tightened in place to lock the angle-shaped members 58 in select conditions of adjustment relative to the I-beam 34 . Links 44 , corresponding to those of the FIG. 3 embodiment, adjustably suspend the spine members (not illustrated) from the FIG. 9 clamp.
The second embodiment bearing plate construction ( FIG. 11 ) differs from the first embodiment in that a single T-shaped support 66 is provided for each of the spine members S in place of the paired angles 18 . Each T-shaped support comprises a bearing plate portion 68 having an upright portion 70 welded thereto. The upright portions 70 are bolted to the spine members S through means of lower bolts 24 and elongate bolts 28 corresponding to the like numbered bolts of the first embodiment support illustrated in FIG. 10 . The bolts 24 and 28 extend through complimental openings therefor in the upright portions 70 and through enlarged openings 26 , 30 in the spine members. Like the first embodiment of FIG. 10 , the enlarged openings 26 and 30 of the FIG. 11 embodiment permit the spine members to be adjusted horizontally and vertically relative to the bearing plate portions 68 . Tightening of the bolts through means of the nuts thereon serves to clamp the spine members to the upright portion 70 . The nuts on the elongate bolt 28 also accommodate adjustment of the spine members towards and away from each other.
The third embodiment bearing plate construction of FIG. 12 corresponds identically to the first embodiment construction of FIG. 10 , except that the inner angles, designated 18 A, are provided with more elongate bearing plate portions 20 A. These more elongate portions provide additional stability and are desirable in applications of the invention where the distance between paired spine members is increased.
The fourth embodiment bearing plate construction of FIG. 13 is essentially a variation of the second embodiment of FIG. 11 , wherein the single support plate for the spine member S comprises an L-shaped angle 18 B, rather than a T-shaped member. The L-shaped member 18 B has a lower bearing plate portion 20 B and an upright portion 22 B. As shown in FIG. 13 , however, a single spine member, only, is supported on the angle 18 B. Short bolts 24 extend through the enlarged openings 26 , 30 of the spine member and complimental openings therefor in the upright portion 22 B. Like the other embodiments, the enlarged openings in the spine member permit adjustments of the spine member relative to the angle 18 B. Tightening of the bolts serves to secure the spine members in adjusted condition.
FIG. 14 illustrates that the support structure of the present invention may be used to adjustably support a generally rectilinear spine member, designated S 1 . As there shown, the spine member S 1 is provided with a centrally disposed aperture 74 for receipt of an intermediate support link, such as that shown in FIG. 3 .
FIG. 15 also shows the support system of the present invention used to support a generally rectilinear spine member, designated S 2 . The spine member S 2 has an angle 56 A, similar to the angle 56 of the FIG. 5 embodiment, welded thereto intermediate S-ends for engagement with an intermediate support such as that shown in FIG. 5 .
CONCLUSION
All embodiments of the present invention provide multi-directional adjustment for the lintel support, thus avoiding the requirement that special supports be preconstructed for each job. The invention is defined in the following claims.
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A masonry lintel having a concealed spine which spans between piers to either side of an area to be arched and supports masonry bricks through means of horseshoe shaped plates which ride on the spine. The bricks are supported on the spine by stitching rods which extend through apertures in the plates and the bricks. The plates are received in the grouting space between the bricks and, in the finished lintel, are grouted over to be completely hidden from view. Variations in the relative positions of the piers and the width of bricks used to construct the lintel are accommodated by adjustable supports between the spine and the piers which enable the position of the spine relative to the piers to be selectively adjusted. In the embodiments employing multiple generally parallel spines, these supports provide for adjustable spacing of the spines. Center supports for the spines are adjustable both vertically and horizontally to accommodate various structural design parameters.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a lock device which prevents a work machine of a construction machine from being tilted by the weight thereof. Especially, the present invention relates to a lock device which prevents a boom of a backhoe work machine from being rotated downward by the weight thereof.
2. Background Art
Conventionally, there is well known a so-called tractor loader backhoe constructed so that a loader is attached to a front portion of a traveling vehicle and a backhoe is attached to the rear portion thereof. With regard to such a kind of a tractor loader backhoe, a side column supporting a boom is standingly provided on a side frame at the front portion of the tractor, a bucket is supported at the tip of the boom, and the boom and the bucket can be rocked respectively by hydraulic cylinders, whereby a front loader is constructed. A boom is supported in the rear portion of the tractor so as to be rotatable vertically and laterally, an arm is supported at the tip of the boom so as to be rotatable vertically, a bucket is supported at the tip of the arm so as to be rotatable vertically, and each of them can be rotated by a hydraulic cylinder, whereby a backhoe is constructed.
The front loader is operated by an operation part arranged at a side of a seat. The backhoe is operated by a lever or the like provided on an operation column standingly provided on a frame of the rear portion while the seat is reversed longitudinally.
The tractor loader backhoe travels by wheels so that the tractor loader backhoe can travel at relatively high speed. At the time of traveling, if the loader or the backhoe which is a work machine is fallen by vibration, leak of pressure oil or the like, the travel may be hindered. Then, there is well known an art for locking the work machine at the time of not operating the work machine (for example, see the Patent Literature 1).
Patent Literature 1: the Japanese Patent Laid Open Gazette 2004-360331
BRIEF SUMMARY OF THE INVENTION
However, with regard to the art of the Patent Literature 1, the movement of the operation lever is restricted, and leak of pressure oil causes fall of the work machine by the weight thereof. Then, there is an art preventing the fall mechanically. For example, a lock member is provided at the rotary basal part of the boom and an operation member is extended from the operation column so as to operate the lock member, thereby locking the boom. However, the operation member always touches the lock member so that friction occurs every time each mechanism is actuated so that the touch part is abraded and rusts, whereby the life of the members is shortened.
Thus, the present invention is intended to provide a lock device comprising an engaging member and an engaged member such that lock operation can be performed manually easily.
The above-mentioned problems are solved by the following means.
According to a first aspect of the present invention, a lock device of a work machine including a main body and an excavating device is provided for locking a boom of the excavating device to the main body. In the lock device, an engaging member is provided on one of the boom and a boom bracket provided on the main body, and an engaged member is provided on the other of the boom and the boom bracket. The engaging member is constituted by a plate formed on one side thereof with a hook part, and on the other side thereof with a slot. A support pin is inserted into the slot, and a guide member is disposed above the support pin, so that the support pin and the guide member support the engaging member. The engaging member is provided on the other side thereof with first and second surfaces so that the first surface is parallel to the slot, and the second surface is slanted from the slot. When the engaged member is released from the hook part, either the first surface or the second surface can touch the guide member. When the engaged member is engaged with the hook part, the second surface touches the guide member.
According to a second aspect of the invention, the guide member is provided on the boom, and does not become horizontal while the boom is rotated between its highest position and its lowest position.
According to a third aspect of the invention, an end surface of the one side of the engaging member at which the hook part is positioned is enabled to touch the engaged member and is slanted toward a lengthwise center of the engaging member.
According to a fourth aspect of the invention, a slip-prevention plate is fixed to a tip of the support pin and the support pin can be inserted into the slot through the slip-prevention plate at a prescribed angle.
According to a fifth aspect of the invention, a member supporting the engaging member is projected from the boom bracket and the guide member is formed integrally with the boom bracket.
According to sixth aspect of the invention, the engaging member is provided with upper and lower guide members such as to slidably touch upper and lower surfaces of the other side of the engaging member.
The present invention constructed as the above brings the following effects.
According to the first aspect of the present invention, the lock device is constructed easily, and by sliding the engaging member along the slot and by touching the guide member with either the first or second surface of the engaging member, the engaging member can be held in the lock position or the lock release position.
According to the second aspect of the present invention, at any rotation position of the boom between the highest position and lowest position, the engaging member maintains the lock position, whereby it is not necessary to provide a holding mechanism for the engaging member so that the lock device is simplified and the cost is reduced.
According to the third aspect of the present invention, at the time that the engaging member moves to the lock side, when the boom is rotated to the lock position, the engaging member can evade by the slanting of the end surface of the one side of the engaging member, thereby preventing the engaging member and the engaged member from being damaged by their touching.
According to the fourth aspect of the present invention, the engaging member is inserted while the support pin is disposed at the predetermined angle, and the engaging member is prevented from slipping off by changing the angle of the support pin. Accordingly, the slip-prevention mechanism is constructed easily and it is not necessary to provide any slip-prevention member separately, whereby the number of parts is reduced, and the number of assembly processes is also reduced.
According to the fifth aspect of the present invention, it is not necessary to provide any guide member separately, whereby part number is reduced. It is not necessary to assemble the guide member, whereby number of assembly processes is reduced so as to reduce the cost.
According to the sixth aspect of the present invention, the engaging member is guided at its upper and lower sides, whereby the guide of the engaging member is stabilized so as to prevent ricketiness. Force applied on the guide member is dispersed into two, whereby the guide member is constructed small and the life of the lock mechanism is prolonged.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 It is an entire side view of a work vehicle according to the present invention.
FIG. 2 It is a side view of a lock device according to the present invention.
FIG. 3 It is a perspective view of the lock device.
FIG. 4 It is a side view of the lock device in a lock state.
FIG. 5 It is a side view of the lock device in the state that a boom is fallen to the lowest position.
FIG. 6 It is a side view of the lock device in the state that a lock plate is slid to a lock side so as to touch a lock pin.
FIG. 7 It is a perspective view of the vicinity of the boom that an operation lever is provided on the lock plate.
FIG. 8 It is a side view of an embodiment that the lock plate is provided at a side of a boom bracket.
FIG. 9 It is a rear view of the same.
FIG. 10 It is a rear view of the same in the state that a support pin is removed.
FIG. 11 It is a rear view of the same in the state that the support pin is inserted into the lock plate.
FIG. 12 It is a rear view of the same in the case that the support pin is in slip-prevention state.
DETAILED DESCRIPTION OF THE INVENTION
Next, explanation will be given on the mode for carrying out the present invention. FIG. 1 is an entire side view of a work vehicle according to the present invention. FIG. 2 is a side view of a lock device according to the present invention. FIG. 3 is a perspective view of the lock device. FIG. 4 is a side view of the lock device in the lock state. FIG. 5 is a side view of the lock device in the state that a boom is fallen to the lowest position. FIG. 6 is a side view of the lock device in the state that a lock plate is slid to lock side so as to touch a lock pin.
Firstly, explanation will be given on entire construction. A work vehicle 1 shown in FIG. 1 is a tractor loader backhoe equipped with a loader 2 and an excavating device 3 . An operation part 4 is provided at the center of the work vehicle 1 . The loader 2 is disposed before the operation part 4 , and a backhoe as the excavating device 3 is disposed behind the operation part 4 . The work vehicle 1 is equipped with front wheels 8 and rear wheels 7 so that the work vehicle 1 equipped with the loader 2 and the excavating device 3 is enabled to travel.
A steering wheel 5 and a seat 6 are disposed in the operation part 4 . A travel operation device and an operation device of the loader 2 are disposed at the side of the seat 6 . Accordingly, steering operation of the work vehicle 1 and operation of the loader 2 can be performed at the operation part 4 .
The loader 2 , i.e., a loading device, is connected to side portions of the work vehicle 1 and is extended forward, and a bucket is equipped on the tip of the loader 2 . An engine is disposed in the front portion of a frame 9 which is a chassis of the work vehicle 1 , and a bonnet 30 disposed on the frame 9 covers the engine. The loader 2 is disposed outside the bonnet 30 .
The work vehicle 1 is detachably equipped on the rear portion thereof with the excavating device 3 , and the excavating device 3 is operated with a lever and the like on an operation column 11 disposed behind the seat 6 .
A pressure oil tank 90 is disposed at a side portion of the operation part 4 , and the pressure oil tank 90 also serves as a step to the operation part 4 . A step constructed by a fuel tank is disposed at the opposite side of the operation part 4 .
An attachment part for a work machine is provided at the rear end of the frame 9 , and a work machine frame 13 of the excavating device 3 is fixed to the attachment part. The operation column 11 is standingly provided at the lateral center of the work machine frame 13 , and the operation lever and the like are disposed on the operation column 11 . Stabilizers 10 are provided at both left and right sides of the work machine frame 13 and can be rotated vertically by expansion and contraction of hydraulic cylinders 20 . A boom bracket 15 is attached to the rear portion of the work machine frame 13 so as to be rotatable laterally centering on the vertical axis and is rotated by a hydraulic cylinder (not shown). A basal part of a boom 16 is pivotally attached to the rear portion of the boom bracket 15 so as to be rotatable vertically centering on the lateral axis and is rotated by a boom cylinder 21 . A basal part of an arm 17 is pivotally attached to the tip of the boom 16 so as to be rotatable vertically centering on the lateral axis and is rotated by an arm cylinder 22 . A bucket 18 is attached to the tip of the arm 17 through a linkage mechanism so as to be rockable and is rocked by a bucket cylinder 23 .
As shown in FIG. 2 , the boom bracket 15 is substantially U-like shaped when viewed in side. Support parts 15 a and 15 b are respectively formed in the upper front portion and the lower portion of the boom bracket 15 . Support holes are respectively formed vertically in the support parts 15 a and 15 b . The boom bracket 15 and the work machine frame 13 are pivotally connected to each other through two pivot pins 27 which are lateral-rotation fulcrums so that the boom bracket 15 is laterally rotatably supported at the lateral center of rear portion of the work machine frame 13 . Two pivot parts 15 c are respectively formed in the lower portions of both left and right sides of the boom bracket 15 , and support holes are respectively formed vertically in the pivot parts 15 c so that each of the pivot parts is connected pivotally to a tip of a swing cylinder, whereby the boom bracket 15 is rotated laterally by the swing cylinder. A support part 15 d is projected rearward from the lower rear portion of the boom bracket 15 and a support hole is bore laterally in the support part 15 d so as to support pivotally the lower portion of the boom 16 by a pivot pin 25 . A support hole is bore laterally in the upper rear portion of the boom bracket 15 so as to pivotally support the lower portion of the boom cylinder 21 by a lock pin 54 also serving as a pivot pin.
Next, explanation will be given on a lock device 51 of the present invention according to FIGS. 2 to 6 .
The lock device 51 comprises the lock pin 54 provided in the boom bracket 15 of the vehicle so as to serve as an engaged member, a lock plate 52 serving as an engaging member of the work machine engaging with the lock pin 54 , and a guide member 53 keeping the lock plate 52 at a prescribed position.
Explanation will be given according to FIGS. 2 and 3 showing the state that the boom 16 is raised to the highest position (rotated forward).
The lock plate 52 and the guide member 53 are attached to the side surface of the boom 16 , and the lock pin 54 is projectively provided on the side surface of the boom bracket 15 . In addition, to the contrary, it may alternatively be constructed that the lock pin is attached to the boom and the lock plate is attached to the boom bracket. A hook part 52 a which is substantially C-like shaped and opened downward is formed at one of sides of the lock plate 52 , and a forward-slanted surface 52 b is formed at the tip (front end) of the lock plate 52 . The forward-slanted surface 52 b is slanted downward to the opened side of longitudinal center of the lock plate 52 when viewed in side.
A slot 52 c which is elongated longitudinally is opened at the other side (rear side) of the lock plate 52 . A support pin 55 is inserted into the slot 52 c so as to support the lock plate 52 rotatably and slidably. The support pin 55 is projectively provided on the side surface of the boom 16 along the same direction as the lock pin 54 .
The lock plate 52 is formed at the rear end thereof with a rearward-slanted surface 52 d , and is provided with a rear upper surface 52 e before the rearward-slanted surface 52 d so as to have an obtuse angle between the rearward-slanted surface 52 d and the rear upper surface 52 e . When the support pin 55 is positioned in the rear portion of the slot 52 c , the lock plate 52 can be rotated vertically between the lock position and the release position, while the angle of the lock plate 52 is regulated by the guide member 53 in cooperation with the rearward-slanted surface 52 d and the rear upper surface 52 e due to the substantially trapezoidal shaped rear portion of the lock plate 52 . Namely, as shown in FIG. 6 , the part where the rear upper surface 52 e is contiguous to the rearward-slanted surface 52 d is circular arc-like shaped centering on the axis of the support pin 55 while the lock plate 52 is slid forward. The slot 52 c is disposed parallel to the rear upper surface 52 e , and the shortest distance between the axis of the support pin 55 and the rear upper surface 52 e is the same as that between the axis of the support pin 55 and the rearward-slanted surface 52 d . In addition, though it is not shown in the drawings of this embodiment, it may alternatively be constructed that one of ends of a link or wire is connected to the part of the lock plate 52 in the vicinity of the hook part 52 a and the other end of the link or wire is connected to an operation member arranged in the operation part 4 , whereby the lock and release operation by the lock plate 52 can be performed by operating (pushing and pulling) the operation member at the operation part 4 .
As shown in FIG. 7 , it may alternatively be constructed that one of end of an operation lever 56 is supported in the vicinity of the hook part 52 a of the lock plate 52 and the other end of the operation lever 56 is engaged with the front side (back surface) of the boom 16 . The operation lever 56 is substantially inverse U-like shaped when viewed in front. The open end of the operation lever 56 is inserted into an engaged hole opened in the hook part 52 a and is pivotally supported. The other end of the operation lever 56 is extended upward along the boom 16 , and two engage fittings 57 constructed by metal leaves or the like are fixed to the front surface of vertical middle portion of the boom 16 so as to be engaged with both left and right sides of the other end of the operation lever 56 . Accordingly, when the lock plate 52 is disposed in the lock position or the release position, the other end of the operation lever 56 is engaged with and held by the engage fittings 57 , and at the time of operation, the closed side of the operation lever 56 is gripped by a hand and the operation lever 56 is rotated to this side so as to release the engagement, and then the lock or release operation is performed and the operation lever 56 is engaged with the engage fittings 57 again. In addition, though the lock plate 52 is provided at each of the left and right sides in this case, it may alternatively be constructed that the lock plate is provided at one of the left and right sides and operated by one operation lever. The engagement of the operation lever 56 is not limited to the above-mentioned construction.
The guide member 53 is formed by bending a plate L-like shaped when viewed in rear, and is fixed to the side surface of the support pin 55 at the side of basal part of the boom 16 so that the upper surface of the guide member 53 is projected sideward. In other words, as shown in FIG. 2 , when the boom 16 is positioned vertically (at the foremost position), the support pin 55 is positioned below the front end of the guide member 53 . In addition, the guide member 53 may alternatively be constructed integrally with the boom 16 . In the state of FIG. 2 , the distance between the support pin 55 and the guide member 53 is slightly longer than the distance between the inner surface of the slot 52 c and the rear upper surface 52 e of the lock plate 52 so that the lock plate 52 is attached longitudinally slidably. In the state of FIG. 4 , the distance between the support pin 55 and the guide member 53 is slightly longer than the distance between the inner surface of the slot 52 c and the rearward-slanted surface 52 d of the lock plate 52 . Accordingly, when the lock plate 52 is slid forward to the lock position, the lock pin 54 is engaged therewith and the rear portion of the rearward-slanted surface 52 d touches the lower surface of the guide member 53 so as to prevent further downward rotation of the lock plate 52 .
With regard to the tilt angle of the guide member 53 , as shown in FIG. 4 , when the boom 16 is rotated the foremost position, i.e., the lock position, and the hook part 52 a of the lock plate 52 is engaged with the lock pin 54 , the rearward-slanted surface 52 d is parallel to the guide member 53 and touches the guide member 53 , whereby the guide member 53 is slanted rearward. As shown in FIG. 5 , when the boom 16 is rotated to the lowest position, the angle between the guide member 53 and a horizontal line GL is positive. In other words, the angle of the surface of the guide member 53 touching the lock plate 52 is always positive (in the first or second quadrant).
Accordingly, when the lock plate 52 is in the release state that the rear upper surface 52 e touches the guide member 53 as shown in FIG. 2 , the state can be maintained even if the boom 16 is rotated to any position. Namely, even if the lock plate 52 is projected along the slot toward the bucket 18 by vibration or the like, the rear upper surface 52 e is fallen along the guide member 53 or the slot 52 c is fallen along the support pin 55 by the weight thereof so as to return to the original position. Even if the lock plate 52 is locked at the lowest position (projected), the lock plate 52 is rotated rearward by the weight thereof centering on the support pin 55 and slid downward so as to reach the release position automatically.
When the boom 16 is rotated forward so as to be locked at the time of finishing the work, even if the lock plate 52 is at the lock position (projected) by vibration or the like as shown in FIG. 6 , the forward-slanted surface 52 b touches the lock pin 54 so that the lock plate 52 is lifted and rotated upward centering on the support pin 55 , thereby prevented from being stretched against the guide member 53 and damaged. When the boom 16 is rotated to the foremost position while the lock plate 52 is projected, the lock pin 54 moved from the forward-slanted surface 52 b reaches the hook part 52 a of the lock plate 52 so that the lock plate 52 is engaged with the lock pin 54 so as to be locked.
The lock pin 54 is projectively provided from the side surface of upper rear portion of the boom bracket 15 and can be engaged with the lock plate 52 . In this embodiment, the lock pin 54 is arranged at the lower end of the boom cylinder 21 , that is, at a side of a fulcrum pin 26 pivotally supporting the tip of the rod. In addition, the lock pin 54 may alternatively be constructed integrally with the fulcrum pin 26 or constructed to also serve as the fulcrum pin 26 .
With regard to the above-mentioned construction, at the time of work of the excavating device 3 , the lock plate 52 is disposed at the release position where the rear upper surface 52 e touches the lower surface of the guide member 53 and the support pin 55 is positioned in the slot 52 c at the side of the center of the lock plate. When the vehicle travels after finishing the excavation work of the excavating device 3 , when the loader work is performed, or when the machine is to be stored, the boom cylinder 21 is contracted so as to rotate the boom 16 to the foremost position (toward the operation part 4 ). In this state, the lock plate 52 is pulled forward and rotated downward about the rear portion of the slot 52 c as a fulcrum so as to engage the hook part 52 a with the lock pin 54 , whereby the boom is locked. Accordingly, the boom 16 is prevented from being unexpectedly rotated forward by vibration, leak of operating oil or the like.
When the lock is released, in the order opposite to the above mentioned, the front portion of the lock plate 52 is lifted, the hook part 52 a is disengaged from the lock pin 54 , and then the lock plate 52 is slid rearward along the slot 52 c to the release position.
Next, explanation will be given on another embodiment that the lock device 51 is provided on the boom bracket according to FIGS. 8 to 11 .
With regard to the lock device 51 , the lock pin 54 as the engaged member is projected sideward (not shown) from the side surface of the boom 16 of the work machine, a lock plate 60 as the engaging member to engage with the lock pin 54 is provided on the boom bracket 15 of the vehicle, and guide members 58 and 59 are disposed in the boom 16 so as to hole the lock plate 60 at a prescribed position and to guide the lock plate 60 at the time of operation.
The lock plate 60 , formed in the substantially same shape as the lock plate 52 , includes a hook part 60 a , a forward-slanted surface 60 b and a slot 60 c . Since the boom bracket 15 is not tilted forward or backward at the time of work, the lock plate 60 does not comprise any rearward-slanted surface. The lower guide member 58 and upper guide member 59 guide the upper and lower parallel surfaces of the lock plate 60 , and are projectively provided integrally on the side surface of the boom bracket 15 . A support pin 61 is disposed in the substantial middle of the guide members 58 and 59 . The lower guide member 58 is longer than the upper guide member 59 so that the lock plate 60 is held stably by the weight thereof while released, and the lower surface of the lock plate 60 touches the upper rear tip of the lower guide member 58 while locked.
When the lock plate 60 is shifted from the released state to the locked state, the upper guide member 59 touches the upper surface of the lock plate 60 , and is slid thereon so as to guide the lock plate 60 stably. The guide member 59 reaches the place above and before the support pin 61 so that the lock plate 60 can be rotated rearward downward after reaching the highest position. A lower end of an operation lever 62 is fixed to the hook part 60 a , and the grip of the operation lever 62 is extended upward forward toward the operation part so as to make the operation easy.
In the state that the boom 16 is rotated to the foremost position, the lock plate 60 is lifted upwardly rearward by operating the operation lever 62 while being guided by the guide members 58 and 59 , and then while the support pin 61 touches the end of the slot 60 c , the lock plate 60 is rotated downwardly rearward so as to be engaged with the lock pin 54 , whereby the lock operation has been performed. Otherwise, when the boom 16 is not positioned at the foremost position and the lock plate 60 is slid upward and rotated rearward by the operation lever 62 so that the upper front portion of the lock plate 60 is separated from the guide member 59 , the lock pin 54 touches the forward-slanted surface 60 b by rotating the boom 16 forward so that the lock plate 60 is slid, lifted and engaged automatically with the hook part 60 a similarly to the above mentioned, whereby the lock operation has been performed.
With regard to the release operation, opposite to the above mentioned, the lock plate 60 is rotated rearward by operating the operation lever 62 so as to be released from the lock pin 54 , and then is pulled rearward so as to be held at the released position.
The support pin 61 supports the lock plate 60 and pivotally supports the tip of the piston rod of the boom cylinder 21 . The slip-prevention construction after inserting the support pin 61 to the lock plate 60 is made simple so as to reduce part number and make the assembly easy.
A slip-prevention plate 64 is fixed to the tip of the support pin 61 and the slip-prevention plate 64 is rotated so as to make the prescribed angle which is the same as that of the slot 60 c , thereby enabled to be inserted into the lock plate 60 . After the insertion, the support pin 61 is rotated to the fixed position so as to be prevented from slipping off from the slot 60 c.
Namely, an oval rotation-prevention plate 63 is fixed to one of ends of the support pin 61 perpendicularly to the axis, and a bolt hole 63 a is opened at the tip of the rotation-prevention plate 63 . Then, a bolt of the like is screwed into a bolt hole 15 e opened in the boom bracket 15 so as to prevent the support pin 61 from being rotated at the time of work, and to fix the angle of the support pin 61 .
A small diameter shaft part 61 a , whose diameter is in agreement with the shorter diametric width of the slot 60 c of the lock plate 60 , is formed in the other end of the support pin 61 so as to be inserted into the lock plate 60 . A slip-prevention plate 64 is fixed to the tip of the support pin 61 perpendicularly. The slip-prevention plate 64 is constructed so that upper and lower sides of a disc larger than the shorter diametric width of the slot 60 c are shaved so as to form slot surfaces, whereby the disc is formed ovally. The width of the slip-prevention plate 64 in its shorter direction is substantially in agreement with that of the slot 60 c so that the small diameter shaft part 61 a of the support pin 61 can be inserted into the lock plate 60 in the state that the slip-prevention plate 64 is disposed parallel to the slot 60 c.
As shown in FIGS. 8 , 10 and 11 , in the state that the lock plate 60 is arranged between the guide members 58 and 59 and the lengthwise direction of the slot surfaces of the slip-prevention plate 64 of the support pin 61 are parallel to the lengthwise direction of the slot 60 c , the support pin 61 can be inserted into the lock plate 60 . The position of the support pin at which the support pin can be inserted into the lock plate 60 is offset from the bolt hole 63 a of the rotation-prevention plate 63 and the bolt hole 15 e of the boom bracket 15 .
In this state, by pushing the support pin 61 as shown in FIG. 9 , the small diameter shaft part 61 a is inserted into the slot 60 c . After the insertion, as shown in FIG. 12 , the slip-prevention plate 64 is rotated so as to make the bolt hole 63 a in agreement with the bolt hole 15 e and then a bolt is screwed into the bolt holes, whereby the ends in the lengthwise direction of the slip-prevention plate 64 overlap the part of the plate around the slot 60 c so that the lock plate 60 cannot be pulled off from the support pin 61 . Furthermore, the lock plate 60 is regulated its upper and lower sides by the guide members 58 and 59 and can be slid only in the lengthwise direction of the slot 60 c . Accordingly, even if the lock plate 60 is slid to any position, the lock plate 60 is prevented from being removed by the slip-prevention plate 64 . In addition, the slip-prevention is also adoptable to the construction that the lock plate is attached to the side of the boom.
Accordingly, at the time of assembly of the lock plate 60 , the support pin 61 is inserted into the boom bracket 15 and the tip of the piston rod of the boom cylinder 21 and the slot surfaces of the slip-prevention plate 64 is made parallel to the lengthwise direction of the slot 60 c , and then the support pin 61 is inserted into the lock plate 60 . After that, only by rotating the rotation-prevention plate 63 , the lock plate 60 is prevented from slipping off, whereby the assembly can be performed easily.
INDUSTRIAL APPLICABILITY
The lock device according to the present invention is adoptable for locking a boom, an arm or the like in the state of stored in a main body, and is available in an excavating device, a loader, a crane and the like.
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A lock device is improved in durability by operating the operation member of a boom lock device in a non-contact state to solve a problem in a conventional work machine because there is a problem that the operation member is worn at the lateral rotating part of a boom bracket. In the lock device 51 for locking a boom 16 of the excavating device to the main body, an engaging member is provided on one of the boom and a boom bracket 15 provided on the main body, and an engaged member is provided on the other of the boom and the boom bracket. The engaging member is constituted by a plate formed on one side thereof with a hook part 52 a , and on the other side thereof with a slot 52 c . A support pin 55 is inserted into the slot, and a stopped 53 is disposed above the support pin, so that the support pin 55 and the stopper 53 support the engaging member.
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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 exterior siding, and more particularly to hardboard siding configured to give the appearance of vertical solid wood planks with decorative edge details.
The art has recognized that it is possible to achieve considerable savings in both labor and materials by employing hardboard siding panels in place of conventional solid wood planks. Prior art panels of this type have been produced with a variety of surface effects, including horizontal lap siding, vertical board and batten siding, and simulated cedar shake siding. Among the variations of horizontal lap siding which have been available are various lap sidings including straight edge and colonial edge beaded lap siding. There are currently a wide variety of panels available with both smooth and textured facings.
Because one of the main advantages of hardboard panel siding is its substantial surface area in a relatively thin sheet, damage to the edges of the panels has heretofore been a problem. It has been possible to control damage by effective packaging, a critical requirement for panels with edges configured to form shiplap joints. There is a difficulty, however, in providing good resistance to edge damage in panels having anything but the simplest shiplap edge configurations. Thus, where detailed surface designs, especially those of a vertical nature such as the simulation of solid wood planks having an edge detail, are desired it is difficult to provide a realistic simulation of the intended design and at the same time provide adequate damage resistance at the edges.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide exterior grade hardboard siding panels which provide the appearance of a multiplicity of vertically-applied solid lumber planks having a bead and cove detail and which are mateable to form a surface, wherein the mating area between the panels is virtually indistinguishable from the individual areas on the panel which define the planks.
Another object of the present invention is to provide an exterior grade of hardboard siding panel which provides the appearance of a multiplicity of vertically-applied lumber planks having a bead and cove detail wherein the design is modified slightly at the shiplap edge to provide added resistance to damage during transport and handling.
These and other objects are accomplished according to the present invention which provides an exterior grade hardboard siding panel for application to vertical surfaces to protect the surfaces from the weather and to provide the appearance of a multiplicity of vertically-applied solid lumber planks having a bead and cove detail, comprising a thin rectangular panel having: (a) a front surface configured with a plurality of adjacent areas each simulating a vertical solid wood plank, wherein each area has a shallow cove recess at one edge and a like cove recess adjacent to a bead at the opposite edge, and said plurality of areas are arranged such that (i) the cove recess of one edge of one area and the cove recess adjacent to the bead of the next adjacent area have their recessed surfaces facing said bead of said next adjacent area, (ii) both said coves are separated from said bead by narrow grooves, and (iii) said bead extends upwardly from the base of said grooves to a crest which is approximately tangential to the outermost plane of the front surface; (b) a substantially planar back surface; (c) a first edge of reduced thickness forming the bottom lap of a shiplap joint, the back surface of which is a continuation of said substantially planar back surface, and the front surface of which is recessed to a level below the base of a groove which terminates the front surface configuration directly adjacent to the recessed area; and (d) a second edge of reduced thickness opposite said first edge, forming the top lap of shiplap joint, the back surface of which is recessed from said substantially planar back surface, and the front surface of which is a substantially continuation of the front surface configuration and terminates with a recessed cove.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become better understood and the advantages will become more apparent in view of the following detailed description, especially when read in connection with the attached drawings, wherein:
FIG. 1 is a perspective view of a hardboard siding panel according to the present invention, being partially broken away at the lower edge and in a longitudinal central portion;
FIG. 2 is a cross section taken along line 2--2 in FIG. 1; and
FIG. 3 shows the detail of the shiplap joints which mate the individual panels according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The panels provided according to the present invention are exterior grade hardboard siding panels which have as their primary utility the application to vertical surfaces on the exterior of building structures to protect the surfaces from the weather. While this is the primary purpose of panels of this type, it is well recognized that they can also be employed on horizontal surfaces, especially for soffit applications, as well as purely decorative applications where protection from weathering is not essential. These panels may also be employed as substitutes for interior paneling. The panels comprise thin rectangular sheets which are typically four feet in width and from 7 to 16 feet in length. However, the present invention is not restricted to these particular outside dimensions. It is considered important, however, that the panels be relatively thin. Typically, exterior siding panels of this type will have thicknesses ranging from about 3/8 of an inch to 1/2 of an inch. It is within the contemplation of the present invention to form panels of thicknesses ranging from 1/4 inch to about 3/4 of an inch.
A panel is shown generally as 10 in FIG. 1 to have a plurality of areas 12 which provide the appearance of a multiplicity of vertically-applied solid lumber planks having a bead and cove detail. The panel 10 is shown in the figures as having a saw-textured, wood grain surface; however, it is within the contemplation of the invention to provide smooth surface panels. The critical feature of the present invention is not the particular texture of the plank area surfaces, but the provision of a panel having a realistic appearing simulation of solid wood planks having cove and bead detail which are suitably resistant to normal damaging stresses encountered in handling and shipment.
The front surface 12 of the panel 10 is configured with a plurality of adjacent areas 14 each of which simulates a vertical solid wood plank. On each area 14 there is a shallow cove recess 16 at one edge and a like cove recess 18 adjacent to a bead 20 at the opposite edge. As shown in FIG. 1, a plurality of these areas 14 are arranged such that the cove recess 16 of one edge of one area and the cove recess 18 adjacent the bead 20 of the next adjacent area 14 have their recessed surfaces facing the bead 20 of the next adjacent area 14. As shown, both of the coves 16 and 18 are separated from the bead 20 by narrow grooves 22. Each bead 20 extends upwardly from the base of grooves 22 on either side of the bead 20 such that its upper surface or crest is approximately tangential to the outermost plane of the front surface 12 of the panel 10.
The back surface 24 of the panel 10 is substantially planar. By this it is meant that there is no requirement for any particular rear surface detail according to the invention. It is intended, however, that the rear surface 24 can have whatever detail is conventional for non-facing hardboard panel surfaces. Thus, it is well recognized in the art that the rear surface of a hardboard panel can be randomly or non-randomly roughened to permit better adhesion with adhesives employed to fasten, position or seal the panel to a substrate.
The panel has a first edge 26 of reduced thickness for forming the bottom lap 28 of a shiplap joint shown in cross section in FIG. 3. The back surface of the edge of reduced thickness 26 is a substantial continuation of the planar back surface 24. The front surface of the edge of reduced thickness 26 is recessed to a level below the base of a groove 22 which terminates the front surface configuration directly adjacent to the recessed area at the edge portion 26.
Similarly, a second edge of reduced thickness 32 is formed on the edge of the panel opposite the first edge 26. This second edge forms the top lap 34 of a shiplap joint as shown as 30 in FIG. 3. The back surface of the second edge 32 is recessed from the substantially planar back surface 24. The front surface of the second edge 32 is a substantial continuation of the front surface configuration and terminates with a recessed cove 16.
According to a preferred embodiment of the present invention, the detail of the first edge 26 and the second edge 32 and the associated cove and groove detail directly adjacent thereto are slightly differently dimensioned to make these vulnerable edges of the panels as thick as possible to minimize damage in shipping and handling. These differences in dimensional detail provide a desirable balance between the provision of maximum edge strength in a panel of this type and the overall appearance of the panel. Thus, according to this preferred embodiment, the cove 16 which terminates the front surface of the second edge 32 has a radius of curvature less than the coves 16 and 18 formed on the remainder of the panel. However, the linear extent of the cove 16 across the width of the panel 10 is substantially the same as for the coves 16 and 18 formed on the remainder of the panel 10, whereby the strength of the second edge 32 is improved while not adversely affecting the appearance of the bead and cove detail.
According to one preferred embodiment of the invention a panel is formed 483/4 inches in width with a series of 6 plank defining areas 14 each being approximately 8 inches in width. This configuration leaves 3/4 of an inch for a first edge portion 26 for the shiplap joint. The second edge 32 opposite the first edge 26 has a recess extending 3/4 of an inch across the back width of the panel. The panel itself has a 7/16 inch nominal thickness. The grooves 22 are formed to a depth of 3/16 of an inch, are 1/16 inch wide and border a 9/16 inch diameter bead 20 the upper surface of which is approximately tangential to the outermost plane of the front surface of the panel. The coves 16 and 18 are 3/4 inch radius recesses which extend 1/8 of an inch in depth into the panel and 3/8 of an inch across the width of the panel. The cove recess 16 at the second edge 32 of the panel has a radius of curvature less than the radius of curvature of the other cove recesses. By this arrangement, the cove recess at the end of the second edge 32 still extends 3/8 of an inch along the width of the front surface 12 of the panel, however the depth of recess is less than the depth of the other cove recesses. The thickest area of the second edge 32 is 7/32 of an inch while the thinnest area at the extreme edge of the panel is 3/32 of an inch. Thus, in accordance with the subject invention, th shallower curve utilized to define the cove recess at the second edge 32 of the panel results in less material being removed from the panel leaving a thicker, less vulnerable edge area, which will not substantially change the appearance of the board. The first edge thickness is 1/8 of an inch. A panel of these desirable dimensions provides a realistic simulation of solid wood planks having a bead and cove detail, in combination with suitable strength for standing up to shipping and handling.
The hardboard panels of the present invention can be made according to conventional technology and are not limited in this regard; however, it is preferred for the best balance of strength, surface detail and integrity, and economy, to provide panels having a density of about 31 pounds per cubic foot or greater. Preferably, these panels are prepared from ligno-cellulosic fiber and will typically have a resinous binder such as phenol formaldehyde incorporated therein. The panels are typically formed by pressing under elevated temperature and pressure.
The above description is for the purpose of describing the invention to the person of ordinary skill in the art and it is not intended to detail all those obvious modifications and variations of it which will become apparent upon a reading. It is intended, however, that all such obvious modifications and variations be included within the scope of the present invention which is defined by the following claims.
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Disclosed is an exterior grade hardboard siding panel which gives the appearance of vertically-applied solid lumber planks having a bead and cove detail. The front surface of the panel has a plurality of adjacent areas which each simulate a vertical solid wood plank. Each of these areas has a cove recess at one edge and a bead adjacent to a cove at the opposite edge. The areas are arranged with the cove of one area and the cove adjacent to the bead of an adjacent area, both facing the bead. The coves are separated from the bead by narrow grooves which provide good breaking points in the design and added damage resistance at the edges of the panels which are joined with shiplap joints.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application is a continuation application based upon the applicants pending application Ser. No. 441,564, filed Nov. 15, 1982 and assigned to Completion Tool Company.
This application is related in subject matter to U.S. Pat. Nos. 4,420,159 and 4,402,517 which were copending with this prior application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to packer inflation systems and more particularly to the valves which control the inflation of packers.
2. Description of the Prior Art
The control of the inflation of well packers is important to obtain integrity between the packer and the well bore for purposes of working within the bore. It is known in the art to inflate packers by various mechanisms. See, for example, U.S. Pat. No. 3,503,445, issued Mar. 31, 1970, to K. L. Cochran et al, entitled "Well Control During Drilling Operations"; U.S. Pat. No. 3,351,349, issued Nov. 7, 1967, to D. V. Chenoweth, entitled "Hydraulically Expandable Well Packer"; U.S. Pat. No. 3,373,820, issued Mar. 19, 1968, to L. H. Robinson, Jr. et al, entitled "Apparatus for Drilling with a Gaseous Drilling Fluid".
In U.S. Pat. No. 3,437,142, issued Apr. 8, 1969, to George E. Conover, entitled "Inflatable Packer for External Use on Casing and Liners and Method of Use", there is disclosed an inflatable packer for external use on tubular members such as casings, liners, and the like. A valving arrangement is disclosed therein for containing fluid within the interior of the inflatable member after it has been inflated to prevent its return to the tubular member.
Arrangements of valving have been known in the prior art to prevent further communication between the interior of the tubular member and the interior of the inflatable element after the inflatable element has been inflated and set in a well bore. See, for example, U.S. Pat. No. 3,427,651, issued Feb. 11, 1969, to W. J. Bielstein et al, entitled "Well Control"; U.S. Pat. No. 3,542,127, issued Nov. 24, 1970, to Billy C. Malone, entitled "Reinforced Inflatable Packer with Expansible Back-up Skirts for End Portions"; U.S. Pat. No. 3,581,816, issued June 1, 1971, to Billy C. Malone, entitled "Permanent Set Inflatable Element"; U.S. Pat. No. 3,818,922, issued June 25, 1974, to Billy C. Malone, entitled "Safety Valve Arrangement for Controlling Communication Between the Interior and Exterior of a Tubular Member"; and U.S. Pat. No. 3,776,308, issued Dec. 4, 1973, to Billy C. Malone, entitled "Safety Valve Arrangement for Controlling Communication Between the Interior and Exterior of a Tubular Member".
Inflatable packers have also been used in other operations, such as sealing the annular space between a jacket and a piling. See for example U.S. Pat. No. 4,063,427, issued Dec. 20, 1977, to Erwin E. Hoffman, entitled "Seal Arrangement and Flow Control Means Therefor".
The seals that are used in valves, such as in Malone, are usually hardened rubber. Such rubber tends to extrude under extreme pressure differential across the rubber and cause friction between rubber and metal that adversely affects valve operation. None of the prior art, however, provides for mechanism for equalizing pressures across the seals of the valves used to inflate packers to prevent such extrusion.
SUMMARY OF THE INVENTION
The present invention utilizes a unique arrangement of sealing mechanisms in conjunction with a valve or valves to permit the inflation of an inflatable packer element while at the same time equalizing pressure around the rubber seals of the valve or valves to prevent distortion of the seals from undue high differential pressure, and the resulting friction.
The present invention, like the prior art, is constructed and arranged so that the valve or valves remain seated to prevent communication between the interior of a tubular member and the interior of an inflatable element carried on the exterior of the tubular member until at least a predetermined pressure has been reached. This reduces the possibility of premature inflation of the inflatable element by sudden pressure changes or pressure surges which may occur within the tubular member as the tubular member is being positioned within a well bore.
However, the valve arrangement of the inflation system of the present invention includes an appropriate arrangement of the valve structure to compensate for bore pressure to prevent extrusion from undue high differential pressures across the seals of certain rubber seals which must move in the valving operation.
BRIEF DESCRIPTION OF THE DRAWINGS
For further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein:
FIG. 1 is a cross-section of a packer showing the three-valve collar for inflation of the packing;
FIG. 2 is an enlarged cross-section of the valve arrangement of FIG. 1 taken along section line 2--2 of FIG. 1;
FIGS. 3A-C are pictoral views of the cross-section of the valve arrangement of the present invention showing the valve and the sequence of steps for inflation of the packer shown inverted to the normal position of insertion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A tubular inflatable packer 10 is shown in FIGS. 1 and 2. This type of packer is specifically illustrated for a three valve embodiment and may be a casing packer as illustrated in copending application Ser. Nos. 407,898 and 408,123, filed Aug. 13, 1982 entitled "Packer Valve Arrangement" by Edward T. Wood and Edward T. Wood/Robert E. Snyder, respectively. Now U.S. Pat. Nos. 4,420,159 and 4,402,517 respectively. However, it should be understood that only one valve pocket is needed in the present invention although additional poppet or check valves could be included. The tubular inflatable packer 10 includes a short casing joint or casing sub 12 for connection to other tubular members and is secured by suitable means, such as threads as illustrated in FIG. 1, to a valve collar 14 secured to a tubular pipe member or mandrel 11. It should be noted that in one aspect of the present invention, the valve collar 14 could also be and is preferably secured to the sub 36 of other end of tubular pipe member 11. The valve collar 14 includes a valve mechanism 16 or system of valves and passageways (See FIG. 2) for placing fluid in the bore 21 of the pipe member 11 in fluid communication with a fluid channel or chamber 20 (See FIG. 2) under the inflatable packing element 30 carried externally on the tubular pipe member 11.
The inflatable packing element 30 includes spaced apart annular packer heads 24, 26. The head 26 is secured to the valve collar 14 while the upper head 24 is secured to a top or upper collar 35. The inflatable packing element 30 extends between the packer heads 24, 26 and is also secured to the pipe member 11 which extends along the inside surface of the packing element 30 between the valve collar 14 and the upper collar 35. The inflatable packing element 30 may be of any suitable length and is an elastomer cover and two sets of steel anti-extrusion ribs 32. The ribs 32 are connected to the elastomer cover, such as, for example, by vulcanizing the elastomer cover to the ribs 32 so that the ribs 32 extend into the ends of the elastomer cove. Each set of ribs 32 is connected to a steel back-up sleeve 34, and one set is connected to the valve collar 14 while the other set is connected to the valve collar 35. Sleeve 34 is also connected to the elastomer cover, such as vulcanized with the rubber, and to the valve collar 14. A tubular sub 36 is connected to the valve collar 35 for use with other tubular members in a string of pipe or casing (not shown).
As shown in FIG. 2, a first set of annular grooves 38 is formed in the valve collar 14. The set of grooves 38 includes internal, circumferential or annular grooves 40, 42 spaced longitudinally apart from one another and covered by juxtaposed screen sleeve 44. The screen sleeve 44 includes a hole 46 which receives a knock-off rod or plug 50, usually constructed of plastic, to isolate the valve system from fluid under pressure in the bore 21 of the pipe member during running of the inflatable packer 10 into a well bore containing fluid.
A port 52 extends partially through the wall of the valve collar 14 and connects a passageway 54 to the groove 42. The passageway 54 extends vertically in the wall of valve collar 14 between a valve in the valve mechanism 16 and the port 56 (See FIG. 2).
It should be noted that the valve collar is located at the upper end of the tubular member 10 instead of the lower end. In this manner, pressure cannot be trapped between, for example, the well bottom and the packer 30 which would have an effect on the differential pressure across the valve thereby preventing the valve from closing.
Referring to FIG. 3A, there is diagramatically shown an embodiment which utilizes a single inflation control valve in a single valve pocket 300. The valve pocket 300 is bored into a valve collar 14" (the double prime is used to denote a different collar than collar 14 with substantially the same pocket and passageway configuration, between the interior of the pipe member 21, the exterior of the valve body and the channel 20 to the interior of the packing element 30, except having one valve pocket and except as otherwise described in the description of this embodiment) or formed in a sleeve or other suitable location. Bore 301, first counterbore 302 and second counterbore 304 are the single valve pocket 300. Counterbores 302 and 304 are separated by stop wings 306, and the counterbores are formed by drilling or other suitable operation in pocket 300. Stop wings 306 form an upwardly facing shoulder 316 with counterbore 302 and a downwardly, outwardly facing shoulder 307 with enlarged counterbore 304. Passageways 54, 303, 137 and 236 are formed in the valve collar 14" to be in communication to bore 21 of the pipe member 11, the external surface of valve collar 14" on the outside of the packer 10, the fluid channel 20 and the interior of the packing element 30, respectively, and to the valve pocket 300. The valve element 318, which is inserted into the valve pocket 300, includes a first valve body member 320 having an upper surface 373 and a lower surface 346 located in a counterbore 304, a spring 322 located in a bore 302, and a second valve body member 324 having upper surface 372 located in bore 301 and a lower surface 374 located in a counterbore 302 in the initial assembled position. Passageway 303 has a lower surface 315 substantially coplaner with spring 322 in the initial assembled position.
First valve body member 320 includes an enlarged valve portion 330 having a groove 332 formed thereabout for reception of a seal 334 therein. Seal 334 is sized to sealingly engage the wall of the counterbore 304 and the bottom surface 336 of the groove 332. Valve stem 338 on the valve body member is of smaller diameter than the valve portion 330 and extends from the valve portion 330 longitudinally to the end of the counterbore 304 approximately coplaner with the shoulders 316. The diameter of valve stem 338 is substantially less than the diameter of the valve body portion 330 and forms a shoulder 340 at the interface between the valve stem 338 and the valve body portion 330. Stop wings 342 extend laterally from the valve stem 338 and are appropriately positioned along the length of stem 338 to perform as set out below approximately midway along the length of the valve stem 338. The longitudinal placement of the stop wings 342 is determined by the dimension of the shoulder 307. The stop wings 342 must be sufficiently displaced from the shoulder 340 along the surface of the valve stem 338 to permit the stop wings 342 to extend above the shoulder 316 when the shoulder 340 meets the lower downwardly outwardly extending surface 307. A first shear pin 344, or collet, or other suitable mechanism for prevention of reciprocation, extends through the surface of valve collar 14" and into the base 346 of the valve portion 330 and releasably holds the valve portion 330 in its initial position.
Spring 322 is of any suitable material having an inner diameter larger than the diameter of the valve stem 338 and having a collapsed length substantially equal to the distance from the shoulder 316 to the lower surface 315 of the passageway 314.
The upper valve element 324 includes a valve base portion 350 having a diameter greater than the diameter of the bore 301. The upper valve element 324 is reduced in size along the portion extending away from the valve base portion 350 to form a valve stem portion 352 having a smaller diameter than bore 301 with a shoulder 354 formed at the juncture of the valve stem portion 352 and the valve base portion 350. Two grooves 356, 358 are formed along the circumference of the valve stem portion 352 spaced such that circumferential seals 360, 362 may be fit therein and sealingly engaging the walls of bore 301 and the walls 364, 366 respectively of the valve stem portion 352. Grooves 356, 358 are spaced apart sufficiently so that the seals 362, 366 engage the walls on either side of the passage 137 when the shoulder 354 abuts the shoulder 368 formed between the counterbore 302 and the bore 301. A shear pin 369, or collet, or other suitable mechanism for prevention of reciprocation, extends through the surface of valve collar 14" and into a bore 370 formed in the valve stem portion 352 upon initial assembly and releasably holds the valve stem portion 352 in its initial position.
Referring to FIGS. 3A-3C, in operation the pressure from the bore 21 of the pipe member 11 is applied through the passageway 54 against the surface 372 of the upper valve body element 324. At the same time, pressure in the borehole external to the valve collar 14" is applied via passageway 303 to the areas defined by seals 362 and 334 in the pocket. Pressure in the borehole external to the valve collar 14" is applied via the packing element 30 and the passageway 236 to the other side of seal 334 and is applied via the packing element 30 and to the passageway 137 to the portion of the bore 301 located between the seals 360 and 362. When the pressure within tubular pipe member 11 is sufficient to overcome the shear strength of the shear pin 369, the shear pin 369 shears (FIG. 3B) permitting the pressure acting on the surface 372 to move the second valve body member 324 longitudinally towards second valve body member 320 and to compress the spring 322. Accordingly, the valve seal 360 no longer prevents flow of fluid from the passageway 54 to the passageway 137, and fluid then flows to passageway 137 from passageway 54. Fluid passageway 137 flows into channel 20 and thence to the interior of the packing element 30 and inflates the packing element 30. Fluid communication with the interior of the packing element 30 is accomplished through the passageway 236 equal to the pressure within the packing element 30. It will be noted that the pressure area across the seal 334 is larger than the pressure area across the seal 356 and thus when the fluid in the passageway 236 has reached a predetermined pressure, greater than or equal to the pressure in the passageway 303, as determined by the shear force of the shear pin 344, the shear pin 334 shears (FIG. 3C) forcing the second valve body member 320 to rise or move and the end surface 373 of the second valve body member 320 to abut the surface 374 of first valve body member 324. Because the surface area of the surface 346 is substantially greater than the surface area of the surface 372, the pressure in the passageway 236 acting on the surface 346 will eventually force both the second valve body member 320 and the first valve body member 324 to move through their respective bores until the shoulder 340 on the second valve body member 320 contacts the inclined surface 307. At this point, the seals 360, 362 on the second valve body member 320 would be again spaced around or to either side of the passageway 137 to prevent further flow of fluid into the passageway 137 from passageway 54 thereby retaining the inflation pressure in the packing element 30. Should there be a small loss in pressure in the passageway 236 against surface 346, the wings 342 (which can be optional) would prevent the valve body member 320 and the valve body member 324 from moving sufficiently to again permit flow between the passageways 54 and 137.
Although the system described in detail above is most satisfactory and preferred, many variations in structure and method are possible. For example, wings 342 may be eliminated. Also, the members may be made of any material suitable for the environment. Further, reciprocating member or valve body member 324 may be split horizontally so that the member has two pieces, each piece having one seal and the lower seal being of a poppet type.
The above are examples of the possible changes or variations.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught and because modifications may be made in accordance with the descriptive requirements of the law, it should be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A valve system for use in inflating packers mounted on mandrels is disclosed. The valve system uses one valve to permit, through the use of seals, the flow of fluid from the interior of a tubular mandrel to the interior of the inflatable packer when pressure applied in the mandrel exceeds at least a minimum pressure.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] This invention relates to methods and means for the harvesting of oil slicks.
[0002] In British Patent Specification No. 2 310 381 there is described an oil slick harvesting vessel which has a mid-mounted endless belt conveyor for conveying spilled oil from one side of the vessel to the other and deployable hinged end panels which can be connected to the end panels of other like vessels to encompass an area into which the spilled oil can be directed in operation of the endless belt conveyors of the interconnected harvesting vessels.
[0003] It is an object of the present invention to provide an improved method and means for harvesting oil slicks.
SUMMARY OF THE INVENTION
[0004] According to a first aspect of the present invention there is provided a method of harvesting an oil slick, which method includes:—
a) providing an oil slick harvesting vessel which has an endless belt conveyor for conveying spilled oil from one side of the vessel to the other and deployable hinged panels which extend along both ends and said other side of the vessel, b) deploying the hinged panels so that they encompass an area on said other side of the vessel and within which the spilled oil can be collected, and c) operating the endless belt conveyor to transfer the spilled oil into the encompassed area.
[0008] The endless belt conveyor is preferably so arranged that the end thereof at said one side of the vessel is at a lower level than the other end thereof so that, during operation of the endless belt conveyor, spilled oil contacted by the endless belt conveyor will be lifted and transferred into the encompassed area.
[0009] Pump means may also be provided for drawing water towards said endless belt conveyor and into the vessel from said one side thereof and discharging it downwardly from the vessel.
[0010] The pump means (if provided) and the endless conveyor will thus be operated in such manner that the flow of water into or towards the vessel produces a flow of the spilled oil into contact with the endless belt conveyor for transfer thereof into the encompassed area.
[0011] According to a second aspect of the present invention there is provided an oil slick harvesting vessel which has an endless belt conveyor for conveying spilled oil from one side of the vessel to the other, and deployable hinged panels which extend along both ends and said other side of the vessel and which are deployable so that they encompass an area on said other side of the vessel and within which the spilled oil can be collected.
[0012] The hinged panels are preferably provided with sealing means in the form of gaskets to stop any egress of oil from the encompassed or circumscribed area.
[0013] The hinged panels preferably comprise two hinged panels at each end of the vessel, each of which has a length substantially equal to the width of the vessel. The hinged panels preferably also comprise three hinged panels at said other side of the vessel, each of which has a length substantially equal to the length of the vessel.
[0014] Pump means may be provided for drawing water towards and into the vessel from said one side thereof and discharging it downwardly from the vessel, the arrangement being such that, on operating the pump means and the endless conveyor, a flow of water is produced into the vessel so as to produce a flow of the spilled oil into contact with the endless belt conveyor for transfer thereof into the encompassed area.
[0015] The discharge outlets of the pump means are preferably located below the vessel and arranged for rotation to provide steerable thrust.
[0016] The endless belt conveyor preferably includes a number of parallel flat belts which extend side by side within the vessel and, unlike the conveyor of the harvesting vessel described in British Patent Specification No. 2 310 381, do not include scoops. The arrangement is thus such that the oil is transferred from one side of the vessel to the other, i.e. to the encompassed area, due to the natural viscosity of the oil. The picked up oil is preferably scraped off the endless belts by means of blades or bars, each of which extends for the full width of the associated belt and is located at or adjacent the uppermost end of the belt. An access platform is preferably provided above the vessel.
[0017] The harvesting vessel preferably has a length of the order of 10 metres and a width of the order of 5 metres, with two hingedly connected panels at each end of the vessel and pivotally connected to the ends of said other side of the vessel. The free ends of the hingedly connected panels at the ends of the vessel are then pivotally connected to the three hingedly connected panels which each extend for substantially the length of the other side of the vessel.
[0018] The panels will preferably have a height (or depth) of the order of 9 metres with the arrangement such that the water line will be about 3 metres below the tops of the panels, giving a depth of about 6 metres below the water line.
[0019] The vessel will preferably have a Global Positioning System (GPS) for communication and control purposes and, in an emergency, several vessels will normally be transported to an oil slick by means of helicopters, by ship or by road and placed at strategic points, working independently of each other while maintaining communication with one another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a diagrammatic perspective view of an oil slick harvesting vessel with its panels fully deployed,
[0021] FIG. 2 is a diagrammatic plan view of the oil slick harvesting vessel of FIG. 1 with its panels fully folded, and
[0022] FIGS. 3 and 4 are diagrammatic plan views of the oil slick harvesting vessel if FIG. 1 with its panels partially deployed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The vessel 10 shown in the drawings is of rectangular form in plan view and has a length of the order of 10 metres and a width of the order of 5 metres, with two hingedly connected panels 11 A and 11 B or 12 A and 12 B at each end of the vessel 10 . The panels 11 A and 12 A are pivotally connected to the ends of one of the sides of the vessel 10 and the panels 11 B and 12 B are pivotally connected to the ends of the panels 11 A and 12 A. Each of the panels 11 A, 11 B, 12 A and 12 B has a length which is substantially equal to the width of the vessel 10 so that, when the panels 11 A, 11 B, 12 A and 12 B are in their compact storage or travelling positions, they are located against the ends of the vessel 10 and extend substantially parallel to the adjacent end of the vessel 10 .
[0024] The free ends of panels 11 B and 12 B are then pivotally connected to three hingedly connected panels 13 A, 13 B and 13 C which each extend for substantially the length of a side of the vessel 10 . Panel 13 A is pivotally connected to panel 11 B, panel 13 B is pivotally connected to panel 13 A and panel 13 C is pivotally connected at its one vertical edge to panel 13 B and at its other vertical edge to panel 12 B. When the panels 13 A, 13 B, and 13 C are in their compact storage or travelling positions, they are located against the side of the vessel 10 and extend substantially parallel to the adjacent side of the vessel 10 .
[0025] When the vessel 10 reaches a location at which there is an oil slick which requires collection, the panels 11 A, 11 B, 12 A, 12 B, 13 A, 13 B and 13 C are moved under the action of hydraulic piston and cylinder mechanisms (not shown) from the positions shown in FIG. 2 into the positions shown in FIG. 3 , and then into the positions shown in FIG. 4 , and finally into the positions shown in FIG. 1 , such movements of the panels being carried out progressively under the control of the piston and cylinder mechanisms such that, when the panels are in the positions shown in FIG. 1 , a substantial area is encompassed or circumscribed by the panels and by the side of the vessel 10 to which panels 11 A and 12 A are pivotally connected. The panels will typically be provided with sealing means in the form of gaskets fitted to the hinged or pivotal connections between adjacent panels and between panels 11 A and 12 A and the side of the vessel 10 .
[0026] A series of endless belt conveyors 14 are mounted on the vessel 10 , with the belts of the conveyors 14 extending parallel to one another from side to side of the vessel 10 . The belts of the conveyors 14 are inclined to the horizontal with the lower ends of the conveyor runs on the side of the vessel 10 remote from the area encompassed by the panels. During operation of the conveyors 14 , the oil which comes into contact with the belts of the conveyors 14 is transferred from the side of the vessel 10 remote from the encompassed area to the other side of the vessel 10 due to the natural viscosity of oil. The picked up oil is scraped off the endless belts by means of a series of blades or bars, each of which extends for the full width of the associated belt and is located at or adjacent the uppermost end of the associated belt.
[0027] The belts of the conveyors 14 are designed so that the seaward side of each belt adjusts so that the bottom of the belt has maximum contact with the oil as, if the conveyor belts are immersed too deeply into the water, they tend to convey only a small amount of water mixed with oil. Even though a certain amount of water is picked up by the conveyor belts, when the mixture of oil and water is deposited into the encompassed area, it will tend to travel downwardly through the oil, mixing with the water below.
[0028] Pumps (not shown) can be provided for drawing water towards and into the vessel 10 from the side thereof remote from the deployed panels and discharging it downwardly from the vessels, the arrangement being such that, on operating the pumps and the endless conveyors 14 , a flow of water is produced into the vessel 10 so as to produce a flow of the spilled oil into contact with the endless belt conveyors 14 for transfer thereof into the encompassed area. The oil slick is encouraged by the pumps to remain in contact with the conveyor belts.
[0029] The discharge outlets of the pumps will be located below the vessel 10 and arranged for rotation to provide steerable thrust to facilitate suitable positioning of the vessel 10 .
[0030] The harvesting vessel 10 typically has a length of the order of 10 metres and a width of the order of 5 metres, while the panels 11 A, 11 B, 12 A, 12 B, 13 A, 13 B and 13 C will typically have a height (or depth) of the order of 9 metres with the arrangement such that the water line will be about 3 metres below the tops of the panels, giving a depth of about 6 metres below the water line. To enable the vessel to sit two thirds below the water line and, at the same time, to be as light as possible for transport purposes, the majority of the required ballast will be provided by allowing water to flood tanks within the vessel. The hingedly connected panels will have buoyancy for the top third, while the outer skin of each panel facing away from the encompassed or confined area will be perforated with holes allowing water to fill the void and act as ballast.
[0031] If harvesting a volatile mixture, such that there is a high risk of explosion either through the production of an inflammable vapour by evaporation or as a result of the mixture itself being of a highly inflammable nature, a foam barrier containing a fire preventative agent is preferably sprayed onto the surface within the encompassed area. The foam barrier will have a composition such that it floats on the surface of the harvested oil. The oil and water mix will have a density greater than that of the foam barrier so that the oil and mixture conveyed into the encompassed area will travel downwardly through the fire barrier. The mixture will then separate allowing the oil to build up below the fire barrier while the water will sink to below the layer of oil.
[0032] Harvesting of the oil slick will be continued such that the oil within the encompassed area will build up to a level approaching the full depth of the vessel 10 , at which time a conventional tanker can be used to surface pump the collected and separated oil from within the encompassed area. With a vessel having end and side panels of the size described above, the encompassed area will be of sufficient size to enable 1 million litres of oil to be harvested. Most of the harvested oil will have been unaffected by the recovery process and can, therefore, be recycled.
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A method of harvesting an oil slick includes: a) providing an oil slick harvesting vessel ( 10 ) which has an endless belt conveyor ( 14 ) for conveying spilled oil from one side of the vessel ( 10 ) to the other and deployable hinged panels ( 11, 12 and 13 ) which extend along both ends and said other side of the vessel ( 10 ); b) deploying the hinged panels ( 11, 12 and 13 ) so that they encompass an area on said other side of the vessel ( 10 ) and within which the spilled oil can be collected, and c) operating the endless belt conveyor ( 14 ) to transfer the spilled oil into the encompassed area.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of a provisional application with Ser. No. 61/305,289 which was filed on Feb. 17, 2010, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The disclosed subject matter is directed to the production of pre-cast blocks for constructing modular columns.
BACKGROUND
[0003] Decorative stone columns are widely used by homeowners and businesses for a variety of purposes such as the monuments at the entrance of a driveway, as supports between fence sections, as a base for a statue, and as pillars at the entrance to a building to name just a few uses. The construction of decorative stone columns normally requires the services of a skilled mason and the utilization of specialized masonry tools. The average individual does not typically have the necessary tools or requisite skill for constructing appropriate concrete forms or for completing decorative stone column construction. As a result, most decorative stone columns are usually constructed by a skilled mason and at a high cost. Producing a high quality, durable and aesthetically pleasing column at a reasonable cost can be accomplished with the assistance of modular column construction as is outlined below.
SUMMARY
[0004] The present invention pertains to the construction of a decorative column and the method of producing the modular blocks that comprise the decorative column. The column comprises a rigid center post surrounded by a plurality of modular blocks. Each modular block has a hole extending through it so the block can fit onto the rigid center post and remain fixed in place on the post. Each modular block is stackable upon another block of similar construction. The present invention pertains to a method for not only producing the modular blocks with compressible inserts but also the erecting of a decorative column that is capable of accommodating ground heaving due to freezing temperatures and thermal expansion which is particularly important, for example, when the column is utilized to support fence sections.
[0005] The method comprises the steps of producing a flexible mold for forming the modular blocks, positioning a compressible insert into the mold, filling the open area created by the walls of the mold and the exterior surfaces of the compressible insert with a lightweight cementitious material, waiting for the cementitious material to cure and then removing the modular block from the flexible mold.
[0006] Once the modular blocks with the compressible inserts are removed from the mold they are positioned onto the rigid center post so that the compressible insert center opening is aligned with the rigid post and can slide down the post to either the ground or atop another modular block. The process of placing the modular blocks on the center post can be repeated as necessary to produce a decorative column of the desired height.
[0007] The compressible inserts are instrumental in reducing the weight of the modular blocks as the inserts are preferably comprised of materials such as EPS foam or cellular PVC to name but a few available options. In addition, the compressible inserts facilitate placement of the modular blocks on the rigid center post particularly for posts of a substantial height as the compressible and flexible material will not bind against the post as the blocks are lowered into position on the post.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 is a perspective view of a three rail fence constructed with modular columns;
[0009] FIG. 2 is a perspective view of a panel fence constructed with modular columns;
[0010] FIG. 3 is a perspective view of a center post of a modular column being constructed with pre-cast ornamental blocks;
[0011] FIG. 4 is a plan view of an embodiment of a pre-cast block without side slots utilized in a modular column;
[0012] FIG. 5 is a plan view of an embodiment of a pre-cast block with single dimension side slots utilized in a modular column;
[0013] FIG. 6 is a plan view of an embodiment of a block with dual dimension side slots utilized in a modular column;
[0014] FIG. 7 is a plan view of an embodiment of a block with single dimension side slots utilized in a modular column;
[0015] FIG. 8 is a cross sectional view of FIG. 2 revealing the interior features of a modular column;
[0016] FIG. 9 is a perspective view of an empty mold with a center post for forming a block for use in a modular column;
[0017] FIG. 10 is a perspective view of a mold showing a compressible insert surrounding the center post used for forming a block for use in a modular column;
[0018] FIG. 11 is a perspective view of a mold showing the addition of a cementitious material to the open area of the mold for forming a block for use in a modular column; and
[0019] FIG. 12 is a perspective view of a mold showing the cementitious material leveled at the top of the mold for purposes of forming a block for use in a decorative modular column.
DETAILED DESCRIPTION
[0020] Referring now to the drawings wherein like reference numerals refer to similar of identical parts throughout the several views. FIG. 1 reveals a fence section comprised of two modular columns 10 connected by fence rails 54 . FIG. 3 details the process by which a modular block 58 is lowered being lowered into position over a post 12 onto several pre-cast blocks 14 , 16 , 18 already in position. Pre-cast blocks can be used to efficiently and with high aesthetic appeal produce columns 10 for various embodiments of a rail fence such as seen in FIG. 1 as well as for various embodiments of a panel fence such as seen in FIG. 2 . Numerous other embodiments and uses of columns utilizing this modular pre-cast block technology are also contemplated and are only limited by the imagination.
[0021] The production of a pre-cast block 58 begins with the use of a flexible mold 20 such as one produced from silicone and as depicted in FIG. 9 . The mold 20 includes four sides 22 A, B, C and D a center post 24 as well as textured interior walls 26 . The textured interior walls 26 are intended to replicate on the finished modular block a stone face including a desirable and contrasting coloration. Prior to the addition of any cementitious material into the mold 20 the textured interior walls are coated with a coloration mixture of mineral iron oxides, cement, water and an acrylic modifier. The coating is applied consistent with the stone facing molded into the interior walls 26 so as to give the impression that the stone faces are of varying color as might be created by a mason using natural stone. Varying the mineral iron oxides content allows different colors to be formulated to satisfy customer preferences. This coloration mixture may be hand applied to specified portions of the interior wall. Alternatively, automated techniques may also be employed such as the use of robotic systems to apply the coloration mixture.
[0022] Once the subset of the textured interior walls 26 are coated with the above referenced mixture a compressible insert 28 is positioned over the center post 24 as shown in FIG. 10 . The compressible insert 28 is lightweight, and preferably comprised of materials such as EPS foam or cellular PVC. The insert 28 includes an upper surface 32 , and creates an interior space 33 that will prevent the intrusion of cementitious material and also includes a plurality of exterior walls 34 . The insert upper surface 32 is preferably at the same elevation and not above the upper surface 36 of the textured interior walls 26 .
[0023] Once the compressible insert 28 is secured in position over the center post 24 , the open space 38 between the mold walls 26 and the exterior walls 34 of the compressible insert 28 is filled with a cementitious material 40 as seen in FIG. 11 . The cementitious material 40 is preferably a light weight wet cement that readily flows to fill the open space 38 . An exemplary mixture of cementitious material would comprise an expanded slate lightweight concrete, such as Stalite™, a dry pigment, aggregates and water combined to form a flowable, lightweight mixture.
[0024] Once the open space 38 is completely filled the mold 20 is vibrated to remove voids from the cementitious material 40 , allow for settling and to facilitate the movement of the coloration mixture painted onto the mold interior walls 26 into the cementitious material 40 instead of remaining at the surface thereby giving a three dimensional penetration of the coloration mixture into the block and improving the weatherability of the block's surface coloration. In addition, as best seen in FIG. 12 , the cementitious material 40 is leveled at the upper surface 36 to create a smooth even surface that facilitates the stackability of the blocks when the cement is cured.
[0025] In about twelve hours the cementitious material is fully cured and the block, along with the compressible insert, can be removed from the mold 20 . Manipulation of the flexible mold 20 , either manually by overturning the mold and popping out the block as is well known in the art, or by injection of air into an orifice in the mold bottom effectively inverting the silicone mold, will facilitate release of the block from the mold 20 . Because the cementitious material 40 permeates the pores of the exterior walls 34 of the compressible insert 28 , the insert is securely bound to the cementitious material and will not separate during use.
[0026] As seen in FIGS. 4 through 7 , alternative embodiments of the block may be cast in the mold 20 with or without slots. FIG. 4 reveals a standard block 42 without slots that would properly be employed, for example, as shown at the lowermost block 18 in the column in FIG. 3 . This lowermost slotless block 18 would typically be employed in a column utilizing between one and four fence rails, such as exemplified in FIG. 1 .
[0027] An alternative block embodiment as depicted in FIG. 5 reveals a block 50 with slots 52 on opposed sides of the compressible insert 28 . These opposing slots 52 serve to hold rails 54 in position as is best seen in FIG. 1 . FIG. 3 also serves to highlight how the slot 52 of block 58 integrates with the slot and block 14 positioned immediately below it in the column to create an opening for securing the rail 54 in position. It will be readily apparent to one versed in the construction of columns that the placement of the slots 52 in a modular block 10 may be offset by 90 degrees, instead of 180 degrees, should a block be needed for a corner column with fence rails extending outwardly at 90 degrees instead of 180 degrees. In addition, a block may have only a single slot 52 should a column be needed that is adjacent a building or other structure and the rails need only extend in a single direction.
[0028] FIG. 6 depicts a third embodiment of a block 60 that is utilized in the construction of a panel fence such as that shown in FIG. 2 . The narrower and shorter slot 62 serves to secure in place the edge of the entire height of the fence panel 67 . The configuration of this slot 62 can also be viewed in cross section in FIG. 8 which shows four separate blocks 61 A, 61 B, 61 C and 61 D positioned at the top of the column. Block 61 A serves as a capping block and includes no slots since the fence panel does not extend upwardly to that height. Block 61 B includes an upper exterior surface 65 with no slot and a lower portion with a slot 64 . The slot 64 on block 61 B, in conjunction with slot 64 in block 61 C serves to secure one end of the upper rail 66 , as best seen in FIG. 2 , in position within the column. Block 61 C also includes a small slot 62 that is intended to facilitate securing the top portion of the panel 67 in position. Finally, block 61 D includes only a small slot 62 but no larger slot 64 , such as that depicted in FIG. 7 . The configuration of block 61 D is repeated on blocks lower in the column until reaching the lower rail 68 where a similar configuration of blocks is utilized to support the rail 68 and the panel 67 as seen at the top of the column with blocks 61 B and 61 C. The dimensions of the slots 62 , 64 may be tailored to any preferred dimension during production to suit the specific dimensions of the fence rails 66 , 68 and panels 67 that are being utilized. To produce slots of the desired dimension one or more inserts are positioned within the mold prior to introduction of the cementitious material 40 or the molds may have the inserts already included. Whether specifically designed into the mold for purpose of occluding the presence of the cementitious material or removable inserts are positioned within the mold 20 , once the cementitious material 40 has been cured the slots are formed into the finished block and they are ready for column construction.
[0029] The various embodiments of the present invention may be utilized to create a structurally sound and aesthetically pleasing column that can stand alone or be incorporated into a fence of a wide range of configurations including rail fences or panel fences. The use of pre-cast blocks 58 with their aesthetically pleasing exterior surfaces, preconfigured slots and lightweight but structurally rigid material greatly facilitates the construction of the columns. Turning again to FIG. 3 , a rigid center post 12 is placed into the ground or secured by some other means so that it stands in a substantially vertical orientation. The center post 12 is preferably a vinyl composition post because of its resistance to weathering and insects, but may be of any sturdy material such as wood, metal or concrete. Additionally, the center post 12 can be of a wide range of dimensions such as 5 inches square or 3 inches square. Alternatively a rectangular of circular configuration for the rigid center post 12 also may be employed. The center post 12 must, however, be of only slightly lesser dimensions than the hole dimension of the compressible insert 28 so that proper alignment of the pre-cast blocks on the modular column 10 can be accomplished.
[0030] As seen in FIG. 3 , once the center post 12 is secured in a substantially vertical orientation, the central opening 33 of the pre-cast block's 58 compressible insert 28 is aligned over the center post 12 . The first pre-cast block 18 to be installed is then moved onto the lowermost support surface which will either typically be a ground surface or a prepared level surface such as concrete. The process of placing additional pre-cast blocks on the column is greatly simplified with the use of a compressible insert 28 . The compressible insert material is soft and pliable and therefore will not bind against the center post 12 because of interference between the insert 28 and the post 12 . Moreover, as noted above, because of the light weight of the compressible insert and the fact that it occupies a significant percentage of the block interior volume that otherwise would be occupied by cementitious material 40 the pre-cast block weighs far less than a pre-cast block constructed without a compressible insert 28 . The nominal weight of a pre-cast block greatly facilitates the construction of a decorative modular column as placement of a pre-cast block with a compressible insert onto a center post 12 requires lesser physical exertion than installation of blocks comprised entirely of cementitious material 40 .
[0031] As further seen in FIG. 3 , a multitude of modular blocks 14 , 16 , 18 , 58 may be placed onto the rigid center post 12 to create a decorative column of any desired height depending upon how the columns is to be employed, for example, as a fence post, a support column or a mailbox stand. If building a fence rail column then, as previously discussed, slots 52 , 62 , 64 may be configured to satisfy the dimensional requirements of the fence rails and panels. Advantageously, no mortar need be placed between the pre-cast blocks to secure them in position as the blocks simply reside one atop the other creating a seamless textured stone exterior along the entire length of the column. Also advantageously, the compressible insert 28 greatly facilitates the resiliency and longevity of the decorative column 12 in areas where there is heaving of the ground due to the freeze-thaw cycle. Because of these compressible inserts 28 , the pre-cast blocks can float on the center post 12 thereby avoiding the accumulation of tensile and compressive forces that can readily fracture hand crafted stone columns or even those with pre-cast blocks that are mortared and locked into fixed positions. For stone columns, such as those shown in FIG. 1 , that are employed as fence columns, the thermal expansion of the fencing segments can produce significant lateral loads on the stone columns that can be absorbed by the compressible inserts 28 thereby avoiding damage to the stone columns through cracking of the column materials.
[0032] Those skilled in the art appreciate that variations from the specified embodiments disclosed above are contemplated herein and that the described embodiments are not limiting. The description should not be restricted to the above embodiments, but should be measured by the following claims.
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A decorative column comprising a rigid center post, a plurality of pre-cast pieces with each piece having a hole extending therethrough so the pre-cast piece slides onto the center post and remains in place on the center post. Each pre-cast piece being stacked upon another pre-cast piece, the pre-cast pieces being of a predefined shape, and a compressible center core liner filling a portion of the hole of the pre-cast piece. The compressible center core including a cutout shape consistent with the cross sectional shape of the rigid center post thereby allowing passage of the center post through the compressible center core.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] The invention relates to a sliding door system for freight elevator landings and, more particularly, to a door suspension system that is easily and quickly installed and adjusted.
PRIOR ART
[0002] Horizontal sliding doors for freight elevator landings are typically suspended from overhead tracks. Building codes and good workmanship dictate that the door panels have a limited clearance with the sill plate at the landing floor. Achieving a certain working clearance without exceeding specified limits can be tedious and time-consuming. Typically, a door system is installed by attaching various hardware components to the existing building. Relevant parts of the building are ordinarily of masonry construction and by the nature of such construction, are neither perfectly flat nor regular in hardness and finish. These physical conditions make it difficult for even a skilled installer to initially mount system hardware in a precise location. Prior art arrangements for adjusting the door panels vertically have been less than ideal, requiring, for example, individual adjustment of each door with eccentric roller mounts or use of spacers. Eccentric roller mounts give a non-linear response to adjustment and can throw a panel out of plumb each time one of a pair of rollers is adjusted. Use of spacers, known in the art, is typically troublesome from both a manufacturing standpoint and an installer's perspective. Where door panels in prior art arrangements are individually vertically adjusted, the time required to set all of the panels will ordinarily be proportional to the number of door panels being installed.
SUMMARY OF THE INVENTION
[0003] The invention relates to an improved system for suspending horizontal sliding door panels at freight elevator landings that reduces installation time and effort while, at the same time, being simple and economical to manufacture. The system has a vertical adjustment arrangement that facilitates the original installation of the overhead track for the door panels and, additionally, serves to provide for the final vertical adjustment of the door panels. The arrangement, moreover, preferably, uses a screw to raise or lower the track components and door panels with relative ease and with linear, stepless precision.
[0004] In the preferred embodiment, the invention includes a plurality of wall mounted brackets that suspend overhead tracks for the sliding door panels. The brackets are situated along the header over the landing opening. The brackets are each initially attached to the wall with an anchor bolt that, besides securing the bracket to the wall, serves as a vertically fixed peg or platform on which the bracket can be jacked up or down. The bracket assembly has a vertically slotted leg and an apertured block which together are assembled on an exposed portion of the installed wall anchor. A jacking screw carried in a threaded hole in the bracket body bears against the block enabling this screw to raise or lower the bracket relative to the anchor with the vertical slot accommodating this motion. Several identical or similar brackets are installed in the same manner along the entrance header to collectively support the tracks from which the door panels are suspended.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a somewhat schematic fragmentary elevational view of a freight elevator landing door assembly as seen from the shaft;
[0006] FIG. 2 is a perspective view of the tracks and supporting brackets of the door assembly;
[0007] FIG. 3 is a perspective view of a typical track mounting bracket and portions of tracks;
[0008] FIG. 4 is a cross-sectional view of a typical bracket taken in the plane 4 - 4 indicated in FIG. 3 ; and
[0009] FIG. 5 is a fragmentary cross-sectional view of the door assembly taken in the plane 4 - 4 indicated in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] Referring now to the drawings and in particular to FIG. 1 , there is shown, from the shaft side, a freight elevator landing door installation 10 including a set of four horizontal sliding door panels 11 in a closed position. The door panels 11 protect an opening to the elevator shaft at a landing. The panels 11 are suspended from overhead tracks 13 in a generally conventional manner. Each panel 11 has a pair of associated traction rollers 14 that roll on a horizontal surface 23 ( FIG. 5 ) of a respective track 13 . The rollers 14 of each panel are mounted on a bracket 16 ( FIG. 5 ), a separate bracket being associated with each panel 11 . Preferably, each bracket 16 ( FIG. 5 ) is bolted to the top edge of a respective panel 11 . The door panels 11 in the illustrated case are in pairs, two associated with the left (as viewed in the figures) and two associated with the right. The panels 11 of each pair are in staggered vertical planes with the outer panels adjacent the plane of the shaft or building wall, designated 17 , and the central panels spaced from the wall slightly more than the thickness of the outer panels. The panels 11 can be identical or nearly identical in construction, as desired.
[0011] With reference to FIG. 5 , the bottoms of the door panels 11 are guided by gibs 18 . Preferably, a pair of gibs is associated with each panel. The gibs 18 , which are bolted to the panels to enable their replacement, are received in and slide along respective slots 19 in a sill assembly 21 .
[0012] The illustrated suspension tracks 13 are fabricated from steel stock into a J-shape with the hook end including a rectangular tube 22 or an equivalent form to provide the horizontal roller support surface 23 . The tracks 13 ( FIG. 4 ) are secured to the underside surfaces 24 of a plurality of bracket assemblies 26 spaced along the header, designated 27 ( FIG. 1 ) of the opening 12 ( FIG. 5 ).
[0013] The bracket assemblies 26 ( FIG. 4 ) can be identical (with the exception that the central bracket can have a double set of track mounting slots). A main body 28 of the bracket assembly 26 can be made, preferably, of a single sheet of steel bent and welded into the illustrated shape. The main body includes a vertical leg 31 and a horizontal leg 32 . The lateral edges of the legs 31 , 32 are interconnected by triangular gussets 33 . The top of the bracket 28 has a horizontal web 34 and a downwardly extending reinforcing flange 36 . The web 34 is integral with the vertical leg 31 and the downwardly extending flange is integral with the web. The web 34 and flange 36 , preferably, are welded at their lateral edges to the gussets 33 . A boss 37 is welded or otherwise fixed at a hole 38 in the web 34 centered between the gussets and has a vertical internally threaded bore 39 . A jacking screw 41 in the form of a threaded machine bolt, is assembled in the threaded boss 37 . A vertical slot 42 in the vertical bracket leg 31 is centered between the gussets 33 and a round hole 43 is formed through the vertical bracket leg on a common vertical center line with the slot. Thus, preferably, the slot 42 and hole 43 are symmetrically disposed about a vertical plane perpendicular to the vertical bracket leg 31 and passing through the axis of the jacking screw 41 .
[0014] A rectangular block 46 , preferably of steel, is proportioned to slide vertically between the gussets 33 and includes a central hole that aligns with the slot 42 . The block 46 has a thickness sufficient when in contact or near contact with the vertical bracket leg 31 to extend under the jacking screw 41 and, ideally, completely under its diameter to provide a full bearing surface for the end face of the screw. The horizontal bracket leg 32 has a series of slots 47 , each slot overlying a respective one of the tracks 13 . The illustrated brackets 16 are arranged to support three tracks corresponding to a six-panel door. For illustrative purposes, the third track is shown in phantom ( FIG. 3 ).
[0015] The door installation 10 ( FIG. 1 ) can be initiated by mounting a sill assembly 21 at the shaft wall 17 at the level of the landing floor with appropriate masonry anchor bolts or other accepted technique. Thereafter, a bracket assembly 26 can be mounted on the shaft wall 17 centered above the door opening a specified distance above the sill assembly 21 . This is accomplished by first drilling a hole in the header area 27 of the wall 17 sized to work with a specified anchor bolt. Thereafter, with an anchor bolt 51 positioned in the drilled hole, designated 52 , the bracket body 28 , block 46 , washers 53 and nut 54 are assembled on the anchor bolt 51 as shown in FIG. 4 . With the first bracket assembly 26 installed, the remaining bracket assemblies 26 can be similarly installed. A recommended procedure to accomplish this task is to use the tracks 13 with factory-installed upstanding threaded studs 55 to laterally locate the remaining bracket assemblies 16 . A first stud 55 is inserted into the proper slot 47 in the central bracket body 28 . The central bracket assembly 28 can be provided with a double set of slots 47 to receive respective studs 55 at the ends of left and right sections of the tracks 13 . The tracks 13 are preliminarily leveled and temporarily held in place with suitable clamps and/or props. Other bracket assemblies 26 are positioned so that appropriate studs 55 are received in their respective slots 47 . Holes 52 are drilled in the shaft wall header 27 at the center of the slots 42 of the additional bracket assemblies 26 and these bracket assemblies are provisionally installed as described for the center bracket assembly. A track spacer plate 56 has holes for receiving and locating the studs 55 , and therefore locating the tracks 13 in a desired spacing relative to one another. A spacer plate is associated with each bracket 26 . Nuts 57 are assembled on upstanding track studs 55 to fasten the tracks 13 to the brackets 26 . The slots 47 permit the tracks 13 to be adjusted horizontally towards and away from the shaft wall 17 as required.
[0016] In the illustrated arrangement, as described above, each door panel 11 has an associated hanger or bracket 16 on which is assembled a pair of traction rollers 14 . The hangers or brackets 16 are installed with the rollers on the track support surfaces 23 . With the hangers 16 located on appropriate tracks 13 , the door panels 11 can be bolted onto the hangers. For example, bolts (not shown), assembled vertically through holes in horizontal webs of the hangers 16 can be turned into threaded holes in the upper edges of the door panels 11 to secure the door panels to the hangers. With each door panel 11 secured to a respective hanger 16 , the panels are suspended overhead from the tracks 13 .
[0017] The bracket assemblies 26 afford a convenient, accurate and fast way of adjusting a gap 61 ( FIG. 5 ) between the bottom of the door panels 11 and the sill 21 to meet building code requirements and assure smooth opening and closing operation of the door panels. With the nuts 54 slightly loose on the studs of the anchor bolts 51 , the jack screws 41 can be rotated in either direction as needed to raise or lower the tracks 13 and, therefore, the door panels 11 . The jack screws 41 bear against the top surface of their respective blocks 46 thereby transferring the weight of the tracks 13 and door panels 11 to the anchor bolt 51 while allowing the respective bracket assemblies 26 to move vertically within limits of the slots 42 . One or more bracket assemblies 26 are adjusted as necessary. The adjustment mechanism afforded by the jack screw 41 has the desirable characteristic of being linear, lifting or lowering the door panels 11 a distance directly proportional to the angle through which a screw is turned. All of the door panels 11 are adjusted at the same time rather than being adjusted one at a time. When the door panels have been properly adjusted, each of the bracket assemblies 26 can be locked in position by drilling a hole in the building wall header 27 using the hole 43 as a pilot. Thereafter, an anchor bolt 63 , shown in phantom in FIG. 4 , is positioned through the bracket hole 43 into the drilled hole. A nut 64 on this second anchor 63 can then be tightened for additional securement of the bracket assembly 26 . Additionally, the nut 54 associated with the first anchor bolt 51 is fully tightened at this time.
[0018] It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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A method and apparatus for adjustably mounting tracks that suspend horizontal sliding doors at a freight elevator landing. The apparatus comprises a plurality of brackets adapted to be mounted in the shaft on the header above the landing opening. The brackets are each secured to the header with anchor bolts. Each anchor bolt is set in the header but initially allows vertical movement of the bracket. An adjusting screw, carried on each bracket, is arranged to easily and precisely move the bracket up or down relative to the anchor bolt as needed to position the tracks and, therefore, the door panels at a proper height. Once adjusted such that a specified gap is established between the lower edges of the door panels and the threshold, each anchor bolt can be tightened to fix its respective bracket in its adjusted position.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. provisional application No. 60/760,117 filed Jan. 19, 2006 and is hereby incorporated by reference as if fully disclosed herein.
INVENTIVE FIELD
The inventive field is directed towards devices, systems and methods for controlling motorized window coverings with light control. More specifically, the inventive field relates to the hardware and/or software utilized in a device, system and/or method and includes a control system, one or more switches with push buttons and various motors, actuators and assemblies used to control the operation of the motorized window covering with light control.
BACKGROUND
It is well known that it is frequently desirable to place retractable coverings on architectural openings such as windows. It is also desirable to be able to adjust the transmissivity of the retractable covering. A proposal to solve the problem of a retractable covering for an architectural opening is disclosed in U.S. patent application, entitled “Remote Control Operating System and Support Structure for a Retractable Covering for an Architectural Opening,” Joseph E. Kovach et al., filed Dec. 10, 2003, U.S. application Ser. No. 10/732,747, now U.S. Pat. No. 7,147,029 (the subject matter of which is incorporated herein by reference in its entirety).
Although various control systems exist for operating retractable coverings, there remains a need for improved devices, systems and/or methods used to control the retraction, extension and transmissivity of window and other architectural coverings.
Prior attempts to control the automated retraction and extension of a covering have employed remote controls or manual switches with up and down buttons. Such control systems generally result in the extension or retraction of a window covering at a single speed. What is needed are devices, systems and methods which support the extension and/or retraction of a covering at varying speeds. Further, such an invention desirably supports the automated opening or closing (or therebetween) of the covering, for purposes of transmissivity or the like, but at desired speeds.
SUMMARY
A method is disclosed for using a switch with a plurality of buttons to activate a motor to control the configuration of a window covering. The method comprises monitoring a signal from the switch to detect the pressing of a button; monitoring the speed of the covering; upon determining that a button is pressed, setting the speed and direction of motor rotation; and upon determining that no button is pressed, setting the speed of motor rotation.
A control system is disclosed for activating a motor to adjust a window covering. The control comprises a switch having a plurality of buttons; a microprocessor adapted to (a) monitor a signal from the switch to detect the pressing of a button; (b) monitor the speed of the covering; (c) upon detecting the pressing of a button, setting the speed and direction of motor rotation; and (d) upon detecting that no button is pressed, setting the speed of motor rotation.
Other embodiments utilize a motor with a plurality of speeds such that a first speed is used to position the covering while a second speed is used to rapidly extend or retract the covering. Other embodiments of the present invention use limit stops to prevent over/under extension of the covering.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary isometric view of the top and front of a retractable covering.
FIG. 2 is a front view of a switch suitable for use with at least one embodiment of the present invention including, without limitation, the embodiment shown in FIG. 1 .
FIG. 3 is a cross-sectional view of the head rail used, for example, in the embodiment shown in FIG. 1 , wherein the covering is in its fully retracted configuration.
FIG. 4 is a cross-sectional view of the head rail used, for example, in the embodiment shown in FIG. 1 , wherein the covering is in its fully extended configuration.
FIG. 5 is a block diagram of a control system.
FIG. 6 is a flow chart of the logic used by a control system.
FIG. 7 is a flow chart of the logic used by a control system.
FIG. 8 is a flow chart of the logic used by a control system.
FIG. 9 is a flow chart of the logic used by a control system.
FIG. 10 is a flow chart of the logic used by a control system.
DETAILED DESCRIPTION
In general, the various embodiments disclosed herein relate to devices, systems and methods for controlling a retractable covering for architectural openings such as windows. As depicted in FIGS. 1 and 2 for one embodiment, the apparatus comprises a control system which can be mounted, for example, in a switch 20 (or provided elsewhere in the system). The control system is configured to control the extending, retracting, and otherwise adjusting of one or more coverings, such as the covering 30 shown in FIG. 1 . The covering 30 can be attached between a head rail 40 and a bottom rail 50 . The control system may be operated using the switch 20 . Mounting brackets 60 can be used to attach the head rail 40 to a desired mounting surface (e.g., a wall above the window). Two limit switches 70 can be utilized to prevent over-retraction and/or under-retraction of the covering 30 . An example of a covering 30 suitable for use with one or more of the various embodiments of the present invention can include, but is not limited to, a first flexible sheet 80 and a second flexible sheet 90 with vanes 100 attached between these first and second flexible sheets, respectively. The first and second flexible sheets 80 , 90 , respectively, are secured to the bottom rail 50 . Left and right end caps, 110 , 120 , respectively, support components, aesthetically shield various internal components from view, and include auxiliary support pockets 130 that may be used in select applications to position the head rail 40 above a window opening to be covered. In one embodiment, the control system monitors a switch 30 having an up button 140 , a stop button 150 , and a down button 160 . Based upon signals received from such buttons, the control system can control the direction, configuration (e.g., full open, partially open and the like) and speed of movement of the covering. In one embodiment, a reversible, direct current (dc) motor (not shown) is used to move the covering. Likewise, the motor may be used to facilitate the adjusting of the transmissivity of the covering. Further, it is to be appreciated that one or more motors may be used.
The general operation of one embodiment of a retractable covering 10 , suitable for use in various embodiments is described next. The covering 30 may be in the configuration depicted in FIG. 3 , which is in its most retracted configuration. To lower the retractable covering 30 , the down button 160 on the switch 20 can be pressed. The down button can be pressed for a predetermined minimum time. For example, in one embodiment, a minimum time period of two seconds is utilized. In other embodiments, the down button 160 may be pressed over a range of time periods (e.g., more than two seconds but less than four seconds or the like). Further, the control system can be configured such that when the down button is first pressed for a first time period, the motor begins to extend the covering at a slow speed. In at least one embodiment, once the down button 160 has been depressed for at least the predetermined minimum time period (in this example, two seconds), the motor switches from a first speed to a second speed while extending the covering 30 . For certain embodiments, the first speed may be slower than the second speed. For this embodiment, once the motor is operating at the second speed, it will continue to extend the cover 30 , even if the down button is released, until the fully extended position is reached. However, upon the subsequent pressing of any button on switch 20 , while the cover is being extended, at either the first or second speeds, the control system will instruct the motor to stop the extension of the cover. When the blind is in the resulting “fully opened” configuration, any further pressing of the down button 160 on switch 20 has no effect on the configuration of the covering 30 .
Limit stops 70 can be used to prevent over-extension of the retractable covering 10 . Likewise, timers, potentiometers, and various other well known sensors and/or actuators can be used to prevent the over/under extension of the covering. Further, it is to be appreciated that precise positioning of the cover 30 can be accomplished by using one of the at least two available operating speeds, for example, a slower of the at least two speeds. A slower of the at least two operating speeds can be initiated upon the control system detecting that the down button 160 , for example, has been depressed for less than the predetermined minimum time (e.g., for less than two seconds in at least one embodiment). In this mode the motor continues to operate at slow speed while extending the cover 30 .
Further, the control system may be configured such that, when operating in the slower of the at least operating modes, upon releasing the down button, the extension of the cover automatically stops.
The covering 30 may be in its fully open configuration as shown in FIG. 4 . To raise the retractable covering 10 , the up button 140 on switch 20 is pressed for a desired minimum time, for example, two seconds. When the up button 140 is first pressed, the motor begins to retract the covering at a first speed. Once the up button has been depressed for the desired minimum time, the motor switches from the first speed to a second speed while retracting the covering. As before, the first speed can be slower or faster than the second speed. Once the motor is operating at the second speed, it will continue to retract the covering even if the up button is released. Pressing any button again on switch 20 will stop the motor and retraction of the covering. If not stopped, the motor will continue to retract the covering until the covering is at its highest position. When the blind is in the resulting “fully closed” configuration, any further pressing of the up button 140 on switch 20 has no effect on the configuration of the covering.
Limit stops 70 can be used to prevent over-retraction of the retractable covering 10 . When precise positioning of the covering 30 is desired, the covering can be raised using the first speed. This is done by tapping the up button 140 . For at least one embodiment, less than two second taps can be used to control the operation of the blind. In this mode, the motor continues to operate at the first speed while retracting the covering 30 . Releasing the up button automatically stops the motor and retraction of the covering.
When the covering 30 is stopped in an intermediate position, it may be raised or lowered by pressing the up button 140 or down button 160 , respectively.
Transmissivity of the extended covering 30 is also fully adjustable using switch 20 . When the covering is in its fully extended configuration, the transmissivity of the covering (i.e., the amount of light or air that is permitted to pass through the covering) may be adjusted by toggling between the up and down buttons, 140 , 160 , respectively. This causes the motor to operate at its first speed while configuring the transmissivity of the covering. By toggling between the up and down buttons, the covering can be configured for maximum transmissivity, minimum transmissivity, or any desired level of transmissivity between the maximum and the minimum.
Pressing the stop button 150 on switch 20 causes the blind 30 to stop moving if it is in motion. If any button on switch 20 is pressed while the covering 30 is moving at the second speed, the covering stops moving.
For example, if the covering 30 is being extended and the bottom rail 50 is traveling downward at the second speed but has not yet reached its lowest point of travel, if the up button 140 , the down button 160 , or the stop button 150 on switch 20 is pressed and released, the control system instructs the motor to cease all motion of the covering 30 . If the down button 160 is then pressed, the motor will be commanded to continue extending the covering 30 at the first speed. If, on the other hand, the up button 140 is pressed after the covering 30 was stopped, the motor will be commanded to reverse the direction of rotation, and will begin to retract the covering 30 at the first speed. Similarly, if the covering 30 is being retracted at the second speed and the up button 140 , the down button 160 or the stop button 150 is pressed and released, retraction of the covering 30 stops. Then, if the up button 140 is pressed again, retraction of the covering 30 commences at the first speed. If, on the other hand, the down button 160 is pressed after stopping the retraction of the covering 30 , the motor will begin to rotate at the first speed so as to extend the covering 30 .
In summary, if any button on the switch 20 is pressed while the motor is operating at the second speed and the covering 30 has not yet reached a fully extended or fully retracted configuration, the motor will be commanded to stop moving the covering.
While the various embodiments discussed hereinabove have been described with respect to two operating speeds, it is to be appreciated that any number of operating speeds may be utilized in conjunction with the present invention. When three or more operating speeds are utilized, the control system can be configured to sequentially proceed through the operating speeds, to automatically return to a slowest operating speed when any button is pushed at a faster operating speed, to automatically proceed to the fastest operating speed (for example, button holds of longer than five (5) seconds and the like).
FIG. 5 is a block diagram of the control system electronics. Power supply 180 supplies power to the electronics. Batteries and other alternative power systems can additionally or separately be used to power the control system, device and systems. Microprocessor 190 monitors switch 20 to detect whether or not a button is pressed. Timer 210 is used by microprocessor 190 to determine when a button has been pressed for a minimum amount of time (for example, two seconds). A motor 200 is controlled by microprocessor 190 to retract, extend or adjust the transmissivity of the covering 30 .
FIG. 6 comprises a flow chart representation of the logic used by the control system for one embodiment of the present invention. The logic may be implemented in software or firmware for execution by the microprocessor. All times shown in the flow chart are nominal. Actual times may vary. For at least one embodiment, times may vary by +−25%. Items in a box are actions that are performed. Items in a diamond are tests that are made and the possible outcomes are written next to the arrows leaving the diamond.
The following scenarios provide examples of how the control system electronics operate for various embodiments having a varying number of buttons on switch 20 , a varying number of speeds for the motor 200 and limit stops 70 .
FIG. 6 shows one embodiment of the logic executed by the control system electronics. When power is first applied, for example, upon a reset, the control system is initialized by, for example, commanding the motor to stop, resetting the timer 210 to zero, and performing any other operations necessary or desired to put the control system into a known state (Operation 300 ). The control system then determines if a button on switch 20 is pressed (Operation 310 ). If a button is pressed, the control system determines which button on switch 20 has been pressed and instructs the motor 200 to begin rotating and thereby retracting or extending the covering in the corresponding direction (Operation 340 ). The control system also determines if the button has been pressed for a minimum time, for example, but not limited to, two (2) seconds (Operation 350 ). If the button has been pressed for the minimum time, the motor 200 is instructed to rotate at a second speed (which in one embodiment is faster than the first speed) resulting in the covering being extended or retracted faster (Operation 370 ). The control system then returns to Operation 310 .
Referring back to Operation 310 , if no button is pressed on switch 20 the control system determines if motor 200 is operating at its second speed (Operation 320 ). If the motor is operating at its second speed, the control system takes no further action (e.g., the window covering continues to be extended or retracted at high speed). That is, once a button has been pressed for the minimum time, it can be released and the motor will continue to move the covering at the second speed. The control system then returns to Operation 310 . Referring back to Operation 320 , if the motor is not running at its second speed, the control system instructs the motor 200 to stop thereby stopping movement of the covering (Operation 330 ). That is, if the covering is being moved at the first speed when the button is released, movement of the covering is stopped. Positioning of the covering can be achieved by toggling between the up and down buttons. The control system then returns to Operation 310 .
Referring back to Operation 350 , if the button has not been pressed for the minimum time, the control system determines if motor 200 is running at its second speed (Operation 360 ). If the motor is running at its second speed, the control system commands the motor to stop (Operation 330 ). That is, the covering was being extended or retracted by motor 200 at the second speed when a button is pressed indicating that movement of the covering is to be stopped. The control system then returns to Operation 310 . Referring back to Operation 360 , if the motor is not running at its second speed, the control system instructs the motor 200 to run at its first speed (Operation 380 ). The control system then returns to Operation 310 .
FIG. 7 shows another embodiment of the logic executed by the control system electronics when switch 20 has a stop button in addition to an up button and down button. The operation of the control system is similar to that described in FIG. 6 except for the following differences. When the control system determines that a button has been pressed (Operation 410 ), the control system then determines if the stop button on the switch 20 has been pressed (Operation 435 ). If the stop button has been pressed, the control system instructs the motor 200 to stop (Operation 430 ). The control system then returns to Operation 410 . Referring back to Operation 435 , if the stop button has not been pressed, the control system determines which other button on switch 20 has been pressed and instructs the motor 200 to begin rotating and thereby retracting or extending the covering in the corresponding direction (Operation 440 ). The other operations of the control system are as described for FIG. 6 .
FIG. 8 show another embodiment of the logic executed by the control system electronics when the motor 200 has a first speed, a second speed and a third speed. The operation of the control system is similar to that described in FIG. 6 except for the following differences. After the control system determines which button on switch 20 has been pressed and instructs the motor 200 to begin rotating and thereby retracting or extending the covering in the corresponding direction (Operation 540 ), the control system then determines if the button has been pressed for a first minimum time, for example, but not limited to, two (2) seconds (Operation 550 ). If the button has not been pressed for the first minimum time, the control system determines if the motor 200 is running at a speed greater than the first speed (Operation 560 ). If the motor 200 is running at a speed greater than the first speed, the control system instructs the motor to stop moving the covering 200 (Operation 530 ). When the motor 200 is running at a speed other than the first speed, the pressing of a button indicates that movement of the covering 30 is to be stopped. The control system then returns to Operation 510 .
Referring back to Operation 560 , if the motor 200 is not running at a speed greater than the first speed, the control system instructs the motor 200 to rotate at its first speed. The control system then returns to Operation 510 . Referring back to Operation 550 , if the button has been pressed for more than the first minimum time, the control system then determines if the button has been pressed for a second minimum time, for example, but not limited to, four (4) seconds (Operation 555 ). If the button has been pressed for the second minimum time, the control system instructs the motor 200 to rotate at its third speed (Operation 570 ). That is, the motor 200 is rotating at its second speed and the button has been pressed for the second minimum time indicating that the covering is to be moved at the third speed. The control system then returns to Operation 510 . Referring back to Operation 555 , if the button has not been pressed for the second minimum time, the control system instructs the motor to run at its second speed (Operation 565 ). That is, the motor has been rotating at its first speed and the button has been pressed for the first minimum time indicating that the covering is to be moved at the second speed. The control system then returns to Operation 510 . The other operations of the control system are as described for FIG. 6 .
FIG. 9 shows yet another embodiment of the logic executed by the control system for motor 200 having three speeds and switch 20 having an up button, a stop button and a down button. The operation of the control system is similar to that described in FIG. 8 except for the following differences. When the control system determines that a button has been pressed (Operation 610 ), the control system then determines if the stop button on the switch 20 has been pressed (Operation 635 ). If the stop button has been pressed, the control system instructs the motor 200 to stop (Operation 630 ). The control system then returns to Operation 610 . Referring back to Operation 635 , if the stop button has not been pressed, the control system determines which other button on switch 20 has been pressed and instructs the motor 200 to begin rotating and thereby retracting or extending the covering in the corresponding direction (Operation 640 ). The other operations of the control system are as described for FIGS. 6 and 8 .
FIG. 10 shows yet another embodiment of the logic executed by the control system when limit stops 70 are used to prevent the motor 200 from over rotating. The operation of the control system is similar to that described in FIG. 6 except for the following differences. After the control system has been initialized (Operation 700 ), the control system determines if the motor 200 is rotating (Operation 702 ). If the motor 200 is running, the control system then determines if a limit stop 70 has been reached indicating that the covering has either been fully extended or fully retracted (Operation 705 ). If the limit stop 70 has been reached, the control system instructs the motor 200 to stop (Operation 730 ). The control system then returns to Operation 702 . Referring back to Operation 705 , if the limit stop 70 has not been reached, the control system then determines if a button has been pressed (Operation 710 ).
Referring back to Operation 702 , if the motor 200 is not running, the control system determines if a button has been pressed (Operation 710 ). The other difference is that after the control system either runs the motor 200 at its second speed (Operation 770 ) or at its first speed (Operation 780 ), the control system returns to Operation 702 . The other operations of the control system are as described for FIG. 6 .
Although various embodiments of this invention have been described above, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. Further, all references (e.g., first, second, up, down, leftward, rightward, bottom, top, inner, outer, above, below, clockwise, and counterclockwise) used above are to aid the reader's understanding of the present invention, but should not create limitations, particularly as to the orientation of the apparatus. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting.
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An improved system for controlling motorized window coverings with light control includes an improved control system including a switch with an up button, a stop button and down button to activate a motor to control the configuration of the covering, including the extension or retraction of the covering, and the transmissivity of the covering.
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